J1._Seed_Project_Specification.pdf

NAVFAC WO 1562198

CONTRACT LINE ITEM NUMBER 001

ONE (1) TWO-TON UNDERRUNNING UNDERHUNG ELECTRIC TRAVELING

BRIDGE CRANE

FOR

BUILDING 124

NAVAL AIR WARFARE CENTER AIRCRAFT DIVISION,

LAKEHURST, NEW JERSEY

PREPARED BY:

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

CLIN 001 2

PART 1 GENERAL

1.1 REFERENCES

1.2 UNIT PRICES

1.3 SYSTEM DESCRIPTION

1.4 SUBMITTALS

1.5 QUALITY ASSURANCE

1.6 DELIVERY, STORAGE, AND HANDLING

1.7 PROJECT/SITE CONDITIONS

1.8 SEQUENCING AND SCHEDULING

1.9 CONTRACTOR REQUESTED ENGINEERING CHANGES

1.10 WARRANTY

1.11 MAINTENANCE

PART 2 PRODUCTS

2.1 MATERIALS

2.2 MANUFACTURED UNITS

2.3 EQUIPMENT

2.3.1 STRUCTURAL DESIGN

2.3.2 MECHANICAL DESIGN

2.3.3 ELECTRICAL DESIGN

2.4 COMPONENTS

2.5 ACCESSORIES

2.6 MIXES

2.7 FABRICATION

2.8 TESTS, INSPECTIONS, AND VERIFICATIONS

PART 3 EXECUTION

3.1 EXAMINATION

3.2 PREPARATION

3.3 ERECTION

3.4 INSTALLATION

3.5 APPLICATION

3.6 FIELD QUALITY CONTROL

3.7 ADJUSTING AND CLEANING

3.8 DEMONSTRATION

3.9 PROTECTION

3.10 SCHEDULES

CLIN 001

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

60529 - Degrees of Protection Provided by Enclosures

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

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)

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 ELECTRICAL CONTRACTORS ASSOCIATION (NECA)

1-2015 -Standard Practice of Good Workmanship in Electrical Contracting

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

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

NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

P-307 -Weight Handling Program Management

NAVSEA TECHNICAL PUBLICATION

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

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

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

WIRE ROPE TECHNICAL BOARD

Wire Rope User’s Manual - Federal Specification RR-W-410

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 underrunning, underhung, single girder electric traveling crane. The crane shall be installed on new, crane contractor provided, runways in Building 124 at Naval Air Warfare Center Aircraft Division, in Lakehurst, New Jersey. The crane shall be pendant controlled. The existing underrunning underhung crane (Crane 124-3), runway electrification system, and associated runway girder, will be removed and require disposal by the Contractor.

A new runway electrification system shall be provided for the crane by the Contractor. 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 underrunning runway girders shall attach to the facility structure, as shown in Appendix A-1. Attachment to the structure shall be performed by the crane contractor. New attachment hardware shall be provided by the Contractor.

The hoist capacity, span length, runway length and hook lift shall be as follows:

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

Crane #124-3 4,000 21’ -06” 38’ -00” 22’ -01” A-1

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

1.3.1 Design Requirements

The design of the crane shall conform to 29 CFR 1910.179, 29 CFR 1910.306, paragraph (b), ASME B30.2, CMAA No. 74, and other requirements specified herein. The crane shall be equipped with a single under running motor-operated trolley including wire rope. Crane 124-3 shall be pendant controlled, and designed to operate on 480 VAC 3-phase, 60-Hertz, 30 Amp system in an indoor environment with an ambient temperature range of 50°F to 130°F. The crane shall comply with all applicable requirements ("shall" statements) and recommendations ("should" statements) of CMAA 74 and MMA MH 27.1 for class C service (minimum) with all "should" statements shall be considered "shall" statements. The crane shall comply with all applicable requirements of ASME B30.11 and ASME HST-4, for packaged hoists.

The crane contractor shall provide new runway electrification that is powered from the existing floor level disconnect.

Packaged hoist design shall be in accordance with applicable requirements (“shall” statements) and recommendations (“should” statements) of ASME HST-4 for duty class H4 service. A packaged hoist is defined as a hoist where the components are mounted via c, d, or p-face flanges as opposed to base mounted. All packaged hoists shall be produced by established manufacturers of the crane industry.

The crane shall be designed to fit and operate in the space shown on the sketches in Appendix A-1.

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-1. See Appendices A-1 for attachment point locations and maximum allowable loads for the existing structure. The contractor shall also verify all clearance and other building/crane interface, including those features shown in Appendix A-1.

The contractor shall install new patented track crane runway systems for the crane. The alignment tolerance of the new runways shall be in accordance with the requirement of MMA MH27.1.

1.3.2 Performance Requirements

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

Crane Function Capacity (lbs) Rated Speed

(fpm) Minimum

Speed (fpm)*

Crane #124-3 Bridge 4,000 50 4 Trolley 4,000 50 5 Hoist 4,000 15 4

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

1.3.3 Capacity Sign

Provide two capacity plates with permanent lettering on each side of the single girder. 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 insert applicable information Manufacturer’s name and crane serial number Voltage, Phase and Frequency of AC power supply Crane Number _124-3_____

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

1.3.4 Unique Identifier Tag

In accordance with DFARS 252.211-7003, the Contractor shall assign a unique identifier to each crane, the Unique Identification Tag shall be attached to the outside of the 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-1 prior to design of the crane. The Contractor shall follow the guidelines for the site specific installation in Section H.

1.3.6 Crane Removals

The Contractor shall be responsible for the removal and disposal of the existing crane, crane runways (including the hardware attaching to the facility structure), and runway electrification prior to the installation of the new crane. The Contractor shall coordinate the removal effort with the activity as to minimize the time of impact to regular facility operations.

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.

1.4 SUBMITTALS

The Contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter for the crane. Large electronic files (e.g. 5MB) shall be submitted via AMRDEC Safe (https://safe.amrdec.army.mil/safe/). 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. Review of crane design packages and installation and removal plans will be tracked through ProjNet (https://www.projnet.org/).

For submittals that reference a NAVCRANECEN form, all forms can be found at https://www.navfac.navy.mil/navfac_worldwide/specialty_centers/ncc.html under the “Downloads” tab.

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. Second General Arrangement and Design Submittals

e. Government Review of Second Design

f. Third General Arrangement and Design Submittals

g. Government Review of Third Design

h. Fabrication Initiation

i. Fabrication Completion

j. On-Site Pre-Installation Conference

k. Government Witnessed Shop Test

l. Contractor Site Mobilization

m. Existing Crane Removal

n. New Crane Installation

o. Government Crane Inspection

p. Field Acceptance Test

q. Crane Acceptance

r. Contract Completion Date

s. Receipt of Final O&M Manuals

t. Completion of Warranty

SD-02 Drawings

The Contractor shall submit the drawings listed below for approval. The initial drawing submittal shall bear a complete title block with a permanent drawing number and a registered professional engineer’s original seal with a dated signature. Subsequent submittals shall bear a new revision number and engineer’s seal with a dated signature for each sheet that has been modified. After NAVCRANECEN design approval and prior to shop test, the Contractor shall submit a complete set of Final design drawings.

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. Drawings shall be created for viewing in AutoCAD 2010 with a drawing file format of .dwg or .dxf, and a separate copy viewable in Adobe Acrobat as a bookmarked portable document format (.pdf). An index for all drawings shall be included.

SD-02.G General Arrangement Drawings

The crane, major components (e.g. runways, girders, end trucks, trolley/hoist, etc.), and component assemblies shall be shown in plan and elevation views to demonstrate proper interface with the facility and other crane components.

The drawings shall include, at minimum:

a. The crane operational envelope and necessary clearances (e.g. OSHA) from obstructions

b. Hook coverage (i.e. side and end approaches)

c. Lift heights

d. Spans

e. Wheel spacing

f. Speed (e.g. hoist, trolley, bridge)

g. Loads applied to the facility (e.g. maximum wheel load, maximum hanger load, bumper force on end stops, etc)

h. Electrical power supply

i. Location and size of components such as brakes, motors, speed reducers, and control panels

j. Estimated weights of the completely assembled crane and major components

SD-02.E Electrical Drawings

These drawings shall show the layout of electrical equipment on the crane, 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. Mechanical drive arrangements (including assembled components)

b. Drawings for any non-commercial items that require calculations in paragraph SD-

05.M1 of this specification including each component material specification.

c. Lubrication information showing the location of lubrication points, type of lubricant to be used, quantity required, and the frequency of lubrication.

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. The requirements of FAR 52.236-21 for shop drawings shall also be accounted for in the structural drawings submittals.

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), approximate center of gravity location, and estimated weight for each major component listed below shall be provided on the structural design drawings.

Structural drawings shall be provided to verify design compliance with all design requirements specified in Specification Section 2.3.1. The following drawing shall be provided as a minimum:

a. Girder Fabrication

b. End Truck Fabrication

c. Trolley Fabrication (for modified commercial products or non-commercial components)

d. End Stop Fabrication (trolley and bridge)

e. Lift Points (if applicable)

f. Crane Runway and Connection Fabrication and Details

SD-03 Product Data

The Contractor shall submit the product data listed below for approval. Manufacturer’s product data shall be provided for all major components of the crane. The product data 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. Product data 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. Product data shall be submitted in one file viewable in Adobe Acrobat and bookmarked as to the location of each product. The Contractor shall submit for approval the products listed below (as applicable):

SD-03.M Mechanical Product Data

SD-03.M1 Speed Reducers including gear ratio SD-03.M2 Brakes (including electrical information, installation/service manuals and all information required to set or adjust brakes) SD-03.M3 Bearings and Bearing Housings

SD-03.M4 Couplings SD-03.M5 Load Blocks and Hooks SD-03.M6 Wheels and sheaves SD-03.M7 Complete Hoist/Trolley Units

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 (including 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 SD-03.S4 Trolley Frame SD-03.S5 Painting System SD-03.S6 End Stops SD-03.S7 Lift Points (if applicable) SD-03.S8 Patented Track Runway Beam and Support System (including attachment products and method)

SD-04 Samples

Not applicable for this specification.

SD-05 Design Data

The Contractor shall submit the design data (hereinafter calculations) listed below for approval.

The calculations shall demonstrate compliance with all design requirements. Design data and calculations will not be approved if their evaluation/review is dependent on data or information not previously approved. Variables shall be listed and defined at the beginning of each calculation section and variables shall be in accordance with required references. The calculation submittal shall bear a registered professional engineer’s original seal with a dated signature. Revised calculations shall include a revision number for each sheet that has been modified.

SD-05S Structural Calculations

SD-05.S1 Calculations verifying compliance with Section 3 of CMAA No. 74 or Section 5 and 6 of MMA MH27.1, and Section 2.3.1.1 for any non-commercial item.

SD-05.S2 Calculations verifying the design of structural connections in accordance with section 2.3.1.2 of this specification for any non-commercial items.

SD-05.S3 Calculations verifying design of all bumpers in accordance with Section

2.3.1.8. Calculations verifying design of runways and trolley end stops to absorb the maximum kinetic energy and impact force developed by the striking bumper as determined in Section 2.3.1.8.

SD-05.S4 Calculation verifying runway patented track selection in accordance with the manufacture’s requirements.

SD-05.S5 Calculation verifying bridge girder patented track selection in accordance with the manufacture’s requirements.

SD-05.S6 Calculation verifying any bridge girder patented track modifications in accordance with design requirements of MMA MH27.1 and Section

2.3.1.1 of this specification if not completed per patented track manufacture recommendations.

SD-05.S7 Calculations verifying compliance with the maximum allowable load at runway track beam support point specified in Appendix A-1.

SD-05.S8 Calculations verifying end truck selection in accordance with the manufacturer’s requirements.

SD-05.S9 Calculations showing the crane system facility loading and attachment method specifics, verifying compliance with Appendices A-1.

SD-05M Mechanical Calculations

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

SD-05.M2 Calculations verifying brake selections and settings per SD-09.1 and 2.3.2.6 and 2.3.2.7

SD-05.M3 Calculations verifying coupling selections (for non-packaged hoists)

SD-05.E Electrical Calculations

SD-05.E1 Minimum required horsepower for each drive motor. For the bridge drive the acceleration time to rated speed shall be 4 seconds. For the trolley drive the 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-05E4 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

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 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, or the actual breaking strength of a sample taken from the reel and tested.

Certification shall be traceable to the hoist, crane and reel.

SD-07.2 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-07.3 Crane Runway Rail

The Contractor shall install the runway rails for the crane and provide a rail survey performed in accordance with the criteria of MMA MH27.1. The Contractor shall certify that the runway rails are straight, parallel, and level in accordance with the requirements of MMA MH27.1. The survey shall be performed by a registered design professional. All surveys and rail certifications shall be supplied to the Contracting Officer prior to field testing.

SD-07.4 Hazardous Material

The Contractor shall certify that the cranecontain 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 (Not applicable for coupling between components mounted via c, d, or p-flanges).

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 shaft alignments shall be made using laser alignment equipment. Barrel couplings may be aligned using lasers or the OEM recommended method. The data records shall be taken after the coupling's final installation. Coupling alignments shall be verified by the Contractor and witnessed by the Government 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 and Hook Nut Proof Test

Only applies to custom designed and non-ferrous hooks.

The Contractor shall submit certification that the hook and hook nut has been proof tested based on the rated capacity of the hoist it is installed on and satisfies the acceptance criteria of ASME B30.10.

The proof test shall be performed prior to the Hook NDT specified in SD-06.1.

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 crane.

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

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-1 of this specification.

SD-08.2 Crane Installation and Removal 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 section 11.1 shall be submitted by the contractor, for review and acceptance by the Government. The construction crane and rigging gear shall comply with OSHA requirements and any local requirements. Lifts of all major components for crane removal and installation are considered to be critical lifts and include any lifts performed by equipment such as forklifts and jacks. Actual locations of center of gravity and location of lifting points for completely assembled crane and for each major component (girders, hoist/trolleys, and end trucks) shall be provided with the crane installation plan.

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

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

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

SD-09 Manufacturer’s Field Reports

SD-09.1 Brake Adjustment Records

The Contractor shall provide a brake adjustment record and installation/maintenance manuals for each brake on the crane. The brake adjustment record shall be submitted on the applicable brake 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, location of measurements, 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 on NAVCRANECEN Rework List. The Rework shall be signed utilizing the “Shop Test Sign In - Post Shop Test Sign Off” tab. The Crane Contractor representative, NAVCRANECEN representative, and Supported Command representative (if applicable) shall each sign and date the form and forward 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.

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

SD-11.2 Operation and Maintenance Manuals

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

SD-11.3 Control System Parameter Record

After the crane has passed the final field test, the Contractor shall complete a control system parameter record for the crane and provide the crane parameter file downloaded from the crane at time of acceptance, if applicable. The record shall include the Contractor’s name and address, date, all control system parameters and their final settings. Each control system parameter shall be designated as either used or unused.

SD-11.4 Product Data

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

SD-11.5 Frequency Allocation Application

Not applicable to this specification.

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 for each parameter specified in Appendix F used on the crane. The crane Contractor-determined design range shall be the applicable portion of the drive’s default range for each parameter. The crane Contractor must provide justification for each range of each parameter on the list. When necessary, the justification shall include appropriate calculations.

SD-11.7 Property Transfer Verification

After the 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. The Contractor shall submit a copy of the signed invoice.

1.5 QUALITY ASSURANCE

1.5.1 Qualifications

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

1.5.3 Post-Award Conference

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

1.5.4 Pre-Installation Conference

The Contractor shall attend a Government conducted pre-installation conference that will 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, the Contracting Officer will notify the Contractor.

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 crane shall be designed to operate in an indoor environment with an ambient temperature of 50° to 130° F.

Operation of the crane 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, 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 crane Contractor, facility representative, and the NAVCRANECEN 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.

1.7.3 Government Furnished Equipment

The government will provide certified test weights and rigging gear at the facility for acceptance testing of this delivery order. The government shall be notified a minimum two weeks prior to testing. This time is required to ensure the test weights and rigging gear are on-site when needed.

1.8 SEQUENCING AND SCHEDULING

1.8.1 The Government will continue its normal activities during the contractor’s work at each site, and the contractor shall carry on work with the least possible interference to Government activities.

The contractor shall schedule work as to cause the least amount of interference with naval facility operations. The contractor shall provide an onsite work schedule with time durations and desired start/stop dates. The Government will determine a final mobilization date. The contractor shall provide notice a minimum of thirty days prior to the desired mobilization date at the activity. The contractor shall mobilize one time for removal and installation of the crane.

1.8.2 The Contractor shall provide a minimum of 14-day advance notification of the date the crane will be completed and ready for shop testing.

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 http://navfac.navy.mil/navfac_worldwide/specialty_centers/ncc.html 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 components directly supporting the load shall be of ductile material. For the purposes of this specification, ductile is defined as having a minimum elongation of 5% in 2 inches. Gray cast iron shall not be utilized.

2.1.2 Structural Steel

Structural steel material shall conform to the standards referenced in section 2.3.1.

2.1.3 Cast Steel

Cast steel shall conform to ASTM A27 or ASTM A148.

2.1.4 Ductile Cast Iron

Ductile Cast Iron shall conform to ASTM A536.

2.1.5 Forged Steel

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

2.1.6 Steel Shafts

Steel shafts shall conform to ASTM A434.

2.1.7 Aluminum Castings

Aluminum castings shall conform to ASTM B26 or ASTM B108.

2.1.8 Welding Materials for Crane

Welding materials 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 MMA MH27.1, OSHA 1910.179, ASME B30.11, OSHA 29 CRF, Part 1910.23, AISC 360, and other requirements specified herein.

2.3.1.1 Additional Load Combinations

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

Test Loads

The crane will be periodically tested up to 125% of rated capacity; therefore, a test load of 125% of rated capacity shall be included in Case 3.

Seismic forces

Not applicable for this specification.

2.3.1.2 Structural Connections

Structural connections shall be designed in accordance with AISC-360.

Welding procedures and qualifications shall be in accordance with the requirements of AWS D14.1 and D1.1, as applicable.

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

Girder to end truck connections shall be structural bolted connections unless the girder and end truck are commercial products by the same manufacture with a specified connection type. The manufacturer’s specified connection type shall be specified in the product data.

2.3.1.3 Bridge Girders

Bridge girders shall be patented track beam type conforming to MMA MH27.1. Splices in the bridge girders are not permitted.

2.3.1.4 Bridge and Trolley End Trucks

Provision shall be made to prevent bridge end truck and trolley from dropping more than one inch in case of wheel or axle failure.

2.3.1.5 Bridge Rails

Not applicable for this specification.

2.3.1.6 Walkways

Not applicable to this specification.

2.3.1.7 End Stops

Trolley and runway end stops shall be designed to absorb the maximum kinetic energy and impact force developed by striking the bumper as determined in Section 2.3.1.8.

Runway end stops shall be placed in the same locations as the existing end stops on the new runway girders.

2.3.1.8 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 in accordance with CMAA #70, #74, ASME B30.2, and B30.17, as applicable. 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.

2.3.1.9 Lift Points

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.

2.3.1.10 Runway Rails

Runways shall be patented track beam type conforming to MMA MH27.1. If required, splices shall be done in accordance with the patented track manufacturer’s recommendations and requirements. The lower T-section ends shall be aligned to minimize the horizontal gap on the running surface to not greater than 1/16” and not greater than a vertical difference of 1/32” for the wheel running surface alignment for a smooth crossing by the wheels. Splice assemblies shall be from the same manufacture as the patented track and shall be located under structural support members. Runway will be attached to the existing facility’s structure shown in Appendix A-1 (contractor shall verify exact dimensions and structure prior to runway design).

2.3.2 Mechanical Design

The mechanical design of the crane shall conform to MMA MH27.1, ASME HST-4 Duty Class H4, ASME B30.11, ASME B30.16 and other requirements…