Specification_N6247013R4022.pdf

N62470-13-R-4022

NAVFAC

Work Order Number: 1312536 Appropriation: NWCF

ONE (1) 15-TON OVERHEAD ELECTRIC TRAVELING BRIDGE CRANE

FOR

MICHELSON LABORATORY NAVAL AIR WARFARE CENTER WEAPONS DIVISION,

CHINA LAKE, CALIFORNIA

PREPARED BY:

Navy Crane Center (NAVCRANECEN)

Bldg. 491, Norfolk Naval Shipyard

Portsmouth, Virginia 23709-5000

SPECIFICATION PREPARED BY:

Lead Design Engineer: Bryan Barber, P.E.

Project Manager: Nick Kent, P.E.

Contract Specialist: Luke Clay

Quality Assurance Specialist: Mindy Miller

PART 1 GENERAL 4

1.1 REFERENCES 4

1.2 UNIT PRICES 7

1.3 SYSTEM DESCRIPTION 7

1.3.1 DESIGN REQUIREMENTS 7

1.3.2 PERFORMANCE REQUIREMENTS 8

1.3.3 CAPACITY PLATE 8

1.3.4 UNIQUE IDENTIFIER TAG 8

1.3.5 CRANE INSTALLATION 8

1.3.6 CRANE REMOVAL 8

1.4 SUBMITTALS 9

SD-01 PRECONSTRUCTION SUBMITTALS 9

SD-02 DRAWINGS 10

SD-03 PRODUCT DATA 11

SD-04 SAMPLES 13

SD-05 DESIGN DATA 13

SD-06 TEST REPORTS 14

SD-07 CERTIFICATES 15

SD-08 MANUFACTURER’S INSTRUCTIONS 16

SD-09 MANUFACTURER’S FIELD REPORTS 17

SD-10 OPERATION AND MAINTENANCE DATA 17

SD-11 CLOSEOUT SUBMITTALS 18

1.5 QUALITY ASSURANCE 19

1.5.1 QUALIFICATIONS 19

1.5.2 REGULATORY REQUIREMENTS 19

1.5.3 POST-AWARD CONFERENCE 19

1.5.4 PRE-INSTALLATION CONFERENCE 19

1.6 DELIVERY, STORAGE, AND HANDLING 20

1.7 PROJECT/SITE CONDITIONS 20

1.7.1 ENVIRONMENTAL REQUIREMENTS 20

1.7.2 EXISTING CONDITIONS 20

1.7.3 GOVERNMENT FURNISHED EQUIPMENT 20

1.8 SEQUENCING AND SCHEDULING 20

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES 20

1.10 WARRANTY 21

1.11 MAINTENANCE 21

PART 2 PRODUCTS 21

2.1 MATERIALS 21

2.1.1 DUCTILE MATERIAL 21

2.1.2 STRUCTURAL STEEL 21

2.1.3 CAST STEEL 21

2.1.4 DUCTILE CAST IRON 21

2.1.5 FORGED STEEL 21

2.1.6 STEEL SHAFTS 21

2.1.7 ALUMINUM CASTINGS 21

2.1.8 WELDING MATERIALS 21

2.2 MANUFACTURED UNITS 22

2.3 EQUIPMENT 22

2.3.1 STRUCTURAL DESIGN 22

2.3.2 MECHANICAL DESIGN 24

2.3.3 ELECTRICAL DESIGN 30

2.4 COMPONENTS 38

2.5 ACCESSORIES 38

2.6 MIXES 38

2.7 FABRICATION 39

2.7.1 SHOP ASSEMBLY 39

2.7.2 SHOP AND FACTORY FINISHING 40

2.7.3 TOLERANCES 41

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS 41

2.8.1 CONTRACTOR’S SELF TEST 41

2.8.2 GOVERNMENT WITNESSED SHOP TEST AND INSPECTION 41

PART 3 EXECUTION 41

3.1 EXAMINATION 41

3.2 PREPARATION 41

3.3 ERECTION 42

3.4 INSTALLATION AND REMOVAL 42

3.5 APPLICATION 42

3.6 FIELD QUALITY CONTROL 42

3.6.1 FIELD INSPECTION AND TEST 42

3.6.2 ACCEPTANCE 43

3.7 ADJUSTING AND CLEANING 43

3.8 DEMONSTRATION 43

3.9 PROTECTION 43

3.10 SCHEDULES 43

PART 1 GENERAL

1.1 REFERENCES

The following documents, of the issue in effect on date of 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 NATIONAL STANDARDS INSTITUTE (ANSI)

A14.3 - Fixed Ladders – Safety Requirements

AMERICAN GEAR MANUFACTURERS' ASSOCIATION (AGMA)

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

2015 - Accuracy Classification System 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

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 NON-DESTRUCTIVE TESTING (ASNT)

Recommended Practice No. SNT-TC-1A Topical Outlines for Qualification of NDT Personnel

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

B1.1 - Unified Inch Screw Thread B4.1 - Positional Fits and Tolerance for Cylindrical Parts B17.1 - Keys and Keyseats B18.8.2 - Taper Pins, Dowel Pins, Straight Pins, Grooved Pins, and Spring Pins (Inch

Series) B30.2 - Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple

Girder, Top Running Trolley Hoist) B30.10 - Hooks

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 A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High

Pressure and High Temperature Service A275 - Magnetic Particle Exam of Steel Forgings A307 - Standard Specification for Carbon Steel Bolts and Studs, 60 000 PSI Tensile

Strength 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 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)

No. 70 - Specification for Top Running & Gantry Type Multiple Girder Electric

Overhead Traveling Cranes

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

DFARS 252.211-7003 Item Identification and Valuation

FEDERAL ACQUISTION REGULATIONS (FAR)

FAR Part 2 Definition of Words and Terms

INTERNATIONAL STANDARDS ORGANIZATION (ISO)

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

NATIONAL ELECTRICAL MANUFACTURERS' ASSOCIATION (NEMA)

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

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 - National Electric Code NFPA 70E - Standard for Electrical Safety in the Workplace

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)

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

WIRE ROPE TECHNICAL BOARD

Wire Rope Users Manual

1.2 UNIT PRICES

Not applicable for this specification.

1.3 SYSTEM DESCRIPTION

The intent of this specification is to procure one double girder, radio controlled, overhead electric traveling crane with a 15-ton main hoist. The crane shall be installed in the Machine Shop of the Michelson Laboratory at Naval Air Warfare Center Weapons Division (NAWCWD), China Lake, California.

The crane shall be designed, fabricated, assembled, shop tested, delivered, installed, inspected, field tested, and made ready for use in accordance with this specification. The crane shall be built to the design drawings of a registered Professional Engineer (PE). The crane’s capacity, span, runway and hook lift shall be as follows:

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

Machine Shop 30,000 49’-0” 380’-0” 21’-6”

NOTE: Span and runway dimensions are approximate. Final values shall be verified by the Contractor.

1.3.1 Design Requirements

The design of this crane shall conform to OSHA 29 CFR 1910.179 and1910.306 paragraph (b), ASME B30.2, CMAA No. 70, and other requirements specified herein. The crane shall be radio controlled and designed to operate on 480 VAC, 3-phase, 60 Hertz in an indoor environment.

The crane shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements) of CMAA No. 70 for class C service (minimum), as well as ASME B30.2 (all “should” statements shall be considered “shall” statements).

Packaged hoists shall not be permitted. 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 and mass produced by established manufacturers of the crane industry.

The crane shall be designed to operate in the space, and match the runway dimensions and rails shown on the sketches in Appendix A. All crane dimensions in the appendix 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 Appendix A. The crane’s maximum wheel load (without impact) due to dead load and the rated capacity live loads, with the trolley in any position, shall not cause greater shear or moment in the runway girders than that produced by the design wheel load and spacing shown in Appendix A. Building designs/drawings shall be provided to the Contractor for planning the design, shipping, and erecting of the components.

Runway electrification from the junction box for the runway disconnect shall be furnished and installed by the Contractor. The existing electrical disconnect is located at column F-19.

1.3.2 Performance Requirements

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

Function Capacity (lbs) Rated Speed (fpm) Minimum Speed (fpm)*

Bridge 30,000 150 7.5

Trolley 30,000 50 2.5

Main Hoist 30,000 25 2.0

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

1.3.3 Capacity Plate

Provide two capacity plates with permanent letterings, one for each side of the bridge. Each plate shall indicate the rated hoisting capacity of the hook in pound units, and shall be securely attached to the bridge. Beneath the rated capacity, the following information shall be included:

Naval Facilities Engineering Command

Contract Number N62470-13-D-XXXX; DO XXX

Manufacturer’s Name, Address, and Crane Serial Number

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

1.3.4 Unique Identifier Tag

The Contractor shall assign a unique identifier to the crane in accordance with DFARS 252.211- 7003. The Unique Identification Tag shall be attached to the outside of the crane main electrical disconnect panel.

1.3.5 Crane Installation

The Contractor shall verify all crane envelope clearances and other building/crane interface features, including those identified in Appendix A prior to design of the crane. The Contractor shall follow the guidelines for the site specific installation in Section H.

1.3.6 Crane Removal

The Contractor shall be responsible for the removal of the existing 15-ton crane and runway electrification prior to the installation of the new crane. The Contractor shall coordinate this effort with the activity as to minimize the time of impact to regular facility operations. The activity plans to dispose of the existing crane through their recycling station. The Contractor shall coordinate the crane removal with the recycling center. The recycling center shall provide a truck/lowboy at the construction site in which the crane will be loaded onto by the Contractor.

The truck/lowboy can handle parts up to 12’ wide, 40’ long, and weighing up to 65,000 pounds.

The Contractor shall make any cuts needed to the crane in order to meet these specifications.

The weight of the existing crane components shall be verified by the Contractor. The Contractor shall ensure that the lifting and handling equipment to be used is sufficient for the actual weight of the crane to be removed. The Contractor is advised that the existing crane contains lead base paint and shall adhere to the activity’s lead abatement procedures. The existing crane may also contain asbestos insulation and other hazardous materials. The Contractor shall adhere to all local, state, and federal regulations in the handling and preparation for disposal of these hazardous materials if these materials become dislodged during crane removal. For the material sampling report, see Appendix H.

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 NAVCRANECEN form, all forms can be found at https://portal.navfac.navy.mil/portal/page/portal/NAVFAC/NAVFAC_WW_PP/NAVFAC_NCC _PP under the “Downloads” page.

SD-01 Preconstruction Submittals The 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 a 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, and for designs under review – indicate level of Government review and projected approval dates. It shall also list and describe current Contractor Change Request Forms (CCRF), 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 (CORs), list all contract modifications issued, provide a summary of work planned in the next month, and provide any necessary supporting documentation as an attached appendix. An updated milestone schedule shall be provided 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. At 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 NAVCRANECEN 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 PE. Final and “as-built” drawings shall bear a complete title block with a permanent drawing number and a registered PE’s original seal and dated signature.

Drawings within each category (general, structural, mechanical, electrical) 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 2006 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat as a bookmarked portable document format (.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 the crane shall be shown including: clearances, lifts, spans, wheel spacing, speeds, trolley gage, hook approaches on all sides, maximum wheel loads, electrical power supply, and general locations of components such as: brakes, motors, speed reducers, and control panels (including size). In addition, estimated weights shall be shown for the completely assembled crane and major components.

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 (including rail detail and trolley end stops)

b. Bridge End Truck Fabrication

c. Trolley End Truck Fabrication

d. Trolley Fabrication

e. Walkway and Ladder Fabrication

f. Lift Point Fabrication

g. End Stop Fabrication

SD‐02.M Mechanical Drawings

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‐02.E Electrical Drawings

These 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. Locations of contacts and coils shall be cross-referenced to each other within 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

e. Layout diagrams showing component placement in control panel enclosures

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

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. The Contractor shall submit for approval the catalog cuts listed below in accordance with Exhibit A.

SD‐03.S Structural Product Data

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

SD-03.S2 Trolley Rails

SD-03.S3 Painting System

SD-03.S4 End Stops

SD-03.S5 Lift Point(s)

SD-03.S6 Bumpers

SD‐03.M Mechanical Product Data

SD-03.M1 Speed Reducers including gear ratio

SD-03.M2 Brakes (including electrical information)

SD-03.M3 Bearings and Bearing Housings

SD-03.M4 Couplings

SD-03.M5 Load Blocks

SD-03.M6 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-04 Samples Not applicable to 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 and variables shall be in accordance with required references.

SD‐05.S Structural Calculations

SD-05.S1 Calculations verifying load cases in accordance with Section 3 of CMAA No. 70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05.S2 Calculations verifying girder design in accordance with Section 3 of CMAA No. 70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05.S3 Calculations verifying bridge and trolley end truck design in accordance with Section 3 of CMAA No. 70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05.S4 Calculations verifying trolley design in accordance with Section 3 of CMAA No. 70 and section 2.3.1.1 of this specification for any non-commercial items.

SD-05.S5 Calculations verifying design of end stops in accordance with AIST TR-13 and all bumpers in accordance with the dynamic requirements of AIST TR- 06.

SD-05.S6 Calculations verifying bumper selection

SD-05.S7 Calculations verifying compliance with the maximum allowable wheel loading and spacing as specified in Appendix A.

SD‐05.M Mechanical Calculations

SD-05.M1 Calculations verifying compliance with Section 4 of CMAA No. 70 for any non-commercial items

SD-05.M2 Calculations verifying brake selections

SD-05.M3 Calculations verifying coupling selections

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. 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-05.E5 Lighting calculations demonstrating specified illumination level (if applicable)

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% 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 criteria 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 equipment being certified. Each certification shall clearly identify the hoist, drive, component, 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 crane and support systems are capable of being load tested semi-annually up to and not exceeding 131.25% of the rated capacity without any detrimental effects.

SD‐07.3 Crane Runway Rail

Prior to shipment of the crane, the activity shall complete a rail survey in accordance with the criteria of CMAA No. 70. The Contractor shall provide a certificate stating that the new crane will operate properly on the runway; if the crane(s) cannot operate without restriction, the Contractor shall indicate crane limitations.

SD‐07.4 Hazardous Material

The Contractor shall certify that the crane contains no asbestos, lead paint, Polychlorinated Biphenyls (PCBs), 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 can be performed without any detrimental affects to the electronic control system.

SD‐07.6 Coupling Alignments

The Contractor shall submit coupling alignment data records with certification that the alignment of all shafting connected by means of flexible couplings are within the 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. Barrel coupling alignment data record(s) shall be submitted on the official NAVCRANECEN form titled “Drum Barrel Alignment Data Sheet” located on the NAVCRANECEN website. All other coupling alignment data record(s) shall be submitted on the official NAVCRANECEN form titled “Shaft/Coupling Alignment Record Form” located on the NAVCRANECEN website.

SD‐07.7 Hook Proof Test

The Contractor shall submit certification that the hook has 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 inspectors(s), and the welding procedure qualification meet the requirements of AWS D14.1 for all work performed in manufacturing the crane.

The Contractor shall also provide a certificate stating that all welders, welding operators, weld inspector(s), and the welding procedure qualification meet the requirements of AWS D1.1 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 PE. The certificate shall indicate the name, state of licensure, and license number of the PE.

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.

SD08.2 Crane Removal and Installation Plan

The Contractor shall submit a plan detailing the logistics involved in crane mobilization to the site, removal of the existing crane, 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 Paragraph 1.7.2 shall be submitted by the Contractor, for review and acceptance by the Government. In addition the Lifting and Handling Plan shall include the details for loading the existing crane onto the Government supplied truck/lowboy. 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 center of gravity location and lifting point locations 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, Exhibit A, and Exhibit B, and shall be submitted for review and comment by the Contracting Officer. Installation of the crane cannot proceed prior to the review and acceptance of the APP by the Contracting Officer.

SD‐08.4 Training Course Outline

Not applicable to this specification.

SD-09 Manufacturer’s Field Reports

SD‐09.1 Brake Adjustment Records

The Contractor shall provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. The brake adjustment record shall be submitted on the official NAVCRANECEN form titled “Brake Adjustment Record Form” located on the NAVCRANECEN website. Each brake measurement shall have a tolerance traceable to the associated brake manual or documentation provided by the brake manufacturer, and the actual brake setting. Changes made to settings of the brake, at any time, will void the record.

SD‐09.2 Shop Test Deficient Items List

Upon completion of the Government witnessed shop test and inspection of the crane, a list of deficient items will be compiled and attached to the “Navy Crane Center Post Shop Test Sign Off Sheet,” and signed by the Contractor, NAVCRANECEN 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 crane, 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 that will demonstrate operation, capacity, and safety of the crane. Any deviations to the field test required by the 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 a 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.

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.

Maintenance instructions shall include alignment, adjustment, and calibration instructions for commercial components and parts lists. Programming instructions shall include a complete listing of all control system parameters with an explanation of their functions.

Parts information shall include a recommended spare parts list, all information on all Contractor-designed parts, and 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 2006.

The file shall be in .dwg or .dxf format and a separate copy in a bookmarked .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 three (3) hard copies following final Government acceptance of the manuals. The manuals shall be a bookmarked and indexed .pdf document.

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 and provide the crane parameter file downloaded from the crane at time of acceptance, if applicable. 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

Catalog cuts shall be submitted electronically, in .pdf format, as one unit with a cover sheet containing a title block and an index sheet identifying each catalog cut. Ensure each page is numbered and identified to allow proper filing if separated. Linked bookmarking is acceptable vice page numbering for the .pdf file. The minimum sections for indexing shall be the sections noted in paragraph SD-03.

SD‐11.5 Frequency Allocation Application

The technical section of the frequency allocation application attached as Appendix G, addressing the Contractor’s equipment, shall be completed by the manufacturer of the radio control equipment being furnished under this contract. Frequency availability at this activity shall be verified prior to design approval.

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

After the crane has 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. The design parameter range, determined by the Contractor, shall be the applicable portion of the drive’s default range for each parameter. The 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 crane has passed the final field test, the Contractor shall transfer possession of all small items associated with the operation and maintenance of the crane, including but not limited to keys, control software, computer cabling, remote controls, etc. The property shall be given to the point of contact at the supported command. The Contractor shall prepare and submit an itemized dated invoice showing the quantity and description of items transferred with a signature and date from the recipient.

1.5 QUALITY ASSURANCE

1.5.1 Qualifications

Crane design shall be accomplished by, or directly supervised by, a registered PE. PE licensing shall be by a board or agency authorized to license and register PEs in the U.S. or Canada. The PE may be the 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. The PE’s shall only undertake and perform work under this contract in the branch(s) of engineering in which they are licensed.

1.5.2 Regulatory Requirements

All crane functions and components shall comply with all OSHA requirements and other listed references in this specification. Anchorages to which personnel fall arrest equipment is attached shall be capable of supporting at least 5,000 pounds per person attached, or it must be designed, installed, and used as part of a complete personal fall arrest system which maintains a design factor of at least 2.0 under the supervision of a qualified person as required by 29 CFR 1910.66.

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, the APP and Crane Installation Plan, roles and responsibilities of the entities involved, and the overall 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 typically be held at the installation site. This conference will provide the Contractor and any Sub-contractors, NAVCRANECEN, and the supported command with the ability to review any necessary precautions to ensure a safe and accurate installation. The Contractor shall prepare meeting minutes and submit for review and approval by the Government in accordance with Exhibit A.

1.6 DELIVERY, STORAGE, AND HANDLING

The Contractor shall be responsible for transporting the new crane to the job site. In the event that the Government is unable to receive the crane from the 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 crane from storage to the jobsite. Moisture control (desiccant) shall be included in all electrical panels as a 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.

1.7 PROJECT/SITE CONDITIONS

1.7.1 Environmental Requirements

The crane shall be designed to operate in an indoor environment with an ambient temperature of 70° to 95° F.

Operation of the crane 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 Contractor, a facility representative, and a NAVCRANECEN representative to document the condition of all existing construction and record any existing damage. A “Pre/Post Installation Building Inspection Checklist,” shall be initiated at that time. Upon completion of the work, the Contractor, a facility representative, and a NAVCRANECEN representative shall again inspect the facility to determine the extent of any damage that may have occurred as a result of the work performed under this contract. During this final inspection, the NAVCRANECEN form documented above 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 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. A two week notice to the Government is required in order to coordinate availability.

1.8 SEQUENCING AND SCHEDULING

The Contractor shall be responsible for transporting the new crane to the jobsite. The Contractor’s onsite work may impact the on-going operations within the building. The Contractor shall provide an onsite work schedule with time durations and desired start/stop dates.

The Contracting Officer will negotiate with the Building Manager and determine a final mobilization date. The Contractor shall provide notice a minimum of thirty days prior to desired mobilization date at Michelson Laboratory NAWCWD, China Lake.

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

All Contractor requested engineering changes must be submitted to NAVCRANECEN on the “Contractor Change Request Form.” The “Contractor Change Request Form Cost Worksheet” shall be attached to any engineering changes. Both forms are located on the NAVCRANECEN website. 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 the “Contractor Change Request Form Cost Worksheet.”

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 Material

For the purposes of this specification, ductile is defined as having a minimum elongation of 5% in 2 inches.

2.1.2 Structural Steel

Structural steel shall conform to ASTM A36, A572, A588, or A992.

2.1.3 Cast Steel

Cast steel shall conform to ASTM A27 or 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 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 B108.

2.1.8 Welding Materials

Welding materials for the crane shall conform to AWS D14.1. Welding materials for the facility 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 CMAA No. 70 using ASTM A36, A572, A588, or A992 structural steel. It shall also be in accordance with OSHA 29 CFR 1910.179, 1910.23, and 1910.27, ASME B30.2, AISC 360, and other requirements specified herein.

2.3.1.1 Additional Load Combinations

In addition to load cases 1, 2 and 3 of CMAA No. 70, the following additional load combinations shall be considered.

Test Loads

The crane will be periodically tested up to 131.25% of rated capacity. Combined stresses for the following load combinations shall be calculated to ensure structural adequacy during testing.

Case 3: Test Loads (Stress Level 3)

DL (DLFB) + TL (DLFT) + LL (1 + HLF) + IFD + SK+WLO

Note: (1) LL = 1.3125 x rated capacity.

(2) Test and extraordinary loads shall not be considered in the fatigue analysis.

(3) Formula abbreviations correspond to principal loads as defined in CMAA #70 Section 3.3.

(4) The subscripts “T” and “B” refer to trolley and bridge, respectively.

Case 4: Seismic Load (Stress Level 3)

Seismic forces shall be considered in the design of the cranes for facilities with an Ip equal to 1.0 and Seismic Design Category of D, E or F per ASCE 7. Provide seismic analysis in accordance with ASCE 7 or statement that seismic is not a required 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 any 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 Girders

Bridge girders shall be box section type. Splices in the bridge girders shall be kept to a minimum and splices in locations of high stress shall be avoided. Splices shall be made with complete joint penetration welds. Field (on-site) splices are prohibited. Bridge girders shall be designed to be end notched to fit over the end truck. Girders shall be reinforced at the notches with vertical diaphragms and horizontal stiffeners. Bottom flanges shall be tapered towards the notches.

2.3.1.5 End Trucks

End trucks shall be box section design with wheels centered between the webs. The bridge and trolley wheels shall be equipped with rail sweeps conforming to ASME B30.2. Provisions shall be made to prevent bridge end truck and trolley from dropping more than one inch in case of axle failure. Tapered alignment pins (two per corner) shall be used to maintain original shop alignment between the bridge girders and the end trucks when reassembling the joints on-site.

As an alternative, permanent squaring marks may be used to ensure original alignment.

2.3.1.6 Bridge Rails

Bridge rails shall be selected from the sizes listed in CMAA No. 70, Table 4.13.3-4; solid stock material (square, round or rectangular) shall not be used for bridge rails. The rails shall be selected so that the allowable wheel loads do not exceed the design rated load of the hoist. The rails shall be attached to the bridge girders with pairs of rail clips spaced not more than 36 inches apart. Rail clips shall be secured to the top flange of the bridge girder by welding. If rail joints cannot be avoided due to the length of the span, the joints shall be staggered and located directly over girder diaphragms. The gap at the rail joints shall be less than 1/32 of an inch. Rails shall have creep bars welded in place at each end.

2.3.1.7 Service Platforms (Footwalks)

Access to the drive girder walkway from the ground will be by personnel aerial lift. Access to all other areas of the crane from the drive girder walkway shall be by fixed ladders, stairs, or platforms as specified herein. Walking surfaces shall be of the slip-resistant type.

Service platforms shall meet the requirements of 29 CFR 1910.179, CMAA 70 Section 3.7, and ASME B30.2 Section 2-1.7. Allowable stresses shall not exceed those of stress level 2 in CMAA 70 Section 3.4.2. Platforms located adjacent to ladders and ladder openings shall comply with ANSI-ASC A14.3. The design and installation of fixed ladders shall meet the requirements of

ANSI-ASC A14.3.

Swing gates shall be installed at each access opening on elevated platforms and walkways.