Specifications.pdf

Heavy-Lift Test Weight Specifications

1 Design and Fabrication Requirements

1.1 Test Weight Overview:

1.1.1 The test weight procurement order shall be composed of the following individual weights:

1.1.1.1 (3) Three 80,000 lb. Test Weights (Base Contract)

1.1.1.2 (1) One 80,000 lb. Test Weights (Option/Future)

1.1.2 Total nominal weight:

1.1.2.1 240,000lb. (Base Contract)

1.1.2.2 320,000 lb. (Base Contract Plus Option/Future)

1.2 Test Weights:

1.2.1 PNSY-D-711-20-001 shall be used for quotation purposes.

1.2.2 Test weights shall be stackable and nest level with one another without deformation.

1.2.3 Each of the test weights shall be fully interchangeable with respect to its position within the stack-up.

1.2.4 Each test weight shall be capable of holding its own weight (80,000 lbs.), the weight of the other three weights (240,000 lbs.) and an additional 140,000 lbs. (of existing weights currently owned by Portsmouth Naval Ship Yard) as seen in PNSY-D-711-20-001.

1.2.4.1 The weight each test weight will be capable of holding shall be 380,000 lbs.

1.2.4.2 The combined maximum total value of the designed stack-up shall be 460,000 lbs. and will be designated as the "Working Load Limit" (WLL).

1.3 Surface Texture:

1.3 .1 Break all burrs and sharp edges; all surfaces must be smooth and without surface defects, flaws, or waviness. All welds must be ground smooth.

1.3 .2 Special emphasis should be paid to surface texture of lifting channels and recessed anchor points which will contact the synthetic rigging gear.

1.3 .2.1 Chains shall not be used in direct contact within the lifting channels and recessed anchor points to lift the test weights during or after fabrication.

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1.4 Dimensional Tolerances:

1.4.1 Test weight quantities and dimensional tolerances are included in each respective drawing set.

1.4.1.1 These tolerances are required to be met unless otherwise approved in writing by the Government.

1.4.2 Dimensional or fabrication drawing changes may be made with Government approval based on a review of fabrication drawings submittal.

1.4.3 Dimensional tolerances for final fabrication are as follows:

1.4.3.1 Test Weight (Geometry)

1.4.3.1.1 Measurements less than 12 in=+/- 1/16 in

1.4.3.1.2 Measurements greater than or equal to 12 in=+/- 1/8 in

1.4.3.2 Special Attributes (Geometry and Location)

1.4.3.2.1 Lifting Channel tolerance:+/- 1/16"

1.4.3.2.2 Recessed Anchor Point(s) tolerance:+/- 1/16"

1.4.3.2.3 Nesting Stud(s): +/- 1/16"

1.5 Weight Tolerances:

1.5.1 Test weight quantities and weight tolerances are included in each respective drawing set.

1. 5 .1.1 These tolerances are required to be met unless otherwise approved in writing by the Government.

1.5.2 Dimensional or fabrication drawing changes may be made with Government approval based on a review of fabrication drawings submittal.

1.5.3 The tolerance for each individual test weight is as follows:

1.5.3.1 +800 lb./-0 lb. for the 80,000 lb. weight (e.g. 80,000lb to 80,8001b on certificate is acceptable)

1. 5 .4 Center of gravity shall be at geometric center (X and Y axis of horizontal plane) of each weight.

1.5.5 Center of gravity shall be sufficiently aligned with the lifting channels to ensure that test weights are between level and 5° from horizontal when lifted.

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1.6 Material:

1.6.1 Test weights shall be of steel construction,

1.6.1.1 The general mass of the test weight shall be AISI 1008 Steel

1.6.1.1 .1 Minimum of 41 ksi yield strength and 49 ksi ultimate strength.

1.6.1.2 The nesting studs and recessed anchor points of the test weight shall be ASTM

A36 Steel

1.6.1.2.1 Minimum of 36 ksi yield strength and 58 ksi ultimate strength.

1. 6 .2 Each test weight shall have a minimum yield safety factor of 3, and a minimum ultimate safety factor of 3.

1.7 Welding:

1. 7 .1 Any welding performed for the fabrication of test weights shall be done in accordance with AWS Dl.l.

1. 7.2 If multiple plates are welded together to achieve required weight thicknesses, these welds shall be 100% all-around to eliminate water intrusion.

1. 7.3 Electrode shall have a minimum of 60 ksi ultimate strength.

1.8 Weight Calibration:

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

1.9 Corrosion Protection:

1.9.1 Upon completion of fabrication, each test weight shall be blasted, primed, and painted with a lead-free epoxy paint system to protect against corrosion. Top coat color shall be black.

1.9.2 SDS sheets shall be provided for each individual product used in the painting process (i.e.

cleaning agents, primers, paints, thinning/thickening agents, sealants, fillers, etc.) All products shall be lead-free.

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1.10 Markings:

1.10.1 Stencil each test weight, with lead-free paint, the actual weight (in pounds) of each test weight on a minimum of two opposing sides. The markings shall be in a similar location on each test weight. Letters shall be white in color, and a minimum of (3) three inches tall. Weight quantity shall be prefixed by "W:" and followed by "LB".

1.10.2 Stencil each test weight, with lead-free paint, the weight each is capable of bearing on top of itself (Working Load Limit (WLL)) stenciled (to the nearest whole pound, in pounds) on a minimum of two opposing outermost sides. The markings shall be in a similar location on each test weight. Color shall be yellow and a minimum of (3) three inches tall. The label shall read on a single line "WLL: 460,000 LB".

1.10.3 Stencil each recessed anchor point, with lead-free paint, the force each is capable of handling and warning labels. The markings directly adjacent to each recessed anchor point shall be in a similar location on each test weight. Color shall be white and a minimum of (1) one inch tall. The label shall read on three individual lines respectively

"4,000 LB MAXIMUM FORCE", "FOR CAPTIVATION ONLY", "NOT FOR

LIFTING OF TEST WEIGHT"

1.10.4 Stencil each test weight, with lead-free paint, vertical lines in similar locations, a minimum of (1) one inch wide. Vertical lines shall be at center of each side of each test weight to assist with stack alignment and centering of weights. Color of stripe shall be white.

1.10.5 The serial number of each test weight shall be marked on the weight by welding on one side, a minimum of (3) three inches tall. Serial numbers shall be unique and sequential.

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2 SUBMITTALS

2.1 General:

2.1.1 The contractor shall submit to the Contracting Officer all items of technical documentation listed hereinafter. 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 government and by both field and acceptance inspections.

2.2 Schedule:

2.2.1 The contractor shall submit a timeline schedule that identifies key milestone events in the design and fabrication of the test weights. At a minimum, the schedule shall include approximate dates for the following events in the given order:

2.2.1.1 Post award tele-conference, to discuss project and answer any questions.

2.2.1.2 Fabrication initiation.

2.2.1.3 In-process Government representative field (on-site) inspection and testing.

2.2.1.4 Fabrication completion.

2.2.1.5 Submittal and acceptance of final as-built inspection documents, certification documents and material SDS sheets.

2.2.1.6 Delivery by the contractor to PNSY (arrival at Portsmouth Naval Shipyard).

2.3 Material:

2.3.1 A manufacturer's certified metallurgical test report for all steel materials used during the construction test weights shall be provided.

2.4 Coatings:

2.4.1 Provide original equipment manufacturer's specifications and SDS for all cleaning agents, primers, paints, thinning/thickening agents, sealants and fillers used on main paint system and stenciling for each weight. All products shall be lead-free.

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2.5 Weight Certification:

2.5.1 Certificate shall be an original hard copy, indicating the measured weight of each test weight by marked serial number, and it shall be signed by the certifying official.

2.5.2 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. actual weight shall be within+/- 2% of indicated weight).

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

2.5.3 .1 Original Equipment Manufacturer (OEM)

2.5 .3.2 Serial Number

2.5.3.3 Model Number

2.5 .3.4 Accuracy

2.5 .3.5 Date(s) Calibrated Equipment Was Used

2.5 .3.6 Calibration Date of Equipment

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3 TEST, INSPECTION, AND ACCEPTANCE TERMS

3.1 In-process Inspection and Testing {Field):

3 .1.1 The contractor shall, at a minimum, fabricate ( 1) one unpainted test weight for inspection and testing. After the contractor's preliminary inspection and operational test of each weight is complete, the contractor shall notify the Government.

3.1.2 A site inspection will be conducted by the Government, along with the contractor. The contractor will make the test weight(s) available for Government witnessing of the inspection and operational testing. 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.

3.2 Final Inspection and Acceptance (Destination):

3.2.1 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 33, DD Form 250, or the Wide Area Workflow (WA WF) Receipt and Acceptance Receiving Report.

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

3.2.2.1 All weights within the approved contract have been delivered from the location of manufacturing to the approved location at PNSY. The Contractor is responsible for all transportation and associated logistics. The Contractor shall coordinate delivery ( date and location) with PNSY so that the shipyard may facilitate the delivery as necessary.

3.2.2.2 Contractor receives Government approval for all data items.

3.2.2.3 The weights pass a final inspection by the Government.

3.2.2.4 All deficient items have been corrected or methods ofresolution 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.

3.2.2.5 Final as-built engineering/design documents and material SDS sheets have been received and accepted by the Government.

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4 TEST WEIGHT INSPECTIONS PROCEDURE

4.1 Pre-Paint Inspection:

4.1.1 Perform the following for each individual weight ((3) Three Base Contract, (1) One Option/Future):

4.1.1.1 Ensure all dimensions of 80,000 pound weights match dimensions of DWG.

PNSY-D-711-20-001. Dimensions must be within dimensional tolerance range in noted section.

4.1.1.2 Measure radii ofload bearing sections to ensure they match callouts in DWG.

PNSY-D-711-20-001.

4.1.1.3 Inspect surfaces to ensure there are no sharp edges or burrs.

4.1.1.4 Inspect surfaces to ensure they are smooth without surface defects, flaws or wavmess.

4.1.1.4.1 Special emphasis should be paid to surface texture of lifting channels and recessed anchor points that will contact synthetic nggmg gear.

4.1.1.5 Inspect all welds to ensure they are ground smooth, and fully welded.

4 .1.1. 6 Ensure test weights stack properly and nest level with each other in any order.

All vertical faces and sling channels shall be aligned when stacked.

4 .1.1. 7 Verify welding has been performed by an A WS D 1.1 certified welder.

4.1.1.8 Verify a unique serial number for each test weight is marked by welding on one side, a minimum of (3) three inches tall.

4.1.1.9 Verify that AISI 1008 Steel was used for the fabrication of the general mass of the test weight.

4.1.1.9.1 Minimum of 41 ksi yield strength and 49 ksi ultimate strength.

4.1.1.10 Verify that ASTM A36 Steel was used for the fabrication of the nesting studs and recessed anchor points.

4.1.1.10.1 Minimum of 36 ksi yield strength and 58 ksi ultimate strength.

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4.2 Post-Paint Inspection:

4.2.1 Perform the following for each individual weight ((3) Three Base Contract, (1) One Option/Future):

4.2.1.1 Ensure each weight is fully painted black.

4.2.1.2 Obtain original equipment manufacturer's specifications and SDS for all cleaning agents, primers, paints, thinning/thickening agents, sealants and fillers used on main paint system and stenciling for each weight. All products shall be lead-free.

4.2.1.3 Verify each test weight has the actual measured weight stenciled (to the nearest whole pound, in pounds) on a minimum of two opposing outermost sides. The markings shall be in a similar location on each test weight. Color shall be white and a minimum of (3) three inches tall. Quantity shall be prefixed by "W:" and followed by "LB" for display.

4.2.1.4 Verify each test weight has the weight it is capable of bearing on top if itself

(Working Load Limit (WLL)) stenciled (to the nearest whole pound, in pounds) on a minimum of two opposing outermost sides. The markings shall be in a similar location on each test weight. Color shall be yellow and a minimum of

(3) three inches tall. The label shall read on a single line "WLL: 460,000 LB".

4.2.1.5 Verify each test weight has the force each recessed anchor point is capable of handling and warning labels. The markings directly adjacent to each recessed anchor point shall be in a similar location on each test weight. Color shall be white and a minimum of (1) one inch tall. The label shall read on three individual lines respectively "4,000 LB MAXIMUM FORCE", "FOR

CAPTIVATION ONLY", "NOT FOR LIFTING OF TEST WEIGHT"

4.2.1.6 Verify each test weight is painted with vertical lines in similar locations, a minimum of (1) one inch wide. Vertical lines shall be at center of each side of each test weight to assist with stack alignment and centering of weights. Color of stripe shall be white.

4.2.1.7 Verify each weight is listed on a hard copy original certificate(s), identifying the measured test weight by serial number and must be signed by the certifying official.

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4.2.1.8 Verify each certificate(s) clearly indicate each test weight was measured using calibrated equipment traceable to the National Institute of Standards and Technology (NIST), with a minimum accuracy of +/-2%. Verify each certificate(s) includes Original Equipment Manufacturer, Serial Number, Model Number, Accuracy, and Calibration Date for the calibration measurement equipment used. Ensure the weight on each certificate matches the weight stenciled on the side of each respective weight.

4.2.1.9 Measured weight of each individual test weight shall be correct within 1 % weight tolerance range as noted on the drawing:

4.2.1.9.1 +800 lb./-0 lb. for the 80,000 lb. weight (e.g. 80,000lb to 80,8001b on certificate is acceptable)

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