Specification _N62470-13-R-4025.pdf

N62470-13-R-4025

NAVFAC

ONE (1) TWO-TON UNDERRUNNING UNDERHUNG ELECTRIC TRAVELING BRIDGE

CRANE

for

Building 1816 Room 107

NAVY SUBMARINE TORPEDO FACILITY (NSTF)

YORKTOWN, VIRGINIA

PREPARED BY:

Navy Crane Center Bldg. 491, Norfolk Naval Shipyard Portsmouth Virginia 23709-1044

SPECIFICATION PREPARED BY:

Lead Design Engineer: Scott Emerson, P.E Project Manager: Phil Dill, P.E.

Contract Specialist: Luke Clay Quality Assurance Specialist: David Moore

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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

2.3.3 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

3.5 APPLICATION

3.6 FIELD QUALITY CONTROL

3.7 ADJUSTING AND CLEANING

3.8 DEMONSTRATION

3.9 PROTECTION

3.10 SCHEDULES

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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

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-6 - Specification for Electric Overhead Traveling Cranes for Steel Mill Service TR-13 - Design of Mill Buildings

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

360 - Specification for Structural Steel Buildings

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

B4.1 - Preferred Limits and Fits for Cylindrical Parts

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE/SEI)

7 - Minimum Design Load for Buildings and Other Structures

AMERICAN SOCIETY OF MECHANICAL ENGINEERS INTERNATIONAL (ASME)

B30.10 - Hooks B30.11 - Monorails and Underhung Cranes B30.16 - Overhead Hoists (Underhung) HST-4 - Performance Standard for Overhead Electric Wire Rope Hoist

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

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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)

70 - Specification for Top Running & Gantry Type Multiple Girder Electric Overhead Traveling Cranes Leave this reference out if under-running.

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

DEFENSE FEDERAL ACQUISITION REGULATIONS (DFAR)

252.211-7003 -Item Identification and Valuation

MONORIAL MANUFACTURERS ASSOCIATION, INC. (MMA)

MH27.1 - Specifications for 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

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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

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 one (1) two-ton under running single girder electric traveling, ordnance handling crane with the option of three additional cranes. The cranes and new electrification shall be installed on the existing runways in Building 1816 room 107 at Naval Submarine Torpedo Facility in Yorktown, Virginia. The cranes currently located in room 107 will remain. The cranes located in bay 1, bay 2, and bay 3 are to be identical. The crane to be located in bay 4 will have a different span and runway length. See Appendix A-1. 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 hoist capacity, in tons of 2,000 pounds, span length, runway length and hook lift shall be as follows:

Bay Capacity (tons) Span (ft-in) Runway (ft-in) Hook Lift (ft-in)

1-3 2 21’-06” 76’-05” 11’-03”

4 2 14’-06” 65’-00” 11’-10”

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

1.3.1 Crane Installation

The Contractor shall verify all crane envelope clearances and other building/crane interface features, including those identified in Appendix A-1, A-2, and A-3, prior to design of the crane.

1.3.2 Crane Removals

Not applicable to this specification.

1.3.3 Design Requirements

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The design of the cranes shall conform to 29 CFR 1910.179, 29 CFR 1910.306, paragraph (b), and other requirements specified herein. The cranes shall be pendant controlled, and designed to operate on 480 VAC 3-phase, 60-Hertz system in an indoor environment with an ambient temperature range of 40°F to 100°F. The cranes shall comply with all applicable requirements (“shall” statements) and recommendations (“should” statements) of CMAA 74 and MMA MH 27.1 with all “should” statements shall be considered “shall” statements. The cranes shall comply with all applicable requirements of ASME B30.11 and ASME HST-4, for packaged hoists. The duty service classification shall be H4, minimum.

The new runway electrification from the runway disconnects shall be provided by the Contractor.

The cranes shall be designed to fit and operate in the space shown on the sketches in Appendix A- 1, A-2, and A-3. The hook work envelope shall be the maximum practical consistent with good design, but it shall not be less than that indicated in Appendix A-2 and A-3. The loadings of the cranes due to dead load and the rated capacity live loads, with the trolley in any position, shall not exceed the equivalent center load (ECL) and maximum hanger load (MHL) of the existing system.

1.3.4 Performance Requirements

The rated speeds, in feet per minute, shall be as a minimum:

Function Rated Speed (fpm) * Minimum Speed (fpm) Bridge 80 4 Trolley 60 5 Hoist 15 4

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

1.3.5 Capacity Sign

Provide two capacity plates with permanent lettering on 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-XX-D-XXXX DO xxx Manufacturer’s name and crane serial number Voltage, Phase and Frequency of AC power supply

Provide cardinal direction indication letters centered on the bottom of the girder. 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.

1.3.6 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 the main electrical 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

N62470-13-R-4025 7 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 (NCC) form, the form can be found on NCC website https://portal.navfac.navy.mil/ncc 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 Complete

h. Pre-Installation Conference

i. Shop Test

j. Mobilization Start

k. New Crane Installation

l. Field 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 2006 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.

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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.E Electrical Drawings

These drawings shall show the layout of electrical equipment on the cranes, including control panel enclosures, motors, brakes, limit switches, conduits, disconnects, and conductor systems. 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. 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-02.M Mechanical Drawings

a. Drive arrangements (including assembled 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.

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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. End Truck Fabrication

c. Trolley Fabrication

d. End Stops

e. Lift Points (if applicable)

SD-03 Product Data

Manufacturer’s catalog data shall be provided for all major components of the cranes. 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 (as applicable):

SD-03.M Mechanical Product Data

SD-03.M1 Speed Reducers SD-03.M2 Brakes (including electrical information)

SD-03.M3 Bearings SD-03.M4 Couplings SD-03.M5 Load Blocks SD-03.M6 Hoist/Trolley (if packaged)

SD-03.E Electrical Product Data

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

SD-03.E2 Motors SD-03.E3 Electrical Enclosures SD-03.E4 Runway Electrification and Collectors 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 Ancillary Devices SD-03.E12 Circuit Breakers

SD-03.S Structural Product Data

SD-03.S1 Bumpers SD-03.S2 End Trucks (including drive units) SD-03.S3 Patented Track Girder and Support System

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SD-03.S4 Trolley Frame SD-03.S5 Painting System SD-03.S6 End Stops SD-03.S7 Lift Points (if applicable)

SD-04 Samples

Not applicable for this specification.

SD-05 Design Data

These calculations shall demonstrate compliance with all design requirements. Design data 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-05S Structural Calculations

SD-05.S1 Calculations verifying compliance with Section 3 of CMAA 74 or Section 5 and 6 of MMA MH27.1 and Section 2.3.1.2 for any non-commercial item.

SD-05.S2 Calculations verifying compliance with section 2.3.1.1 of this specification for any non-commercial item.

SD-05.S3 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.S4 Calculations verifying compliance with the equivalent center load (ECL) and the maximum hanger load (MHL) specified in Appendix A-2 and A-3.

SD-05M Mechanical Calculations

Not applicable for this specification.

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

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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 signature of an 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 trolley/hoists 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 Contractor shall inspect the existing runway system and provide a certificate stating that the runway is suitable for the new crane to operate without restriction.

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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. Chromates should be avoided where feasible.

SD-07.5 Loss of Power Test

The Contractor shall certify that the hoist loss of power tests as identified in Appendix C can be performed without any detrimental effects to the crane.

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. Coupling alignments shall be verified by the contractor after crane installation. The coupling alignment data record shall be submitted on the appropriate official form, which can be found on the NCC website. Coupling Alignment Records are not applicable for c, d, and p-face motors/connections?

SD-07.7 Hook and Hook Nut Proof Test

Contractor shall submit certification that the hook and hook nut has been proof tested and satisfies the acceptance criteria of ANSI 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 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-8 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 procedures shall be submitted and approved prior to conducting the shop test. As a minimum, the test procedures 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 cranes. 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 section 1.7.2 shall be submitted by the contractor, for review and acceptance by the Government. The construction

N62470-13-R-4025 13 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.

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. Mobilization 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 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 documentation 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 completion of the shop test for the crane(s), 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 each crane. Any deviations to the field test required by the Contractor must be approved by the Contracting Officer. Upon successful completion of all testing, the Contractor shall submit records of all test data for each crane.

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.

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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. 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

The Contractor shall provide as-built drawings on CDs viewable in AutoCAD 2006. 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 cranes. 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 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 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-11.6 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 of the supported command. The Contractor shall provide an itemized invoice showing the quantity and descriptions of items transferred, and obtain the signature of the recipient and date on the invoice. Submit a copy of the signed invoice.

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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 Navy Crane Center.

1.5.4 Pre-Installation Conference

The Contractor shall attend a pre-installation conference that will be typically held at the installation site. The conference shall be scheduled 30 days prior to mobilization to the project site.

This conference will allow the 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. Meeting minutes will be prepared by the Contractor and submitted for review and approval by the Government in accordance with Exhibit A.

1.6 DELIVERY, STORAGE, AND HANDLING

In the event that the supported command is unable to accept the cranes from the Contractor as scheduled by the contract, storage will be arranged, and all expenses shall be the responsibility of the supported command.

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.

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 100° F.

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

1.7.2 Existing Conditions

Prior to installation, the building shall be inspected by the crane Contractor and a representative appointed by the Contracting Officer to document the condition of all existing construction and record any existing damage. Upon completion of the work, the crane Contractor and the appointed

N62470-13-R-4025 16 representative shall again inspect the building to determine the extent of any damage that may have occurred as a result of work performed under this contract. Any damage to either the building 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.

1.8 SEQUENCING AND SCHEDULING

Not applicable to this specification.

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 when cost or credit is requested. 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 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 hoists). 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

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Aluminum castings shall conform to ASTM B26 or ASTM B108.

2.1.8 Welding Materials for Crane

Welding materials for cranes shall conform to AWS D14.1

2.1.9 Welding Materials for Facilities

Welding materials for facility shall conform to AWS D1.1

2.2 MANUFACTURED UNITS

Not applicable for this specification.

2.3 EQUIPMENT

2.3.1 Structural Design

The structural design of the crane shall conform to ASME B30.11, MMA MH27.1 and other requirements specified herein. The cranes shall meet clearance restrictions noted in Appendix A-1, A-2, and A-3.

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

Seismic forces shall be considered in the design of the crane. The total seismic force shall be composed of two simultaneous forces, one acting vertically and one acting laterally, in any location.

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 welding machines 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. Major 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 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 Bridge and Trolley End Trucks

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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.

2.3.1.6 Bridge Rails

Not applicable for this specification (see Bridge Girders, 2.3.1.4).

2.3.1.7 Walkways

Not applicable to this specification.

2.3.1.8 End Stops

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

Contractor shall verify that the new bridge bumpers mate with the existing end stops and the bumpers of the existing crane, or replace as necessary. Existing bridge end stops shall be evaluated for compliance with AIST TR-13.

2.3.1.9 Bumpers

Bumpers of the elastomeric, hydraulic or spring type shall be provided on trolleys (or ends of bridge girders) and bridge end trucks. The bumpers shall be designed to withstand rated load at rated speed IAW AIST TR-06. Bumpers shall fully mate with the end stops or other crane components. Bumpers shall be mounted to provide proper clearance between the crane and surrounding structures when bumpers are fully compressed. Trolley and bridge endtruck frames’ design shall ensure travel wheels do not contact the end stops. Bumpers shall be designed and installed with a means of retaining the bumpers in case of broken or loosened mounting connection(s). Bumpers shall not be drilled through as a means of retention.

2.3.1.10 Major Components Attachments for Lifting and Handling

Major components (e.g. bridge girder(s), end truck(s), 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.

2.3.1.11 Runway Rails

Existing runway rails are patented track and will remain in place. See Appendix A.

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 hoists shall be designed for duty service classification H-4 as defined by ASME

HST-4.

2.3.2.2 Alignment

N62470-13-R-4025 19

All components shall be aligned in accordance with the manufacturer’s instructions. Coupling alignments shall be measured and recording. 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 5 or better, or their international equivalents. Mounting fasteners from flange-mounted components, including keeper bars, may be installed into tapped holes provided that adequate thread engagement is provided 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. The load blocks shall be constructed so that the hooks and hook nuts can be removed without unreeving of the hoist. The load block shall fully enclose the sheaves and wire ropes, except for wire rope slots and drain holes. Block internal arrangement and clearances shall prevent the wire ropes from leaving the sheave grooves under any conditions. The hook shall rotate freely 360 degrees continuously with 131.25% of rated load without wire rope cabling. The thrust bearing shall have a static capacity of no less than 150% of rated load. The ends of the trunnions shall be retained with keeper bars and their fasteners shall be lock wired. The hoist capacity in pounds shall be clearly marked on both sides of the load blocks.

2.3.2.5 Hook and Hook Nut

The hook shall be single barb forged carbon steel conforming to ASTM A668 or ASTM A521 with a minimum longitudinal elongation of 18% in 2 inches. Standard commercial hooks may be used at their published ratings when their published design factors are 5.0 or greater. The hook nut shall be secured to the hook by a commercial standard removable and reusable means (tack-welding is prohibited). Shank and nut threads shall have a Class 2 fit, per ASME B1.1. The hook shall be provided with a safety latch. The hook and hook nut shall be uncoated. The hook shall be uniquely marked in a permanent fashion that is traceable to the NDT certification. The nut shall be marked to match with the hook. The markings shall be visible when the hook and hook nut are assembled on the hook block.

2.3.2.6 Hoisting Wire Rope

The drum line pull shall not be more than 20% of the nominal breaking strength of the wire rope to obtain a minimum wire rope design factor of 5.0 to 1. The hoisting rope shall be 6 x 36 class construction, extra improved plow steel or extra-extra improved plow steel, pre-formed, regular lay, bright (uncoated, non-galvanized), with an independent wire rope core, and in accordance with all requirements of ASTM A1023/A or ISO 4309. The hoist reeving system shall be of double-reeved type and be equalized. Hoisting rope dead end connections to equalizer bar (if used) shall be by means of poured socket connections or swaged fittings installed in a manner that develops the full breaking strength of the hoisting rope, wedge sockets shall be prohibited. The sockets shall be forged steel. Hoisting rope ends on the drum shall be anchored by means of swaged fittings inserted into reinforced pockets or by clamping. Clamped hoisting rope ends shall be neatly and securely seized with wire. Swaged end fittings shall be selected in accordance with the swage fitting and wire rope manufacturer’s recommendations. Poured fittings may be made with molten zinc or resin socketing material approved by Naval Ships Technical Manual Chapter 613, Wire and Fiber Rope and Rigging.

N62470-13-R-4025 20

2.3.2.7 Sheaves

Sheaves shall be steel. The wire rope contact area of sheaves shall be machined or ground to contour and heat treated to a minimum hardness of 320 BHN. The minimum pitch diameters of running and equalizer sheaves shall be in accordance with HST-4 for packaged hoist. Sheave groove depth shall be not less than 1.15 times the hoisting rope diameter. All running sheaves shall be installed with bearings.

2.3.2.8 Drum

The drum shall be a one-piece steel weldment, finish-machined after all welding and stress relieving has been completed. The drum shall include integral stub shafts or shaft hubs for through shafts as required. Drum shall not be mounted in a three bearing configuration. The drum shall be designed such that all hoisting rope is wound in a single layer and not less than two dead wraps of hoisting rope will remain on each end of the drum when the hook is in its extreme low position and at least one empty groove in the extreme high position. Drum grooves shall be helical and machined right and left hand. Drum design of a packaged hoist shall be in accordance with HST-4.

2.3.2.9 Gearing

Gearing shall be designed in accordance with applicable AGMA or ISO standards. Gear quality shall be A5 or higher. Gearing shall be mounted on shafts supported by two outboard bearings.

Shafts with three or more bearing supports shall not be permitted. All gears, shall be pressed on and turn with their shafts or axles.

All gearing shall be of the enclosed (gear reducer) type, except final drive.