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NEWBURGH LOCKS AND DAM HYDRAULIC CYLINDER PURCHASE

TABLE OF CONTENTS

SPECIFICATIONS/DESCRIPTION

1. General

2. Start/Completion Dates

3. Deviations from Specifications

4. Items of Work

5. Corps of Engineers Inspection

6. Technical Point of Contact

7. References

8. Submittals

9. Materials

10. Quality Control

11. Workmanship

12. Dimensional Tolerances of Machined Items

13. General Security Training and Planning

14. Packaging and Shipping

15. Warranty

16. Painting

17. Drawings

Newburgh Hydraulic Cylinder Supply US Army Corps of Engineers

Newburgh Lock and Dam 6877 St Rd 66.

Newburgh, IN 47630

1. GENERAL

The Contractor shall provide all labor and materials to fabricate, test, and deliver base line item 0001, two (2) miter gate hydraulic cylinders per the attached drawings and specifications and option line item 0001, one (1) culvert valve hydraulic cylinders per the attached drawings and specifications. The new cylinders shall have upgrades including but not limited to modern seals, materials, and two each additional ports adjacent to and on the opposite side (180 degrees) ports shown on the original drawings.

2. START/COMPLETION DATES

The Contractor shall begin work within 10 days of award. All packaged parts shall be delivered to Newburgh Lock and Dam 6877 St Rd 66. Newburgh, IN 47630. All hydraulic cylinders and any associated parts shall be delivered within 300 days of award.

3. Deviations from Specifications: Changes to the materials and designs may be allowed only after approval from the TPOC. The changes must not change the fit or function of the hydraulic cylinder detailed on the contract drawings. Some changes could require that the Contractor provide design calculations by an engineer that prove that the change meets the governing standards. The specifications are intended to provide USACE with hydraulic cylinders with more modern seals and materials than that detailed in the original contract drawings. Modern upgrades to the cylinder detailed on the drawings are strongly encouraged and desired, but must be approved by the TPOC.

4. ITEMS OF WORK

LINE ITEM 0001: Miter Gate Cylinder

1. Cylinder shall be manufactured according to the provided drawings for this cylinder. Modernization of cylinder components are strongly encouraged but must be approved by TPOC.

2. Contractor shall supply qty of two (2)

3. As built drawing ON240_1_08 is included for contractor to review dimensions.

4. Supplied drawings show supply/return ports on one side of the cylinder housing, contractor will add additional supply/return ports to the opposite side of the cylinder housing as well.

5. Contractor shall submit engineered drawings, and specifications to TPOC for approval before purchasing or beginning fabrication.

6. It is the contractor’s responsibility to field verify dimensions.

OPTIONAL LINE ITEM 0001: Culvert Valve Cylinder

1. Cylinder shall be manufactured according to the provided drawings for this cylinder. Modernization of cylinder components are strongly encouraged but must be approved by TPOC.

2. Contractor shall supply qty of one (1) if the option is awarded.

3. As built drawing ON210_1_012 is provided for contractor to review dimensions.

4. Attached drawings include one set of supply/return ports. A second set shall be included, located 180° from the as built.

5. Contractor shall submit engineered drawings, and specifications to TPOC for approval before purchasing or beginning fabrication.

6. It is the contractor’s responsibility to field verify dimensions.

5. CORPS OF ENGINEERS INSPECTION

Corps of Engineers personnel shall inspect the progress of any portion of this project at the Contractor’s work site. All parts or assemblies shall not be shipped until the units have been inspected and approved by the Contractor Quality Control Representative (CQCR). The CQCR shall provide reports to the Technical

Representative prior to the shipment of any part or assembly certifying that the part or assembly meets or exceeds the Contract requirements.

6. TECHNICAL POINT OF CONTACT

All questions regarding this contract shall be directed to Zach Jones at (502) 315-6697, zachary.l.jones@usace.army.mil.

7. REFERENCES

American National Standards Institute (ANSI) Specifications.

B4.1 Preferred Limits and Fits for Cylindrical Parts

B16.11 Forged Steel Fittings, Socket-Welding and

Threaded

B31.1 Power Piping

B4.1-1967 (R2009) Preferred Limits and Fits for Cylindrical Parts

B46.1-2009 Surface Texture (Surface Roughness, Waviness and Lay).

American Society for Testing and Materials (ASTM) Standards.

ASTM A27 Steel Castings, Carbon for General Applications

ASTM A105 Forgings, Carbon Steel, for Piping Components

ASTM A108 Steel Bars, Carbon, Cold Finished, Standard

Quality

ASTM A181 Forgings, Carbon Steel, for General-Purpose Piping

ASTM A193 Alloy-Steel and Stainless Steel Bolting Materials

For High-Temperature Service

ASTM A194 Carbon and Alloy Steel Nuts For

Bolts For High-Pressure and High-Temperature Service

ASTM A216 Steel Castings, Carbon,Suitable for Fusion

Welding, for High Temperature Service

ASTM A240 Chromium and Chromium Nickel Stainless Steel

Plate, Sheet, and Strip for Pressure Vessels and for General Applications

ASTM A242 High Strength Low Alloy Steel

ASTM A266 Forgings, Carbon Steel, for Pressure Vessel Components

ASTM A331 Steel Bars, Alloy, Cold Finished

ASTM A516 Pressure Vessel Plates, Carbon Steel, for Moderate and Lower-

Temperature Service

ASTM A519 Seamless Carbon and Alloy Steel Mechanical Tubing

ASTM A564 Hot-Rolled and Cold-Finished Age-Hardening Stainless and Heat-

Resisting Steel Bars and Shapes

ASTM A576 Steel Bars, Carbon,Hot-Wrought, Special Quality

ASTM A659 Steel, Carbon (0.16 Maximum to 0.25 Maximum Percent), Hot-Rolled

Sheet and Strip, Commercial Quality

ASTM A705 Age-Hardening Stainless and Heat-Resisting Steel Forgings

ASTM B148 Standard Specification for Aluminum-Bronze Sand Castings

ASTM B505 Copper-Base Alloy Continuous Castings

ASTM B177 Standard Guide for Engineering Chromium Electroplating

ASTM D3951 Commercial Packaging

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

Studs from ¼” to 1-1/2”

ASTM F594 Standard Specification for Stainless Steel Nuts

NFPA T3.6.7R3 Standard Specification for Industrial Fluid Power

American Society of Mechanical Engineers (ASME) Standards.

ASME B 1.1 (2019) Unified Inch Screw Threads (UN, UNR, and UNJ Thread Form)

ASME Y14.5M Geometric Dimensioning and Tolerancing Standard

ASME B 1.20.1 (2013; R 2018) Pipe Threads, General Purpose, Inch

ASME B16.5 (2020) Pipe Flanges and Flanged Fittings NPS 1/2 Through NPS 24

ASME B 17.1 (1967; R 2013) Keys and Key Seats

ASME B18.2.1 (2012; R2021) Square, Hex, Heavy Hex, and Askew

Head Bolts and Hex, Heavy Hex, Hex Flange, Lobed Head, and Lag Screws (Inch Series)

ASME B18.2.2 (2022) Nuts for General Applications Machine Screw Nuts; Machine Screw Nuts; and Hex, Square, Hex Flange, and Coupling Nuts (Inch Series)

ASME B18.3 (2012) Socket Cap, Shoulder, Set Screws, Hex and Spline Keys (Inch Series)

ASME B31.1 (2022) Power Piping

ASME BPVC Sect II (2023) Materials – Part A-Ferrous Materials Specifications

ASME BPVC Sect VIII Div. 1 (2023) Rules for Construction of Pressure Vessels Division 1

ASME BPVC IX (2023) Welding, Brazing, and Fusing Qualifications

American Welding Society (AWS)

AWS D1.1 Structural Welding Code - Steel

AWS A2.4 (2020) Standard Symbols for Welding, Brazing and Nondestructive Examination

International Organization for Standardization (ISO)

ISO 4406 (2021) Hydraulic Fluid Power - Fluids - Method for Coding the Level of Contamination by Solid Particles

8. SUBMITTALS

General: Contractor submittals shall be furnished in accordance with the specifications below. All listed items shall be submitted for Government approval by the TPOC. Associated work items shall not be performed until receiving approval from the TPOC. TPOC shall provide a response to the shop drawings within one week of receipt.

Shop Drawings: Attached drawings shall not be used for shop drawings. Seal designs and tolerances due to the modernization of the cylinders are the responsibility of the contractor. Shop drawings shall be submitted to the TPOC for approval prior to the start of the related work. In both CAD and PDF format. The Contractor shall make any corrections required by the TPOC. The approval of the drawings by the TPOC shall not be construed as a complete check but will indicate only that the general method of construction and detailing is satisfactory.

Approval of shop drawings by the COR shall not relieve the Contractor of the responsibility for complete conformity with the specifications. Shop, fabrication, or shop assembly drawings shall be provided by the Contractor on information not detailed on the Corps-supplied drawings. Any component part of fabricated items omitted on the contract drawings shall be detailed on the shop drawings. If departures from the contract drawings are deemed necessary by the Contractor (and approved by the Contracting Officer or the designated representative), details of such departures, including changes in related portions of the project and reasons therefore, shall be submitted with the shop drawings. The drawings shall show complete details of materials, tolerances, machined surface finishes, and connections.

As-Built Drawings: Contractor shall provide final as-built drawings to the TPOC for review. As-builts should be cylinder specific, or shall include a table of dimensions to link the measurements to the original cylinder number. Drawings shall be submitted in CAD and PDF formats.

List of Materials: The Contractor shall submit evidence, satisfactory to the TPOC, stating that all materials conform to the requirements of these specifications. The Contractor shall also furnish a shipping bill or memorandum of each shipment of finished pieces or members, giving the designation mark and weight of each piece, the number of pieces and the total weight.

O&M Manual: The contractor shall include an O&M manual to include at a minimum: approved shop drawings (including tolerances of the critical dimensions), manufacturer parts list, parts list shall list include industry standard part numbers, torque specs where applicable, coatings, manufacturer paint specifications, and assembly and disassembly instructions. The O&M manual will be approved by the TPOC.

Quality Control Record: All quality control records for fabrication of the items covered by these specifications shall be provided regularly. Examples of items in this record are chrome layer thickness and hardness, surface finish, welding quality, hydrostatic testing. Hardness testing shall not be performed on the final product.

Welding Procedure Specification (WPS): Welding specifications are required for all weldments. This information shall be submitted for approval prior to start of fabrication. Hydraulic cylinders shall be welded in accordance with the ASME BPVC, Section VIII, Division 1. Piping shall be welded in accordance with ANSI B31.1. Design of structural welded connections shall be in accordance with the applicable provisions of AWS D1.1 except that provisions for repeated stress will not be required.

Welding Procedure Specification (WPS). Qualifications: The names of welders and proof of their ASME Section IX qualification for the type of welding and position of welding must be submitted to the government for approval. The certification must state the type of welding and positions for which the welder is qualified, the code and procedure, the date and name and person certifying the qualification test(s).

Test Reports: Reports for the hydrostatic testing and the stress relieving heat treatment of cylinders shall be submitted and signed by the Contractor's representative. Radiograph reports and the developed film shall also be submitted.

9. MATERIALS

General:

Materials shall conform to the requirements indicated on the drawings or referred to herein, and when not covered thereby, materials and mechanical equipment of the best commercial grade quality suited to the intended use and as approved by the TPOC shall be furnished. The manufacturer's name, address, and catalog number shall be permanently displayed on a nameplate securely attached to each major item of equipment.

Nameplate shall include the finished bore size and include 3 blank lines to allow for documenting future rebuilds.

Hydraulic Cylinders:

The outside of the finished cylinder flanges shall be turned concentric with the bore as well as a minimum of two steady rest areas for 6” in length on the outside of the cylinder barrel, and the interior shall be honed to the dimensions, tolerances, and finish shown on the drawings. The finished wall thickness shall not be less than 1" +/- 1/64”. Flanges shall be welded to the cylinder parallel with each other and perpendicular to the cylinder center line.

Tolerances shall be as shown on the drawings, and to ensure fit up the components. After completion of all welding, the cylinder shall be stress relief heat treated. All full penetration welds shall be radiographed, except welded corners, tee joints and the structural steel support base which shall be tested using magnetic particle or ultrasonic testing. The radiographs and NDT test reports shall be submitted per Welding Test Reports. The Contractor shall repair any weld or material defects discovered by inspections at no additional expense to the Government.

Cylinders shall be stress relief heat treated after the completion of all welding. The assembled cylinders shall be of such straightness that the piston and rod move smoothly herein without any indication of binding or tight spots. The bore shall be hard chrome plated to 68-72 HRC to minimum thickness of 0.005 inches per side and the finish shall not be less than 16 micro inches rms. Hard chrome shall comply with ASTM B177. The surface finish shall be compatible with the seals being used so as to result in zero leakage past the seals. The cylinder material shall be steel conforming to one of the following acceptable materials:

a. Rolled steel plate conforming to the requirements of ASTM A516, Grade 70, and welded flanges conforming to ASTM Al81, Class 70.

b. The tube shall be centrifugal cast steel conforming to the requirements of ASTM A216, Grade WWC, and welded flanges conforming to ASTM Al81, Class 70, or cast from ASTM A216, Grade WWC steel.

c. The flanges shall be a solid trepanned forging conforming to the requirements of ASTM A266, Class 1.

d. The tube shall be machined from ASTM A519, Grade 1018, heavy wall seamless steel tubing and the flanges shall be machined from ASTM A516 Grade 70 plate or ASTM A576 Grade 1018.

Piping Connections:

The long weld neck flanges shall conform to ASTM A105. The orientation of the bolt holes shall conform exactly to the contract drawings to facilitate in-kind replacement with existing cylinders an extra set of piping nozzles and pipe supports shall be added adjacent and 180 degrees from those specified on the original drawings for a total of 4 each per cylinder. After completion of testing and for shipment all piping connections shall be sealed with blind flanges (per ASTM A105) with appropriate gaskets.

Cylinder Heads:

Cylinder heads shall conform to ASTM A181 blind flanges or ASTM A516 Grade 70 steel plate. The appropriate plugs and globe valves shall be provided as shown on the contract drawings.

Piston Rods:

The piston rod shall be fabricated from stainless steel conforming to ASTM A564 or ASTM A705, Type 630. The piston rod shall be heat treated to a condition of H-1150 before final machining. It shall be hard chrome plated to 68-72 HRC to 0.005 inch minimum thickness (per side). Hard chrome shall comply with ASTM B177. The final rod surface shall have a roughness height of not more than 8 micro inches rms. If the piston rod is composed of two or more pieces, the welds shall be radiographed.

Pistons:

The piston shall be made of an approved steel, ASTM A576, 1045 or cast steel, A27, Grade 60-30 with an aluminum bronze overlay, and may have approved wear band(s). The final diameter of the piston shall be sized to match the honed and chromed bore of each cylinder. The finished thickness of the aluminum bronze overlay shall not be less than 1/8 inch per side. All appropriate information concerning materials or alternate materials should be forwarded to the TPOC for evaluation and approval.

O-Ring Seals:

The O-ring seals shall be Buna N or Viton and designed for 1000 psi service and the 1500 psi hydrostatic test.

Rod Wiper:

The rod wiper shall be a high-strength polyurethane scraper ring which will withstand the impact and the abrasion of materials adhering to the piston rod. After lock is submerged periodically rod wiper will remove adhered mud and debris from the river.

Piston Seals:

Piston seals shall be of zero leakage cup type seals, nonadjustable gland type, designed for 1000 psi service and a 1500 psi hydrostatic test, compatible with hydraulic fluid, resistant to extrusion, and automatically compensate for wear. The seals shall be installed per the instructions and recommendations of the manufacturer. The seals shall be free from nicks and cuts, cleaned, and lubricated before installation. Alternate types may be proposed by the Contractor. All appropriate information should be forwarded to the TPOC for evaluation and approval.

Piston Rod Seals:

Piston rod seals shall be U-cup type designed for 1000 psi service and a 1500 psi hydrostatic test. The seal material shall be Buna-N or Viton. The seals shall be installed per the instructions of the manufacturer and shall be replaceable without disassembly of the hydraulic cylinder heads or the attachment at the end of the cylinder. Installed seals may be full circle of the cylinder at original installation. To permit site personnel serviceability the rod seal system shall be so arranged that the seals can be cut according to the seal manufacturer’s recommendation and installed in a staggered arrangement to restore full leakage control.

Instructions for field installing rod seals shall be included in final delivery. Alternate types may be proposed by the Contractor, including the original Chevron packing system.

All appropriate information should be forwarded to the COR for evaluation and approval.

Rod Seal Gland and Locking Device Flange/Bushing:

The rod seal gland and locking device flange shall be fabricated from bronze conforming to ASTM B505, Alloy No.

C95400. These parts shall be designed to be compatible with the new seals and rod. Alternate types may be proposed by the Contractor. All appropriate information should be forwarded to the COR for evaluation and approval.

Bolts, Studs, and Nuts:

All bolts and studs for the head to flange connections for each cylinder shall conform to ASTM Al93, Grade B7, with ASTM Al94, Grade 2H nuts.

Piston Rod Nut:

The piston rod nut shall conform to ASTM A194 Gr. 2H cut to match the width of the nut detailed on Dwg. OL-210.1/12-8 and OL-240.1/4-12. The nut must be secured with a set screw or a jamb nut to prevent the nut from backing off. If a set screw is used, the piston rod threads must be protected. If a jamb nut is used, it must not interfere with the normal operation of the hydraulic cylinder.

Hydraulic Fluid:

The hydraulic fluid to be used during shop testing and to flush the system after installation shall be hydraulic oil which has a high viscosity index, low pour point, and antifoam properties.

The final fill of oil should be ISO 32 with a cleanliness of a minimum of 20/17/14 to ISO 4406. Cylinders are to be shipped full of oil.

Drain Valves:

Two drain valves shall be installed on each head of each cylinder (total of four drain valves per cylinder). The valves shall be ½” Class 800 forged steel gate valves with 11 to 13% chrome trim; threaded both ends. The body and bonnet shall conform to ASTM A105. Each valve shall have a forged steel bull plug threaded in the open end.

Wiper Cap:

ASTM A240 Type 410 corrosion resistant steel.

Spare Parts The Contractor shall furnish spare parts (with the manufacturer's name and part number) in the quantities as listed below:

Item Quantity Rod Wiper 2 sets O-Ring Seals 2 sets Piston and Piston Rod Seals 2 sets Piston Wear Bands 2 sets

10. QUALITY CONTROL

Test of Materials: The Contractor shall, at his expense, perform analyses tests to demonstrate that all materials are in conformity with the specifications. Should the Contractor desire to use stock materials not manufactured specifically for the work covered by these specifications, he shall submit evidence, satisfactory to the TPOC, stating that such material conforms to the requirement specifications. Detailed tests of these materials will then not be required, if so approved by the TPOC. Tests, except where modified shall be made as indicated in the respective detailed specifications or on the drawing and, unless otherwise authorized, in the presence of the TPOC. The Contractor shall furnish the TPOC certified reports in duplicate of all required analyses and tests.

Nondestructive Testing: When doubt exists as to the soundness of any material part, such part may be subjected to any form of nondestructive testing permitted by the TPOC. This may include ultrasonic, magnaflux, dye penetrant, x-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts shall be replaced and retested at the Contractor’s expense.

11. WORKMANSHIP

General: Workmanship shall be of the highest grade in accordance with the best modern practices to conform to the specifications and drawings for the items being furnished.

Quality Control: The Contractor shall establish and maintain a quality control system to assure compliance with the contract requirement. The Contractor’s Quality Control staff will ensure that workmanship is of the highest quality and provide documentation that supports this quality for all work performed by the Contractor, any Sub- Contractor, Fabricator or Supplier.

Protection of Machined Surfaces: Machined surfaces shall be coated with a rust preventative coating.

12. DIMENSIONAL TOLERANCES OF MACHINED ITEMS

Dimensioning and Tolerancing: Dimensioning and Tolerancing of machined elements shall be in accordance with ASME Y14.5M-94.

Finished Surfaces: Surface finishes indicated or specified shall be in accordance with ANSIB46.1, Surface Texture (Surface Roughness, Waviness and Lay). Values of required roughness heights are arithmetical average deviations expressed in micro inches. These values are the maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ANSI B46.1. Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified it shall be that which is most suitable for the surface, provide the class of fit required and be indicated on the detail drawings by a symbol which conforms to ANSI B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

Unfinished Surfaces: Unfinished surfaces shall be true to the lines and dimensions shown and shall be chipped or ground free of all projections and rough spots.

13. REQUIRED SECURITY TRAINING AND PLANNING

15General security requirements and guidance: The security requirements described below apply to all contract personnel (including employees of the prime Contractor (“Contractor”) and all subcontractor employees) supporting the performance requirements of this contract. The Contractor is responsible for compliance with these security requirements. Questions regarding security matters shall be addressed to the designated Government representative (e.g., Contracting Officer Representative (COR), Requiring Activity (RA) representative, or Contracting Officer (if a COR or other RA representative is not appointed)).

Contract personnel are critical to the overall security and safety of US Army Corps of Engineers (USACE) installations, facilities and activities, and security awareness training contributes to those efforts. The Department of Defense (DoD) and Army security training requirements specified below, if applicable, are performance requirements; all applicable contract personnel shall complete initial training within 30 days of contract award or the date new contract personnel begin performance on the contract. Within five business days from the completion of training, the Contractor shall provide written documentation (e.g., email or memorandum) to the Government representative. The documentation shall include the names of contract personnel trained and which training they completed; the Contractor shall maintain training records as part of their contract files and be prepared to provide copies of training certificates to the Government representative. Contractor personnel and vehicles are subject to search when entering federal installations. Additionally, all contract personnel shall comply with Force Protection Condition (FPCON) measures, Random Antiterrorism Measures (commonly referred to as “RAMs”), and Health Protection Condition (HPCON) measures. The Contractor is responsible for meeting performance requirements during elevated FPCON and/or HPCON levels in accordance with applicable RA plans and procedures—this includes identifying mission essential and non-mission essential personnel. In addition to the changes otherwise authorized by the changes clause of this contract, should the FPCON or HPCON levels at any individual facility or installation change, the Government may implement security changes that affect contract personnel. The Contractor shall ensure all contract personnel are aware of their security responsibilities, including any site-specific requirements identified in local policies or procedures.

Physical security and access control requirements: All contract personnel requiring physical access to a federal installation or facility shall comply with the access control procedures of that location. Contract personnel requiring unescorted access to meet contract performance requirements on a DoD installation in the US shall be vetted by the installation/facility Provost Marshal/Directorate of Emergency Services/Security Office using the National Crime Information Center-Interstate Identification Index (commonly referred to as “NCIC-III”) and Terrorist Screening Database (commonly referred to as “TSDB”). Contract personnel shall comply with all personal identity verification requirements specified in installation/facility policies and procedures. Contract personnel who do not meet requirements for unescorted access to USACE facilities shall coordinate escorted access with the Government representative, as needed. Contract personnel who receive keys, access cards, or lock combinations that provide access to government-owned property shall comply with key and lock control procedures of the

RA.

14. PACKAGING AND SHIPPING

Shipping: Packaged parts shall be delivered between the hours of 6:00am and 4:00pm Monday thru Thursday. Contractor shall contact William Edwards (812) 853-8470 a minimum of 7 days in advance to coordinate delivery. Contractor shall notify the project and TPOC 72 hours prior to delivery if crated items exceed 2,000 pounds.

Packaging: The hydraulic cylinders shall be shipped in crates completely assembled. The assembly shall be provided with adequate protective pads, supports, and blocking. Each cylinder shall be securely restrained to prevent distortion or damage to the surfaces in transit. Any loss or damage during shipment, including damage to the surfaces, shall be considered the responsibility of the contractor, and shall be replaced or repaired without cost to the Government. Machined surfaces shall be adequately protected from corrosion and physical damage.

15. WARRANTY

All equipment shall be guaranteed for a period of 2 years from the date of acceptance. Replacement parts shall be guaranteed for 2 years from date of replacement. The warranty shall cover defective materials, design, and workmanship. In cases where the equipment manufacturer’s advertised minimum guarantee is in excess of 2 years, it shall remain in force for its full period. Upon receipt of notice from the Government of failure of any of the parts during the warranty period, new replacement parts shall be furnished and installed promptly at no additional cost to the Government.

Cylinder Tests. The cylinder shall be reassembled and tested in the presence of the Contractor's Officer's representative following the completion of all repairs. The hydraulic cylinder, with the piston rod extended, shall be subjected to a test pressure of 1500 pounds per square inch for a period of 30 minutes and there shall be no leakage across the cylinder heads. Testing of leakage across the piston seal shall be accomplished with the piston rod in the extended position for 15 minutes at a test pressure of 1,000 psi. The leakage rate across the piston shall not exceed 6 ounces for the test. The same test shall be repeated, with the piston rod retracted. There shall be no leakage through the rod seal packing when the cylinder is under the test pressure. The Contractor shall demonstrate that the breakaway pressure does not exceed 50 psi. The cylinder piston leakage rate tests and the breakaway pressure test as specified shall be conducted in a manner meeting the approval of the Contracting Officer. The cylinder shall be operated through 5 complete cycles at rated speed to demonstrate that it is suitable for the purpose intended. Operation shall be smooth and quiet without any vibration. The cylinder shall be 100 percent leak-proof. Detailed test procedures shall be submitted to the Contracting Officer for approval.

16. PAINTING

Surface Preparation. Surface preparation shall be near white metal abrasive blasted to SSPC-SP-10 SSPC- Paint 22. Surface profile shall be between 2.0 – 4.0 mils. As much as practical, the coating system shall be applied to individual components and items before assembly to ensure complete coverage and maximum protection against corrosion.

Priming. Surface shall be primed with an inorganic zinc primer.

Painting. All exposed exterior surfaces of assemblies and equipment except stainless steel, aluminum bronze, chrome, synthetic rubber, and plastic shall be shop primed with a coat of VOC compliant, fast dry, high solids epoxy coating (4-6 Mils F/S 27885 White S/G) and finished with a two-component, engineered siloxane coating (4-7 mils F/S 26270 Haze Gray S/G). The primer paint must be colored off-white. Consult with Technical Representative to approve any other colors. Red, orange, reddish brown, or any versions of these colors will not be approved. Both the priming and finish paints shall be approved prior to use and the manufacturer’s literature shall be sent to the Technical Representative for approval.

Parts and Surfaces Not painted. Paint shall not be applied on corrosion-resistant parts and finished machine surfaces in bolted contact. Unpainted finished machine surfaces shall be protected as specified in paragraph C-6, Protection of Finished Machined Surfaces.