SPECIFICATION SHEETS (7 pages).pdf

Stackable Test Weight Specification

FOR

PUGET SOUND NAVAL SHIPYARD (PSNS) &

INTERMEDIATE MAINTENANCE FACILITY

(IMF)

PREPARED BY:

Code 713

Bldg. 448, PSNS

Bremerton Washington 98314

SPECIFICATION PREPARED BY:

Project Engineer: Fearecia Maddox

Branch Head Supervisor: Bryce Perkins

1. SCOPE:

This specification is to provide requirements for the fabrication and documentation of crane test weights. The weights will be stackable in order to test cranes of different capacities. Each weight will be delivered to Puget Sound Naval Shipyard and Intermediate Maintenance Facility tested, fully assembled, painted, and ready for use.

2. REFERENCES:

American Society of Testing and Materials (ASTM) A-36: Standard Specification for Carbon Structural Steel

American Society of Testing and Materials (ASTM) B308: Standard Specification for Aluminum- Alloy 6061-T6 Standard Structural Profiles

American Society of Testing and Materials (ASTM) B209: Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

American Welding Society (AWS) D1.1: Structural Welding Code – Steel, and D1.2: Structural Welding Code - Aluminum

Puget Sound Naval Shipyard (PSNS & IMF) Drawing 4C30643 The Society for Protective Coatings Surface Preparation (SSPC) SP-10: Near White Blast Cleaning

3. DESIGN AND FABRICATION REQUIREMENTS

3.1. Stackable Crane Test Weights:

3.1.1. A total of 46 test weights are to be constructed, broken down into two (2) sets with different dimensional restrictions. Each set shall have stackable weights as follows:

3.1.2. Set one (1), with a maximum footprint of 24” x 30”

A. 4 x 100 lb.

B. 2 x 150 lb.

C. 2 x 200 lb.

D. 2 x 300 lb.

E. 2 x 500 lb.

F. 4 x 600 lb.

G. 4 x 1200 lb.

H. 2 x 1925 lb.

I. 6 x 2400 lb.

J. 6 x 4800 lb.

3.1.3. Set two (2), with a maximum footprint of 36” x 36”

A. 2 x 2400 lb.

B. 2 x 4800 lb.

C. 6 x 6000 lb.

D. 2 x 7200 lb.

3.1.4. Weights from Set 1 must be able to stack on Set 2.

3.1.5. Weights 1.A – 1.C have unique requirements and are designed as aluminum assemblies of

ASTM 6061-T6. Refer to drawings for further details. Weight 1.J also has unique requirements and is not intended to stack upon other weights. Refer to drawings for details.

3.2. Drawing:

3.2.1. PSNS drawing 4C30643 shall be used for fabrication purposes. At the request of the contractor the government will supply DXFs or STEP files.

3.3. Surface Texture:

3.3.1. Break all burrs and sharp edges; all surfaces must be smooth and without surface defects, flaws or waviness. All welds in sling channels must be ground smooth.

3.3.2. Special emphasis should be paid to surface texture of areas which will contact the synthetic rigging gear. These must be smooth and free of any sharp edges that could damage synthetic rigging gear.

3.4. Tolerances:

3.4.1. Dimensional tolerances for final fabrication are shown on drawing 4C30643.

3.4.2. The tolerance for actual weight of each test weight is as follows: -0%, +2% for all weights.

The actual weight is the certified measured weight see section 4.4

3.4.3. Center of gravity shall be at geometric center of each weight ±2”.

3.4.4. Test weights shall be stackable and nest level with each other without apparent deformation. For each test weight size profile, the vertical faces and sling channels of the test weights shall be aligned when stacked. Set 1 must be able to stack on Set 2 (except for 1.J), but is only required to have faces parallel, not aligned.

3.5. Material: For test weights 1.A through 1.E, the weights shall be fabricated from ASTM 6061-T6 Aluminum materials. See drawing 4C30643 for further details. For test weights 600lbs and above, weights shall be of all steel construction meeting ASTM A-36 requirements or alternate steel grade if approved by the government.

3.6. Welding: All welding performed for the fabrication of test weights shall be done in accordance with AWS D1.1/D1.2 as appropriate. When plates are welded together, welding must be continuous to help prevent corrosion between plates. All welds will be visually examined per

AWS D1.1/D1.2.

3.7. Corrosion Protection:

3.7.1. Upon completion of fabrication, each test weight shall be blasted to Near-White Metal

Blast Cleaning per SSPC-SP 10, primed and painted with a paint system that is used in 2B environmental zones per SSPC or equivalent and has an expected life of 10+ years. The colors shall be as follows:

3.7.1.1. Aluminum weights: White paint with black markings

3.7.1.2. Set 1 steel weights: Yellow paint with black markings

3.7.1.3. Set 2 steel weights: Black paint with white markings.

3.7.2. All paint used shall not contain lead, polychlorinated biphenyl (PCB), or chromates.

(Submittal Required)

3.8. Markings:

3.8.1. Stencil the actual weight (in pounds) of each test weight on a minimum of two opposing sides that are visible when weights are stacked. The markings shall be in a similar location on each test weight. Color of letter shall be as designated in 3.7.1 and a minimum of 2.5 inches tall.

3.8.1.1. Weights 1.A-1.C and 1.F have less vertical space, and are therefore authorized to reduce their markings down to 2 inches tall.

3.8.2. Each test weight will have a name plate affixed to one side with “Property of PSNS&IMF” followed by a serial number in the format P-###. The serial numbers shall start at value P-

123. The Contractor shall provide a list of the assigned serial numbers and each number’s associated weight and size. (Submittal Required)

3.8.3. Mark vertical lines at the center of each side of each test weight to assist with stack alignment & centering of weights. Color of stripe shall match markings color as described in

3.7.1 and be a minimum of 1 inch wide, but not greater than 3 inches wide.

4. SUBMITTALS

4.1. The Contractor shall submit to the Contracting Officer all items of technical documentation listed in this specification. The contractor shall ensure that all submittals are entirely legible and suitable for reproduction. Compliance with the requirements of this specification will be determined by a review of the design and construction submittals by the Contracting Officer and by both field and acceptance inspections.

4.2. Schedule:

4.2.1. The contractor shall submit a timeline schedule which identifies key milestone events in the fabrication of the test weights (Submittal Required). At a minimum, the schedule shall include dates for the following events:

A. Fabrication initiation.

B. In-process Government Representative field (on-site) inspection and testing.

C. Fabrication completion.

D. Delivery (Arrival at destination Bremerton, WA).

4.3. Coatings: Provide original equipment manufacturers’ specifications and Safety Data Sheets (SDS) for all primer and paint used on main paint system, stenciling and marking for each weight. (Submittal Required)

4.4. Weight Certification:

4.4.1. Certificate shall be hard copy original, indicating the measured weight of each test weight by serial number and be signed by the certifying official that is guaranteeing the accuracy of the document and measured weight. (Submittal Required)

4.4.2. The certificate shall indicate each test weight was measured using calibrated equipment traceable to the National Institute of Standards and Technology, with a minimum accuracy of +/-2% (i.e. indicated weight shall be within +/-2% of actual weight).

4.4.3. The certificate shall include the following for all of the calibrated measurement equipment used:

A. Original Equipment Manufacturer (OEM) B. Serial number C. Model number D. Accuracy E. Calibration date

4.5. Welding:

4.5.1. Contractor will submit Welding Procedure Specification (WPS) per AWS D1.1/D1.2 for each material welded per the applicable welding process. All steel welds shall be of the pre-qualified type. Welding Procedure Qualification Test Report must be approved prior to any welding. (Submittal Required)

4.5.2. All records of visually examined welds will be submitted, including any reexamination of deficient welds found after rework if applicable. (Submittal Required)

4.5.3. Welding operator and/or welder certifications will be submitted for all WPS used.

Welding Personnel Qualifications must be approved by the Government prior to any welding. (Submittal Required)

Specification Section

Submittal Required Description Due Date Number of Copies

4.2.1 Fabrication Schedule Describes major fabrication

milestones

30 days after contract award

4.5.1 Welding Procedure

Specification

Per. AWS D1.1/D1.2 10 days before Welding

4.5.2 Weld Examination Records of all visually examined

welds

10 days after Welding

4.5.3 Welding Operator

Certifications

Personnel qualifications 10 days before Welding

4.3 Paint SDS Safety Data Sheets 10 days before

shipping

3.7.2 Prohibited Materials

Guarantee

Guarantee that all paints used to not contain the prohibited ingredients

10 days before shipping

4.4.1 Weight Certification Signed certificate of weight

value

10 days before shipping

3.8.2 Serial Number List List of serial numbers and

weight profile and value

10 days before shipping

5. TEST, INSPECTION AND ACCEPTANCE TERMS

5.1. In-process Inspection and Testing (Field):

5.1.1. The Contractor shall inspect the test weights for form, fit, and function. The contractor shall ensure the test weights nest when stacked, including set 1 weights stacked on set 2, and are level when lifted by the sling channels. Weight 1.J is not expected to stack on any other weights. After the Contractor’s preliminary inspection and operational test of each weight is complete, the Contactor shall notify the Government.

5.1.2. The contactor shall test the weights in the following manner to ensure adequate strength and construction:

5.1.2.1. Weights shall be lifted by synthetic slings only.

5.1.2.2. 100lb weight stacked on 600lb weight and lifted.

5.1.2.3. For set 1, the 2400lb weight stacked on the 4800lb weight and lifted.

5.1.2.4. 6000lb weight stacked on 7200lb weight and lifted.

5.1.3. At the option of the Government, a site inspection will be conducted by the Government along with the Contractor. The Contractor will make the test weights available for Government witnessing of the inspection and operational testing. The Contractor will be prepared to stack / un-stack the test weights and lift test weights using slings in sling channels as needed during the visit. Upon completion of the field inspection and testing, a “punch” list of deficient items will be compiled and signed by the Government representative (if applicable) and forwarded to the Contracting Officer.

5.1.3.1. At the option of the Government, the Government may request photos of the weights during the manufacturing process instead of an in-person visitation. Details should include a representative sample of welds, different weight constructions, general dimensions, and photos of some of the lift tests performed to verify function.

5.2. Warranty: The Contractor's warranty shall apply only to those defects discovered by either the Government or the Contractor within twelve (12) months after government acceptance.

5.3. Final Inspection and Acceptance (Destination):

5.3.1. Inspection and acceptance of the supplies or services to be furnished hereunder shall be made at destination by the receiving activity. Receiving activity shall execute acceptance certificate on the applicable inspection and receiving report form: DD Form 1155, Standard Form 44, DD form 250, or the Wide Area Workflow (WAWF) Receipt and Acceptance Receiving Report.

5.3.2. Following completion of Government inspection, final Government acceptance of the weights shall take place only after the following conditions are met:

5.3.2.1. Contractor receives Government approval for all submittal items.

5.3.2.2. The weights pass a final inspection by the Government.

5.3.2.3. All deficient items have been corrected or methods of resolution have been determined. Deficient items not corrected prior to the Government’s acceptance shall be carried as warranty items, which will be corrected by the Contractor.