Ref e_Att_1_WBD_CNRNW_Spec_DRAFT_for TWH review_12Nov2020.docx

Attachment 1

WORK BOAT DOCKING (WB DOCKING)

COMMANDER, NAVAL INSTALLATIONS COMMAND (CNIC)

SPECIFICATION

REV -

DRAFT FOR TWH REVIEW

12 November 2020

Attachment 1 – WB DOCKING SPECIFICATION DRAFT N00024-19-R-2221

Attachment 1 – WB DOCKING SPECIFICATION, DRAFT Rev - N00024-19-R-2221 x

REVISION HISTORY

TABLE OF CONTENTS

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background The mission of the CNIC Work Boat Docking (WB Docking) is to provide waterborne support at US Navy Installations. The boats are required to have the ability to safely assist vessels for mooring and dry-docking, open and close security barriers, as well as to tow and push floating port operations support equipment. The boats must include propulsion equipment that is optimized for bollard pull, be highly maneuverable, and include sufficient deck fittings and winches to tow astern, alongside, or push.

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General Requirements This Specification is for United States Navy (USN) Work Boat Docking (WB Docking) with steel hull and removable aluminum cabin that includes the following characteristics:

· The hull length (welded structure only) is nominally 23-25 feet (ft).

· The maximum allowable beam (including fendering) is 12.5 ft.

· The maximum allowable static draft at all load conditions is 8 ft to the bottom of the azimuthing drive and guard.

· The maximum allowable air draft at the Minimum Operating Condition is 11.5 ft from the waterline to the Overhead Line Guard.

· The transom freeboard shall be between 20 to 24 inches in the Full Load Condition.

· Minimum static bollard thrust shall be 6,000 pounds (lbs).

· Maximum speed shall be greater than 6 knots at the Full Load Condition.

· Aluminum cabin with heating, ventilation, and air conditioning systems (HVAC).

· Single diesel inboard engine with marine reversing gear.

· Azimuthing drive with nozzled propeller.

· Forward and aft tow provisions.

· Operational Profile is 70% at idle, 20% at cruise (defined by the engine manufacturer), and 10% at maximum (bollard) condition.

· Minimum duration of 24 hours of operation at the above operational Profile prior to refueling.

· Personnel capacity of seven (coxswain, deckhand, engineer, and four passengers), normal crew of two (coxswain and deckhand).

· Removable cabin, overhead line guard, and pusher knees for transportation and maintenance.

The expected service life for the boats delivered under this Specification is a minimum of 20 years. The service life may be extended with major overhauls including replacement of propulsion systems, mechanical systems, electrical systems and hull repair.

Specifications identified in this section provide the minimum required general system characteristics and requirements for the selection, installation, onboard performance, onboard inspection of machinery, equipment and outfit, and pre-installation handling and inspections of materials for construction.

A notional sketch of the Work Boat Docking arrangements is shown in Figure 1, below.

Figure 1 042-2 Referenced Documents The following standards and specifications are referenced in this Specification. Where reference is made to a voluntary compliance or best practice standard, the recommended standards and practices shall be considered mandatory under this Contract.

· 46 CFR Part 111.60, Wiring Materials and Methods

· 46 CFR Part 160.041, Kits, First-Aid, for Merchant Vessels

· 46 CFR Part 164, Materials

· 46 CFR Part 180.70, Ring Life Buoys

· 49 CFR Part 393.102, What are the Minimum Performance Criteria for Cargo Securement Devices and Systems?

· ABS, Rules for Building and Classing Steel Vessels Under 90 Meters in Length, 2019

· ABYC, Standards and Technical Information Reports for Small Craft

· ASME Y14.100, Engineering Drawing Packages

· ASTM A27, Standard Specification for Steel Castings, Carbon, for General Application

· ASTM A36, Standard Specification for Carbon Structural Steel

· ASTM A53, Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless

· ASTM A106, Standard Specification for Seamless Carbon Steel Pipe for High-Temperature Service

· ASTM A500, Standard Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes

· ASTM A501, Standard Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing

· ASTM A607, Standard Specification for Steel, Sheet and Strip, High-Strength, Low-Alloy, Columbium or Vanadium, or Both, Hot-Rolled and Cold-Rolled (Withdrawn 2000)

· ASTM A668, Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use

· ASTM A182, Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

· ASTM A276, Standard Specification for Stainless Steel Bars and Shapes

· ASTM A312, Standard Specification for Seamless, Welded, and Heavily Cold Worked Austenitic Stainless Steel Pipes

· ASTM A351, Standard Specification for Castings, Austenitic, for Pressure-Containing Parts

· ASTM B61, Standard Specification for Steam or Valve Bronze Castings

· ASTM B62, Standard Specification for Composition Bronze or Ounce Metal Castings

· ASTM B466, Standard Specification for Seamless Copper-Nickel Pipe and Tube

· ASTM B467, Standard Specification for Welded Copper-Nickel Pipe

· ASTM B584, Standard Specification for Copper Alloy Sand Castings for General Applications

· ASTM B928, Standard Specification for High Magnesium Aluminum-Alloy Products for Marine Service and Similar Environments

· ASTM C1338, Standard Test Method for Determining Fungi Resistance of Insulation materials and Facings

· ASTM F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs

· ASTM F594, Standard Specification for Stainless Steel Nuts

· ASTM F1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities

· ASTM F1321, Standard Guide for Conducting a Stability Test (Lightweight Survey and Inclining Experiment) to Determine the Light Ship Displacement and Centers of Gravity of a Vessel

· FED-STD-595C, Colors Used in Government Procurement

· IACS Publication No. 47, Shipbuilding and Repair Quality Standard

· IEC 60529, Degrees of Protection Provided by Enclosures (IP Code)

· IEEE 45, Recommended Practice for Electric Installations on Shipboard

· IEEE 1580, Recommended Practice for Marine Cable for Use on Shipboard and Fixed or Floating Facilities

· International Regulations for Preventing Collision at Sea, 1972 (72 COLREGS) which are contained in “USCG Navigation Rules and Regulations Handbook”, U.S. Coast Guard Navigation Standards Branch, U.S. Coast Guard Headquarters, Washington, DC

· ISO 12215-6, Small Craft – Hull Construction and Scantlings - Part 6: Structural arrangements and details

· MIL-DTL-3950, General Specification for Switches, Toggle, Environmentally Sealed

· MIL-PRF-23236, Coating Systems for Ship Structures

· MIL-PRF-24635, Coating Systems, Weather-Resistant, Exterior Use

· MIL-PRF-24647, Paint System, Anticorrosive and Antifouling, Ship Hull

· MIL-PRF-24667C, Coating System, Non-Skid, for Roll, Spray, or Self-Adhering Application

· MIL-STD-1366E, Interface Standard for Transportability Criteria

· MIL-STD-1474E, Design Criteria Standard Noise Limits

· MIL-STD-2035A, Nondestructive Testing Acceptance Criteria

· MIL-STD-209K, Interface Standard for Lifting and Tiedown Provisions

· NAVSEA 0900-LP-060-4010, Fabrication, Welding and Inspection of Metal Boat and Craft Hulls

· NAVSEA S6340-AE-TED-010, Technical Manual for Piping Devices and Flexible Hose Assemblies

· NAVSEA S9086-C6-STM-010, Naval Ships’ Technical Manual (NSTM) Ch. 096, Weights and Stability

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

· NAVSEA TO300-AU-SPN-010A, Fabrication, Welding and Inspection of Small Boats and Craft, Aluminum Hulls

· NAVSEA Drawing no. 803 5184106, Standard Navy Docking Drawing

· NAVSEACOMBATSYSENGSTA Report No. 6660-99 Rev. A, Procedures Manual for Stability Analysis of U.S. Navy Small Craft

· NSWCCD-23-TM-2009/33 Rev B, Hoisting System Design and Certification Process Guidance

· NSWCCD-23-TM-2009/58 Rev B, U.S. Navy Boat Electrical Practices

· NSWCCD-23-TM-2009/61 Rev A, U.S. Navy Boat Example Data Package

· NSWCCD-23-TM-2009/65 Rev C, Towing Fitting Design and Certification Process Guidance,

· NSWCCD-23-TM-2011/05 U.S. Navy Craft Mechanical Practices

· NSWCCD-23-TM-2011/38 Rev A, Mooring Fitting Design and Verification Process Guidance

· NSWCCD-23-TM-2011/39 Rev A, Anchoring System Design and Verification Process Guidance

· NSWCCD-80-TR-2014/038, Weight Management Process Guidance for Boats and Craft

· NSWCCD-80-TM-2020/10, Cyber Start Package Development Standard

· RR-C-271D, Chains and Attachments, Carbon and Alloy Steel

· SAE J1508, Hose Clamp Specifications

· SAE J1273, Recommended Practices for Hydraulic Hose Assemblies

· SAE J1527, Marine Fuel Hoses

· SAE J1942, Hose and Hose Assemblies for Marine Applications

· SAE J516, Hydraulic Hose Fittings

· SAE J517, Hydraulic Hose

· SNAME T&R Bulletin 4-16, Recommended Practices for Ship Heating, Ventilation & Air Conditioning Design Calculations

· UL 489, Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures

· UL 1426, Standard for Electrical Cables for Boats 042-3 Alternate Items Where boat components and equipment are specified by brand name or manufacturer and model number, such identification is intended to be descriptive, not restrictive, and is intended to indicate the required characteristics of the product.

Note: The Government will not accept alternate items for brand name or manufacturer and model specified in the following Sections:

· 233 Inboard Diesel Engine

· 241 Gear/Transmission

· 245 Azimuthing Drive

· 422 Integrated Electronic Navigation Package

· 441 Radio Systems

· 529 Bilge Drainage Systems

· 600 Emergency Position Indicating Radio Beacon (EPIRB) The Contractor may propose the use of other products which are equal to the specified make and model products. The following general requirements shall form the basis for determining the equality of alternate products unless additional specific or alternate requirements are designated within the applicable sections of these specifications:

· The major attributes of form, fit, function, interface, and material of an alternate item shall not degrade the performance of the system within which it is used; nor the boat as a whole. The alternate item shall require no more space or volume than the designated item for installation, operation, or maintenance. The alternate item shall weigh no more than the designated item. The connection fittings required to incorporate the alternate item into a system shall be identical to those necessary to incorporate the specified item. The principles of operation of the alternate item shall be the same as those of the designated item (i.e., hydraulic cylinders shall not be used in lieu of springs, etc.). Input power, capacity, and other operating requirements for the alternate item shall be no greater than those required by the designated item. Output power, capacity, and other performance parameters of the alternate item shall be no less than those required for the designated item and not so much greater than those of the designated item as to require an increased capacity of the system within which the item is installed.

· The materials of construction of the alternate item shall be the same as those of the designated item unless the Contractor can demonstrate to the Government that the proposed alternate material will not adversely affect performance or service life of the item, the system within which it is installed, or the boat as a whole.

· The reliability and maintainability of an alternate item shall be equal to or better than the specified item. The Contractor shall provide evidence of the reliability and maintainability of the alternate item. This evidence may include such things as results of testing, service histories, documentation of successful use in similar applications, planned maintenance requirements, etc. Where the reliability and maintainability of the specified item has been established by testing, the government may require that the alternate item undergo similar testing to demonstrate its reliability and maintainability. Such testing, if required, shall be at the Contractor's expense.

· An alternate item shall conform to the same industry or government specifications or standards as the specified item. Where a specified item has been approved or certified by a regulatory or testing agency, such as USCG or Underwriters' Laboratories, the alternate item shall also be approved or certified. The cost of demonstrating compliance with specifications or standards, or of obtaining approval or certification, shall be borne by the Contractor.

· If the specified item is one with established logistic support any alternative item shall have equivalent logistic support. If equivalent logistic support has not been established for the alternate item, the Contractor shall bear the expense of establishing equivalent support. Logistic support shall include, as applicable: maintenance planning and analysis; training and training support, including training equipment, curricula, and instruction materials; supply support; support equipment such as special tools and test equipment; technical documentation including technical manuals, Product Technical Description (PTD), Planned Maintenance System (PMS), Technical Repair Standards (TRS), and software documentation; computer resource support; facilities for maintenance and training; unique packaging, handling, storage, and transportation requirements; and human engineering considerations.

042-4 Order of Precedence In case of inconsistency between the requirements of the Contract, this Specification, and the documents referenced in this Specification, the following order of precedence applies:

1. Contract requirements,

2. Specification requirements,

3. Other Government specifications and standards, industry standards, and similar referenced documents.

The following are not considered inconsistencies subject to an order of precedence determination:

a. Silence of one document with respect to details shown in another.

b. Broad boat requirements compared to detailed system or component requirements.

042-5 Statement of Work (SOW) This Specification is written to be used in conjunction with the SOW. Additional requirements such as warranty, packaging, delivery, training, et cetera are defined in the SOW.

070 GENERAL REQUIREMENTS OF DESIGN AND CONSTRUCTION

070-1 Boat Characteristics

· Length Overall (LOA) including fendering and appendages: {{xx.xx}} ft

· Hull Length (welded structure only): {{xx.xx}} ft

· [Shall be nominally 23-25 ft per Section 042]

· Beam Overall (BOA) including fendering: {{xx.xx}} ft

· [Shall not exceed 12.5 ft per Section 042]

· Maximum Beam (welded structure only): {{xx.xx}} ft

· Height, Lowest appendage (skeg, azimuthing drive, or azimuthing drive guard) to Fixed Structure (Overhead Line Guard): {{xx.xx}} ft

· Height, Lowest appendage to Moveable Structure (highest mast or antenna): {{xx.xx}} ft

· Air Draft, Minimum Operation Condition waterline to Overhead Line Guard: {{xx.xx}} ft

· [Shall not exceed 11.5 ft per Section 042 and 169]

· Height when rigged for transport (cabin and pusher knees removed): {{xx.xx}} ft

· [Shall not exceed 11 ft per Section 084]

· Width when rigged for transport: {{xx.xx}} ft

· [Shall not exceed 12.5 ft per Section 084]

· Total Installed Fuel Capacity: {{xxx}} gallons

· [Shall be minimum of 200 gallons per Section 541]

· Full Load Displacement: {{xx,xxx}} lbs incl {{x}}% construction or build margin or both

· Longitudinal Center of Gravity (LCG) in Full Load: {{xx.xx}} ft forward of transom and keel intersect.

· Static Full Load Draft (hull): {{x.xx}} ft

· Static Full Load Draft (to skegs or azimuthing drive and its guard): {{xx.xx}} ft

· [Shall not exceed 8 ft, per Section 042]

· Static Full Load Freeboard at the transom: {{xx.xx}} ft

· [Shall be between 20 to 24 inches per Section 042]

· Bollard Thrust {{x,xxx}}

· [Shall be minimum 6,000 lbs per Sections 042 and 245]

· Sprint Speed {{xx.x}} at Full Load in calm water

· [Shall be minimum of 6 knots per Sections 042 and 245] Offeror to provide all parameters above in Attachment 2.

070-2 Environmental Conditions The boat shall be capable of operating in ambient air temperatures between 0°F and 105°F and water temperatures between 28°F and 95°F.

The boat shall be capable of full operation in up to Wilbur Marks Sea State 2 (2.2 ft significant wave height). The boat shall survive up to Sea State 4 conditions (6.9 ft significant wave height) at minimum headway speed. Survive means remain upright and intact and make headway, but heading is driven completely by sea conditions.

070-3 Load Conditions The following load conditions are defined for reference throughout this Specification. These definitions apply to the engineering design values for weight and moments of the boat in the described condition. Weight Management Process Guidance for Boats and Craft, NSWCCD-80-TR-2014/038 shall be used for guidance.

· Light Ship: The boat is complete in all respects including all outfit and ready for service with liquids in machinery at operating levels, but no personnel, fuel, or other variable loads.

· Minimum Payload Capacity: Boat shall be capable of supporting a minimum of 1,160 lbs total payload, including personnel and mission gear. The notional breakdown of payload is three personnel at 220 lbs each and 500 lbs of mission gear. Mission gear is defined as a combination of miscellaneous mission gear and cargo tied down on the deck.

· Full Load Condition: Light Ship plus Minimum Payload and full fuel. Diesel fuel weight shall be calculated using a density of 7.1 lbs/gallon.

· Maximum Load Condition: Light Ship plus Minimum Payload, plus full fuel, and plus 880 lbs (four additional personnel at 220 lbs each). Diesel fuel weight shall be calculated using a density of 7.1 lbs/gallon.

· Minimum Operation (Min Op) Condition: Light Ship plus Minimum Payload with 10% fuel. Diesel fuel weight shall be calculated using a density of 7.1 lbs/gallon.

· PDIT (Pre-Delivery Inspection and Trials) Load Conditions:

· PDIT Load Condition 1: Same as Full Load Condition.

· PDIT Load Condition 2: Same as Min Op Condition.

· Boat Design Hoisting: Full Load less three personnel (220 lbs each), plus 500 lbs for a Service Life Allowance.

· Cabin Design Hoisting: Cabin is complete in all respects including all outfit and ready for service plus 200 lbs for a Service Life Allowance.

070-4 ABYC Standards As a minimum, the boat in all respects shall meet American Boat and Yacht Council (ABYC) standards and recommended practices.

070-5 Alterations Alterations to Original Equipment Manufacturers’ (OEM) products by the Contractor or distributor are highly discouraged. If alterations are necessary, documentation of the change shall be submitted for Government approval and shall be provided with the Technical Data Package (TDP).

070-6 Seakeeping, Dynamic Stability, and Maneuverability The boat shall be able to operate safely up to Sea State 2 on the Wilbur Marks scale and shall be safe and controllable at all speeds and under all loading conditions specified herein. Safe and controllable includes operation where boat orientation, motions, and accelerations do not pose a hazard to the crew or passengers that is not otherwise controllable by good seamanship and boat handling.

070-7 Installation of Equipment, Machinery, and Materials Unless otherwise specified, OEM recommendations for design and installation of their products into the boat shall be followed. Systems and components shall be selected for durability, longevity, safety, and ruggedness. Components shall be selected to maximize the use of Commercial-Off-The-Shelf (COTS) products and commonality between hulls. Systems and components shall be installed with proper tools and aligned with best industry practices.

All systems should be free from leaks and safety hazards. Equipment, components, wiring, and piping shall be supported clear of the bilge to the maximum extent practicable.

All piping shall be cleaned to a degree of cleanliness that results in a surface that is reasonably free of contamination and any remaining residue on the surface does not interfere with system operation or damage system components.

Foundations and brackets for equipment shall be configured to provide access for cleaning, painting, preservation, and maintenance, and to prevent accumulation of water, dirt, and foreign material.

Connecting piping or hose and wiring shall be run to minimize exposure to weather. Bulkhead and deck penetrations shall be as close as practicable to the equipment being served, preferably by direct connection through the adjacent deck or bulkhead.

Systems, equipment, and components shall be installed to facilitate accessibility for operating efficiency and for inspection, adjustment, and repair. Permanent fittings and structure shall be kept clear of routes required for the removal of machinery and equipment. The space behind equipment may be inaccessible after installation; this factor shall be considered in providing proper preservation in way of such equipment and in selecting the location of pipes, ducts, wireways, and other permanent fittings behind such equipment. Nooks, cracks, and openings where water, dirt, dust, or foreign material can accumulate shall be avoided.

Protection of personnel against operating hazards shall be provided. Shafting, couplings, gears, flexible shafts, and similar items shall have adequate guards installed for protection of personnel. Such protective guards shall be removable without dismantling the machinery surrounded.

Guards shall be as lightweight as is practical and consistent with required protection and strength. Guards shall be of sufficient strength to be used as steps or hand holds if located where such use may be anticipated.

Protective guards or insulation shall be installed to prevent contact with equipment where surface temperatures exceed 200°F. If surfaces exceed 140°F in the proximity of controls or manual actuators requiring manipulation by personnel during normal operation, protective guards or insulation shall be installed to prevent contact. For other surfaces exceeding 140°F, caution signs shall be installed.

Protective guards shall also be installed as barriers to prevent personnel from inadvertently contacting energized and exposed electrical circuits, components, and terminals.

Equipment shall be protected against the hazard of personnel brushing against or being thrown against the equipment, particularly under heavy sea conditions, and inadvertently causing damage to exposed components or resulting in maladjustment of exposed functional controls such as push buttons, knobs, and switches. Protection shall be provided by equipment arrangement or design or by installation of enclosures, screens, or guard rails. All sharp edges exposed to personnel shall be dressed, ground or radiused to avoid injury to personnel.

071 ACCESS

071-1 Accessibility Electrical and mechanical components shall be accessible for maintenance and repair. Components are “accessible” if they are capable of being reached for inspection, removal, or maintenance without the removal of permanent boat structure. All items requiring operation or maintenance (e.g. switches, valves, filters, strainers, seacocks, bilge pumps, mufflers, etc.) shall be readily accessible while at the dock or underway. Components are “readily accessible” if they are capable of being reached quickly and safely for effective use under emergency conditions without the use of tools. Stowage and securing of arches, antennas, masts or other items shall not prevent access to critical items such as battery switches, fuel shut off valves or other items that need to be checked, secured or operated, including any of the required transport modes.

071-2 Bilge Access All bilges and voids shall have removable plates or hatches for bilge access and inspection. The access and inspection openings shall be of sufficient size and locations to allow personnel visual access to the entire bilge and void areas.

073 NOISE, VIBRATION, AND RESILIENT MOUNTINGS

073-1 Noise Levels (Exterior) Noise levels on exterior decks shall not exceed 84 dBA during low speed up to 5 knots. If noise levels on the aft deck exceed 84 dBA for an 8 hour time weighted average (TWA) based on the operational profile (Section 042), appropriate noise warning signs shall be provided on the boat advising personnel of the noise hazard and the need for hearing protection (Section 602).

See Section 092 for certification requirements 073-2 Noise Levels (Interior) Noise levels inside the cabin shall not exceed 84 dBA during all operating conditions. Insulation shall be provided as required to achieve required noise levels.

The engine room shall be equipped with appropriate noise warning signs advising personnel of the noise hazard and the need for hearing protection (Section 602).

073-3 Resilient Mounts Mounts for removable components and accessories subject to vibration, including items moved for towing or transport, shall be provided with resilient material as necessary to prevent rattling.

074 WELDING AND ALLIED PROCESSES

074-1 General Welder and weld procedure qualification – weld procedures and welder qualification, including the associated record keeping requirements, shall be in accordance with American Bureau of Shipping (ABS), American Society of Mechanical Engineers (ASME), American Welding Society (AWS), NAVSEA TO300-AU-SPN-010 A dated 5 October, 1992 (NAVSEA SPN-10) or NAVSEA 0900-LP-060-4010 (NAVSEA 4010).

The Contractor shall select one of these welding codes and adhere to all requirements of the selected document for each welding procedure specification. The Contractor may select different regulating codes for different weld procedures; however, all documentation, welding and welder requirements for each procedure (for example the Welding Procedure Specifications (WPSs), the Procedure Qualification Records (PQRs) and the welder qualification and testing of the welds) must follow the same code.

All documentation pertaining to welder and weld procedure qualification shall be maintained by the Contractor and shall be available for inspection by the Government.

074-2 Visual Inspections All welds shall be visually inspected.

Welds shall be free of slag, weld splatter, cracks, sharp irregularities, craters and incomplete fusion.

The weld edge shall not form a reentrant angle with the base metal less than 90 degrees due to lack of fusion, undercut or excessive convexity.

Fillet welds dimensioned 3/8 inch or less shall not vary below the specified size by more than 1/16 inch for a total distance greater than 25 percent of the joint length. Fillet welds dimensioned 7/16 inch and larger shall not be less than the specified size. Fillet welds in excess of the required dimensions shall be avoided; however, oversized welds will be acceptable provided they meet the contour requirements and do not interfere with proper operation of the boat or its components. Fillet weld root openings shall not be greater than 1/16 inch.

Undercut shall not reduce the base metal thickness by more than 1/32 inch.

Welds shall not exhibit porosity or worm holes in excess of two indications 1/16 inch or larger in any 6 inch length of weld, exclusive of weld crater porosity.

Grinding to correct the weld profile shall not reduce the base metal thickness by more than 1/32 inch.

074-3 Dye Penetrant Testing (PT) Critical welded assemblies shall be visually inspected and PT tested per Section 092 as follows:

1. Visually inspect completed critical welded assembly per Section 074-2. If passing, proceed to step 2.

1. Before load testing, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch. If passing, proceed to step 3.

1. Pull test the installed assembly to the load per Section 092.

1. After load testing, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch. If passing proceed to step 5.

1. Visual inspection of fittings and boat structure for signs of failure or permanent deformation.

075 FASTENERS

075-1 Stainless Steel Fasteners Fasteners throughout shall be type 316 Stainless Steel (UNS S31600). Fasteners used for structural applications shall be ASTM F593, Alloy Group 2 (type 316 stainless steel), Condition A or CW. For bolts with high strength requirements, non-stainless steel bolts may be used with Government approval.

Self-locking hardware shall be used unless otherwise specified. Component mounting shall be through-bolted with ASTM F594 (type 316 stainless steel) nylon insert lock nuts and flat washers wherever practicable to suit fastener reinstallation during maintenance and repair. Threaded fasteners shall fully engage nuts with one to five threads protruding. Excessive thread protrusion that poses personnel hazard shall be avoided. Fasteners may be threaded into structural or non-structural materials only with Government approval.

Any pins used for folding, removable, or stowable features shall be secured with stainless steel lanyard to prevent loss. Pin handles may be aluminum. Spring loaded ball bearing type pins shall not be used.

078 MATERIALS

Components or parts of equipment and machinery shall be new. When materials are referred to in this Specification without further identification, they shall be as specified in this section. Other materials for specific applications are defined in the specific sections of this Specification, or on the drawings or referenced documents that require their use.

No plastic (without explicit Government approval), high density polyethylene (HDPE), polyvinyl chloride (PVC) or Chlorinated polyvinyl chloride (CPVC) shall be used except OEM components (e.g. electric bilge pump, National Electrical Manufacturers Association (NEMA) Boxes).

078-1 Structural Material Metal structure shall generally be of welded steel hull construction and aluminum cabin.

Except as otherwise specified or approved by the Government, structural steel materials shall conform to the following specifications:

· Cast: ASTM A27, Grade 60 30, Class 1

· Forgings: ASTM A668, Class B

· Plate, shapes and bars: ASTM A36 or ABS Hull A

· Sheet: ASTM A607 or ABS Hull A

· Pipe: ASTM A53, types E or S, grade B or ASTM A106, grade B

· Tubing: ASTM A500, Grade B or ASTM A501 Except as otherwise specified or approved by the Government, structural aluminum materials shall be used and conform to the following specifications:

· Sand cast (3560 T6)

· Plate and sheet (5086 H116 or 5086-H117 both ASTM B928); for non welded applications 6061 T6 or 6061 T651 may be substituted.

· Extrusions (5086 H111; for non welded applications 6061 T6 or 6061 T52 may be substituted.)

· Drawn tube (5086 H32; for non welded applications 6061 T6 may be substituted.)

· Non-structural components such as handrails, small component brackets, and wire ways may include extruded 6061 materials. Non-structural 6061 components in welded applications shall be approved by the Government prior to fabrication. Aluminum piping for fluid systems, where allowed, shall be welded 5086-H32.

Stainless Steel (if used) shall be:

· Cast for general applications (J92800 or J92500; for non-welded applications UNS J92900 or J92600 may be substituted.)

· Cast for underwater applications (J92800; for non-welded applications UNS J92900 may be substituted.)

· Plate, sheet, bars, shapes, tubing, pipe (S31603; for non-welded applications S31600 may be substituted.)

· Valves and fittings (Grade F 316, UNS S31600 – ASTM A182; or Type 316, UNS S31600 – ASTM A276; or Grade TP316, UNS S31600 – ASTM A312; or Grade CF8M, UNS J92900 – ASTM A351) Bronze (if used) shall be:

· Valves, strainers, and fittings (UNS C92200 – ASTM B61; or UNS C83600 – ASTM B62; or UNS C84400 – ASTM B584) Copper-Nickel (CuNi) (if used) shall be:

· Seamless Pipe and Tube (ASTM B466)

· Welded Pipe (ASTM B467) 078-2 Corrosion Control All parts and fittings required for disassembly of systems shall be of Monel, stainless steel type 316L (or 316 if not welded), or copper alloy containing no more than 10% zinc (except manganese bronze), whichever is compatible with the basic material of the equipment. Stainless steel, if used where it is likely to be submerged in seawater, shall be type 316L.

Components using ferrous metals other than stainless steel shall not be used except where specifically required by this Specification or with prior Government approval. Where ferrous metals other than stainless steel are required by this Specification, they shall be hot-dip galvanized or coated (zinc plating and electro-galvanizing is not be considered an acceptable coating). The protective coating shall be applied after fabrication. Alternatively, ferrous metal items may be replaced with stainless steel items, or items of other non-corroding materials.

Boat mechanical components and subcomponents shall be suitable for a marine environment (corrosion resistant). Joined components shall be galvanically compatible with each other wherever possible, or shall be isolated to prevent galvanic corrosion. Components not available in a corrosion resistant material shall be protected or coated to reduce or eliminate corrosion (e.g. paint, corrosion inhibitor, etc.), with Government approval.

Where it is necessary to join dissimilar metals, faying surfaces of the galvanically dissimilar metals shall be electrically isolated including fasteners, using non-water absorbent dielectric barrier(s), (e.g. gaskets, washers, sleeves, bushings, pipe or hose hangers, etc.), and hose of insulating material, In order to exclude moisture from the joint, faying surfaces between mechanically fastened metal components, except machinery foundation shims, shall be protected by the use of bedding compound or gaskets, as applicable. Unless otherwise specified, gaskets for mechanically attached fitting shall be neoprene.

Use U.S. Navy Craft Mechanical Practices NSWCCD-23-TM-2011/05 for guidance.

078-3 Bedding Compound Bedding compound shall be highly elastic, non-corrosive, paintable, solvent-free, with high adhesion properties and be suitable to the intended environment.

Polysulfide and polyurethane sealants may be used above and below the waterline. Where waterproof adhesive bonds are required, a polyurethane compound shall be used.

078-4 Non-Biodegradable Materials Use of wood and other hygroscopic or biodegradable materials anywhere on the boat is prohibited. All materials shall be marine grade and resistant to corrosion and Ultraviolet (UV) exposure.

078-5 Fabric Material All boat fabric shall be marine grade as well as fade-, stain- and mildew-resistant and a near match in color as the surface it is mounted to or covering unless otherwise noted. Fabrics shall be easy to maintain and waterproof and/or breathable where required. All seams, edges, grommets, fastening points and areas of chafe shall be reinforced. Venting is acceptable to ventilate covers, but must minimize or eliminate the intrusion of water. Seats, seat fabric and foam shall be durable, provide comfort and be flame retardant. Foam shall not retain or absorb water.

078-6 Fire Retardant Interior Materials Unless otherwise specified, all interior materials shall be fire retardant.

Thermal and acoustic insulating materials (Section 635) shall be non-combustible in accordance with 46 CFR Part 164.109.

079 STABILITY

079-1 Intact Stability Stability shall meet NAVSEACOMBATSYSENGSTA Report No. 6660-99 Rev. A, Procedures Manual for Stability Analysis of U.S. Navy Small Craft for intact stability in the Maximum Load, Full Load and Min Op conditions for:

· Beam winds combined with rolling for Harbor Service (wind speed of 60 knots at 10m height).

· Lifting heavy weights over the side

· Crowding of passengers to one side

· Topside icing (3 inch thickness) In addition, the intact stability at the Full Load and Min Op conditions shall be assessed against the requirements of ABS Rules for Steel Vessels Under 90m, Part 5 Chapter 11 Appendix 1, Intact Stability Guidelines for Towing Vessels, to determine the percentage of the towing vessel criteria that is met in the Full Load and Min Op conditions. The vessel shall fully meet the ABS towing criteria with 4,800 lbs. (80% of minimum required thrust [6,000lbs], see Section 042) of propeller thrust (use Attachment 11 for heeling moment calculation).

A VCG margin (increase to calculated VCG) of 0.3 ft shall be used for initial stability calculations. The VCG margin shall be removed for final stability calculations per Section 085. Any gunwale tops, vents, or openings that allow water to enter into the cabin or below deck shall be used as the down flooding points. All windows, hatches, and openings in deck that do not meet ABYC H-3.7.3 test for watertight devices or structures shall be treated as potential down flooding points.

Operational restrictions and service conditions resulting from the stability analysis shall be identified in the Boat Technical Manual (see Section 085) and on the Boat Operations Limit Label Plate (see Section 602).

See Sections 085 and 092 for technical analysis and testing requirements.

Offeror to identify the maximum thrust value for which the proposed boat fully meets the specified ABS towing criteria (Minimum 4,800 lbs, 80% of the minimum required thrust 6,000 lbs) in Attachment 2

084 TRANSPORTATION AND HANDLING

084-1 Road Transport Boat, with cabin and upper portion of pusher knees removed, shall meet all requirements for road transport (wide load with restrictions) via low-boy trailer on Continental United States (CONUS) Highways. Maximum boat dimensions when disassembled for transport shall not exceed:

084-2 Maritime Transport Boat shall be designed for maritime transport and logistical launch and recovery (e.g. crane, deck cargo) from decks of USN, MSC, and commercial shipping.

084-3 Boat Tiedown Fittings Boat shall have tiedown provisions incorporated into existing structure (e.g. Tow Bitts (Section 582), Deck Chocks (Section 582). Labeling of the fittings shall include load ratings of the fittings in lbs. Tiedown provision and adjacent structure shall be sized for maximum applicable load, as follows:

1. OTR Transport: Restraint of boat using Full load condition weight (see Section 070), shall be designed per MIL-STD-1366E Section 5.1.6 and 49 CFR Part 393.102, to provide a minimum safety factor of 1.5 on yield strength, or

2. Marine Transport: Restraint of boat using Full condition weight (see Section 070), per MIL-STD-1366E Section 5.1.6 shall provide a minimum safety factor of 1.5 on yield strength. Fittings’ design limit loads are as follow: 0.5 times the load in the longitudinal direction and 1.0 time the loads in the lateral direction. For calculations, bunk loads can be assumed to restrain the boat in the lateral direction.

See Sections 085 and 092 for technical analysis and testing requirements.

084-4 Water Proof Cover A reusable water proof cover shall be provided for protection from the elements while the cabin is removed for transport, maintenance, or long term storage. Cover design shall prevent pooling of water and shall be vented.

085 TECHNICAL DATA PACKAGE

The TDP shall include all information essential for acceptance, operation, training, maintenance, repair, modification and supply support for the delivered boat. The TDP shall include, but not be limited to:

1. Technical Design Analyses;

2. Construction (“As-built”) boat drawings including or cross referenced to:

3. a Bill of Materials (BOM) to the line replaceable unit (LRU) level;

4. COTS manuals;

5. Boat Technical Manual;

6. OEM certifications;

7. OEM warranty coverage for major systems;

8. Test and Trials Reports;

9. A Master Data Index.

085-1 Technical Design Analyses Technical Design Analyses shall be clear and complete. No steps shall be skipped or presumed. Any descriptive information needed to completely describe the calculations and their methods shall be included. For repetitive calculations, a full example calculation describing methodology, assumptions and any additional descriptive information shall be provided. Subsequent repetitive calculations may be placed in a matrix or tabular form that includes all inputs and outputs to these calculations.

Calculations shall be clear and complete and include the following:

· Clear, complete and concise assumptions presented in a neat, legible manner.

· Any necessary diagrams to fully describe the design situation and its associated calculations.

· Pertinent information from all references, standards and guidelines cited including appropriate excerpts.

· All symbols and acronyms fully defined.

A sample calculation is included as an Appendix to NSWCCD-23-TM-2009/33 Rev C, Hoisting System Design and Certification Process Guidance, October 2009, US Navy Boats Hoisting Guidance document.

The Contractor shall provide the following Technical Design Analyses:

a. Allocated Baseline Weight Estimate (ABWE) (First Boat Only): An ABWE shall be provided for the first boat only, to establish the estimated weight of the boat for all load conditions specified in Section 070. The ABWE shall include margins as applicable to the boat design maturity. Weight Management Process Guidance for Boats and Craft, NSWCCD-80-TR-2014/038, shall be used as guidance.

ABWE shall be submitted to the Government for…