Attachment E_ P111_SPC_ SECTION 08 39 55.00 20.pdf

{P111 EDI: ORDNANCE MAGAZINES} {1645627}

SECTION 08 39 55.00 20

NAVY STANDARD EARTH-COVERED MAGAZINE DOORS

05/24

PART 1 GENERAL

1.1 REFERENCES

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

U.S. DEPARTMENT OF DEFENSE (DOD)

UFC 3-101-01 (2020; with Change 1, 2021) Architecture

UFC 3-301-01 (2023) Structural Engineering

UFC 4-420-01 (2015; R 2022) Ammunition and explosives Storage Magazines

ITALIAN ELECTROTECHNICAL COMMITEE (CEI)

CEI 64-8 (2024) Electrical Systems with Rated Voltage not greater than 1000 V a.c. and 1500 V d.c..

CEI 96-1 (1998) Separation transformers, autotransformers, variable transformers and reactors.

ITALIAN/EUROPEAN HARMONIZATION STANDARDS (UNI EN)(UNI ENV)(CEI

EN)(UNI EN ISO)(UNI ISO)

UNI EN 13674-4 (2019) Railway applications - Track - Rail

- Part 4: Vignole railway rails from 27 kg/m to, but excluding 46 kg/m.

CEI EN 60529 (2019) Degrees of Protection Provided by Enclosures (IP Code).

CEI EN 61439-1 (2024) Low-voltage Assemblies Equipment for Protection and Control (LV Switcboards). Part 1: General Rules.

CEI EN IEC 60947-4-2 (2025) Low-voltage switchgear and controlgear - Part 4-2: Contactors and motor-starters - Semiconductor motor controllers, starters and soft-starters.

UNI EN 1011-3 (2019) Welding - Recommendations for welding of metallic materials - Part 3:

Arc welding of stainless steels.

UNI EN 10058 (2019) Hot rolled flat steel bars for general purposes - Dimensions and

SECTION 08 39 55.00 20 Page 1 tolerances on shape and dimensions.

UNI EN 10059 (2004) Hot rolled square steel bars for general purposes - Dimensions and tolerances on shape and dimensions.

UNI EN 10060 (2004) Hot rolled round steel bars for general purposes - Dimensions and tolerances on shape and dimensions.

UNI EN 10088-4 (2009) Stainless steels - Part 4:

Technical delivery conditions for sheet/plate and strip of corrosion resisting steels for construction purposes.

UNI EN 10297-1 (2003) Seamless circular steel tubes for mechanical and general engineering purposes - Technical delivery conditions - Part 1: Non-alloy and alloy steel tubes.

UNI EN 13674-4 (2019) Railway applications - Track - Rail

- Part 4: Vignole railway rails from 27 kg/m to, but excluding 46 kg/m.

UNI EN ISO 9606-1 (2017) Qualification testing of welders - Fusion welding - Part 1: Steels.

EC DIRECTIVES

Directive 2006/42/EC Directive of the European Parliament and of the Council of 17 may 2006 on machinery, and amending Directive 95/16/EC.

ITALIAN LAWS AND NORMS

D.M. 17.01.2018 Technical Standards for Constructions (NTC 2018).

D.Lgs. 81 (2008) Unique text on health and safety at work.

1.2 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for Contractor Quality Control approval. Submit the following in accordance with Section 01 33 00

SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Manufacturer's Qualifications; G

Installer's Qualifications; G

Acceptance Testing Procedure; G

Field Testing Instructions; G

SECTION 08 39 55.00 20 Page 2

Coating Submittal Package; G

Sequence of Welding; G

Manufacturer's Installation Instructions; G

Installation Plan; G

Quality Control Plan; G

SD-02 Shop Drawings

Doors; G

Electrical Package; G

Trench Package; G

Boltworks Locking System; G

SD-03 Product Data

Doors; G

SD-05 Design Data

Design Data; G

SD-07 Certificates

Welding Procedures and Welder's Qualifications; G

NDT Certificates; G

SD-10 Operation and Maintenance Data

Training Video; G

Door Description Information; G

Draft Operations and Maintenance Manual, Data Package 2; G

Final Operations and Maintenance Manual, Data Package 2; G

SD-11 Closeout Submittals

Weld Inspection Report; G

Report of Special Inspections; G

Shop and Field Operating Test Reports; G

Acceptance Testing Report; G

Manufacturer's Warranty; G

1.3 DOORS

Doors constructed in accordance with this specification are used in

SECTION 08 39 55.00 20 Page 3 magazine standard drawings approved by the Department of Defense Explosive Safety Board (DDESB) as a 7-bar earth covered magazine and may be sited as an exposed site magazine from other potential explosion sites storing up to hazard division 1.1 explosives. The design and detailing of the magazine for blast loading is the sole responsibility of the government. The government is the engineer of record for the blast door. Any deviation from these standard drawings, except for foundation modifications, without the written approval from the Department of Defense Explosive Safety Board (DDESB) is not permitted as it may require the magazine to be considered an undefined magazine and may severely restrict the allowable storage capacity.

1.3.1 Door Systems

The general contractor must select a single manufacturer to provide a complete blast door system, including but not limited to the blast door and all associated components, hardware, rail, trench, trench cover assembly, plow-type trench cover lifting system (plow system), and embedded plates, including controls, motors, and installation. Provide blast-resistant magazine door system in accordance with the non-deviational standard drawings for door type Box Type H and UFC 4-420-01 .

This door system is designed to resist all wind, seismic, and blast effects, including fragment, ballistic, and forced entry resistance. Door system includes flashing, seals, weather stripping, controls, operators, electrical power, low voltage, security, and grounding as well as access for installation, maintenance, and replacement of all door components including, but not limited to, operators, motors, and drive. The door system size and arrangement of doors, top guides, bottom rails with drainage, and plow system, including details at head, sill, jambs, and door/frame and door/sill interfaces are specifically indicated based upon the performance standards required by the Government. The single manufacturer is responsible for providing all door components and completing the design of items not fully designed in the standard drawings. The entire door system described in the standard drawings must be manufactured and installed by a single manufacturer or the single manufacturer's representative, sanctioned by the manufacturer.

Submit Shop Drawings sealed by the door manufacturer's Registered Professional Engineer, Product Data, and Design Data consisting of catalog cuts, brochures, circulars, specifications, calculations, and product data that show the complete door system including all components. Submit Manufacturer's Installation Instructions and Field Testing Instructions.

Submit Door Description Information, bound in manual form consisting of manufacturer's safety precautions, preventive maintenance, and schedules, troubleshooting procedures, special tools, parts list, and spare parts data. All material shown on the shop drawings must be cross referenced to the door designations shown on the standard drawings.

1.3.2 Door System Components

The door design is structurally complete and is non-deviational, including the headwall and locking system. Materials, dimensions, strengths, and connections included in the standard drawings must be strictly adhered to.

Stronger material grades will not be permitted as they may result in increased reactions and altered performance under blast loading.

Door seals are critical to door system performance. All seals and weather-stripping must be positively contacted when the door is closed, and all seals and weatherstripping must be inspectable and replaceable with the door in place.

SECTION 08 39 55.00 20 Page 4

1.3.3 Cybersecurity

Design all control systems (including systems separate from a utility monitoring and control system). Implement cybersecurity requirements to mitigate vulnerabilities to all facility-related control and security systems.

1.4 QUALITY CONTROL

The blast door manufacturer is solely responsible for manufacturing, shipping, installing and erecting the blast door and will submit a Quality Control Plan which details quality control procedures to be undertaken at each phase of this work. The Quality Control Plan will be an item of discussion at the preconstruction meeting and include inspection and approval of all embedded items prior to placement of concrete.

1.4.1 Welding

Welders, welding operators, and weld inspectors must be qualified in accordance with UNI EN ISO 9606-1 .

1.4.2 Quality Control Plan

Develop and submit for approval a blast door fabrication and installation quality control plan as specified herein. The plan must include the following:

a. Indicate the contractor's understanding and explanation of the QC process.

b. Include Special inspector qualifications and responsibilities.

c. Include shop QC manager (or in-house inspector) qualifications and responsibilities.

d. A list of challenging issues (available material challenges, shipping challenges, and schedule challenges).

e. Special procedures and processes.

f. Include a discussion of SI record keeping and required bi-weekly submittals and any other submittals to the contractor's QC manager.

g. Show coordination between SI inspector, in-house inspector, Shop QC manager, KTR QC manager.

h. Provide quality control reports to the Contracting Officer and Quality Manager.

Upon completion of the Quality Plan and a minimum of 2 weeks prior to beginning fabrication or construction activities, a preconstruction meeting must be held to review the Magazine Door Quality Plan. The meeting must include the DOR, Contractor's Quality Manager, Special Inspector, Fabrication Shop Quality Manager, in-house inspector, Contractor Superintendent, the Government Construction Manager, and a government representative familiar with Blast Doors, or their designated representative(s).

SECTION 08 39 55.00 20 Page 5

1.4.3 Manufacturer's Qualifications

The manufacturer providing the complete door system, must be regularly engaged in the fabrication, erection, and service of large, horizontal rolling, blast resistant, steel doors of the type, complexity, and size required for this project. The manufacturer must have at least 10 years of demonstrated experience fabricating, erecting, and servicing similar horizontal rolling, blast resistant steel doors weighing a minimum of.

Similar doors must have comparable function and design including size, configuration, type of use, elements, safety features, controls, and other key engineering elements as the door being specified. It is acceptable to show that a series of similar doors collectively meet all comparable elements to the door being specified, although not necessarily individually. The manufacturer must submit written evidence on a minimum of 5 examples of similar past doors listing the name, location, contact information of owners, installation dates, overall sizes, features, and other relevant information for experience and qualifications evaluation for approval by the Contracting Officer. Only manufacturers who can submit this evidence of actual installations where the products have proven practical and durable, and require a minimal amount of maintenance, will be qualified under this specification.

1.4.4 Installer's Qualifications

The manufacturer is responsible for the installation of the entire blast door system, including all components, and achieve final approval and acceptance by the Navy. A manufacturer's representative, skilled and experienced in the erection of horizontal rolling, blast resistant, steel doors of the type specified may be utilized if supervised by the manufacturer of the door system in accordance with approved shop drawings.

For each installer, submit written evidence of similar past door installations listing the name, locations, contact information of owners, installation dates, overall sizes, features, and other relevant information for experience and qualifications evaluation.

1.4.5 Welding Procedures and Welder's Qualifications

Welders, welding operators, and weld inspectors must be qualified in accordance with UNI EN ISO 9606-1 . Provide copies of all Welder's Certifications for welders both in the shop and in the field.

Welding procedures which are considered pre-qualified as specified in UNI EN ISO 9606-1 as applicable will be accepted without further qualification. Submit for approval a listing or an annotated drawing to indicate the joints not pre-qualified. Procedure qualification is mandatory for these joints.

1.4.6 Manufacturer's Warranty

Furnish manufacturer's written warranty covering the blast door assembly for 5 years after acceptance by the Government. Warranty must provide for repair and replacement of the blast door assembly, individual hardware, mechanical, electrical, and accessory items in the event of malfunction due to defects in design, materials, and workmanship.

1.5 DELIVERY, STORAGE, AND HANDLING

Deliver materials which are not shop installed on the doors in original rolls, packages, containers, boxes, or crates bearing the manufacturer's

SECTION 08 39 55.00 20 Page 6 name, brand, and model number. Store materials and equipment in dry locations with adequate ventilation, free from soil, water, dust, and contaminants, and to permit access for inspection and handling. Handle doors carefully to prevent damage. Remove damaged items that cannot be restored to like-new condition and provide new items.

PART 2 PRODUCTS

2.1 DOORS

2.1.1 Structural Steel

Construct all structural steel in accordance with D.M. 17.01.2018 .

Structural steel bars, plates, and shapes must conform to UNI EN 10058 , UNI EN 10059 , and UNI EN 10060 as indicated in the standard drawings, including steel grades. Hollow Structural Steel Sections must conform to UNI EN 10297-1 as indicated in the standard drawings. Provide stainless steel in accordance with UNI EN 10088-4 and design in accordance with UNI EN ISO 9606-1 for trench covers, trench weldments, and embedments.

2.1.1.1 Bolted Connections

Provide bolted connections as shown in the standard drawings.

Provide bolt heads of the supplied fasteners marked with the manufacturer's identification mark, the strength grade, and type specified by UNI specifications. Provide the following:

Anchor Bolts: D.M. 17.01.2018 , Grade as specified

High Strength Bolts: D.M. 17.01.2018 , Grade as specified

Provide compatible nuts and washers corresponding to the bolt grades and strengths above.

2.1.1.2 Welded Connections

Provide welds as shown in the standard drawings.

Provide Welding Electrodes and Rods in accordance with UNI EN ISO 9606-1 .

2.1.2 Concrete

Concrete properties are specified in the standard drawings and must also comply with Section 03 30 00.02 CAST-IN-PLACE CONCRETE MAGAZINES. For concrete reinforcement, provide stainless steel expanded metal reinforcement of the type, size and gage as specified in the standard drawings. Refer to the standard drawings for the required concrete weight, mix design, admixtures, placement, and curing.

2.1.3 Wood

Refer to the standard drawings for species, size, and arrangement of wood to be utilized in the door. Provide wood that is kiln dried.

SECTION 08 39 55.00 20 Page 7

2.1.4 Components

2.1.4.1 Top Door Guide Assembly

Provide the Top Door Guide Assembly to resist the minimum lateral load capacity as shown on the standard drawings and permit magazine and door construction tolerances and temperature changes without binding or disengaging the door from the top door guide. Door roller guide will be welded to the door per manufacturer's calculations and recommendations and include horizontal stainless-steel rollers with sealed bearings which can be removed and replaced with the door remaining in place. Size and weld retention angles and plates per manufacturer's calculations and recommendations to resist forces and to permit construction tolerances and smooth door operation.

2.1.4.2 Door Stop

Provide door stops to resist the impact of the door at each extent of travel. The stop must not scratch or scar the door finish when the door engages the stop. Door silencers must also be provided to cushion the impact of the door so that steel-to-steel contact is not made during closing.

2.1.4.3 Door Seals

Door seals are critical to door system performance. Doors must have the full door perimeter and all door penetrations sealed. Provide as indicated between door leaves and on vertical edges, sills, and heads to afford a weathertight installation and form a portion of the Air Barrier in accordance with UFC 3-101-01 . All seals must be positively contacted when the door is closed. Seals must be capable of sealing the mating surfaces, resistant to the atmospheric environment, and be inspectable, adjustable, and replaceable with the door in place. One spare set of gasket seals must be provided for each door assembly for which seals are specified. Provide flexible door seals in all specified locations including on vertical edges, sills, and heads. Seals must be the dimension shown, but not less than 51 mm, and be a minimum of two-ply cloth-inserted EPDM material with a minimum thickness of 3 mm and retained continuously for its full length with flat head socket cap and secured with rust-resistant fasteners spaced no more than 152 mm on center. Provide weather stripping at bottom of the door to match the lowest height of the jamb weather stripping.

2.1.4.4 Wheel and Motor Drive System

Machine wheels from a single piece of material. Provide steel plate bottom wheels having a minimum tread diameter as required for the actual wheel loading, but not less than 457 mm. Construct wheel assemblies to permit removal of the wheel without requiring removal of the door.

Concrete filled doors require wheels offset nominally toward the interior side of the door to be located at the door's center of gravity. Door manufacturer must calculate and verify center of gravity, prior to final fabrication.

2.1.4.4.1 Treads

Machine wheel treads are to be concentric with bearing seats. The maximum

SECTION 08 39 55.00 20 Page 8 clear distance between flanges cannot exceed the width of the rail by more than 3 mm at the tread nor more than 6 mm at the edge of the flange.

Machine internal bearing seats accurately for a press fit. Heat treat wheels to obtain a rim hardness of 320 Brine1l.

2.1.4.4.2 Wheel Bearings

Provide tapered roller or spherical bearings, either internal or cartridge type, arranged so that both horizontal and vertical loads are transferred to the rail only through the bearing. Provide bearings tightly sealed and equipped with high-pressure grease fittings.

2.1.4.4.3 Traction Drive

Provide a traction drive door system where the leading edge (door closing) wheel box contains both a wheel and a chain drive power system. The trailing edge wheel is not powered and only contains an idler wheel.

Provide a door system with a manual system override including motor brake disengagement and 13 mm standard female socket that is capable of both opening and closing the door system.

2.1.4.4.4 Motor Drive

Design motor drive to move its door at a speed of approximately 4.5 meters per minute. Design the operating units to consist of a separate motor and gear reducer, high-speed shaft brake, and necessary roller chains and sprockets. Provide the systems with overload protection for the drive units. Provide Directive 2006/42/EC , and CEI 64-8 ,high-starting torque, reversible type motor with sufficient horsepower and torque output to operate its door in both directions from any position at not more than 75 percent of its rated capacity. Select motor to operate on current voltage of the characteristics indicated at not more than 3600 rpm. Provide Directive 2006/42/EC , and CEI 64-8 totally-enclosed, fan-cooled (TEFC) and design using a minimum service factor of 1.2. Provide calculations and product data.

Provide braking systems to ensure stoppage of the doors under normal, dry rail conditions. Provide either a magnetic, spring-set, solenoid-released brake or hydraulic type braking systems. Provide a hand release to release the brake when it becomes necessary to move the door manually.

Provide an automatic reset type hand release so that the brake will be operable during subsequent electrical operation of the door.

2.1.4.5 Rail and Trench System

Provide rail(s) as indicated in the standard drawings per UNI EN 13674-4 .

Provide the plow trench cover system and complete the notionally detailed design shown in the standard drawings. Provide all rail and trench system including all components in the Trench Package.

2.1.4.5.1 Rail Tolerance

In accordance with the design, the blast door and components must meet the following tolerances for trueness and levelness:

All trenches and door guide rail must have a 6 mm maximum differential tolerance per every 11 meters.

SECTION 08 39 55.00 20 Page 9

2.1.4.6 Plow-type Trench Cover Lifting System (Plow System)

The plow trench cover assembly is notionally detailed in the standard drawings. The system to be provided by the manufacturer may vary based upon the door manufacturer's approved design. Dimensions noted with an asterisk (*) must be coordinated with the door manufacturer designing and providing the plow system to provide a door trench cover roller with a smooth transition between closed and open positions.

All plates are to be 6 mm thick plate minimum unless noted otherwise and weld all joints with a minimum 5 mm fillet unless noted otherwise in the details.

2.2 FABRICATION

Fabricate doors in accordance with the applicable provisions of D.M. 17.01.2018 . Workmanship must be equal to standard commercial practice in modern metal shops. Fabricate and assemble in the shop to the greatest extent possible.

2.2.1 Frames and Framing

Provide welded or bolted construction of doors as shown in the standard drawings. Provide continuous vertical members throughout the height of the door, unless noted otherwise in the standard drawings. Provide frames and framing members true to dimensions and square in all directions; no bowed leaves, warped, or out of line in the vertical or horizontal plane of the door opening by more than 1 mm in 2 meters. Do not deviate from the standard drawings for any reason, including to resist operational loads and packaging to withstand shipping loads. Grind smooth any exposed welds and prepare, prime, and coat steel as specified in paragraph

FINISHES.

2.2.2 Weldments, Embedments, and Trench Covers

Provide UNI EN 10088-4 , Type 304 Stainless Steel for door systems including door jamb, door head and locking pilaster.

2.2.3 Shop Assembly

Welding is a critical component in the success of constructing these doors, including meeting door construction tolerances. Welding must be in accordance with UNI EN ISO 9606-1 . For the doors, welding might cause significant residual stresses; therefore, the contractor must submit for approval by the Contracting Officer a detailed Sequence of Welding, augmenting the requirements given by the UNI specifications. Stainless steel must be welded using electrodes conforming to UNI EN 1011-3 .

Fabricated steel must be well-formed to shape and size, with sharp lines and angles. Intermediate and corner joints must be coped or mitered.

Exposed welds must be dressed smooth. The stiles and top of built-up structural steel doors must be closed using channel shapes or plates as shown in the standard drawings. Weld all steel in accordance with the standard drawings.

2.2.4 Door Tolerance

In accordance with the design, the blast door and components must meet the following tolerances for trueness and levelness:

SECTION 08 39 55.00 20 Page 10

Blast door cannot exceed a total maximum flatness tolerance of 7 mm either vertically or horizontally.

2.2.5 Quality Assurance Demonstration

The door manufacturer must commence a shop demonstration of each door in the presence of the Contracting Officer or their designee, consisting of a successful cycle of opening and closing the door by controls, opening and closing of trench plates by door plows, locking and unlocking door, and alignment of door in security pilaster. The demonstration must be a minimum of half the length of the door travel. Demonstration must also include manual operation of the blast door in both directions.

2.3 OPERATION

Each door is individually operated. For each door provide a separate, traction-drive operating unit driving one of the bottom wheels. On each door provide a motor-mounted, springset, solenoid-released motor brake.

Provide doors that are operated from pilaster mounted controls with visibility of the door's leading edge.

2.3.1 Controls

Provide control equipment conforming to Directive 2006/42/EC and CEI 64-8 .

Provide [mushroom] [guarded] head type push buttons, mounted in heavy-duty, oiltight enclosures conforming to CEI EN 61439-1 , except that enclosure for the VFD with disconnect switch requires Type 12 for interior application, type ATEX 21 T6. Provide watertight enclosures for exterior push buttons conforming to CEI EN 61439-1 .

When the Internal Locking Device (ILD) Boltworks Locking System is locked, the Variable Frequency Drive (VFD) is not powered. When unlocked, the VFD is powered. Provide constant pressure push buttons for each individually operated door. Door movement will be stopped upon removal of pressure from the button. Provide push buttons mounted on the exterior face of locking pilaster next to the ILD locking boltworks. Provide the open control button on top of the color green and provide a closer button below the open button of the color red.

2.3.1.1 Safety Interlocks

When mechanical rooms are included in the design, door controller must be provided for the blast door adjacent to the associated mechanical room with safety interlock feature when sensing mechanical room is open. Door control feature must include a door contact/relay interlocking with blast door control system and mechanical room door so that once the mechanical room door is in 'open mode' or 'unlocked', the control system of the adjacent blast door will be disabled from moving the blast door.

2.3.2 Variable Frequency Drive(s)

For each door, provide a Variable Frequency Drive (VFD) in CEI EN 60529 , IP54 enclosures, type ATEX 21 T6 equipped with access door-controlled, CEI EN 61439-1 Molded Case Circuit Breaker (MCCB) with a through-the-door disconnect switch. The control system includes but is not limited to a VFD equipped with overload and undervoltage protection, relays and timing devices as required, control circuit transformers, and a numbered terminal strip. Provide a control circuit transformer capable of reducing the

SECTION 08 39 55.00 20 Page 11 voltage in the control circuits to 120 volts or less and conforms to CEI 96-1 . Provide each VFD to move its door at a speed of approximately

4.5 meters per minute. The VFD in each door must automatically transition to crawl speed at each confirmed limit of door movement (full open and full close).

Provide each operating unit with a separate motor and gear reduction unit, highspeed shaft brake, and necessary roller chains and sprockets. Provide the systems with overload protection for the drive units and a means for emergency tractor towing operation.

2.3.2.1 Gear Reduction Unit(s)

Provide gear reduction units that allow a reversal of effort through the gears without damage to the units.

2.3.3 Operations and Maintenance Manual

Submit in accordance with Section 01 78 23 OPERATION AND MAINTENANCE DATA.

Include wiring and control diagrams. Door manufacturer must submit a complete Draft Operations and Maintenance Manual, Data Package 2 to the Contracting Officer for approval and must also submit a Final Operations and Maintenance Manual, Data Package 2 for record.

2.4 LIGHTNING PROTECTION SYSTEM

The Lightning Protection System (LPS) consists of a complete grounding system which electrically bonds all steel doors, frames, and components to the magazine's reinforcing cage in order to maintain equipotential.

Provide a grounding reel at top of the door with a grounding path in the door to all components. Provide local bonding with a dedicated path tied to the facility grounding systems to maintain equipotential. All structural and miscellaneous items embedded in the concrete must be electrically bonded to the reinforcing cage by wire ties.

2.5 ELECTRICAL

Provide conduit, wire, flexible cables, boxes, devices, and accessories[, and install trolley duct,] under Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM. If permanent electrical power is not available when door installation is complete, provide temporary power in accordance with distribution system requirements in Section 26 20 00 INTERIOR DISTRIBUTION SYSTEM, for testing and adjusting the doors.

Submit the door manufacturer's Electrical Package including complete schematic wiring diagram, field wiring diagram, and a complete physical location drawing showing the location of controls with the runs of conduit, size of conduit, number and size of wires in each conduit, location of junction boxes, and full details of control mountings.

2.5.1 Electrical Work

It is the door manufacturer's responsibility to provide the proper electrical equipment and controls built in accordance with the latest CEI EN 60529 , CEI EN IEC 60947-4-2 , and CEI EN 61439-1 standards. Provide all equipment and controls, and circuits that conform to CEI 64-8 . Provide automatic control devices necessary for motor operation of the door, including push button stations, limit switches, variable frequency drive with CEI EN 61439-1 MCCB motor circuit protection, control circuit

SECTION 08 39 55.00 20 Page 12 transformers, relays, timing devices, warning devices, and draped or festooned cable system with extra flexible Type SD cable.

2.5.2 Intrusion Detection System (IDS)

Coordinate with the Contracting Officer for the size and locations of balanced magnetic switches and motion sensors, and routing of all IDS conduit. Balanced magnetic switches, motion sensors, and conductors will be installed and connected to the Intrusion Detection System (IDS) by the Government. Pathway, conduit, and junction boxes will be provided by the contractor.

Coordinate with the Contracting Officer for the locations, routing of conduit, and connection of the Internal Locking Device (ILD) Boltworks Locking System which must be installed and connected to the Intrusion Detection System (IDS) by the Government. Pathway, conduit, and junction boxes will be provided by the contractor.

2.6 FINISHES

Clean, prepare, and coat all exposed and non-exposed ferrous metal surfaces as part of the Section 09 96 00 work, including all requirements, submittals, certifications, testing, and inspections required by Section 09 96 00. Do not coat finished bearing surfaces. Alternative coating systems or products will not be considered. Prepare surface and apply coatings in the shop, following all temperature, humidity, and testing requirements listed in Section 09 96 00. After installation of the door, prep and touch up surfaces damaged during assembly and installation of the door. Prep and coat unfinished ferrous metal accessories such as bolts and brackets. Provide details and document compliance path in the Coating Submittal Package.

2.7 SPECIAL INSPECTIONS

Special inspection requirements are included in the standard drawings, UFC 3-301-01 , and UFC 4-420-01 which must be adhered to, and the successful final results of all Special Inspections will be submitted in the Report of Special Inspections. Systems requiring special inspections include, but are not limited to:

Fabricator Certification and Quality Control Procedures

Fabrication Inspection

Shop Demonstration

ECM Grounding

Grounding System

Individual Bonds

LPS Components

LPS Testing

Door Laps

SECTION 08 39 55.00 20 Page 13

Embedded and Attached Items (Doors, Frames, and Trenches)

2.8 ACCESSORIES

2.8.1 Hardware

Coordinate with the Contracting Officer for procurement and installation of the Internal Locking Device (ILD) Boltworks Locking System and the distribution of key sets for each magazine door. The ILD Boltworks Locking System must be procured with two unique keys for operation. Contact the DoD Lock Program for directions on how to procure the ILD Boltworks Locking System and the qualifications for procuring a qualified Boltworks Manufacturer.

DoD Lock Program: https://navfac.navy.mil/go/locks

Email: ILD_Field_Support@navy.mil

ILD Support Hotline: 805-982-5625

DoD Lock Program Technical Support: 800-290-7607 or 805-982-1212

2.8.2 Nameplate

Each door assembly must have a permanently affixed nameplate that displays the manufacturer's name, place, year of manufacture, and applicable peak overpressure, and impulse. Mount nameplate on a nearby interior wall.

PART 3 EXECUTION

3.1 ERECTION

Assemble and install the doors and accessories in accordance with the manufacturer's recommendations and installation manual. Provide all work associated with these door systems under the direct supervision and control of the manufacturer for safety, quality control, and control of product performance and liability. Coordinate the erection of the doors with the work of other trades. Coordinate electrical work, including locations of all panels, equipment, motors, and other components for required clearances for maintenance, access, and routing of power.

3.1.1 Procedure

Erect and install in accordance with the manufacturer's written instructions, D.M. 17.01.2018 , and D.Lgs. 81 and submit an Installation Plan which is covered in the preconstruction meeting. Use erecting equipment suitable for the work and in proper working condition. Where parts cannot be assembled or fitted properly as a result of errors in fabrication or of deformation due to handling or transportation, report such condition immediately to the Contracting Officer, obtain approval of the method of correction, and make the correction in their presence. The straightening of plates and angles or other shapes must be done by the methods approved by the Contracting Officer. If heating of metal is approved for straightening, it must not be to a higher temperature than that producing a dark "cherry red" color. After heating, the metal must be cooled as slowly as possible. Evidence of fracture on the surface of the metal after straightening is not allowed. Drain steelwork properly;

fill pockets exposed to the weather with an approved waterproof material.

SECTION 08 39 55.00 20 Page 14

3.1.2 Erection Tolerances

Steel construction must be in accordance with the tolerances in D.M. 17.01.2018 , unless noted otherwise. Concrete construction must be in accordance with the tolerances in D.M. 17.01.2018 , unless noted otherwise.

3.1.3 Temporary Welds and Backing Strips

Temporary Welds and Backing Strips must be removed.

3.2 ELECTRICAL WORK

Provide all conduit, wiring, and mounting of controls in accordance w CEI 64-8 . Provide and install all 400V 3-phase supply power to all components such as main, auxiliary, controllers, panels, motors, and other devices which require low voltage supply power. Provide and install all conduit for the control level power. Provide and install all wiring for control level power in accordance with the approved submittals.

3.3 TESTS, INSPECTIONS, AND VERIFICATIONS

Submit Shop and Field Operating Test Reports that include values for opening and closing forces and times, forces required to operate latches, and a description of all operating tests performed.

3.3.1 Inspection

The manufacturer of the doors must provide a field inspection engineer to perform the following:

a. Check installation of embedded items before placing of concrete (after forms or shoring are in place) to ensure that the dimensional tolerances recommended by the door manufacturer have been complied with.

b. Recheck embedded items to verify the accuracy of dimensions after shoring and forms are removed from concrete.

c. Supervise any necessary corrective action.

d. Supervise the job site assembly and installation of the doors and operators.

e. Inspect final assembly of doors and operators after corrections and adjustments have been made to doors.

f. Demonstrate to the Contracting Officer that operation of the door assembly is as specified.

3.3.2 Visual Inspection of Welding

Furnish the services of AWS-certified welding inspectors for fabrication and erection inspection and testing and verification inspections in accordance with UNI EN ISO 9606-1 . Perform visual inspections on 100 percent of all shop and field welds with a Certified Welding Inspector.

Document this inspection in the Weld Inspection Report.

Inspect for proper preparation, size, gaging location, identification

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3.3.3 Nondestructive Testing

Perform nondestructive testing (NDT) in accordance with UNI EN ISO 9606-1 .

Perform ultrasonic testing in accordance with Table 6.2 of UNI EN ISO 9606-1 . Test 50% of all welds, with sampling representative of all weld types and locations for the entire door system, for the duration of the fabrication schedule and both shop and field welds. All personnel performing NDT are required to be certified in accordance with UNI EN ISO 9606-1 in the method of testing being performed. Submit NDT Certificates showing compliance with UNI EN ISO 9606-1 for all NDT technicians. If more than 10 percent of welds made by a welder contain defects identified by testing, then all groove welds made by that welder are required to be tested by ultrasonic testing, and all fillet welds made by that welder are required to be inspected by magnetic particle testing (MT) or dye penetrant testing (PT). When groove welds made by an individual welder are required to be tested, MT or PT may be used only in areas inaccessible to ultrasonic testing. Retest all repaired areas.

Submit Weld Inspection Report.

Any weld repairs required must be in accordance with UNI EN ISO 9606-1 .

3.4 FINAL CLEANUP, PROTECTION, LUBRICATION, AND ADJUSTMENT

3.4.1 Cleanup

After erection is complete, and before repair of protective coatings, thoroughly clean both the interior and exterior of the door and all abraded surfaces, field welds, and field bolts.

3.4.2 Protective Coatings

Complete all protective coating systems in accordance with the paragraph entitled, "Finishes" including repair of all damage to the protective coating system in accordance with the requirements of Section 09 96 00.

Prepare surface and apply coatings following all temperature, humidity, and testing requirements listed in Section 09 96 00.

3.4.3 Lubrication and Adjustment

Upon completion of installation, including work by other trades, lubricate, adjust, and perform preliminary door tests to verify operation in accordance with manufacturer's product data. Final adjustments will be made by the manufacturer. Adjust and retest the doors until the entire installation is fully operational and acceptable.

3.5 ACCEPTANCE TESTING PROCEDURE AND REPORT

Submit an Acceptance Testing Procedure for approval. After Government approval, and after installation is complete, field test each door for operation, clearance, fit, seating, and sealing by operating the door and hardware through a minimum of 10 operating cycles (unlock, full open, full close, and lock is one cycle) within the manufacturer's written time interval between cycles. Test the entire door system including every component and door hardware, and confirm maximum operational forces specified are not exceeded. Provide personnel and equipment required to perform field testing. Perform all field tests in the presence of the

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Contracting Officer. After testing is successfully completed, prepare the Acceptance Testing Report and submit to the Contracting Officer.

3.6 PERSONNEL TRAINING

Provide a 2-hour on-site training session for the Government's door operating personnel and maintenance. Attendees may include base personnel such as facility users, fire department, and others. In the training, outline door safety, normal operation, emergency operation, troubleshooting, maintenance, and repair guidelines. Record this on-site training and provide a Training Video presented in an organized and coherent fashion such that the Government may use the video as the sole training program for future user operators. It is acceptable to utilize stock training video content in this video provided the door operation, safety, and controls are identical to the door system provided.

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1.5 DELIVERY, STORAGE, AND HANDLING

2.1.4.6 Plow-type Trench Cover Lifting System Plow System

2.3.3 Operations and Maintenance Manual