41 22 13.73 26 Am-0001.pdf

Intake Crane Replacement - Gavins Point Dam, South Dakota GP00104

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13.73 26

CRANE APPURTENANCES

PART 1 GENERAL

1.1 GENERAL

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN DATA FOR CRANE APPURTENANCES

1.5 DESIGN CRITERIA

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

PART 2 PRODUCTS

2.1 OPERATOR CAB

2.1.1 General

2.1.2 Functional Requirements, Location, View from Cab

2.1.3 Design Loads

2.1.4 Cab Construction

2.1.4.1 General

2.1.4.2 Framing Materials and Wall Materials

2.1.4.3 Weather-tightness

2.1.4.4 Insulation

2.1.4.5 Rubber Floor Mats

2.1.4.6 Door

2.1.4.7 Windows

2.1.5 Operator Cab Air Conditioning Unit

2.1.6 Cab HVAC

2.1.6.1 Radiant Heaters

2.1.6.2 Cab Heating/Cooling Heat Pump Units

2.2 MACHINERY HOUSING

2.2.1 General

2.2.2 Functional Requirements and Clearances

2.2.3 Design Loads and Criteria

2.2.4 Provisions for Machinery Maintenance

2.2.4.1 Maintenance Lifting Eyes and Access Hatches

2.2.4.2 Machinery Housing Lifting Eyes

2.2.5 Machinery Housing Construction

2.2.5.1 Framing Materials and Wall Materials

2.2.5.2 Roof

2.2.5.3 Weather Tightness

2.2.5.4 Louvers

2.2.5.5 Bird Screens

2.2.5.6 Wind Speed Monitor Roof Access

2.2.5.7 Door

2.2.5.8 Main Hoist Trolley Insulation

2.2.6 Emergency Egress

2.2.6.1 Personnel Lowering Device Anchor Points

2.2.6.2 Personnel Lowering Devices

2.2.7 Main Hoist HVAC

2.2.7.1 Radiant Heaters

2.3 PERSONNEL ACCESS

SECTION 41 22 13.73 26 Page 1

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2.3.1 Platforms and Walkways

2.3.2 Stairs

2.3.3 Ladders

2.3.4 Safety Gates

2.4 FALL PROTECTION ANCHOR POINTS

2.5 MAINTENANCE HOISTS

2.5.1 General

2.5.2 Hoist, Trolley, and Bridge

2.5.3 Rigging Enclosure

2.6 TRASH RACK GUIDES

2.6.1 Access Platforms for Trashrack Deployment

PART 3 EXECUTION

3.1 TESTING AND INSTALLATION

3.1.1 Operator Cab Shop Inspection And Testing

-- End of Section Table of Contents --

SECTION 41 22 13.73 26 Page 2

SECTION 41 22 13.73 26

CRANE APPURTENANCES

PART 1 GENERAL

1.1 GENERAL

All relevant requirements from SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK and 41 22 13.74 26 INTAKE GANTRY CRANE REPLACEMENT ELECTRICAL WORK must be applied to this SECTION. This includes, but is not limited to the following paragraphs: "Design Criteria", "Connections", "SUBMISSION OF CRANE DESIGN DATA", "FINAL APPROVED VERSIONS OF CONTRACTOR-PREPARED DRAWINGS AND CALCULATIONS", and

"FIELD MEASUREMENTS".

1.2 REFERENCES

The publications listed below form a part of this specification to the extent indicated by the reference. The publications are referred to in the text by basic definition only.

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2023) Steel Construction Manual

AMERICAN NATIONAL STANDARD INSTITUTE (ANSI)

and AMERICAN SOCIETY OF SAFETY PROFESSIONALS (ASSP)

ANSI/ASSP A1264.1 (2017) Safety Requirements for Workplace Walking/Working Surfaces and Their Access;

Workplace, Floor, Wall and Roof Openings;

Stairs and Guardrail/Handrail Systems

ANSI/ASSP Z359.1 (2016) The Fall Protection Code

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI A14.3 (2008) Ladders

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B30.2 (2022) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME B30.11 (2010) Monorails and Underhung Cranes - Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings

ASME B30.16 (2022) Overhead Underhung and Stationary Hoists

ASME B30.17 (2020) Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoists)

SECTION 41 22 13.73 26 Page 3

ASME HST-1 (2017) Performance Standard for Electric Chain Hoists

ASTM INTERNATIONAL (ASTM)

ASTM A123/A123M (2017) Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 70 (2020) Specification for Top Running Bridge and Gantry Type Multiple Girder Electric Overhead Traveling Cranes

CMAA 74 (2020) Specifications for Single Girder Cranes

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2023) National Electrical Code

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2024) Safety -- Safety and Health Requirements Manual

1.3 SUBMITTALS

Government approval is required for submittals with a "G" designation;

submittals not having a "G" designation are for information only or as otherwise designated. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. Submit the following in accordance with SECTION 01 33 00

SUBMITTAL PROCEDURES:

SD-03 Product Data

Maintenance Hoist Product Data; G, HDC

SD-05 Design Data

Design Data For Crane Appurtenances; G HDC

Maintenance Hoist Design Data; G, HDC

SD-07 Certificates

Maintenance Hoist Load-Test Certification; G, HDC

1.4 DESIGN DATA FOR CRANE APPURTENANCES

Submit Design Data For Crane Appurtenances as specified here in and in specification 41 22 13.70 26 SUBMISSION OF CRANE DESIGN DATA for approval. Design Data For Crane Appurtenances must be approved prior to procurement of associated materials and equipment.

All crane appurtenances submitted are to meet the requirements of

SECTION 41 22 13.73 26 Page 4 paragraph "SUBMISSION OF CRANE DESIGN DATA" in 41 01 20.74 26 NEW INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK, unless noted otherwise. This includes, but is not limited to drawing index, bill of materials, dimensioned assembly drawings, detailed shop drawings, product data, design calculations, and stamping of the computations and drawings by a registered professional structural engineer.

Submit Crane Design Data for crane appurtenances in a logical order with the major components submitted first and the lesser components submitted afterwards. Examples of Structural Crane Appurtenances include, but are not limited to those listed below:

1. Operator Cab

2. Machinery/Trolley House

3. Walkways and Guardrails

4. Stairs and Ladders

5. Fall Protection Anchor Points

6. Trashrack Guides

7. Access Platforms for Trashrack Deployment

1.5 DESIGN CRITERIA

Design all crane appurtenances in accordance with the requirements and loads specified below and as specified in paragraph "Structural Design Criteria" and "Connections" in SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK. Do not superimpose live loads used to design crane appurtenances with primary load combinations for crane design. Do not detail arrangement and connection of crane appurtenances to be loaded by crane frame deflection in response to primary loads. Do not attach crane appurtenances carrying persons using bolts in direct tension.

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

Include final approved versions of contractor prepared drawings and final calculations for all appurtenances with the Final Calculations submittal package from SECTION 41 22 13.72 26 INTAKE GANTRY CRANE MECHANICAL AND

STRUCTURAL WORK.

PART 2 PRODUCTS

2.1 OPERATOR CAB

2.1.1 General

Provide an operator cab designed and constructed in accordance with CMAA 70, EM 385-1-1 , and ASME B30.2 . Submit the complete design, including applicable component cut sheets, calculations, and shop drawings for approval. Submit calculations, dimensioned detailed drawings, and cab lines of sight for Government approval prior to fabrication.

2.1.2 Functional Requirements, Location, View from Cab

The operator cab must house the operator control station, panelboards, and other equipment as required by these specifications. The arrangement of operator control station, placement of equipment, and required clearances is as shown on the drawings, and as per the approved design layout and detail drawings. Locate equipment items so they do not obstruct vision

SECTION 41 22 13.73 26 Page 5 through any window. The following views are critical in considering the cab lines of sight:

a. The underside of all trolleys.

b. The view down the intake deck during gantry travel in both directions.

c. View extreme ends of unit bulkhead slots while lowering bulkheads.

d. View of the trash racks at the upper end of each trash rack slot.

e. View of the jib hoist when positioned from 0 to 180 degrees North to South in the upstream direction, with 0 degrees being the upstream South crane leg and 180 degrees being the upstream North crane leg.

2.1.3 Design Loads

Design structural parts for the cab not affected by primary loads, and the connection of the cab to the gantry frame, in accordance with AISC 325 .

Design connections of cab to frame per CMAA 70 such that bolt assemblies are in shear and cab is adequately braced to prevent excessive sway and/or vibration. Design the cab using the live loads stated below, in addition to the self weight of the cab and the weight of all items permanently attached to the cab. Apply all distributed area roof, floor, and wind loads simultaneously. Place the concentrated live load in the most adverse location for each structural component.

a. Distributed Area Floor Live Load: 100 psf.

b. Distributed Area Roof Live Load: 50 psf.

c. Wind Load: 30 psf (applied over the projected wind area).

d. Concentrated Live Load: 300 pounds.

2.1.4 Cab Construction

2.1.4.1 General

Provide hidden wireways in the floor of the cab for wire and cable as necessary between the control cabinets and other equipment included in the cab. Continuously weld and grind smooth the wireway seams, and ensure no screws or bolts protrude into the inside of the wireway, and all edges and corners of raceways are rounded and smooth. Construct wireway covers of aluminum, weighing no more than 50 pounds each. Provide covers with recessed handles for lifting. Covers must protect wireways from all foreign debris.

2.1.4.2 Framing Materials and Wall Materials

a. Construct the cab using the following materials:

(1) Frame - Structural steel shapes.

(2) Ceiling and exterior unglazed portions of walls and doors - Reinforced steel sheets not less than 1/8 inch thick.

(3) Floor - Reinforced steel plate not less than 1/4 inch thick.

SECTION 41 22 13.73 26 Page 6

b. The final skin plate installation must be free of sharp protuberances and edges.

c. Provide all horizontal skin plates with drain holes covered with bird screen and be sloped to allow moisture accumulation from minor leakage and condensate to drain out.

d. Areas made inaccessible once skin plate is installed must receive at minimum one coat of primer prior to insulation and skin plate installation.

e. Provide 7-foot minimum floor to ceiling clear headroom inside cab (i.e. provide 7-foot minimum headroom from top of cab floor surface to bottom of cab lighting fixtures - cab lighting fixtures may be recessed to achieve this).

f. The interior sides of walls and ceiling must be painted and covered with sound-proof foam. Sound-proof foam must be black, 1-inch thick, closed cell, moisture-resistant, fire-retardant, dust free, and mold-resistant.

g. Paint the cab to match the crane structure, See Section 09 97 02.10 26 PAINTING: STEEL STRUCTURES for requirements.

h. Provide the cab with a ceiling and a hatch covering the cab access hole to keep conditioned air from escaping the cab. Provide a chute between the cab access hatch and the cab ceiling (connecting the cab ceiling to the cab access hole on the lower bridge walkway deck).

Provide the hatch with a hinge and made of aluminum floor plate with recessed handle for ease in opening and closing. Provide a latching mechanism for locking the hatch in the open position.

2.1.4.3 Weather-tightness

Design and fabricate the cab to provide a weather-tight housing. Provide flashing and slope roof away from the crane structure. Provide drip edges and flashing to direct run off away from doors and windows. Provide watertight pipe and conduit entrances into the cab.

2.1.4.4 Insulation

Insulate the cab with fire retardant, mold, and moisture resistant insulation material providing a minimum R value of 6. Provide insulation material free of asbestos. Protect all insulation by weather-tight steel sheet skin plate.

2.1.4.5 Rubber Floor Mats

Cover the floor of the cab with a fiber-reinforced rubber mat that is 1/2 inch thick and has a smooth top. Color must be black. Cover mat seams with metal strips to secure mat edges. Provide the rubber mat for floor areas not covered by permanently installed equipment.

2.1.4.6 Door

a. Provide a weather-tight door. Provide weather-stripping around the

SECTION 41 22 13.73 26 Page 7 door frame to exclude rain and wind.

b. Fabricate the door of aluminum sheets not less than 14-gauge thick and insulate with fire retardant, mold- and moisture-resistant insulation material.

c. Provide the door with aluminum lever-type handles with bronze cylinder lock that accepts BEST 8 pin Core. Provide keys for the lock that are compatible and identical to locks provided for the electrical cab doors and machinery housing doors.

d. Provide glass panel not less than 14 inches by 24 inches.

2.1.4.7 Windows

Windows of the cab are to meet the following requirements:

a. Use double-glazed polished low-emissivity glass of the laminated safety type to avoid shards of glass falling down on personnel in case of breakage.

b. Provide 60 percent total solar energy rejection (TSER) tinting on windows.

c. Bars must not run across windows obstructing views.

d. Design the retention of glazing to positively prevent windows from falling outward.

e. Provide sliding windows as shown on the contract drawings.

f. Floor windows must be a minimum of 1-inch thick and capable of supporting 500 pounds.

g. Provide at least one window on the north and south sides of the cab capable of being opened to facilitate direct verbal communication between the operator and personnel on the intake deck.

2.1.5 Operator Cab Air Conditioning Unit

a. Provide an air conditioning unit for the operator cab. Determine the minimum cooling capacity and indoor unit airflow to provide a comfortable working environment and submit for approval. Assume 120 degrees F outside temperature and all heat generating loads installed as part of this contract; assume a wind velocity of 20 miles per hour when sizing air conditioning unit. The air conditioner must be able to lower the cab temperature to 60 degrees F maximum when operating.

The air conditioning unit must have a thermostat control for operation. Thermostat must be the industrial type with 120 volt coil, wired to operate a contactor, rated 600 volts. Thermostat must be adjustable from 55 to 90 degrees F. The unit must be factory fabricated, assembled, operationally tested and pre-charged. The enclosures must be rated for outdoor use. Provide separate breakers for supplying power to the operator cab air conditioner. Provide wireless remote for controlling the air conditioning unit. Submit drawings for approval showing location of new air conditioner and include details for wiring and interconnection with the new crane power and lighting systems. Install new air conditioner such that water does not enter the cab or insulation area.

SECTION 41 22 13.73 26 Page 8

b. See Section 41 22 13.18 26 for additional requirements on air conditioning equipment and requirements for wall mount style radiant heaters to be installed inside the operator cab.

2.1.6 Cab HVAC

2.1.6.1 Radiant Heaters

Provide an electric heater for the cab that meets the following requirements. Install heater in accordance with the manufacturer's recommendations, including but not limited to clearances.

a. Heater must be *Am-1 infrared radiant **Am-2 type and must be wall-mounted type.

b. Size the heater to maintain a minimum cab temperature of 70 degrees F, based on an outside temperature of 32 degrees F. Heater must be a minimum of 500 watts.

c. Position the operator cab heater for the operator's comfort while in the operator's chair. Install and locate heater in accordance with all manufacturer's requirements.

d. Heater must be UL-listed.

e. The body of the heater must be made of 20 gauge steel (minimum) that is galvanized or high-temperature powder-coated.

f. The heater must have an integral junction box for wiring connections .

2.1.6.2 Cab Heating/Cooling Heat Pump Units

a. Provide a heat pump for each cab. Provide all appurtenances for a complete installation, including flashing and through-the-wall or through-the-ceiling aluminum or shop-painted zinc-coated steel flanged sleeves, designed to restrict driving rain and prevent water from getting into the cab. Provide outside cabinets, custom-constructed if necessary, including but not limited to metal grilles, to protect condenser coils, of zinc-coated steel or aluminum. Steel and zinc-coated surfaces must receive at least one coat of primer and manufacturer's standard factory-applied finish. Cabinets must be insulated to prevent condensation and run-off moisture. Provide mounting hardware made of corrosion-resistant material or protected by a corrosion-resistant finish. Provide air filters of the permanent washable type, removable without the use of tools.

b. Units must be factory fabricated, assembled, operationally tested, and pre-charged. The unit must be capable of fan-only operation.

Heat pump must have rated cooling capacity of 12000 BTUH or more, and rated heating capacity of 14400 BTUH or more. Wired, wall-mounted thermostats must be provided with each heat pump. Thermostats must be adjustable from +4 to +32 degrees C (+40 to +90 degrees F). Units must be similar or equal to Mitsubishi Electric Mr. Slim M series #MSZ-GE12NA. See SECTION 41 01 20.73 26 GANTRY CRANE ELECTRICAL REPLACEMENT for electrical requirements.

SECTION 41 22 13.73 26 Page 9

2.2 MACHINERY HOUSING

2.2.1 General

Provide a machinery house for each trolley and for the jib hoist designed and constructed in accordance with CMAA 70, EM 385-1-1 , ASME B30.2 , and NFPA 70 . Submit the complete design, including applicable component cut sheets, calculations, and shop drawings for approval. Submit calculations and dimensioned detailed drawings for Government approval prior to fabrication. The projected wind area must be clearly stated on the shop drawings and included in the trolley drive design calculations and the jib hoist slew drive calculations.

2.2.2 Functional Requirements and Clearances

Design the machinery house to enclose the hoisting and drive equipment as required by these specifications and as shown. Provide required clearances as needed to traverse the area and to perform maintenance on all applicable equipment inside the machinery house.

The machinery housing must be removable from the trolley frame in order to provide access to the machinery for maintenance and for removal of hoist components. The jib hoist machinery housing must be removable from the gantry frame mounting points in order to provide access for equipment removal and maintenance. Do not attach permanent equipment or conduit to the housing structure with the exception of lighting, maintenance hoist(s), and electrical power to the maintenance hoist(s).

Provide clearance between the roof framing and the machinery floor or any raised floor intended as walking surface of not less than measured directly vertical, unless otherwise specified or approved by the government. Provide a minimum clearance of 7'-0" below lights and other equipment mounted on the ceiling.

2.2.3 Design Loads and Criteria

Design structural parts for the machinery housing not affected by primary loads, and the connection of the housing to the trolley/jib frame, in accordance with AISC 325 . Design the machinery housing using the live loads stated below, in addition to the self weight of the machinery housing and the weight of all items permanently attached to the machinery housing. Apply all distributed area roof loads and wind loads simultaneously. Place the concentrated live load in the most adverse location for each structural component. Design the machinery housing for the combined effects of the self weight of the housing and the weight of all items permanently attached to the machinery housing plus the machinery maintenance hoisting loads to 75% of AISC 325 allowable strengths.

a. Distributed Area Roof Load: 50 psf.

b. Concentrated Live Load: 300 pounds.

c. Wind Load: 30 psf (applied over the projected wind area).

d. Machinery Maintenance hoisting loads.

2.2.4 Provisions for Machinery Maintenance

For all lifting eyes provided, assure that the working load limit exceeds

SECTION 41 22 13.73 26 Page 10 the anticipated lift. For any custom designed lifting eyes and lift points, provide calculations showing a safety factor of five (5) against ultimate tensile strength of the material.

2.2.4.1 Maintenance Lifting Eyes and Access Hatches

Provide adjustable pad-eyes above the item for lifting hoist equipment (brakes, motor, latching hoist assembly etc). Provide adjustable pad-eyes above for lifting main trolley drive equipment. Provide additional removable hatches and/or openings in the machinery housing and trolley deck, as needed, for hoist and trolley drive component removal and replacement.

2.2.4.2 Machinery Housing Lifting Eyes

Provide lifting eyes or rigging points on the machinery housing to facilitate installation and removal of the machinery housing.

2.2.5 Machinery Housing Construction

2.2.5.1 Framing Materials and Wall Materials

Provide a housing for each trolley and for the jib hoist, constructed of structural shapes, sheets, and plates as conceptually shown on the drawings. Construct the sides and roof of the housing of steel sheets not less than 1/8-inch thick.

2.2.5.2 Roof

Slope roof as shown and to prevent accumulation of water. Provide means to prevent large sheets of ice and snow from sliding off the roof onto the deck.

2.2.5.3 Weather Tightness

Each housing must be weather-tight. Design the roof to prevent the entrance of rainwater. Provide drip edges and flashing to direct run-off away from doors, louvers, and wind speed monitor access hatch. Limit pipe and conduit entrances into the housing, but when used provide watertight pipe and conduit entrances that do not interfere with removal of the housing.

2.2.5.4 Louvers

Provide louvers of an adjustable type designed to prevent air leakage when closed. Locate louvers to allow full ventilation flow without conflict between electrical cabinets, storage cabinets, or other equipment inside the trolley/jib hoist.

2.2.5.5 Bird Screens

Provide features to make each housing bird-tight by means of 1/2-inch by 1/2-inch bird screens, or a maximum of 1/2-inch by 1-inch diamond mesh expanded metal covering the louvered openings and rubber flaps covering the wire rope slots in the floor. Fit the underside of each trolley with sections of netting, screen, expanded metal, or other devices to eliminate bird access for roosting or nesting.

SECTION 41 22 13.73 26 Page 11

2.2.5.6 Wind Speed Monitor Roof Access

Provide wind speed monitor atop the main hoist trolley. Locate wind speed monitor access ladder inside the machinery housing. Construct a weather-tight hatch accessing wind speed monitor for maintenance and inspection with suitable materials to make light enough for one person to open/close the hatch and include locking mechanism to lock hatch in the open position when maintenance is being performed. Provide hatch with air-cylinder or similar to prevent hatch from slamming shut. Provide hatch with lock for securing in the closed position, securing tight against seal and making weather-tight. Design hatch, hatch hinges, air-cylinder, and lock for maximum wind gusts in excess of 100 mph.

Provide fall protection for personnel accessing the wind speed monitor for maintenance by either providing guardrails or a fall arrest post that personnel can clip into.

2.2.5.7 Door

Provide weather stripping around the door frame to exclude rain and wind.

Fabricate the door of aluminum sheets not less than 18-gauge thick and insulate with fire retardant, mold- and moisture-resistant insulation material. Provide the door with aluminum lever-type handles with bronze cylinder lock that accepts BEST 7 pin Core. Provide glass panel not less than 14 inches by 24 inches. Provide keys for the lock that are compatible and identical to locks provided for the electrical cab doors and machinery housing doors. Door must be weather-tight.

2.2.5.8 Main Hoist Trolley Insulation

Insulate the main hoist trolley with fire retardant, mold, and moisture resistant insulation material providing a minimum R value of 6. Provide insulation material free of asbestos. Protect all insulation by weather-tight steel sheet skin plate.

2.2.6 Emergency Egress

2.2.6.1 Personnel Lowering Device Anchor Points

Locate an anchor point for the personnel lowering device in a location that may also be accessed at the operator cab walkway level. Locate the anchor points 6'-6" above the floor level. The user must be able to hook up the personnel lowering device on the anchor point and to his escape belt before opening the personnel lowering swing gate. Provide D-ring anchor points.

2.2.6.2 Personnel Lowering Devices

Provide a personnel lowering device for each operator cab meeting the following requirements:

a. Provide a compact industrial descent personnel lowering device for emergency egress.

b. Lowers the user to intake deck level at a controlled rate of descent and self adjusts for each person's weight, operating by gravity, and uses no electricity or power.

c. Requires no adjustments or special skills needed to operate the device.

SECTION 41 22 13.73 26 Page 12

d. Device contains an installation carabineer, two escape belts, and a cable storage reel.

e. Cable lengths long enough to safely lower a person to the intake deck.

f. Provide a device capable of handling a person weighing a minimum 300-pounds and be Sellstrom/RTC 1003-DEVXXX Escape-Rite, or approved equal.

g. Provide weathertight storage cabinets that are mounted on the walkway handrail, trolley handrail, or wall of the machinery house for storing the personnel lowering devices.

h. Provide an O&M Manual and Customer Training for the personnel lowering device. See SECTION 41 01 20.71 26 INTAKE GANTRY CRANE DATA, TESTING AND TRAINING for personnel lowering device training requirements.

2.2.7 Main Hoist HVAC

2.2.7.1 Radiant Heaters

Provide an electric heater for the main hoist machinery housing that meets the following requirements. Install heater in accordance with the manufacturer's recommendations, including but not limited to clearances.

a. Heater must be *Am-1 infrared radiant **Am-1 type and must be wall-mounted type.

b. Size the main hoist machinery housing heater to maintain a minimum main hoist trolley temperature of 50 degrees F, based on an outside temperature of -25 degrees F. Based on calculations performed during the design process, it is estimated that a 12,000 watt heater will be needed for this application. Contractor to verify heater sizing based off of final trolley design.

c. Position the main hoist machinery housing heater for optimal heating of the machinery housing while allowing for adequate clearances and safe standoff distances. Install and locate heater in accordance with all manufacturer's requirements.

d. Heater must be UL-listed.

e. The body of the heater must be made of 20 gauge steel (minimum) that is galvanized or high-temperature powder-coated.

f. The heater must have an integral junction box for wiring connections .

2.3 PERSONNEL ACCESS

Provide platforms, walkways, stairs, and ladders as shown as per approved detail drawings. Hot dip galvanize personnel access features to the maximum extent practicable in accordance with ASTM A123/A123M . Coat items not galvanized in accordance with 09 97 02.10 26 PAINTING: STEEL

STRUCTURES.

SECTION 41 22 13.73 26 Page 13

2.3.1 Platforms and Walkways

a. Provide platforms and walkways as shown and as approved in accordance with the provisions in EM 385-1-1 and ANSI/ASSP A1264.1 .

b. Design new platforms and walkways using the live loads stated below, in addition to self weight and the weight of all items permanently attached. Place the concentrated live load in the most adverse location for each structural component.

(1) Distributed Area Live Load: 100 psf.

(2) Concentrated Live Load: 300 pounds.

c. Unless shown otherwise on the contract drawings, provide a minimum clear width of 30 inches.

d. All decking to be heavy-duty steel grating unless otherwise shown or specified.

e. Provide guardrails as shown and as required, with welded joints.

2.3.2 Stairs

a. Provide stairs as shown and as approved in accordance with the provisions in EM 385-1-1 and ANSI/ASSP A1264.1 .

b. Design new stairs using the live loads stated below, in addition to self weight and the weight of all items permanently attached. Place the concentrated live load in the most adverse location for each structural component.

1) Distributed Area Live Load: 100 psf.

2) Concentrated Live Load: 300 pounds. (on stair treads applied over a 2 inch by 2 inch area).

c. Unless shown otherwise on the contract drawings, provide a minimum clear stair width of 22 inches, and stair treads at least 12 inches deep. Do not exceed 50 degrees in stair rise over run.

d. All stair treads to be heavy-duty steel grating unless otherwise shown or specified.

e. Provide guardrails and handrails as shown and as required, with welded joints.

2.3.3 Ladders

a. Provide ladders as shown and as approved in accordance with the provisions in EM 385-1-1 and ANSI A14.3 . For ladders greater than 20-feet in length, provide each ladder with a ladder climbing device (LCD) meeting EM 385-1-1 as required. Ladder cages are not permitted in place of a ladder climbing device.

b. Design ladders, including fastenings, for the following loads:

SECTION 41 22 13.73 26 Page 14

(1) Design each ladder rung for a single concentrated live load of 250 pounds.

(2) Minimum design live load of two loads of 250 pounds each concentrated between any two consecutive ladder attachment points.

(3) Impact loads from ladder climbing devices.

(4) Design vertical ladders, including fasteners, for a total load of 1,000 pounds.

c. Provide ladders not less than 16 inches wide, measured inside the rails, and rungs not less than 7/8-inch in diameter, equally spaced on approximately 12-inch centers.

d. Unless otherwise shown in the drawings or otherwise specified, design ladders with the following clearances:

(1) Outwards - 30 inches, measured from the center of the rungs

(2) Inwards - 7 inches, measured from the center of the rungs

(3) Side - 15 inches, measured from the centerline of the ladder

e. Provide ladder rungs with non-slip surfaces.

f. Provide ergonomic siderail extension for ladder to platform transition.

g. Provide a safety gate on all ladder to platform transitions where the fall is more than 30 inches

2.3.4 Safety Gates

Provide safety gates at all openings in the guardrails. Permanently attach safety gates to the guardrails. Provide self-closing adjustable type safety gates, designed for easy passage (will not require personnel to stop and lift a bar or undo chains for passing through). Provide safety gates that are adjustable using stop bolts, and include stainless steel spring for automatic gate closure. Construct the gate from structural steel as defined in Section 05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS, matching handrail design, and painted to match the guardrails. Force test the gate up to 300 pounds and designed in accordance with ANSI/ASSP A1264.1 .

2.4 FALL PROTECTION ANCHOR POINTS

a. Provide fall protection anchor points on the crane for performing safe operations and inspections of all components, equipment and systems designed and provided. Some anchor point locations are identified on the drawings and in the specifications, however additional locations may be required to safely operate, inspect, and perform maintenance on the crane.

(1) Four anchor points per trolley, attached to the top of the gantry frame, for the purpose of inspecting the gantry frame, trolley rails, all fasteners, and the trolley frame and machinery.

(2) Two anchor points at each maintenance hatch, for personnel use

SECTION 41 22 13.73 26 Page 15 when hatch is open for maintenance hoist operations. Install on the interior side wall or ceiling of the trolley housing.

(3) In addition to item 2 above, provide four anchor points inside each trolley housing and located on the interior side walls or ceiling. Locate two each near each trolley drive.

(4) 4 anchor points per leg, accessible by personnal at intake deck elevation 1234.0 feet, attached to each face of the gantry leg.

b. Design the anchor points for a 5,000-pound force and installed in accordance with EM 385-1-1 Section 21.I "Personal Fall Protection System." Design anchor point allowable stresses in accordance with AISC 325 . Furnish anchor points containing a D-ring. Provide a strap containing two D-rings for each anchor point that is higher than 6'-0" above deck level. All fall protection anchor points/devices (weld on pivot links, D-rings, eye-bolts, etc) must meet the requirements of the associated product standard and the fall protection device(s) must bear an ANSI/ASSP Z359.1 marking or be represented as being in compliance with ANSI/ASSP Z359.1 standard. Fall protection equipment must be compatible with systems currently in use at the project site.

2.5 MAINTENANCE HOISTS

2.5.1 General

In both the main and auxiliary hoist trolleys, provide an overhead 1/2-ton bridge crane maintenance hoist (also called tool hoist throughout the specifications and contract drawings) system with electric powered chain hoist mounted on a movable manual push/pull bridge and trolley, complete, tested, and ready for operation. Submit Maintenance Hoist Product Data, Maintenance Hoist Design Data, and Maintenance Hoist Load-Test Certification for Government Approval prior to acquisition of the maintenance hoist.

Maintain a minimum 7-foot clearance from the trolley floor to the hoist hook. All equipment, materials, installation, examination, inspection, and workmanship must conform to the applicable requirements of NFPA 70 , ASME B30.11 , ASME B30.16 , ASME B30.17 , ASME HST-1, and CMAA 74 as modified and supplemented by this specification. The hoist must be capable of lifting items from the intake deck to its respective trolley floor.

The maintenance hoist must be capable of removing the main and auxiliary hoist motors, brakes, upper sheave nests, equalizer sheaves, main and auxiliary hoist gearbox covers for full access to internal gears, and the trolley drive gearmotor(s) (externally-mounted chain drives for the auxiliary trolley are exempt from this requirement if a chain drive is selected), without interference with any component of the trolley or machinery house. Removal of additional components of the trolley must not be necessary to provide clearance. The hoist hook upper travel limit must be high enough such that all activities described above do not engage the upper travel limit, and each hoist lower limit must be sufficient to reach the intake deck level.

2.5.2 Hoist, Trolley, and Bridge

Provide a commercially available off-the-shelf electric chain hoist. The maintenance hoist must have motorized hoist and manual push/pull trolley

SECTION 41 22 13.73 26 Page 16 and bridge functions. All aspects of the hoist and trolley must comply with ASME HST-1, Class H3 or better, and ASME accordingly. The maintenance hoist power cable must be wired directly using a dedicated circuit. The hoist must have the following salient features:

a. The hoist must have a minimum rated capacity of 2,000 pounds (1 ton).

b. Provide a hoist with 2 lifting speeds with the ability to be adjustable. Low speed must be a minimum of 5 feet per minute and High speed must be a minimum of 28 feet per minute.

c. Equip hoist with adjustable upper and lower limit switches and stops to prevent over-travel in both the raising and lowering directions.

d. Size corrosive resistant lifting chain length so that the hook can reach the walking surface of the intake deck at its lower limit and clear the trolley floor by at least 7 feet. Submit load chain proof test results.

e. Provide a load block with a single safety hook fitted with self-closing, spring loaded steel safety latch, and that can swivel. Provide a hook permanently marked with an identification number and rated capacity.

f. Provide a pendant control that has push buttons to operate the hoist and an emergency stop push-button in accordance with ASME B30.11 recommendations. The pendant cord must be arranged in a festoon or cable track to the hoist trolley/carrier. The pendant cord must be of sufficient length to allow full length of travel of the trolley and bridge and have the ability to be stored.

g. Provide the hoist with a manual push/pull trolley and bridge. Size the wheels to match the provided monorails and have anti-friction type roller bearings that are considered to be lifetime lubricated by the manufacturer.

h. Equip the hoist with a container sized to hold the entire length of load chain.

i. Provide manufacturer installed identification plates of non-corrosive metal showing, in clearly legible permanent lettering, the manufacturer's name, model number, capacity rating, and other essential information.

j. Powered hoists must include a brake, a controlled braking means, and an overload limiting device set to 125% of rated capacity.

k. Overcurrent protection for the control circuit and control circuit transformer; fuse or circuit breaker protection for branch circuit short circuit and ground fault protection; and overload protection for a motor, motor controller, and branch circuit conductor must all conform to the NFPA 70 .

l. Provide hoist system operating on 480 Volts 60 Hz power supply.

The maintenance hoist power cable must be wired directly using a dedicated circuit.

SECTION 41 22 13.73 26 Page 17

m. Provide AC totally enclosed fan-cooled (TEFC) hoist motor. Motor insulation must be Class F. Equip all motors with thermal trip type over-temperature protection. Maximum motor speed must not exceed 1800 RPM.

n. The trolley and bridge must have the ability to be secured in a parked position when not in use that prevents the maintenance hoist from moving. The parked position of the hoist must allow a minimum of 7 feet clearance from the trolley floor, not require special tools to engage/disengage the parked position, and not interfere with any portion of the crane or other equipment.

o. Provide stops at both ends of travel to limit trolley and bridge movements. The end stops must retain the hoist and bridge on the tracks.

p. The maximum allowable vertical and lateral deflection must conform with CMAA 74, with the hoist(s) at rated load(s) and at any location(s).

2.5.3 Rigging Enclosure

Provide a rigging enclosure made of stainless steel and is NEMA 4X for exterior use as defined by NEMA 250. Collaborate with the Government when locating the rigging enclosure. Locate the rigging enclosure in an agreed upon convenient location (such as inside the machinery house, gantry sill beam, other convenient location). Design and locate cabinets such that cabinet doors are able to open without obstruction or colliding with other objects. The enclosure must have double doors with continuous hinges and, as a minimum, have a barrel slide bolt and a security hasp with provisions for locking. The enclosure must be constructed of 12 gauge thickness and have three reinforced shelves and a large lower storage area for larger items. Minimum size of enclosure must be 48 inches wide, 48 inches high and 24 inches in depth.

2.6 TRASH RACK GUIDES

Provide guides on the upstream face of the crane to allow for an angled deployment of the trash racks by use of the auxillary hoist. Slope the guides to 12:1.75 matching the face of the dam and the embedded trashrack guide slope. The length of the guides should be a minimum of 11 feet.

Provide a 1 inch clearance between the guides and the intake deck.

The guides must be capable of receiving the lifting beam smoothly without binding. Design the guides to match the embedded trash rack guides found in the reference drawings. Contractor to verify existing crane's trash rack dimensions, clearances, and slope as well as those of the embedded trash rack guides prior to designing trash rack guides for the new crane.

2.6.1 Access Platforms for Trashrack Deployment

Provide lower access platforms on the outer face of the upstream crane legs to allow maintenance personnel to view the trashracks being deployed or retrieved. Provide dimensions and elevations to match the existing crane. The platform must meet EM 385-1-1 safety and access requirements.

SECTION 41 22 13.73 26 Page 18

Provide upper access platforms above the upstream sill beam to allow maintenance personnel to assist in deploying the trashracks into the slot.

The upper access platform must have removable guardrailing. The platform must meet EM 385-1-1 safety and access requirements.

PART 3 EXECUTION

3.1 TESTING AND INSTALLATION

Completely design, fabricate, assemble, coat, and perform shop assembly fit-up for all crane appurtenances which attach to the crane prior to on-site delivery. Complete all assembly and testing per SECTION 41 01 20.74 26 NEW INTAKE GANTRY CRANE MECHANICAL AND STRUCTURAL WORK and 41 01 20.71 26 INTAKE GANTRY CRANE DATA, TESTING AND TRAINING. Design and provide all supports, brackets and other provisions for erecting the new appurtenances and installing them on to the crane structure at site.

3.1.1 Operator Cab Shop Inspection And Testing

Test in the shop all wire and cable installed on the cab in the shop.

Testing must conform to SECTION 41 01 20.73 26 GANTRY CRANE ELECTRICAL REPLACEMENT, paragraph WIRING FIELD TESTING. Unless waived in writing, after completion of shop assembly but prior to shipping, inspect the operator cab for conformity to these specifications and approved shop drawings by the Contracting Officer.

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SECTION 41 22 13.73 26 Page 19