A01.16_Solicitation_Ammendment_3.docx

W9123817R0094

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 30 - BLOCK 14 CONTINUATION PAGE

The following have been added by full text:

QUESTIONS AND ANSWERS

UTTR CRANE - ADVERTISEMENT PHASE INQUIRIES

TECHNICAL SCOPE OF WORK QUESTIONS

1.2 DESCRIPTION OF WORK BASE CLIN 0001 – Bldg. 60000 (Pad II) Question: The drawings provided the hoist drums are perpendicular to the bridge girders. Will this crane be used to upright a rocket? If yes we would suggest the drums be placed parallel to the girders. It appears Crane Bldg. 60015 Pad I has the drum parallel to the girders. With the features on new cranes hook approaches may not be the same as what you have now (Features: drum brakes, redundant reeving etc.).

Answer: The crane will not be used to upright a rocket motor.

Question: After the site visit it appears only a 50 Ton hoist is required for each crane. They would be provided with express speed that increases the 50 Ton base speed by roughly 70% for loads from 0- 10,000 lbs. Please confirm.

Answer: Each crane has two hoists as described in the RFP. The primary hoist is rated at 50 tons and the auxiliary (aux) hoists are smaller. The aux hoists are used to lift some of the smaller fixtures and equipment into place because the user has difficulty placing these items with the larger hoist. The larger hoist with the larger hook cannot get close enough to the headwall of the thrust block to effectively place the smaller fixtures and equipment. If the new crane can be configured to get closer to the headwall, the aux hoists will not be required. The user confirms that adding the express speed to the 50 ton hoist is acceptable if the aux hoists are not provided.

Question: Are you going to stay with the 50/25 Ton design or change to a 50 ton only with Express speed for a lighter load of 5 tons?

Answer: A single 50 ton hoist is acceptable provided that the crane can be designed so that the 50 ton hoist can place equipment and fixtures close to the head wall on the thrust block the way the smaller hoist do with the existing crane.

Question: I questioned your needing an isolated hook, when at the job site, the men were asked about that requirement and they said that they do not perform any tasks with the crane requiring one, will this be dropped from the specification.

Answer: We do not need an isolated hook.

1.2.1.1 CONTROLS

Question: The specifications call out the speeds for the hoists, would this apply to both the main and aux hoists?

Answer: The speeds can apply to both hoists if an auxiliary hoist is provided. The aux hoists are used to lift some of the smaller fixtures and equipment into place because the user has difficulty placing these items with the larger hoist. The larger hoist with the larger hook cannot get close enough to the headwall of the thrust block to effectively place the smaller fixtures and equipment. If the new crane can be configured to get closer to the headwall, the aux hoists will not be required. The user confirms that adding the express speed to the 50 ton hoist is acceptable if the aux hoists are not provided.

Question: In the same section it refers to Section 6.2.5 of Appendix 1, specifically 6.2.5.1.8. Reeving: In this section we interpret that the cranes hoists must have an equalizer bar since we need to have dual load paths for the wire ropes. One rope will be left hand and the other right hand. An equalizer sheave would not be applicable to the cranes you are requesting correct?

Answer: In the AFSPCMAN 91-710 (Appendix 1), Section 6.2.1.10. Reeving: For dual-reeved hoists, equalizer sheaves shall be self-aligning with the load line. Therefore, an equalizer sheave will be required even with double reeving capabilities. In section 6.2.5.1.8 referenced, the equalizer system shall have the means to allow movement of the system to level the block. This is also confirmed in ASME B30.2 2-1.14.4 Equalizers: If a load is supported by more than one part of rope, the tension in the parts shall be equalized.

Question: In addition we believe the bridge and trolley drive motors should be continuous duty rated for VFD control?

Answer: From AFSPCMAN 91-701, Section 6.2.5.1.2. Bridge and Trolley Travel Limit Switches: each bridge and trolley shall be equipped with travel limit switches that will first slow the bridge or trolley to “creep” speed and a second limit switch that will remove power and apply the brake before it engages the bumper or other mechanical stop, but with subsequent creep-speed override to enable hard stop contact. Therefore, it is correct that the bridge and trolley drive motors shall be continuous duty rated for VFD control.

Question: Will trolley and bridge slow down and stop limits be required?

Answer: From the AFSPCMAN 91-710, Section 6.2.5.1.2. Bridge and Trolley Travel Limit Switches. Each bridge and trolley shall be equipped with travel limit switches that will first slow the bridge or trolley to “creep” speed and a second limit switch that will remove power and apply the brake before it engages the bumper or other mechanical stop, but with subsequent creep-speed override to enable hard stop contact.

Question: We are assuming the emergency load lowering pneumatic controller will be mounted on the trolley. Also we are assuming you want to have gauges for the tank pressure and the individual brake caliper air pressures? The pneumatic lowering control needs to be infinitely variable also correct?

Answer: That is correct.

Question: The existing crane controls are explosion proof. Do the new pendant controls need to be the same? Also we are assuming the crane controls do not need to be explosion proof. What is the explosion proof rating for example Class I Div II Groups C and D for pendants?

Answer: The new controls will need to be explosion proof since the operator will be closer to the motor. The controls shall have an explosion proof rating of Class I, Division II, Groups C and D.

1.2.1.2 ELECTRICAL

Question: The specification calls out NEMA 250 and NEMA ICS 6, but it does not tell us what NEMA rating, normally NEMA 12 or NEMA 4 for bridge cranes. Please let know what type

Answer: The enclosures should be rated NEMA 12 to protect against oil seepage.

Question: Will the drive mechanism motors need to conform to NEMA MG 1 and have motor insulation that is at a minimum Class F, with a Class B temperature rise. And shouldn’t each hoist motor be AC vector duty, totally enclosed non-ventilated (TENV) or totally enclosed blower cooled (TEAV), for continuous duty at any speed?

Answer: The drive mechanism motor will need to conform to NEMA MG 1 and have motor insulation of Class H with class B temperature rise. Each hoist motor shall be AC vector duty totally enclosed non-ventilated (TENV) enclosures.

Question: Since the cranes will be pendant controlled. Are we correct to assume the brake lights called out would be mounted to the bottom of the cranes? Will they need to be the LED type? Is a rotating beacon required for any crane movement? Will a lamp test button be required on the pendant station?

Answer: The brake lights should be mounted where they are visible to the operator. The bottom of the crane seems like a good location. They should be LED type. A rotating beacon is not required. I do not believe the exiting cranes have a rotating beacon. A lamp test button on the pendant would be good to have but is not required.

Question: It is our understanding that the lightning protection system has special needs due to the static and the materials place into the building. It appears the roof will need to have sections removed and then replaced to remove the old crane and install the new crane. As such the Lightning protection system will need to be disconnected and reconnected. This building will then require recertification of the system. This process cost is in the range of 50K and would need to be performed prior to project completion by anyone whom removes the roof panel. Please confirm our understanding of this condition as correct or not.

Answer: It is not a requirement of this contract to disconnect the lightning protection system to remove portions of the roof. The lightning protection system runs along the edge of the roof and along the ridge line of the roof. There are four vents on each roof and an air terminal is installed on each of the four vents. If you can remove sections of the roof without disturbing the lightning protection system, recertification will not be required. The existing lightning protection system does not currently meet code. If you need to “touch” the lightning protection system which will require recertification, at least the portion of the system attached to the building will need to be replaced with an aluminum system to meet the recertification requirements. The cost for replacement and recertification should be include in your proposal if you need to “touch” the system.

1.2.1.4.1 BRIDGE AND TROLLEY BRAKES

Question: We want to confirm you want electro mechanical brakes mounted on the end of the motors with a manual brake release and not worm drive brakes.

Answer: The overhead crane bridge and trolley shall be equipped with fail-safe brakes in both directions, designed in accordance with the stopping distance requirements of CMAA 70/74. There is no requirement in CMAA 70 (referenced from AFSPCMAN 91-710) Section 4.9.3 (Trolley Brakes) or Section 4.9.4 (Bridge Brakes) to provide electro mechanical brakes. Worm drive brakes will also be acceptable.

1.2.1.4.2 HOIST BRAKES

Question: Section 6.2.5.1.4. Hoist Braking: This sections makes sense, however 1.2.1.4.2 seems to indicate you want two electromechanical brakes and the drum brake (not including the Flux Vector braking). Please indicate how many electromechanical brakes you would like. In addition we would recommend only a shoe brake for this application due to the emergency lowering required. The brake sizing also isn’t clear, it mentions 125% and also 150% please clarify.

Answer: The AFSPCMAN 91-710 requires three systems: Load Control Brake, Load Holding Brake, and Emergency Brake (on the hoist drum). These three braking systems shall each be capable of braking and holding at least 150 percent of torque exerted by full rated load on the hook. The most stringent requirement should govern the design which would be the 150% in this case. Electromechanical brakes can be used for all three systems but are not specifically required. It is my understanding that a shoe brake is an electromechanical brake. The Flux Vector braking can be used as the one of the three braking systems if desired.

1.2.1.5 HOIST CONSTRUCTION

Question: Normally only fabricated steel gearboxes (horizontally split) would be allowed for this type of application due to the drum brakes. This means cast iron and ductile cast iron would not be acceptable. Is this true?

Answer: Correct, cast iron materials acceptable so long as they are not used for any load bearing part. Cast iron can be used for the gear box enclosure provided that it is not load bearing. All commercial gearboxes are to be sized according to gearbox manufacturer's recommendations.

Question: After discussions with our estimating engineering Department we have determined the following:

A. If the Corps would accept the drum of the hoist between two steel pillow block bearings and a cast iron gear box (not supporting the drum) since this hoist has a Caliper emergency brake on the drum flange actuated by a speed switch, it would still be failsafe even if the Gear box exploded.

B. If the insulated hook is dropped from the specification (See ”things asked when at the site below”). We feel that if either this paragraph of the specification can be removed or the configuration described above accepted to mean that the gear box is not “Load bearing” if it is not supporting the drum but only ( turning it, the delivery could be shortened considerably.

Answer: We determined on site that an insulated hook will not be required. Using cast iron for the gear box housing is acceptable provided that it is not load bearing.

Question: Asked about 1.2.1.5 removing the cast iron clause from the spec (Steel gear cases of this size for Hoists carry a 20 to 22 week delivery).

Answer: Paragraph 1.2.1.5 prohibits cast iron from use on load bearing parts only. The housing for the gear box can be cast iron if the gear box is not load bearing.

1.2.1.6 ACCESS

Question: Do the existing cranes have a cross over foot walk? If yes that is ok, if not just be aware that it may limit the trolley hook travel due to its size.

Answer: The existing cranes are equipped with a caged ladder up to a cross over foot walk for access to the bridge. The crane shall be designed to allow for the hoist on the trolley to be able to get close enough to the head wall to install the load-trains. The contractor shall be responsible for providing fall protection and safe access to perform routine maintenance on all crane equipment.

Question: Is the contractor designing and installing the new overhead crane to also refurbish the building access system with new ladders, stairs, railing etc. for crane and roof access?

Answer: No, you are not required to refurbish the existing access to the cranes and the roof. Fall protection and safe access will need to be provided and constructed so the existing access ladders can be used.

Question: In this section you mention SFP. Are we to assume any SFP welds need to be left un-painted for future NDT inspection? What is the weld inspection requirements, will SFP need to be tested after the field 125% load test?

Answer: SFP weld inspections will only take place during the initial inspection and shall be painted before the cranes are turned over to the government. AFSPCMAN Appendix 1, Section 2.5.7.1.4 directs the NDE plan and test results for crane hooks and SFP components and SFP welds on crane support structures, overhead crane and hoist support structures, and 10 percent of non-SFP welds on overhead crane and hoist support structures.

Question: Are we to install a personal fall restraint system in the existing facility?

Answer: You will only need to provide fall protection/restraint to allow for safe access during routine maintenance of all crane components.

1.2.2 TESTING AND INSPECTION

Question: Will the crane need to have a complete NRTL certification?

Answer: USACE: Per CMAA 70 Section 1.11.1, “Testing in the manufacturer's plant is conducted according to the manufacturer's testing procedure, unless otherwise specified.” For factory testing, we have not specified any other testing. For the final inspection and acceptance testing, the statement of work covers extent of the testing as directed by AFSPCMAN 91-710. NRTL is not mentioned anywhere in this manual. NRTL (Nationally Recognized Testing Laboratory) is an OSHA program that accredits a testing agency based on their compliance with OSHA testing guidelines and registration dues. Given the constraints of this project’s time and costs, an NRTL certification is excessive. There is already a clear guideline for the final inspection and acceptance tests implemented in the scope of work that will be reviewed by base safety.

Question: Can the Corps supply the Load testing weights and rigging?

Answer: The user can supply the load testing weights and the rigging that we use to do routine load testing of the cranes.

1.2.2.1 SHOP ASSEMBLY

Question: In this section it talks about gantry, cab, lifting beams, and trolley hoist covers, are we correct to assume these items are not applicable?

Answer: Correct, those items will not be applicable since they are not required for these cranes.

GENERAL CONTRACT QUESTIONS

Question: The delivery is called out at 120 days, this does not seem possible for this type of crane product.

Answer: The 120 days was a consensus from industry suppliers based on the dimensions and capacity of the cranes being replaced in the buildings. The 120 days will commence with the award of contract.

Question: The schedule was discussed, we need to know the amount of time the USACE would review submittals.

Answer: USACE will have 15 working days to review submittal items.

Question: Can a hole be provided in the ceiling of the facility to help remove the old crane and the new?

Answer: A hole can be made in the roof to help with the removal of the old crane. Keep in mind that these are historic buildings and anything done to the exterior of the building will need to be restored to its original condition. Any physical change to the appearance will require coordination with base environmental and the COR. Further approval from SHPO may also be required if altering the appearance of the building. Any work done on the roof should avoid the lightning protection system. EM 385-1-1 shall be followed for critical lifts where the crane operator loses sight of the load.

Question: What is the max ground loading in the facility and on the pads?

Answer: The maximum ground loading in the facility is not known. The center 20 feet of the floor of the facility is directly over a portion of the concrete thrust block which has a minimum thickness of three feet. We anticipate that the middle 20 feet of the floor should support the loads anticipated for the installation of the crane. This floor construction is known to be 3 feet of reinforced concrete.

Question: Requested drawings on the existing cranes with weights, wheel loads, clearances, etc.

Answer: We have not found any drawings on those specific cranes. We may be able to provide drawings of similar cranes made by the same manufacturer and built for essentially the same purpose.

Question: If in addition we are able to have a meeting shortly after the award to show you what major components we will be using (Gearbox, Brakes, Motors, Drums etc.) and you allow us to order them very soon after award rather than waiting until all drawings are approved, and if the order was placed shortly, and if the drawing approval time is shortened from 30 days to 15 days, and If when returned they are marked “approved as noted” . We are confident we would be able to fast track deliver the cranes in 15-16 working weeks based on the current specification.

Answer: The user is willing to work with you on this schedule provided that it is acceptable to the USACE and their contracting officer.

Question: Can we be guaranteed that hookups will be available for our RV’s/Trailers?

Answer: There are hookups available just outside of the gate to UTTR. The design build contractor will be using some of the hookups. There should be enough for you if you only need a few.

Question: What is the weight of the largest item of the existing overhead cranes to be removed?

Answer: The user does not have that information.

Question: What is the size and type of the existing roof panels?

Answer: We don’t know the size of the roof panels but they are insulated galvanized metal. The gage is not shown on the drawings but it is most likely 18 gage. It is believed that the existing panels are the original panels installed in the mid-1960s.

Question: What is the review time of design allowed for the COE; the schedule is extremely tight and this could be the critical path?

Answer: The user is willing to work with a shortened review time if allowed by the USACE and their contracting officer.

Question: The requirements are for the PPQ to be submitted with the proposal. Is a PPQ form included with the documents in the RFP? I do not find a PPQ form with the solicitation although the documents say included.

Answer: PPG form included in amendment 2.

Question: Where does and in what is the proposal to be furnished? Is it email, disk, paper with binders etc.?

Answer: Offers’ must submit their proposals by e-mail to arrive not later than 1600 PST 29 January 2018. Submit to: tilden.l.brooks@usace.army.mil Two hard copies of the proposal must be submitted to arrive NLT 1500 PST 31 January 2018.

HARD COPIES SENT TO :

DEPARTMENT OF THE ARMY

U.S. ARMY ENGINEER DISTRICT, SACRAMENTO

CORPS OF ENGINEERS

ATTN: CT-B (BROOKS)

1325 J STREET

SACRMENTO, CALIFORNIA, 95814-2922

Question: Are we to submit bridge cranes scope and or drawings with the proposal or just SOW clarification that meets the owner’s needs.

Answer: offerors submittal must provide all information required by the Scope of Work and submittal requirements of the solicitation. The information must demonstrate the Offeror understands the requirement and how they propose to meet the requirement. The offeror must include enough information on their proposed crane(s) showing it meets the requirements and is technically acceptable.

REVISED STATEMENT OF WORK

Scope of Work Replace Building 60000 (Pad II) Crane Utah Test and Training Range (UTTR), UT

1. WORK COVERED BY CONTRACT DOCUMENTS

1.1 OVERVIEW

The work for this project consists of removing and replacing the overhead bridge cranes in Building 60000 (Pad II) and Building 60015 (Pad I, Option) at the Utah Test and Training Range (UTTR). The new crane hoist shall be rated at a capacity of not less than 50 tons with a 25 ton auxiliary hoist. The Contractor shall provide all labor, equipment, transportation, material and supervision required to perform the crane removal, procurement, construction, delivery, installation and testing. Installation shall include the removal of the existing crane. The Contractor shall make an initial site visit to verify the existing crane conditions for installation prior to submitting proposals for the work at hand. Civil, structural, utilities, security, mechanical, electrical, and communications proficiency shall be required to support the work described herein and in Appendix 1 and 2.

1.2 DESCRIPTION OF WORK

Supply all labor, materials, equipment and supervision necessary to provide and install the items below:

A) BASE CLIN 0001 – Bldg. 60000 (Pad II) Remove and dispose of the existing overhead bridge crane currently installed in the building. This removal shall include the entire bridge, including girders and end trucks, as well as the trolley with hoist equipment. The crane is known to have asbestos containing material and lead based paint. Brake shoes are likely composed of asbestos and the peeling paint may be lead-based. The removal shall require the use of a mobile crane or other equipment to lift the existing trolley, hoist, and bridge rails down from the runway rails on the structure. The Contractor shall be responsible for disposing of waste in compliance with all Federal, State, and local laws and regulations, and shall be responsible for coordinating with Hill AFB if there are any effects to the exterior structure. The government will retain ownership of existing crane hooks after the crane is removed from the building.

B) BASE CLIN 0002 – Bldg. 60000 (Pad II) Supply and install a new CMAA Class “D”, overhead bridge crane equipped with a 50 ton rated main hoist. The hoist shall be configured to allow for the lifting and placement of smaller fixtures and equipment against the headwall of the thrust block based on the orientation and positioning of the existing auxiliary hoists. If this orientation and positioning cannot be obtained by the new main hoist alone, the contractor shall provide and a 25 ton rated auxiliary hoist. Each hoist shall be mounted to match the existing operational orientation and be able to support the 46’7” lift height. The new crane shall be mounted on the existing crane runways and match the existing 35’9” crane span. The hoist shall be configured on the trolley to match the existing hoist configuration to the extent possible. maintain the function of the existing hoist and auxiliary hoist to the extent possible.

C) OPTION CLIN 0001 – Bldg. 60015 (Pad I) Remove and dispose of the existing overhead bridge crane currently installed in the building. This removal shall include the entire bridge, including girders and end trucks, as well as the trolley with hoist equipment. The crane is known to have asbestos containing material and lead based paint. Brake shoes are likely composed of asbestos and the peeling paint may be lead-based. The removal shall require the use of a mobile crane or other equipment to lift the existing trolley, hoist, and bridge rails down from the runway rails on the structure. The Contractor shall be responsible for disposing of waste in compliance with all Federal, State, and local laws and regulations, and shall be responsible for coordinating with Hill AFB if there are any effects to the exterior structure. The government will retain ownership of existing crane hooks after the crane is removed from the building.

D) OPTION CLIN 0002 – Bldg. 60015 (Pad I) Supply and install a new CMAA Class “D”, overhead bridge crane equipped with a 50 ton rated main hoist. The hoist shall be configured to allow for the lifting and placement of smaller fixtures and equipment against the headwall of the thrust block based on the orientation and positioning of the existing auxiliary hoists. If this orientation and positioning cannot be obtained by the new main hoist alone, the contractor shall provide and a 25 ton rated auxiliary hoist. Each hoist shall be mounted to match the existing operational orientation and be able to support the 20’ lift height. The new crane shall be mounted on the existing crane runways and match the existing 34’ crane span. The hoist shall be configured on the trolley to maintain the function of the existing hoist and auxiliary hoist to the extent possible. match the existing hoist configuration to the extent possible.

1.2.1 CRANE FEATURES

For CLIN 0002 and OPTION CLIN 0002, the Contractor is required to comply with the crane features listed herein. The crane must be procured as a package unit including the hoist, trolley, bridge, service walkways access points, and all additional items required for the complete mounting and integration with the existing structural and power connections. The crane shall be double-girder overhead bridge type with a top running trolley system to support the hoist. The crane package shall be delivered to the site and mounted to the existing 60’ crane runways in each building. The trolley and bridge shall be driven by electric motors integrated with each component. Crane hoists shall be package units and include all motors, gearboxes, brakes, and electronic controllers required for hoisting operations. The hoists must be able to provide true vertical lift between the lower limit and upper limit of travel.

1.2.1.1 CONTROLS

The crane shall be controlled by an operator pendant control station. The bridge and trolley motors shall include 2 speed variable frequency drives for controlling the motor speeds. The hoist motors shall also be equipped with a 2 step, infinite variable Flux Vector VFD to allow for a range of hoisting capabilities. Speed selector switches shall be equipped with the ability to toggle the VFD and modulate the motors up to 5 Hz. The VFD shall be an ElectroMotive Flux Vector Drive with encoder feedback or approved equal. The bridge and trolley motors shall be rated for continuous duty and VFD control. The crane hoist, trolley, and bridge shall be designed to operate up to the following range of maximum speed limits:

Hoist: 10±2 FPM Bridge: 40±10 FPM Trolley: 20±5 FPM The Contractor shall also satisfy all crane and hoist motion controls requirements found in Sections 6.2.1.11 to 6.2.1.13 of Appendix 1. The operator controls for the hoists shall be provided with a lockout feature to prevent simultaneous loading of the main and auxiliary hoists. Controls shall take input from the load cell and prevent operation of multiple hoists until it has been unloaded. Additional requirements for cranes and hoists used to handle critical hardware found in Section 6.2.5 of Appendix 1 shall be met, including control capabilities, travel limit switches, overload protections, brake fail-safe systems, hoist emergency lowering, and reeving.

1.2.1.2 ELECTRICAL

The crane must be terminated into the existing power circuit left from the previous crane. The Contractor shall be responsible for locating the 480V, 3 phase, 60 Hz service and connecting the crane to the dedicated 125 amp service. It will be the responsibility of the Contractor to furnish all conductors and wiring accessories for configuring the crane controls and energizing the crane. The crane shall be furnished with new electrical conductor systems capable of providing continuous power to the bridge, trolley, and hoist along their intended lengths of travel. Brakes lights shall be mounted on the crane in a location visible to the crane operator. Lights shall be LED type.

All provided enclosures for control panels, controls, and brakes shall comply with NEMA 250 and NEMA ICS 6. The drive mechanism motor shall conform to NEMA MG 1 and have motor insulation of Class H with class B temperature rise. Each hoist motor shall be AC vector duty totally enclosed non-ventilated (TENV) enclosures. The controls shall have an explosion proof rating of Class I, Division II, Groups C and D. Grounding requirements for cranes and hoists used to handle critical hardware found in Section 6.2.5 of Appendix 1 shall be followed.

1.2.1.3 WHEELS

The crane wheels for the new bridge component shall be compatible with the existing U.S. Steel Number 105 (lb./yd.) rail which currently runs the 60’ span of each building. Trolley and bridge wheels shall be double flanged of rolled-to-shape wrought or forged steel. Wheels shall be rim toughened to not less than 320 Brinell Hardness Number (BHN). Wheel sizing and flange-to-rail head clearances must be in accordance with CMAA 70 recommendations.

1.2.1.4 BRAKES

The overhead crane bridge and trolley shall be equipped with fail-safe brakes in both directions, designed in accordance with the stopping distance requirements of CMAA 70/74. Brakes must be able to decelerate and/or stop as well as hold. The movement of the bridge and trolley shall also be controlled by VFD’s for the drive motors that allow for deceleration of the drive speed during crane operation.

1.2.1.4.1 BRIDGE AND TROLLEY BRAKES

Provide bridge and trolley drives with electro-mechanical brakes capable of stopping the motion of the bridge or trolley within a distance in feet equal to 10 percent of the full load speed in feet per minute when traveling at full speed with a full load. Brakes must have an externally accessible means to manually defeat the brake.

1.2.1.4.2 HOIST BRAKES

Powered hoists shall have three independent braking systems: a load control means system, a load holding brake system with a flux vector VFD with two holding brakes rated at 125% of rated capacity, and an emergency brake system on the hoist drum. The emergency brake shall be of the caliper-type disk brake. The hoist shall be instrumented with a speed-sensing device. If the hoist speed exceeds 110 percent of its rated speed, all braking systems and audio and visual warning devices shall be activated. All braking systems shall each be capable of braking and holding at least 150 percent of torque exerted by full rated load on the hook. Hoist braking shall comply with all requirements for emergency braking, load holding, and emergency brake fail-safe systems specified in Section 6.2.5.1.4 of Appendix 1. The hoist emergency lowering system shall have a fail-safe capability for emergency lowering of the load in the event of a power failure or hoist drive mechanism malfunction.

1.2.1.5 HOIST CONSTRUCTION

Crane hoists shall be wire rope construction and shall not be rotation resistant type. Cast iron materials are prohibited from use on any load bearing part. The crane hooks and reeving requirements shall comply with all items listed in the Section 6.2.1.9 and 6.2.1.10 of Appendix 1.

1.2.1.6 ACCESS

Access platforms and/or footwalks with personnel tie-offs shall be provided to allow for safe and adequate access to all components required for inspection, service, repair, or replacement. Access shall include the drive girder side, and idler girder side with crossovers on the end trucks. New walkways access points shall be accessible from existing crane access points. Crane and hoist design shall provide for visual and physical accessibility of all SFP components, welds, and other safety critical parts. Minimum clearances between the crane and stationary structures shall be 3 inches overhead and 2 inches laterally.

1.2.1.7 MARKING/LABELING/IDENTIFICATION

Manufacturer, part number, serial number, date of manufacture or initial acceptance, rated capacity, weights of the top assembly and separate subassemblies, and weight of bridge and trolley shall be clearly marked on all new equipment. The directions of the crane’s bridge and trolley movements shall be displayed on the underside of the crane. These directions (North, East, South, and West) shall correspond to the directions on the operator station and visible and legible from the floor and any operator station.

1.2.2 TESTING AND INSPECTION

The Contractor is responsible for performance of quality control inspections, testing and documentation of the crane as follows.

1.2.2.1 SHOP ASSEMBLY AND TESTING

Contractor shall perform in-shop inspections and testing prior to the shipment and delivery of the crane.

1.2.2.1.1 SHOP ASSEMBLY

Shop-assemble all hoists, trolleys, trolley drives, gantry trucks and gantry drives, operators cab, electrical cab and lifting beams. Service all equipment after shop assembly is complete. Provide all necessary grease and oil of approved quality and grade for the initial servicing.

Permanent wiring must be installed except wire that would be disassembled or partly disassembled for shipment. Wire the main hoists, latching hoists, trolley drives, and gantry drives to the operator cab, electrical cab and electrical panels. Wire the maintenance hoists to the electrical panels. Machinery and electrical equipment must be completely manufactured, adjusted, lubricated, and otherwise made ready for operation. Permanent conduit (except conduit attached to walkways), ladders and stairs, must be installed.

1.2.2.1.2 SHOP TESTING AND INSPECTION

In-shop testing shall demonstrate that the various parts and components are correctly fabricated, assembled, and fitted; and operate properly. The inspection shall verify that the trolley and hoists have been assembled without initial stresses, forced or improvised fits, misalignments, nicks of high-strength structural steel components, and rough burrs. Methods of repairing the discontinuities is subject to review by the Contracting Officer. The hoists, trolley drives, and gantry drives must be operated under their own power and using the actual controls that will be supplied by the Contractor.

1.2.2.1.2.1 INSPECTION OF HOOK ASSEMBLY

Contractor shall be required to inspect the new hook prior to delivery and furnish documentation of hook inspection to the Contracting Officer prior to field operational testing. As part of the acceptance standard, linear indications greater than 1/16 inch are not allowed. Welding repairs of hook are not permitted. A hook showing linear indications, damage or deformation is not acceptable and must be replaced immediately. The hook shall be tested and documented in compliance with ASME B30.10.

1.2.2.1.3 WITNESS AND DOCUMENTATION OF SHOP TESTS

All inspections and no-load performance tests must be performed by qualified crane inspectors and findings recorded. The contractor shall be responsible for submitting an in-shop inspection and test procedure at least 90 days prior to performing in-shop inspection and tests. The test will be witnessed by the Government unless waived in writing, demonstrating that the various parts and components are correctly fabricated, assembled, and fitted; and operate properly. The Contracting Officer shall be notified of dates of the In-Shop Inspection and Test a minimum of 14 calendar days in advance. An in-shop inspection and test report shall be submitted to for approval within 10 days after completion of testing.

1.2.2.2 FINAL INSPECTION AND ACCEPTANCE TESTS

The Contractor shall be required to fulfil the requirements outlined in the Material Handling Equipment, Section 6.1, and Crane and Hoist Inspection and Test Requirements, Section 6.2.2, of Appendix 1. Since this crane will be used to handle critical hardware, additional requirements from section 6.2.5.2 and 6.2.5.3 shall also be met for initial testing and inspection. Crane, hoist, and hook nondestructive evaluation (NDE) plans shall be submitted to Range Safety for review and approval. The plans shall identify all single-failure points (SFP’s), NDE requirements and methodology, and acceptance criteria. Definitions and terminology used in test and NDE plans shall be in accordance with standard methodology used in Section 6.2.1.1 of Appendix 1. Crane and hoist data requirements shall be submitted in accordance with Appendix 1, Section A1.2.5.7. All crane specifications, test plans, and test results shall be reviewed and approved by Hill AFB/UTTR Range Safety.

1.2.2.2.1 FINAL INSPECTION AND ACCEPTANCE TESTS SCHEDULE

Government personnel will be available for the Final Inspection and Acceptance testing for a maximum of 10 continuous hours in a 24 hour time period and work must be accomplished on a Monday through Thursday schedule. Coordination of schedule for the testing must be made with the Contracting Officer. Final Inspection and Acceptance testing for the crane shall not occur during the week of a Federal Holiday. The Final Inspection must begin on a Monday and start no earlier than 0800. Written approval to deviate from the above daily work hour restrictions or weekly schedule restrictions will be required from the Contracting Officer.

1.2.3 CERTIFICATION

The Contractor shall be responsible for submitting the following certificates to the Government before the crane can be accepted:

1.2.3.1 OVERLOAD TEST

Submit an Overload Test Certificate stating that the crane can be periodically load tested to 125 percent (plus 0 minus 5) of rated load. Submit a Loss of Power (Panic Test) Certificate stating that a test may be performed in which power is removed from the crane while the hoist, bridge, and trolley are in operation to simulate a loss of power.

1.2.3.2 HAZARDOUS MATERIAL

Submit a Hazardous Material Certificate that the crane does not contain hazardous material, asbestos, lead, cadmium, and chromium, PCBs or elemental mercury.

1.2.3.3 STANDARDS

Submit a Certificate of Compliance with Listed Standards.

1.2.3.4 COUPLING ALIGNMENT

Submit a Certificate of the Coupling Alignment Verification Record.

1.2.3.5 BRAKE SETTING

Submit a Certificate of the Brake Setting Record.

1.2.4 DRAWINGS

1.2.4.1 SHOP DRAWINGS

Submit shop drawings showing the general arrangement of all components in plan, elevation, and end views; hook approaches on all four sides, clearances and principal dimensions, assemblies of hoist, trolley and bridge drives, motor nameplate data, overcurrent protective device ratings, and electrical schematic drawings. Include weights of components and maximum bridge wheel loads and spacing. Shop drawing quality must be equivalent to the contract drawings accompanying this solicitation. Provide integral schedule of crane components on each drawing. Provide maximum wheel loads (without impact) and spacing imparted to the crane runway system track beams. Indicate the crane speeds along the runway, the trolley speeds along the bridge girder, and the hoist lifting speeds; all speeds indicated are speeds with hoist loaded with rated crane capacity load.

1.2.4.2 LOAD AND SIZING CALCULATIONS

Submit calculations reviewed, signed and sealed by a registered professional engineer verifying the sizing of the bridge girder, end trucks, travel drives, and overcurrent protection for motors, controllers, and branch circuits. Include seismic analysis of bridge girder and end trucks.

1.2.5 OPERATION & MAINTENANCE MANUAL AND TRAINING

1.2.5.1 SUBMISSION OF OPERATION AND MAINTENANCE MANUAL DATA

Submit Operation and Maintenance (O&M) Data specifically applicable to this Contract and a complete and concise depiction of the provided equipment, product, or system, stressing and enhancing the importance of system interactions, troubleshooting, and long-term preventative maintenance and operation. Any subcontractors must compile and prepare data and deliver to the Contractor prior to the training of Government personnel. The Contractor must compile and prepare aggregate O&M data including clarifying and updating the original sequences of operation to as-built conditions. Organize and present information in sufficient detail to clearly explain O&M requirements at the system, equipment, component, and subassembly level.

O&M packages shall include sections on the following information: Operating Instructions, Safety Precautions, Operator Prestart, Startup/Shutdown/Post-Shutdown Procedures, Normal Operations, Emergency Operations, Operator Service Requirements (including lubrication, adjustment, inspection, and recording gage readings services), Environmental Conditions for Operation, Manufacturer's Data and Parts Catalogs, Preventive Maintenance, Maintenance Table, Lubrication Data including a table showing recommended lubricants for specific temperature, charts with a schematic diagram of the equipment showing lubrication points, recommended types and grades of lubricants, and capacities in accordance with AGMA, NLGI, SAE, Federal or Military Specifications, as applicable, and a Lubrication Schedule showing service interval frequency, Consumables (grease, oil, filters, etc.) Used, Preventive Maintenance Plan and Schedule, Cleaning Recommendations, Corrective Maintenance (Repair), Troubleshooting Guides and Diagnostic Techniques, Wiring Diagrams and Control Diagrams, Maintenance and Repair Procedures, Removal and Replacement Instructions, and Corrective Maintenance Work-Hours.

O&M Manuals must be submitted before the crane can be accepted and turned over to the Government. O&M Manuals must also include complete original manufacturer's quick-start, reference, programming, and user's manuals, with drawings, logic diagrams, instructions, troubleshooting tips for each type variable frequency drive, dynamic braking unit, and programmable logic controller used, and spare parts. O&M Manuals must also include a complete list of programmed settings (a "snapshot" or "download" of settings, current upon acceptance of the crane) and available field-adjustable settings with descriptions for each variable frequency drive provided. The O&M Manual must also include a detail description on how the control system functions, how to troubleshoot/repair the system, and must, at a minimum, include the following listed below.

(1) Load cell.

(2) Inching or “Jog” feature.

(3) VFD input and output.

(4) Stop and Emergency stop function.

(5) Crane controls faults/alarms that are critical or need attention.

(6) Load monitoring after stopping hoisting/lowering.

(7) Hoist brakes.

(8) Travel brakes.

(9) Programmable Logic Controls and Human Machine Interface displays.

1.2.5.2 PERSONNEL TRAINING REQUIREMENTS

Training must cover all of the items contained in the operating and maintenance instructions for the crane. All O&M Manuals must be approved and made available for the training course. All posted instructions must be approved and posted prior to the beginning date of the training course. Provide the Contracting Officer at least 2 weeks advance notice for the training session. Coordinate the training session with the Contracting Officer and the Contracting Officer Representative (COR) to insure minimum conflicts with ongoing Project work.

Provide information, classroom, and field instructions available from the manufacturers that are needed for use in training Government personnel to properly operate and maintain the equipment and systems. These services must be directed by the Contractor, using the manufacturer's factory-trained personnel or qualified representatives. Submit all instructional materials such as lists, static exhibits, video of training session on DVD-R, and visual aids with the O&M Manuals.

1.2.6 WARRANTY

Warrant all crane parts and accessories for a period of one (1) year, or the contracted period of any extended warranty agreed upon by the Contractor and the Government, after successful completion of all testing of the crane. Any component failing to perform its function as specified and documented must be repaired or replaced by the Contractor at no additional cost to the Government. Items repaired or replaced must be warranted for an additional period of at least one year from the date that the system becomes functional again. The warranty period will start after official turnover of the crane to the Government for beneficial use. This turnover must not occur until after successful onsite testing, approved final calculations and drawings, O&M manual etc.

2. GENERAL PROJECT REQUIREMENTS

2.1 Contractor Qualifications

2.1.1 Qualified Supplier

Overhead electric crane system, including sub-system components manufactured by vendors, must be designed and manufactured by a company with a minimum of 10 years of specialized experience in designing and manufacturing the type of overhead crane required to meet requirements of the Contract Documents.

2.1.2 Qualified Engineer

The professional engineer is required to stamp and sign the structural computations and drawings submitted with the drawings package. The registered professional engineer must have done the design himself/herself or supervised and reviewed work if done by other engineers. The registered professional structural engineer must have the relevant experience defined below.

(1) Have experience and knowledge in performing engineering on cranes of similar size and capacity as the 50 ton bridge crane listed in this contract.

Experience on other overhead cranes may be submitted for consideration and the Contractor must explain the relevancy to this project; it will be the Government's discretion if it is considered relevant.

(2) Have at least three years relevant experience in the design of new cranes and/or design of replacement components for existing cranes being rehabilitated.

The three years of experience must have occurred within the past 10 years to be considered.

(3) Provide a resume for each registered professional engineer submitted. Resume must demonstrate the minimum years of experience; include name of firm(s) the engineer was employed by, name of project(s) they worked on, contract number, project location, contract or project point of contact (POC) with contact information (address, phone number, e-mail), crane type and capacity, and describe relevant crane experience.

2.1.3 Qualified Installers

2.1.3.1 Qualified Craftsmen

Craftsmen must have experience and knowledge in performing work and performed work for at least five years on overhead bridge cranes of similar size and capacity as the crane being installed in this contract. They must have been employed for at least the last two years by a firm specializing in crane work.

2.1.3.2 Qualified Crane Electricians

There must be a minimum of one licensed electrician during field wiring and critical aspects of the crane field work.

2.1.4 Qualified Crane Inspectors/Testing Agency

Crane inspectors must possess the following:

a. Have experience and knowledge in performing inspection on bridge cranes of similar size and capacity as the crane being installed in this contract.

b. Certifications showing they have attended crane inspection training seminars provided by established training institutions such as Morris Material Institute (866-821-4006) and CraneTech (800-290-0007). Certifications issued by the Contractor do not meet this requirement.

c. Are employed as crane inspectors for at least the last two years by a firm specializing in crane inspection work. Demonstrate by providing a resume for each crane inspector submitted. Resume must show they have the minimum years of experience; include name of firm(s) they were employed by, name of project(s) they worked on, contract number, project location, contract point of contact (POC) with contact information (address, phone number, e-mail), crane type and capacity, and describe relevant crane experience. Crane experience must be on bridge cranes with minimum capacity of 50-Tons.

2.2 Contractor Requirements

Contractor shall follow all security requirements for base access. All Contractor and subcontractor personnel will need to obtain badges for all access on base from the security office. The Contractor shall be responsible for maintaining the site and all other Contractor controlled areas in such a manner as to minimize the risk of injury or accident to site personnel or others who may be in the area.

2.3 Contractor/Government Coordination

The Contractor shall be responsible for the coordination of work performed by their employees and all subcontractors. The Contractor shall inspect all work areas prior to bidding. It shall be the Contractor’s responsibility to verify all current record drawings prior to the start of any and all design and /or construction work. The Contractor shall be responsible for the coordination and proper relationship of this work to the building premises and thoroughly familiarize themselves with all details of the work and working conditions, to verify all dimensions in the field, and advise the COR of any discrepancies before performing any work. The Contractor shall provide the COR a minimum 21 calendar day notice for the arrival and installation of the crane at Pad II.

2.3.1 Coordination with Hill AFB

If the Contractor’s use of equipment will require any removal and/or modification of a portion of the exterior structure (i.e. roof), the Contractor shall coordinate with Hill AFB CEG Environmental to ensure any functional or decorative features are identified, retained and preserved. The Contractor shall be responsible for ensuring any removed portions are returned to their original condition.

3. AFTER AWARD OFFICER REPRESENTATIVE (COR) AND POST AWARD POC FOR WORK COORDINATION:

The Contracting…