SOW_475_5-ton_rev_18_sept_18.doc

Rev 18 September, 2018

Description/Work Statement/Specification For Building 475 5-Ton Crane System

1.0 SCOPE: The following specification covers the furnishing and installation of a 5-ton bridge crane system and support structure in building 475, Anniston Army Depot. The crane shall be designed and constructed to Crane Manufactures Association of America (CMAA) 70 Class C.

1.1 Scope Change. The Contractor shall not proceed with any verbal or written change(s) to the scope of work from sources other than the Contracting Officer, who will provide changes in writing.

2.0 GENERAL:

2.1 Standard Products: Materials and equipment shall be standard products of manufacturers regularly engaged in the fabrication of cranes. The crane system shall be top running, single/double girder. All crane components shall be painted yellow.

2.2 Nameplates: Each major component of equipment shall have the manufacturer's name, address, type or style, or catalog number, and serial number on a plate secured to the equipment. The lifting capacity shall be clearly indicated on both sides of the bridge girders.

2.3 Verification of Dimensions: The Contractor shall verify all dimensions and necessary work to be performed in the field and shall advise the Contracting Officer of any discrepancy before performing any work. The contractor shall coordinate the design and layout with the crane manufacturer to provide a bridge crane system (including runway and support structure) that maximizes headroom under the runway beams.

2.4 Concrete: It is shall be assumed that the existing concrete in the building is 9” thick and proper soil compaction. If Footers are found to be required, the cost will be the responsibility of the Government.

2.5 Existing System: There is an existing 2-ton system in the location for the new system. There are footers that can be utilized by the new system. The existing crane system shall be removed from the building and transported approximately 1 mile and offloaded at a location (by the contractor) designated by the COR.

3.0 SUBMITTALS:

3.1 Shop Drawings: Detail drawings shall be submitted and shall consist of a complete list of equipment and materials, including manufacturer's descriptive and technical literature, performance charts and curves, catalog cuts, and installation instructions. Detail drawings shall also contain complete wiring and schematic diagrams; and any other details required to demonstrate that the system has been coordinated and will properly function as a unit. Drawings shall show proposed layout and anchorage of equipment and appurtenances, and equipment relationships to other parts of the work including clearances for maintenance and operation.

3.2 Operation and Maintenance Manuals: Four copies of operation and maintenance manuals are required for the equipment furnished. Operation manuals shall detail the step-by-step procedures required for the system start-up, operation, and shutdown. Operation manuals shall include the manufacturer's name, model number, parts list, and brief description of all equipment and their basic operating features. Maintenance manuals shall list routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides. Maintenance manuals shall include piping and equipment layout and simplified wiring and control diagrams of the system as installed.

3.3 Spare Parts Data: The contractor shall furnish spare parts data for each different item of material and equipment specified. The data shall include a complete list of parts and supplies, with current unit prices and source of supply.

4. DELIVERY AND STORAGE: Equipment delivered and placed in storage (at a location determined by the ANAD at the time of storage) shall be stored with protection from the weather, humidity and temperature variations, dirt and dust, or other contaminants. Delivery and installation shall be done with in 120 day after date of award.

5.0 ELECTRIC HOIST:

5.1 General: Hoists shall be of the heavy duty type, electric motor operated, of the close headroom type to suit the carriers furnished, and shall have the following characteristics. The lower load block and hook shall not be considered part of the rated capacity.

5.2 Capacity: Hoist - 5 Ton, 10,000 lbs.

5.3 Number Required: 3

5.4 Lift and Profile: Available lift capability shall be as a minimum 20’

5.5 Lifting Speeds: There shall be as a minimum two lift speeds with high being 25 ft/min as a minimum (plus 1.5, minus 1.5 ft/min); and the second speed being variable frequency drive (VFD) controlled. (Electromotive G+)

5.6 Electrical Service: 480 Volt, 3-phase, 60 hertz A.C. Contractor will provide the disconnect for the crane and the contractor shall be responsible for connecting to the disconnect.

5.7 Control: The hoist motor control system shall be pendent controlled and remote controlled and shall provide two speeds in each direction. The pendent shall be located at a maximum of 3'-0" from the bottom of the pendant to finished floor.

5.8 Power Source: The hoist and trolley electrification system shall be enclosed conductor bar

5.9 Limit Switches: The hoist shall be provided with a limit switch for control of the hook at maximum raised position and hook in the extreme lower position.

5.10 Lift Height: The lift height shall be as a minimum 17’.

6.0 HOIST CARRIER:

6.1 General: Carriers shall be of the close headroom type, electric motor driven. The carriers shall have sufficient capacity to carry a fully loaded 5-ton electric hoist as specified herein previously.

6.2 Number Required: 3

6.3 Speed: 2 speed - 75 ft/min high; 50 ft/min low (plus or minus 10%). variable frequency drive (VFD) controlled.

7.0 BRIDGE SYSTEM: (3)

7.1 General: Bridge systems shall be dual speed. Bridge and drive system shall be compatible and as generally offered within the manufacturer's product line. Two capacity plates shall be provided, one for each side of the bridges. Each plate shall be lettered to indicate the total rated hoisting capacity of the crane. All lettering shall be of sufficient size to be easily read from the floor. Each lower load block shall be marked with the hoist rated capacity.

7.2 Drive: Drive units shall be dual speed of 115 ft/min high and 50 ft/min low, (plus or minus 10%). VFD controlled.

7.3 Electrical Service: 480 Volt, 3-phase, 60 hertz A.C. Bridge shall operate from insulated type conductor rails.

7.4 Bridge Girders: Bridge girders shall be wide flange beams, standard I-Beams, reinforced beams or sections fabricated from rolled plates and shapes. Bridge shall be designed for all dead and live loads plus a safety factor of 5. The bridge crane span shall be approximately 26 feet; actual dimensions shall be field verified before any actual fabrication begins.

7.5 Stops and Bumpers: Structural trolley stops shall be provided on the bridge to engage the trolley wheels. Stops shall be located to permit maximum trolley travel.

7.6 Bridge Rails: Bridge rails shall be fastened to the top cover plate with welded clips or J-bolts. Bridge rail joints shall be bolted using standard joint bars. Rail joints shall be staggered. A positive stop shall be provided at the bridge rail ends to prevent creep. Bridge rails shall be of the size recommended by the crane manufacturer and specified in the contract drawings.

8.0 ELECTRICAL:

8.1 General: All push-buttons or other manually operated controls shall be energized at a nominal 120 volts through control transformers as may be required. Push buttons shall be oil tight and the heavy-duty type. The hoist control shall satisfy the applicable requirements of National Electrical Manufacturers Association (NEMA), Industrial Control and Systems Standards. All wiring shall be in accordance with the National Electric Code. All electrical panels and boxes shall be marked and labeled in accordance with National Fire Protection Association (NFPA) 70e standards, also written lockout/tagout procedures for this equipment must be provided and attached to lockout/ tagout points.

8.2 Bridge Electrification: Power for the bridge drive motors, trolley, and hoist shall be derived from either bronze, stainless steel, rolled copper, or equal, conductor rails of a design specially suited to the purpose and supported by insulators and clamps at not more than 5 foot spacing, and supported by or on the tracks. Rail shall be in the form of a channel with the bus bars rigidly mounted against the sides and top of the formed channel. The support brackets and conductors shall be supplied and coordinated by the same manufacturer. The conductors shall be protected with plastic insulating shields or metal cover arranged to reduce the risk of accidental contact. The use of a grounded transformer circuit to eliminate one conductor will not be acceptable.

Connector bars and accessories are to be supplied and installed by the contractor along with the crane runway structure.

8.3 Motors: Motors shall be suitable for operation on a 460 volt, 3 phase, 60 hertz electrical power system, shall be of ample capacity to operate the hoist service shall be designed with a 30 minute time rating, 55 degree centigrade rise, and with torque and speed characteristics especially suited to the service.

8.4 Pendant Control Station/Remotes: The pendant control station shall be suspended from the crane by a strain chain or 1/4-inch (minimum) wire rope strain lead of corrosion resistant steel. The pendant station shall be free-floating. The pendant control station enclosure shall be NEMA Type 4. Push buttons shall be heavy duty, dust-and-or-oil-tight type having distinctly felt operating positions. Push buttons shall be so constructed that they cannot become hung-up in the control case. Pendant shall include a separate set of push buttons for each motion and for POWER ON-POWER OFF. All operating characteristics of each crane and hoists are to be controlled from the appropriate pendant located at the hoist hook. The crane shall have all movements controlled by wireless remotes. Two remotes shall be supplied with each bridge system.

8.5 Transformers: Transformers shall be dry type and shall carry full load continuously at rated voltage and frequency without exceeding an average temperature rise of 115 degrees C above an ambient temperature of 40 degrees C. The transformer shall have a totally enclosed case, which shall be furnished to resist corrosion. Transformers shall be fully encapsulated, except for those specifically designed for use as an isolation transformer for static power.

9.0 RUNWAY AND SUPPORT COLUMNS: The runway shall be ASCE crane rail - 2 runs of 90’, with all hard ware for installation. The runways shall meet all CMAA standards for size, and true and parallel runs. The support columns shall be placed as close to the walls as possible. The runway shall be designed such that two bridges can be in the same bay (side by side).

10.0 ACCEPTANCE TESTING:

10.1 Crane Acceptance Test: Equipment will pass the following tests and inspection made by ANAD and contractor personnel.

10.1.1 Test Sequence: The crane shall be tested according to the applicable paragraphs of this procedure in the sequence provided.

10.1.2 Equipment Monitoring: During the load test, improper operation or poor condition of safety devices, electrical components, mechanical equipment, and structural assemblies shall be monitored. Observed defects critical to continue testing shall be reported immediately to the Contracting Officer and testing shall be suspended until the deficiency is corrected. During and immediately following each load test, the following inspections shall be made:

a. Inspect for evidence of bending, warping, permanent deformation, cracking or malfunction of structural components.

b. Inspect for evidence of slippage in wire rope sockets and fittings.

c. Check for overheating in brake operation; check for proper stopping. All safety devices, including emergency stop switches and POWER OFF push buttons, shall be tested and inspected separately to verify proper operation of the brakes.

d. Check for abnormal noise or vibration and overheating in machinery drive components.

e. Check wire rope sheaves and drum spooling for proper operation, freedom of movement, abnormal noise or vibration.

f. Check electrical drive components for proper operation, freedom from chatter, noise or overheating.

g. Inspect external gears for abnormal wear patterns, damage, or inadequate lubrication.

10.2 No-Load Testing:

10.2.1 Hoist Operating and Limit Switch Test: The load hook shall be raised and lowered through the full range of normal travel at rated speed and other speeds of the crane. The load hook shall be stopped below the geared limit switch upper setting. In slow speed only, proper operation of upper and lower limit switches for primary motion shall be verified. The test shall be repeated a sufficient number of times (minimum of three) to demonstrate proper operation. Brake action shall be tested in each direction.

10.2.2 Trolley Travel: The trolley shall be operated the full distance of the bridge rails exercising all primary drive speed controls in each direction. Brake operation shall be verified in each direction.

10.2.3 Bridge Travel: The bridge shall be operated the full distance of the runway exercising all primary drive speed controls, in each direction. Brake operation shall be verified in each direction.

10.2.4 Hoist Loss of Power No-Load Test: Using primary drive, the hook shall be raised to a height of approximately 8 feet or less. While slowly lowering the hook, the main power source shall be disconnected verifying that the hook will not lower and that both brakes will set.

10.2.5 Travel Loss of Power No-Load Test: With the hook raised to clear obstructions and the trolley traveling, the main power source shall be disconnected verifying that the trolley will stop and that the brake will set.

10.3 Load Test:

10.3.1 Hoist:

a. Hoist Static Load Test: Holding brakes and hoisting components shall be tested by raising the test load approximately 1 foot. The load shall be held for 10 minutes.

b. Dynamic Load Test: 100% test load shall be raised and lowered through the full range operating in each speed. The machinery shall be completely stopped at least once in each direction to ensure proper brake operation.

c. Hoist Loss of Power Test: After raising 100% test load to approximately 8 feet, slowly lower the test load, the main power source and the control shall be released verifying that the test load will not lower and that both brakes will set.

d. Trolley Dynamic Load Test: While operating the trolley the full distance of the bridge rails in each direction with test load on the hook (one cycle), the proper functioning of primary drive speed control points and proper brake action shall be tested.

e. Bridge Dynamic Load Test: With test load on the hook, the bridge shall be operated for the full length of the runway in both directions with the trolley at end of the bridge. Proper functioning of all primary drive speed control points and brake action shall be verified. Binding of the bridge end trucks shall indicate malfunction.

10.3.2 Trolley and Bridge Loss of Power Test: Using a test load of 100 to 105 percent of rated load, the load shall be raised clear of any obstructions on the operating floor. Starting at a safe distance from walls or other obstructions, a slow speed shall be selected using the trolley and bridge primary drive. While maintaining a safe distance to obstructions, the main power source shall be disconnected and the brakes shall be verified to have set and that the equipment stops within the distance recommended by the manufacturer.

10.4 All labor and equipment for acceptance testing shall be supplied by the contractor.

11.0 TECHNICAL DATA: Four copies of the following technical data shall be provided as specified on attached DD Form 1423 with the equipment: operator's manuals, maintenance manuals, calibration specifications/procedures, catalogs, and spare parts lists. Maintenance manuals shall include electrical, hydraulic, and pneumatic schematics, as applicable, parts lists, trouble-shooting procedures, preventive maintenance requirements, lubrication schedule, etc. Schematics shall show and identify all parts down to and including components on circuit boards. Catalogs shall fully describe all optional tooling, fixtures, and attachments available for the equipment being furnished. The recommended spare parts lists shall be complete with quantities required, prices, and normal delivery time for the items. In addition, any other technical data normally furnished with the equipment shall be provided. All technical data shall be furnished in the English language.

12.0 INSTALLATION: This equipment is to be installed by the contractor and the contractor shall be responsible for all plant, labor, and materials required for a complete installation. Contractor shall be responsible for insuring that the installation is compatible with existing facilities. Unless otherwise approved by the Contracting Officer, installation shall be done during normal depot working hours. The area where the equipment is to be installed is in operation. The contractor shall not interfere with ongoing Government operations and production unless otherwise authorized by the Contracting Officer. Installation is to be complete and equipment operational within 90 calendar days after contract award.

12.1 Electrical: All electrical work shall comply with American National Standards Institute (ANSI) Publication C2 - National Electric Safety Code and With National Fire Prevention Association (NFPA) Publication No. 70 - National Electrical Code. All materials used in the installation shall conform to applicable National Electrical Manufacturers Association (NEMA) and Underwriters Laboratories (UL) listings. Workmanship shall be in accordance with standard commercial practice. Runs shall be installed perpendicular and parallel to existing facilities and the equipment being installed. When equipment is installed near existing power lines, equipment shall be located for proper clearances in accordance with ANSI C2. New equipment shall not be connected to Government power without prior approval of the Contracting Officer. No high voltage work will be accomplished without prior approval of the Contracting Officer. All connections to Government power and all high voltage work shall be performed in the presence of a qualified Government electrician.

12.2 Plumbing: All plumbing work shall comply with National Association of Plumbing-Heating-Cooling Contractors/American Society of Plumbing Engineers (NAPHCC/ASPE) Publication - National Standard Plumbing Code. All materials used in the installation of the equipment shall conform to industry standards and shall be compatible with and shall meet the performance requirements of the equipment being installed. Workmanship shall be in accordance with standard commercial practice. Runs shall be installed perpendicular and parallel with existing facilities and the equipment being installed. Bypasses shall not be installed at steam reducing stations. All heating coils shall be trapped independently. Unless otherwise specified, steam and condensate piping shall be insulated with 1-1/2 inch thick Calcium silicate with aluminum covers for outside lines and 1-1/2 inch thick Fiberglass with all service jacket for interior lines unless subjected to water or vapor.

12.3 Concrete: Concrete used in the installation of the equipment shall be Class A and shall have a minimum allowable compressive strength at 28 days of 3,000 PSI unless otherwise specified. Samples for concrete strength tests shall be provided, stored, and tested as directed. Unless otherwise specified, the contractor shall be responsible for the design of all concrete work, including formwork and reinforcing. Ready-mixed concrete shall be used and must be delivered and discharged within 45 minutes after the introduction of water to the cement and aggregate. Placing of concrete shall conform to Chapter 4 of the American Concrete Institute Standard ACI 318. Workmanship shall be in accordance with standard commercial practice.

12.4 Foundation Hardware: All foundation hardware is required, the foundation hardware shall be furnished and included in the total bid price.

12.5 Coordination of Trades: Coordination of trades installing the equipment shall be the responsibility of the contractor.

12.6 Instruction for Installation: Four copies of the instructions for installation shall be provided as specified on attached DD Form 1423. The government will use these INSTRUCTIONS to review utility and space requirements of the proposed equipment. Within 30 days after date of contract, contractor shall provide Anniston Army Depot all information necessary for installation of the machine. This installation manual is to include, but not be limited to, the following:

a. Floor plan drawing of the machine and major machine components showing floor space required.

b. Space required around the machine after installation for maintenance purposes.

c. Foundation requirements, if any.

d. Maximum overall length, width, and height dimensions.

e. Approximate location of utility connections on the machine.

f. All utility requirements including electrical, air, water, steam, drains, etc. include amps, GPM, etc.

g. Minimum doorway opening required to bring equipment into the building.

h. Industrial waste disposal requirements, if any.

i. Ventilation requirements, if any.

j. Approximate weight of the equipment.

12.7 Utilities: The Government will provide utilities within 20 feet of the equipment installation site. The capacities of the utilities (wire sizes, pipe sizes, etc.) will be based on information supplied by the contractor under INSTRUCTIONS FOR INSTALLATION noted above. What is provided by the government at the job site is limited to the following:

a. Electrical: The Government will run electrical lines and tie into the contractor furnished and installed main disconnect. The Government will furnish only one voltage to the site.

b. Plumbing: The Government will run pipe within 20 feet of the installation site. Nominal plant pressures supplied to the site will approximately be as follows:

Air 100 PSI

Water 75 PSI

Steam 100 PSI

c. Drainage and waste: Unless otherwise specified in the contract solicitation, the contractor shall place drain lines and tie into existing sanitary, storm, or industrial waste lines as required.

12.8 Site Visit: A site visit is recommended to insure that the proposed equipment will be compatible with existing facilities.

12.9 Shipping, Handling, and Storage: The contractor shall be responsible for all shipping, storage, and handling of the equipment and all materials. The Government shall not be responsible for furnishing any labor, equipment, or warehouse space for the loading, unloading, and storing of any materials. The Government will make available if possible, space for a contractor furnished trailer or van for the storage of the materials. Trailer space will be made available as close to the job site as possible, depending on the parts stored in that area. Should the contractor not wish to furnish a trailer for equipment storage, then the contractor shall coordinate with procurement, Contracting Officer, the date at which time the contractor may deliver his equipment to the building.

13.0 SAFETY PRACTICES AND GUIDELINES: The Contractor shall conform to all federal OSHA standards applicable to the work performed and all safety practices and guidelines contained within this Statement of Work. Contractor shall strictly adhere to the contract clause entitled "Accident Prevention", Army Material Command (AMC) Regulation (R) 385-100, Safety and Occupational Health Regulation ANADR 385-1, Engineering Manual (EM) 385-1-1, 29 Code of Federal Regulations (CFR) 1926/1910, other related Department of Transportation (DOT) Regulations (49 CFR), and all local policies.

13.1 If a contractor employee is observed performing an activity in a manner inconsistent with any of the above cited regulations or is engaged in any activity that is dangerous to life, limb, or government property, the ANAD Safety Representative shall have the authority to notify the employee and/or the contractor’s on-site supervisor of the hazardous activity and require correction of the hazardous activity. This authority does not preclude the Safety Representative from notifying the Contracting Officer’s Representative of the hazardous condition or safety violation in appropriate situations.

13.2 If necessary, the ANAD Safety Representative shall have the authority on behalf of the Contracting Officer to require the contractor and/or its employee to stop the hazardous activity until corrective action is taken to eliminate a hazardous condition or safety violation. Said action shall not be considered to be the basis of a claim and shall be at no cost to the Government.

13.3 Contractor will notify ANAD Safety Office immediately of Reports of Inspections and/or Notices of Violation or other enforcement actions (including warning letters) received from by local, State, and Federal Regulators in which the violation is attributed to the action of the contractor or its subcontractors while working or providing services on ANAD’s installation. Contractor will provide ANAD with a copy of the Inspection Report, Notice of Violation or other enforcement action, and all supporting documentation.

REQUIRED DOCUMENTATION

(a) The bidder shall provide, with its bid, descriptive literature that has previously been used to market the proposed equipment. The literature will be used to technically evaluate the bids and shall describe how the equipment meets the requirements of the specification; specifically the paragraphs:

Information furnished

Ref. paragraph

1. Hoist paragraph 5.1-5.10

2. Carrier paragraph 6.1-6.3

3. Bridge paragraph 7.1-7.4

(b) The features required above to be shown in the descriptive literature are necessary to consider the bid responsive. If the bidder's preprinted literature does not show all these features, the bidder must attach a letter of supplemental information to the literature describing in detail those required features. All literature and supplemental information shall be in the US Customary System of Units and the English language.

(c) The failure of descriptive literature to show that the product offered conforms to the requirements of this solicitation will require rejection of the bid.

(d) Descriptive literature furnished under this solicitation that contains statements similar to "specifications are subject to change without notice", "bid is subject to the following conditions", or "prices are subject to change without notice" shall not be considered for an award. These types of statements qualifies the bid and the Government has no assurance the products offered conforms to the specification; therefore, the bid is not considered a firm bid and will not be considered for an award.

(e) Bidders who furnish a product catalog to satisfy this requirement must indicate which item are the subjects of the bid by highlighting marking and/or citation of model numbers and page numbers from the catalog in Section B of the IFB along with the bid price. Bids, which fail to clearly establish what item or items are bid, will be considered as nonresponsive.