SOW.pdf

CANNELTON LOCK & DAM

SCOPE OF WORK

TECHNICAL SPECIFICATIONS FOR

Auxiliary Chamber Emergency Gate Sheaves

1. General: The contractor shall provide all labor, equipment, and materials to perform all operations necessary to furnish new sheaves for both upstream and downstream emergency gates of the Auxiliary Lock Chamber at Cannelton Lock and Dam.

All work is to be completed in accordance with these specifications, referenced drawings, per Industry Standards and all applicable codes, regulations and ordinances. This includes but is not limited to the machining, Quality Control Testing and Acceptance, part identification, and packaging.

The contractor shall package all items as indicated in these specifications and deliver the completed sheaves to Louisville Repair Station (LRS) in Louisville, KY. All costs associated with packaging, handling, and delivery of the finished sheaves including all labor, material, and equipment shall be the responsibility of the contractor.

a. Technical POC: All technical questions regarding this contract shall be directed to Darren

Roberts at (502) 315-7007, email: darren.c.roberts@usace.army.mil.

All other questions shall be directed to the Contracting Officer designated in the contract.

Invoice must be sent to Technical POC after delivery.

b. Start Dates/Completion: The contractor shall begin work within 10 days of the Notice of Award. All Base line items, along with awarded option items shall be delivered within 140 calendar days (20 weeks) from the date of award. Sheaves shall be completed and delivered No Later Than 9 February 2026.

c. Delivery: The new sheaves shall be delivered to the Louisville Repair Station (LRS).

i. (LRS) Address: 2605 Shippingport Drive, 40212

ii. Must contact William Chapman 48 hours prior to delivery at (502) 416-5880.

d. Packaging: The parts must be packaged in wood crates or wood boxes to ensure the safety of the parts during shipping. Further protection measures shall be taken to prevent damage to the sheaves.

Each crate shall have skids and be able to be moved by forklift. It is preferred the gross weight of each crate be near 6,000 lbs. The weight of each crate shall not exceed 8,000 lbs.

Crates / boxes shall be sufficiently constructed in the manner that allows stacking of the crates up to three high. Lids shall be screwed on and have screws that take a T20 or T25 style bit for removal to facilitate inspection of the crate after delivery without damaging the lid for storage.

Each crate shall be clearly labelled to identify the line item(s) and quantity of parts in the respective crate. Refer to Exhibit __ for example.

e. Safety: The contractor shall complete all work in accordance with the U.S. Army Corps of Engineers Safety and Health Requirements Manual, EM 385-1-1, and all applicable Federal, State and Local Laws, Codes and Regulations.

f. Background: The emergency gates are positioned below water and stored in a recess beneath the floor of the lock chamber. The emergency gates are operated by hoist machinery located on the lock wall and utilize 1-3/4” S.S. lang lay (6x37 or 6x36) wire rope (Max. Breaking strength 113 tons) fed through a series of hoist and gate sheaves to raise and lower each gate.

g. For Reference: The weight of the upstream gate is approximately 140,000 lbs. (70 TN) and the weight of downstream gate is approximately 480,000 lbs. (240 TN). Additionally, it is assumed each gate has 120,000 lbs. of additional silt weight.

There are 14 parts of line on each side of the downstream gate and 8 parts of line on each side of the upstream gate. Assuming a factor of safety (FS) of 5, the wire rope running through each sheave will be rated for 22.6 ton per each part of line. The max anticipated load on the bushing is approximately 1,145 psi to 1,710 psi.

2. SCOPE OF WORK:

This contract is to fabricate (22) new sheaves for the AUX. Chamber upstream and downstream emergency gates per the drawings and specifications herein and includes option lines to install anodes and bushings.

The contractor shall provide to the government representative all required submittals, material certs / mill reports, shop drawings, and details for approval prior to purchase of material and/or fabrication.

Line Item 001: Furnish 52-1/8” O.D. Sheaves with Grooves “A” & “B” as specified

(MK240.1/20-2)

Contractor shall furnish (4) sheaves per the attached drawings and specifications to include both grooves “A” and “B” with felt seals installed/provided as indicated. The face of the sheave hubs shall receive an aluminum bronze overlay as detailed in the drawings.

a. Sheaves shall be fabricated plate steel or machined from steel plate and meet the minimum specifications in Section 3.

b. All machined finishes shall be as shown in the supplied drawings. Other finished surfaces without any designation shall be 125 micro inches unless approved by the TPOC.

c. The bore shall be centered and machined to 15” dia. as shown in the drawing.

i. Contractor shall verify FN-2 fit with government furnished aluminum bronze bushings.

d. Each hub face of the sheave(s) shall receive ¼” thick aluminum bronze overlay as indicated on drawing.

i. Where ¼” aluminum bronze is specified, the steel surface shall be undercut, and the aluminum bronze applied by arc welding in accordance with the specifications and finished to a nominal thickness of ¼’. No bolting of an Aluminum Bronze thrust washer to the sheave(s) will be permitted.

ii. Weld procedure shall be a pure finished layer of aluminum bronze on the surface with no steel mixed into the surface.

iii. Contractor shall submit overlay welding procedure for review before start of work.

e. Grooves “A” and “B” shall be machined and include felt seals as detailed in the drawings.

i. Felt shall be SAE F-3.

f. The wire rope groove shall be faced with 1/8” thick CRES. Contractor shall submit overlay welding procedure for review before start of work.

g. Sheaves are to be shop painted with a corrosion resistant coating to protect the base metal. The paint system shall be suitable for immersion in freshwater.

i. Coatings shall not be applied to the aluminum bronze overlay, rope groove, or other specified machined finished areas indicated that are to be in direct contact with other components and are to slide, rotate, or operate with minimal friction.

Line Item 002: Furnish 52-1/8” O.D. Sheave with only Groove “A” as specified (MK240.1/20-1)

Contractor shall furnish (18) sheaves per the attached drawings and specifications to include groove “A” only with a felt seal installed/provided as indicated. The face of the sheave hubs shall receive an aluminum bronze overlay as detailed in the drawings.

a. Sheaves shall be fabricated plate steel or machined from steel plate and meet the minimum specifications in Section 3.

b. All machined finishes shall be as shown in the supplied drawings. Surfaces without any designation shall be 125 micro inches unless approved by the TPOC.

c. The bore shall be centered and machined to 15” dia. as shown in the drawing.

i. Contractor shall verify FN-2 fit with government furnished aluminum bronze bushings.

d. Each hub face of the sheave(s) shall receive ¼” thick aluminum bronze overlay as indicated on drawing.

i. Where ¼” aluminum bronze is specified, the steel surface shall be undercut, and the aluminum bronze applied by arc welding in accordance with the specifications and finished to a nominal thickness of ¼’. No bolting of an Aluminum Bronze thrust washer to the sheave(s) will be permitted.

ii. Weld procedure shall be a pure finished layer of aluminum bronze on the surface with no steel mixed into the surface.

iii. Contractor shall submit overlay welding procedure for review before start of work.

e. Groove “A” shall be machined and include a felt seal as detailed in the drawings.

i. Felt shall be SAE F-3.

f. The wire rope groove shall be faced with 1/8” thick CRES. Contractor shall submit overlay welding procedure for review before start of work.

g. Sheaves are to be shop painted with a corrosion resistant coating to protect the base metal. The paint system shall be suitable for immersion in freshwater.

i. Coatings shall not be applied to the aluminum bronze overlay, rope groove, or other specified machined finished areas indicated that are to be in direct contact with other components and are to slide, rotate, or operate with minimal friction.

Option Line Item 003: Furnish and mount magnesium anode ribbon on sheave webs as specified. (Option Item can be awarded up to 60 days after award)

If awarded, the contractor shall furnish and mount cathodic protection anode ribbons on each face of the sheave web as shown or similar to the supplemental drawing. The anode ribbon shall be attached to sheave web in such a way that the anodes or mounting hardware does not interfere with other sheaves or components (must be within the max width/depth of the rim and/or hub).

a. Anode ribbon shall consist of Magnesium and meet the specification in Section 3.

i. Anode ribbon shall be approx. 0.38” width by 0.75”.

ii. Shall have a #10 (0.135”) diameter mild steel core or equivalent.

b. Mounting of anode ribbon shall be as shown in the supplemental drawing details or similar.

i. Mounting brackets are to be made from 304 stainless steel (S.S.), unless approved by the TPOC.

ii. If alternate materials are susceptible to corrosion, it shall be painted with a corrosion resistant coating to protect the base metal.

(Option Item can be awarded up to 60 days after award)

Option Line Item 004: Machine O.D. of Government Furnished Aluminum Bronze Bushings and press fit into new sheaves. (Option Item can be awarded up to 60 days after award)

If awarded, the government will furnish aluminum bronze bushings to the contractor to be press fit into the new sheaves. The contractor shall machine the O.D. of the Gov’t furnished bushings to match the sheave bore for a FN-2 fit per ANSI standard fits and tolerances.

The I.D. of the government furnished bushings have been finished with a RC-8 fit matched to one of four pins. It is crucial that special care be taken to sort and mark each sheave with designation of the bushing/pin combination, so each installed bushing corresponds to the correct pin.

The identification and combination of sheaves w/bushings to pins are as follows:

Pin Identification

O.D of Pin (in.)

Total # of Matching Bushings

Qty. and Type of Sheave

#1 13.000 4 (1) MK240.1/20-2 Sheave /

(3) MK240.1/20-1 Sheaves

#2 12.996 4 (1) MK240.1/20-2 Sheave /

(3) MK240.1/20-1 Sheaves

#3 12.976 7 (1) MK240.1/20-2 Sheave /

(6) MK240.1/20-1 Sheaves

#4 12.997 7 (1) MK240.1/20-2 Sheave /

(6) MK240.1/20-1 Sheaves

Please note the OD of the pin correlates to the ID of the aluminum bronze bushings. The OD of the bushings will need to be machined to match the bore diameter (15”) of the sheave(s) with a FN-2 fit.

Contractor will be responsible for all costs associated with picking up or shipping of the government furnished bushing to their facility. The bushings are located at LRS in Louisville, KY.

(Option Item can be awarded up to 60 days after award)

3. Materials:

All materials shall be domestically sourced according to the Buy American Act FAR 52.225-9.

Materials specifications shall be submitted and approved by TPOC before purchasing and or fabrication.

a. SHEAVES:

Materials shall be carbon steel or low alloy with high strength, ductility, and toughness characteristics suitable for this application.

Sheaves shall be fabricated according to the dimensions indicated in the supplied drawing. Sheaves can be fabricated plate or machined plate, provided the steel materials used meet the minimal requirements below and conforms to ASTM and/or AISI, and the specifications of this contract.

Table 3.a - Minimum Tensile Requirements based on ASTM A148 Grade 80-40 Minimum Tensile Strength ksi (MPa) 80 (550) Minimum Yield Strength ksi (MPa)* 40 (275) Minimum Elongation in 2” (50 mm) 18% Minimum Reduction of Area 30%

* - Determined by the 0.2% offset method Note: Original sheave design was ASTM A27 Grade 65-35 cast steel. Minimum tensile requirements may conform to this Grade 65-35 if approved by the

TPOC.

i. Carbon and alloy steel shall be IAW standard requirements including but not limited to ASTM A29, ASTM A36, and/or ASTM A6.

ii. Preferred sheave materials are (AISI) grade 1035 - rolled forged or (AISI) grade 4340 - normalized, quench, and tempered. See tables below.

ASTM A29 Grade 1035 – Tensile Requirements Minimum Tensile Strength ksi (MPa) 84.8 (585) Minimum Yield Strength ksi (MPa) 53.7 (370) Minimum Elongation in 2” (50 mm) 30% Minimum Reduction of Area 53%

ASTM A29 Grade 4340 – Tensile Requirements Minimum Tensile Strength ksi (MPa) 108 (745) Minimum Yield Strength ksi (MPa) 68.2 (470) Minimum Elongation in 2” (50 mm) 22% Minimum Reduction of Area 50%

iii. Alternate grades, specifications, and chemical compositions for sheaves may be acceptable, provided they meet the minimum Tensile Requirements specified in section (3.a) and are approved by the TPOC.

iv. Forging and rolling of carbon or alloy steel shall conform to all applicable ASTM standards.

v. Hardening and heat treatment of carbon or alloy steel shall conform to all applicable ASTM standards.

b. ALUMINUM BRONZE:

Aluminum bronze overlay materials shall conform to AWS 5.7. Aluminum Bronze – A2 (ERCuA1-A2) shall be used for the overlay unless alternate material is approved by the

c. MAGNESIUM ANODE RIBBON:

Extruded magnesium anode ribbon is a flexible anode material generally used in high resistivity water or soil.

Anodes shall be of high-potential magnesium alloy, made of primary magnesium obtained from sea water or brine, and not made from scrap metal. Magnesium anodes shall conform to ASTM B 843 and to the following analysis (in percents) otherwise indicated in Table 3.c.

Table 3.c – Chemical Composition Material High Current

Alloy (%) Aluminum 0.010 (max) Manganese 0.50 – 1.30 Zinc 0.05 (max) Silicon 0.05 (max) Copper 0.02 (max) Nickel 0.001 (max) Iron 0.03 (max) Other Impurities 0.05 each (max) /

0.30 total (max) Magnesium Balance

d. FELT SEAL:

Felt seal shall be SAE F-3.

e. PAINTING OF FINISHED WORK:

Paint system shall conform to UFGS Section 09 97 02 - Painting: Hydraulic Structures.

Paint system shall be suitable for the application as described in section 1.f and for steel surfaces subject to immersion in fresh water of low to moderate velocity and potentially corrosive due to industrial contamination.

In general, storage of paint materials, surface preparation, mixing and thinning, paint application, atmospheric and surface conditions, etc. shall follow the paint manufacturer’s recommendations.

i. Safety - The Contractor shall follow all applicable Federal, State, and Local laws.

ii. Epoxy coatings of the steel sheaves shall follow the paint schedule below:

Full Prime Coat: Amine Cured Epoxy Mastic Hi-Build Coating S/G, Grey – Volume Solids +87% @ 4-5mils Dry-Film Thickness

Second Coat: Amine Cured Epoxy Mastic Hi-Build Coating S/G, Black – Volume Solids +87% @ 4-5 mils Dry-Film Thickness

Third Coat: Aliphatic Polyurethane Mastic Coating Gloss, Black – Volume Solids +65% @ 3-5 mils Dry-Film Thickness

iii. Cleaning and Preparation of Surfaces to be Painted: Components shall be solvent cleaned according to SSPC SP-1 and cleaned to white metal meeting SSPC SP 5 prior to painting.

iv. Paint Application: The finished coating shall be free from holidays, pinholes, bubbles, runs, drops, ridges, waves, laps, excessive or unsightly brush marks, and variations in color, texture, and gloss.

All paint coats shall be applied in such manner as to produce an even, continuous film of uniform thickness. Edges, corners, crevices, seams, joints, welds, and other surface irregularities shall receive special attention to ensure that they receive an adequate thickness of paint.

v. Mixing and Thinning: Shall be to the paint manufacturer’s specifications and recommendations.

vi. Atmospheric and Surface Conditions: Shall be to the paint manufacturer’s specifications and recommendations.

vii. Time Between Surface Preparation and Painting: Surfaces that have been cleaned and/or otherwise prepared for painting must be primed as soon as practicable after such preparation has been completed but, in any event, prior to any deterioration of the prepared surface.

viii. Coverage and Film Thickness: The paint shall be applied at a rate normal for the type of material being used. In any event, the combined coats of a specified paint system shall completely hide the base surface, and the finish coats shall completely hide undercoats of a dissimilar color.

4. Machine Work: The sheaves shall be machined to the tolerances on the drawings where decimal dimensions indicated. Tolerances for non-decimal dimensions shall be within 1/64 inch. The bore diameter of the sheaves shall be cut true to gauges, smooth, and straight for proper fit with mating bushings.

a. Dimensioning and Tolerancing: Dimensioning and Tolerancing of machined elements shall be in accordance with ASME Y14.5 and what is provided in the drawings.

b. Finished Surfaces: Surface finishes indicated or specified shall be in accordance with ANSI B46.1, Surface texture (Surface Roughness, Waviness and Lay). Values of required roughness heights are arithmetical average deviations expressed in micro inches.

These values are 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 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 particular 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.

c. 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.

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

5. Metal Work Fabrication:

a. General: Material must be straight before being laid off or worked. If straightening is necessary, it shall be done by methods that will not injure the metal. Sharp kinks or bends shall be cause for rejection of the material. Material with welds will not be accepted, except where otherwise approved. Where heating is required, precautions shall be taken to avoid overheating the metal, and it shall be allowed to cool in such a manner as not to destroy original properties of the metal. Finished members shall be free from twists, bends and open joints.

b. Welding: All welding shall be performed in accordance with the AWS and ISO; and shall be performed by a certified welder qualified to perform the work.

If sheaves are fabricated by weldments, all welds shall be visually inspected by an AWS Certified Welding Inspector (CWI) and tested accordingly per the ANSI/ASNT.

c. Dimensional Tolerances of Structural Steel Items: Dimensions shall be measured by means of an approved calibrated steel tape of the same temperature as the item or part at the time of measurement. The overall dimensions of the assembled structural unit shall be within the tolerances indicated on the drawings or as required for proper assembly.

6. Quality Assurance:

a. Testing of Materials: The Contractor shall, at their expense, perform analyses and 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, they shall submit evidence, satisfactory to the Contracting Officer, that such material conforms to the requirements of the specifications.

Detailed tests of these materials will then not be required, if so, approved by the Contracting Officer. Tests, except where modified shall be made as indicated in the respective detailed specification or on the drawing and, unless otherwise authorized, in the presence of the Contracting Officer. The Contractor shall furnish the Contracting Officer certified reports in duplicate of all required analyses and tests. The Contractor shall furnish to the Contracting Officer, upon request, specimens and samples for independent analysis and test that are properly labeled and prepared for shipment.

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

c. Workmanship: Workmanship shall be of the highest grade, and in accordance with the best modern practices, to conform with the specifications for the item of work being furnished.

d. Quality Control: The Contractor shall establish and maintain a quality control program to assure compliance with the contract requirements and shall submit records of all quality control operations for the items covered by these specifications. These records shall document material and workmanship compliance. They shall document all inspections and testing completed by the Contractor’s Quality Control staff to ensure compliance to this contract. 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.

e. Quality Control Program: The Plan shall include a detail process of how the Contractor’s Quality Control Program shall function throughout this entire Contract so that all materials delivered to the Government meet the Contract requirements in every aspect.

The Plan shall indicate Contractor Quality Control (CQC) Organization, letters of authority to the CQC staff, testing laboratories to be used, inspection procedures, documentation process to control delivered materials, sample of the proposed CQC daily report, test report forms and other reports necessary to complete this contract.

7. Corps of Engineers Inspection: Corps of Engineers personnel shall be allowed to 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), unless the Technical Representative states otherwise.

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.

8. Submittals: Contractor submittals shall be furnished in accordance with the specifications below. Associated work items shall not be performed until receiving approval from the Contracting Officer or TPOC. TPOC shall provide a response to the shop drawings within one week of receipt.

All listed items shall be submitted for Government approval by the Contracting Officer.

a. List of Materials: Contractor to submit evidence, satisfactory to the technical representative 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. All parts and materials shall conform to FAR 52.225-5 Trade Agreements and FAR 52.225.9 Buy American Act.

b. Material Certifications: All materials used for this contract shall meet the specifications and standards per the ASTM, AISI, etc. Contractor shall submit material certs / mill reports for each material satisfactory to the government.

c. Shop Drawings: Use of the attached drawings for shop drawings shall be at the contractor’s option and risk. If the contractors shop practice requires details in addition to, or different from, those shown on the contract drawings, they shall prepare shop drawings and furnish three sets for approval. If approved by the Contracting Officer, each copy of the drawings will be identified as having received such approval by being so stamped and dated, on set will be returned to the contractor. The contractor shall make any corrections required by the Contracting Officer. The approval of the drawings by Contracting Officer shall not be constructed as a complete check but will indicate only that the general method of construction and detailing is satisfactory. Approval of shop drawings by the Contracting Officer shall not relieve the Contractor of reasonability for complete conformity with the specifications. Shop drawings shall include a table with the finished bore diameters in the sheaves and bushings for each sheave.

d. Welding Procedures: Welding Procedure Specification (WPS) shall be submitted for each process used to include the aluminum bronze and stainless-steel overlay. WPS shall be submitted for approval by the TPOC prior to the start of work.

e. Welder Qualification: Welder qualification shall also be submitted for approval by the

f. Quality Control Program: The Contractor shall submit a Quality Control Plan prior to the start of any work. The Plan shall include a detail process of how the Contractor’s Quality Control Program shall function throughout this entire Contract so that all materials delivered to the Government meet the Contract requirements in every aspect.

g. Quality Control Record: The contractor shall submit all quality control records covered by these specifications shall be provided regularly.

h. Paint System: Contractor shall submit the paint preparation and paint system for approval by the TPOC.

9. Drawing Index: For drawings and details, please see attached Exhibits.

a. Exhibit A – Drawing and Details of Sheaves for Base Line Item 001 & 002.

b. Exhibit B – Reference Drawings & Details for Additional Information; including:

i. Wire Rope Reeving Diagram

ii. Emergency Gate Sheave Assembly Detail

iii. Emergency Gate Sheave Bushing Detail

iv. Upstream Emergency Gate Pin Detail

v. Downstream Emergency Gate Detail

c. Exhibit C – Magnesium Anode Ribbon Details for Option Item 003

d. Exhibit D – Sample of Crate Identification