Amendment_0003.pdf

W68MD960487287

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83)

Prescribed by GSA

FAR (48 CFR) 53.243

Chief Joseph Dam Spillw ay Gates Lifecycle Maintenance

Please see Continuation Page for details.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 3

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 22-Dec-2016

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912DW-17-R-0002

X 9B. DATED (SEE ITEM 11)

29-Nov-2016

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer is extended, X is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE

RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

22-Dec-2016

CODE

USA ENGINEER DISTRICT, SEATTLE

ATTN: CECT-NWS

4735 EAST MARGINAL WAY SOUTH, BLDG. 1202

SEATTLE WA 98134-2388

W912DW 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912DW-17-R-0002

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

The purpose of Amendment three (0003) is as follows:

Incorporate changes to the specifications, provisions/clauses, and wage decision as indicated.

1. Specifcations – revised specifications sections are as follows:

Section 35 01 43 Section 41 22 23.19

The attached revised sections are to be replaced in their entirety. Specifications changes are generally identified, for convenience, either by strikeout for deletions, and double underlining of text for additions or a single dark line in the margin. All portions of the revised sections shall apply whether or not changes have been indicated.

2. Provisions/Clauses – revised clause is as follows:

Section 00 72 00 – Contract Clauses 252.204-7008

3. Wage Decision Revised Wage Determination updated to General Decision Number WA160079 11/25/2016 WA79 (with 4 modifications) – and replaces in its entirety WA160079 09/02/2016 (with 3 modifications).

4. Site Visits – Attendance Rosters and Photos Site visit 1 roster and photos (8 Dec 2016) and site visit 2 roster and photos (20 Dec 2016) are provided for informational purposes only.

4. Proposal Submittal Proposal submittal date/time remains the same: 11 January 2017 at 10:00:00 a.m. LOCAL TIME.

NOTICE TO OFFERORS: Offerors must acknowledge receipt of this amendment by number and date on offer.

Encl:

35 01 43 (revised) 41 22 23.19 (revised) Site Visit Attendance Rosters and Photos (new) Clause (only revised clause included)

W912DW-17-R-0002

SECTION 00 72 00 - CONTACT CLAUSES

The following included by reference have been revised:

252.204-7008 Compliance With Safeguarding Covered Defense Information

Controls

DEC 2015

(End of Summary of Changes)

This page intentionally left blank.

CJD Spillway Gate Life Cycle Maintenance 13028 Bridgeport, WA W912DW-17-R-0002

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

SECTION 35 01 43

WIRE ROPE FOR GATE OPERATING DEVICES

04/08

PART 1 GENERAL

1.1 SUMMARY

1.2 REFERENCES

1.3 SYSTEM DESCRIPTION

1.3.1 Work Plan

1.3.2 Safety Plan

1.3.3 Tools, Equipment and Expertise

1.4 SUBMITTALS

1.5 SUPERVISOR'S QUALIFICATIONS

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 General

1.6.2 Inspection on Delivery

1.7 WARRANTY

PART 2 PRODUCTS

2.1 WIRE ROPE AND SOCKETS

2.1.1 Quantity

2.1.2 Type of Wire Rope

2.1.3 Pre-Stretching Procedure

2.1.4 Wire Strength

2.1.5 Weld Distribution

2.1.6 Pitch Length

2.1.7 Core Strand Wires

2.1.8 End Terminations

2.1.9 Tension Testing

2.1.10 Attaching and Proof Loading Terminations

2.2 LUBRICATION

PART 3 EXECUTION

3.1 EXAMINATION

3.1.1 Inspections

3.1.2 Verify Dimensions

3.2 ATTACHING SOCKETS

3.3 CLEAN AND INSPECT DRUMS AND SHEAVES

3.4 LUBRICATION

3.5 GENERAL REQUIREMENTS

3.6 UN-REELING AND INSTALLING WIRE ROPE

3.7 REMOVAL OF EXISTING (OLD) WIRE ROPE

3.8 FIELD TENSIONING MULTI-LINE HOISTS

3.9 BREAK-IN/TESTING

3.10 ORDERLY WORK AREA/SITE CLEANUP

-- End of Section Table of Contents --

SECTION 35 01 43 Page 1 R0003

SECTION 35 01 43 Page 2 R0003

SECTION 35 01 43

WIRE ROPE FOR GATE OPERATING DEVICES

04/08

PART 1 GENERAL

1.1 SUMMARY

In general, perform the following work in regard to the operating devices for 19 spillway gates at the Chief Joseph Dam Project: remove the existing wire rope, furnish new wire rope, and install the new wire rope. Provide all manufacturing facilities, tools, equipment, personnel, and expertise to accomplish this work. Note that Chief Joseph Dam (CJD) staff will provide stoplogs, crane to install stoplogs, and operator for installation of stoplogs. Note CJD has stoplogs for a total of two spillway gates. Eight gates worth of wire rope are Goverment furnished, and are on site awaiting installation. Contractor is responsible for furninshing additional eleven gates worth of wire rope. The Chief Joseph Dam Project is located on the Columbia River approximately 1.5 miles upstream of the city of Bridgeport, WA.

1.2 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

ASTM INTERNATIONAL (ASTM)

ASTM A148/A148M (2008) Standard Specification for Steel Castings, High Strength, for Structural Purposes

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (Rev G) Wire Rope and Strand

WIRE ROPE TECHNICAL BOARD (WRTB)

WRTB (1993) Wire Rope Users Manual

1.3 SYSTEM DESCRIPTION

1.3.1 Work Plan

The work required in accordance with this specification is of a complicated nature, requiring technical expertise and planning. Submit a work plan, which will indicate how the existing wire rope will be removed and how the new wire rope will be installed, without damaging either existing equipment or the new wire rope. Include in the work plan a schedule indicating how

SECTION 35 01 43 Page 3 R0003 the work will be accomplished within the time limit of this contract.

Submit the approved work plan before any work can be performed, including:

Schedule for delivery.

Schedule for installation.

Removal plan for old wire rope.

Installation plan for new wire rope.

Plan for tensioning wire ropes.

1.3.2 Safety Plan

The work area and conditions, and type of work required create considerable potential for accidents. Submit a safety plan indicating how accidents will be prevented. Include in the safety plan details of how the wire rope will be handled and installed to minimize the risk to personnel. Work shall be in accordance with the U.S. Army Corps of Engineers Safety and Health Requirements Manual, EM 385-1-1. Include the safety provisions of this section in the safety plan required by Section 01 35 26 GOVERNMENT

SAFETY REQUIREMENTS.

1.3.3 Tools, Equipment and Expertise

Furnish all tools and equipment, and expertise needed to perform the specified work.

1.4 SUBMITTALS

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

submittals not having a "G" designation are for information only. When used, a designation following the "G" designation identifies the office that will review the submittal for the Government. The following shall be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:

SD-01 Preconstruction Submittals

Work Plan; G

Safety Plan; G

Pre-Stretching Procedure; G

SD-02 Shop Drawings

End Terminations; G

SD-03 Product Data

Lubrication; G

End Termination Attachment Method; G

SD-06 Test Reports

Tension Testing; G

Attaching and Proof Loading Terminations; G

Wire Strength; G

SECTION 35 01 43 Page 4 R0003

Pre-forming; G

Stress Relief ("Wrapping Test"); G

End Terminations; G

SD-07 Certificates

Manufacturer's Qualifications; G

Supervisor's Qualifications; G

Type of Wire Rope; G

Tension Testing Equipment; G

1.5 SUPERVISOR'S QUALIFICATIONS

Provide, as a minimum, a supervisor at the site experienced in the installation of wire rope. The supervisor shall have performed work similar to that required in this contract on at least three occasions.

Submit the approved Installation Supervisor's experience record before work at the site may begin.

1.6 DELIVERY, STORAGE, AND HANDLING

1.6.1 General

Chief Joseph Dam Point of Contact (POC) will assign the Contractor a storage area in the vicinity of the work area. The wire ropes shall be wound on spools in the same direction as they were bent during manufacturing. The spools shall be covered for protection from rain, snow and road spatter during shipping. After delivery, the wire ropes shall be stored in well ventilated enclosures in the Contractor's storage area, so that they will be protected from the elements.

1.6.2 Inspection on Delivery

Upon delivery to the Contractor's work or storage area, the wire ropes and sockets shall be inspected in the presence of the Contracting Officer. In particular, the wire rope shall be inspected for dings, kinks or other damage. The wire ropes shall be reeled from spool to spool in order to allow complete inspection of the wire ropes over their entire length.

Perform the unreeling/reeling operation, and furnish extra spools or any other equipment required. Upon completion of the inspection, furnish the Contracting Officer with a written report of the results.

1.7 WARRANTY

At the completion of the project, furnish signed copies of a 1 year warranty for all materials and services provided under this section.

PART 2 PRODUCTS

2.1 WIRE ROPE AND SOCKETS

Provide wire rope, nuts, jam nuts, full nuts, pins, eyebolts, clips, sockets and all appurtenances which match the style and construction of existing equipment as shown in included drawings, for replacement-in-kind.

SECTION 35 01 43 Page 5 R0003

Manufacturer shall have experience fabricating flat wire rope that has been in satisfactory use for at least 3 years prior to bid opening. Submit manufacturer's qualifications statement.

2.1.1 Quantity

Furnish 11 flat wire rope assemblies with end terminations (sockets) at both ends, including eyebolts, pins, nuts, and all hardware. Each wire rope shall be of the length indicated on reference drawings and within the tolerance also indicated on drawings. Verify dimensions in the field before ordering additional wire rope. Discrepancies between drawings and field measurement shall be brought to the attention of the Contracting Officer or Representative.

2.1.2 Type of Wire Rope

Submit wire material certification. The wire rope shall be of the following type:

a. Strand configuration: 4 by 19.

b. Lay: Each assembly will be constructed of 5 ropes made right regular lay and 5 ropes made left regular lay, placed parallel to each other on a clean flat surface, alternating the left and right lay ropes.

c. Diameter: 7/8 inch, with a tolerance of - 0 and plus 5 percent

d. Finish: plain

e. Material: AISI 302 stainless

f. Pre-formed: yes

2.1.3 Pre-Stretching Procedure

Submit pre-stretching procedure. The manufacturer shall pre-stretch the wire rope. This shall be done by subjecting them to three cycles at 40 percent of its nominal strength. The 40 percent loads shall be held for 5 minutes with 5 percent loads for 5 minutes between cycles. The manufacturer may propose a method of dynamic pre-stretching.

2.1.4 Wire Strength

The Manufacturer shall perform testing in accordance with FS RR-W-410 to verify wire strength. Submit test results.

2.1.5 Pre-forming

The wire rope shall be pre-formed, and the manufacturer shall perform testing in accordance with FS RR-W-410 to verify pre-forming. Submit test results.

2.1.6 Stress Relief (Wrapping Test")

The wire rope shall be stress relieved, and the manufacturer shall perform testing in accordance with FS RR-W-410 to verify stress relief. Submit test results.

SECTION 35 01 43 Page 6 R0003

2.1.5 Weld Distribution

Wire joints in any strand shall not be closer than 18 inches in any strand.

2.1.6 Pitch Length

Strand pitch length shall not be less than 4-1/2 times the nominal rope diameter.

2.1.7 Core Strand Wires

The number of wires in the core strand shall be equal to or greater than the number of wires in the other strands. The wires shall be of the same material as the wires in the other strands, or of a material with a lower tensile strength.

2.1.8 End Terminations

Submit fabrication drawings, as specified. The wire rope end terminations (sockets) shall be fabricated as indicated on reference drawings, and shall be cast from steel conforming to ASTM A148/A148M, Grade 105-85. Submit materials properties test for casting end terminations.

2.1.9 Tension Testing

Submit rope tension test report with photos of setup, failure, and test apparatus. A tension test shall be performed to verify the wire rope meets the accepted industry standards for nominal strength. Two individual rope samples shall be tested to failure to be sure the expected performance level has been met. The test shall be performed using suitable tension testing equipment and by qualified personnel, both furnished by the Contractor. Submit certification of rope tension testing device. The rope samples shall cut to no less than 3 feet of length. The test will not be considered valid if the failure occurs less than 2 inches from either socket or holding mechanism. Relative speed between the machine heads shall not exceed 1 inch per minute.

Tension destructive test one complete wire rope assembly including threaded fasteners to the breaking force. Take photos of setup, failure, and test apparatus. The assembly wire rope in the destructive sample shall be no less than five feet long. Fasteners and other appurtenances shall be of actual size.

2.1.10 Attaching and Proof Loading Terminations

The manufacturer shall attach the end terminations after pre-stretching the wire rope. The end termination attachment method shall be as indicated on reference drawings. After their attachment, the wire ropes shall be proof loaded at 40 percent of nominal strength of the rope (202,000 lbs). Length of the wire ropes shall be measured to the nearest 0.01 inch at a load of 25,000 pounds. Submit proof load of terminations test report and measured rope lengths.

2.2 LUBRICATION

Submit brand/specifications for factory and field lubricant. The wire ropes shall be lubricated at the manufacturing facility. Apply the lubricant with equipment capable of forcing the lubricant between the rope wires, including the center strand.

SECTION 35 01 43 Page 7 R0003

PART 3 EXECUTION

3.1 EXAMINATION

It is highly recommended that bidders visit the site before submitting bids. Drawings and verbal descriptions cannot fully describe the effort required to satisfactorily complete the contract work. A pre-bid site visit can be arranged.

3.1.1 Inspections

Be prepared to accommodate up to two representatives of the Contracting Officer to witness the various manufacturing processes for the wire rope.

At a minimum, a site visit will be made to witness the tension test, and the wire rope will be inspected upon delivery. Inspection during removal of the existing wire rope and installation of the new wire rope will be ongoing.

3.1.2 Verify Dimensions

After becoming familiar with the details of the work, verify dimensions in the field, and immediately advise the Contracting Officer of any discrepancies before performing any work.

3.2 ATTACHING SOCKETS

Attach the end terminations to the wire rope in accordance with reference drawings and the recommendations of FS RR-W-410 Wire Rope and Strand, and the WRTB Wire Rope Users Manual.

3.3 CLEAN AND INSPECT DRUMS AND SHEAVES

Clean all drums with a power wire brush, and inspect them for wear, abrasion, corrosion or other roughness and verify their dimensions are suitable for the new wire rope. Upon verification of suitability, perform alignment checks on all drums and plates. For all circumstances of misalignment beyond minimum safe tolerances, realign to a tolerance as stated on the drawings.

3.4 LUBRICATION

Lubricate the wire ropes, above the water line only, after they are installed, but before break-in/testing. Submit the proposed method in the work plan. The field and factory lubricants shall be Frontier Lubricants' BIO-CABLE wire rope lubricant or approved equal, compatible, environmentally-friendly substitute. Salient characteristics are that the lubricant is 100 percent food grade, resists emulsification in high moisture environments, contains anti-wear additives, and inhibits corrosion. Also submit a proposed method for field lubrication of the wire rope for after every time the gates are raised or once a month, whichever is sooner.

3.5 GENERAL REQUIREMENTS

This part covers removal of the existing wire rope and installation of the new wire rope.

SECTION 35 01 43 Page 8 R0003

3.6 UN-REELING AND INSTALLING WIRE ROPE

The wire rope(s) shall be attached to drums, pulleys as shown on reference drawings. Ensure that the wire rope is wound under adequate tension and that the each wind of the rope(s) is guided to its proper location. The wire rope shall be wound in the same direction it was bent during its manufacture. Ensure that no twists or loops occur. Submit the proposed method of un-reeling and installing in the work plan.

3.7 REMOVAL OF EXISTING (OLD) WIRE ROPE

After its removal, the old wire rope will become the property of the Contractor who shall then remove the old wire rope from the project.

USACE shall be given the opportunity to destructive examine wire ropes at their choosing. After examination Contractor will remove the old wire rope from the project. (Destructive examination will be cutting wire rope and removing sections).

3.8 FIELD TENSIONING MULTI-LINE HOISTS

Adjust the tension of the wire ropes to ensure that they share load equally. Submit the proposed method field tensioning in the work plan.

After "break-in/testing" the ropes shall be tested to determine if they share load equally, and if not, they shall be re-tensioned.

3.9 BREAK-IN/TESTING

After installation is complete, run the gate-operating device through three complete cycles, fully open to fully closed.

3.10 ORDERLY WORK AREA/SITE CLEANUP

Maintain neat and orderly storage and work areas, as much as possible. The Contract will not be considered complete until all the Contractor's tools, equipment and property have been removed from the site, and the Contractor's storage and work areas have been properly cleaned up. All dirt, debris, litter etc. shall be removed from project and disposed of in a proper manner. Special care shall be taken to ensure that no materials fall into or contaminate project waters.

-- End of Section --

SECTION 35 01 43 Page 9 R0003

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 23.19

TROLLEY RAILS AND TROLLEYS

04/08

PART 1 GENERAL

1.1 REFERENCES

1.2 SYSTEM DESCRIPTION

1.2.1 Design Data: Structural Design Calculations

1.2.2 Design Requirements

1.2.2.1 Design Loads and Loading Criteria

1.2.2.2 Rail or Track Welding

1.2.2.3 Trade Coordination

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Certificates

1.4.2 Pre-Erection Inspection

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Delivery and Storage

1.5.2 Handling

1.6 MAINTENANCE

PART 2 PRODUCTS

2.1 IDENTIFICATION PLATES

2.2 OVERHEAD RAIL SYSTEM AND TROLLEY SYSTEMS

2.2.1 Capacity

2.2.2 Material and Design Requirements

2.2.3 Safety

2.3 RAIL TRACK SYSTEM

2.3.1 Quick Shutoff

2.3.2 Track Beam System

2.3.3 Track Suspension or Track Anchorage System

2.3.4 Track Beam System Materials

2.4 TROLLEYS

2.5 MOTORS

2.5.1 Trolley Motors

2.6 CONTROLS

2.7 BRAKES

2.7.1 Trolley Brake

2.8 LOAD BLOCK, ATTACHMENT POINT, AND HOOK

2.8.1 Non-Destructive Testing

2.8.2 Hook and Hook Nut Magnetic Particle Inspections

2.9 BEARINGS

2.10 PAINTING SYSTEM

PART 3 EXECUTION

3.1 FABRICATION, ERECTION, AND INSTALLATION

3.1.1 Anchorage Installation

SECTION 41 22 23.19 Page 1 R0003

3.1.2 Erection Plan

3.1.3 Fabrication Drawings

3.1.4 Welding

3.1.5 Painting and Priming

3.1.6 Drain Holes

3.2 ERECTION SERVICES

3.3 FIELD QUALITY CONTROL

3.3.1 Government Inspection

3.3.2 Anchorage Testing

3.3.3 Post-Erection Inspection

3.3.4 Operational Tests

3.3.5 Test Data

3.3.6 Hook Tram Measurement

3.3.7 No-Load Test

3.3.8 125 percent Rated Load Test

3.3.9 Rated Load Speed Test

3.4 FIELD TEST PROCEDURES

3.4.1 General Instructions

3.4.2 Equipment Monitoring

3.4.3 Hooks

3.4.4 Preparing For Load Testing

3.4.5 Precautions During Load Testing

3.4.6 Testing

3.4.6.1 No Load Test

3.4.6.2 Hoist Load Testing

3.4.6.3 100 Percent of Rated Capacity (plus 0 percent, minus 5 percent) Load Test

3.4.6.4 125 Percent of Rated Capacity (plus 5 percent, minus 0 percent) Load Test

3.5 Warranty

-- End of Section Table of Contents --

SECTION 41 22 23.19 Page 2 R0003

SECTION 41 22 23.19

TROLLEY RAILS AND TROLLEYS

04/08

PART 1 GENERAL

1.1 REFERENCES

The publications listed below form a part of this specification to the extent referenced. The publications are referred to within the text by the basic designation only.

AMERICAN ASSOCIATION OF STATE HIGHWAY AND TRANSPORTATION OFFICIALS

(AASHTO)

AASHTO MBE (2011) The Manual for Bridge Evaluation - Second Edition

AASHTO LRFD (2014) Bridge Design Specifications - Seventh Edition

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2011) Steel Construction Manual

AISC 326 (2009) Detailing for Steel Construction

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z359 (2012) Fall Protection Code

AMERICAN WELDING SOCIETY (AWS)

AWS A2.4 (2012) Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS D1.1/D1.1M (2012; Errata 2011) Structural Welding Code - Steel

ASME INTERNATIONAL (ASME)

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

ASME B30.23 (2011) Personnel Lifting Systems - Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings

ASME B30.16 (2012) Overhead Hoists (Underhung)

ASME HST-1 (2012) Performance Standard for Electric Chain Hoists

ASME HST-4 (1999; R 2010) Performance Standard for Overhead Electric Wire Rope Hoists

SECTION 41 22 23.19 Page 3 R0003

ASME HST-6 (1999; R 2010) Performance Standard for Air Wire Rope Hoists

ASTM INTERNATIONAL (ASTM)

ASTM A275/A275M (2008; R 2013) Standard Test Method for Magnetic Particle Examination of Steel Forgings

ASTM A325 (2010) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A325M (2009) Standard Specification for Structural Bolts, Steel, Heat Treated, 830 MPa Minimum Tensile Strength (Metric)

ASTM A36/A36M (2012) Standard Specification for Carbon Structural Steel

ASTM A563 (2007a) Standard Specification for Carbon and Alloy Steel Nuts

ASTM A563M (2007) Standard Specification for Carbon and Alloy Steel Nuts (Metric)

ASTM A992/A992M (2011) Standard Specification for Structural Steel Shapes

ASTM E543 (2013) Standard Practice for Agencies Performing Non-Destructive Testing

ASTM A6/A6M (2012) Standard Specification for General Requirements for Rolled Structural Steel Bars, Plates, Shapes, and Sheet Piling

ASTM E709 (2008) Standard Guide for Magnetic Particle Examination

ASTM F436 (2011) Standard Specification for Hardened Steel Washers

ASTM F436M (2011) Standard Specification for Hardened Steel Washers (Metric)

ASTM F959 (2013) Compressible-Washer-Type Direct Tension Indicators for Use with Structural Fasteners

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 74 (2010) Specifications for Top Running and Under Running Single Girder Electric Overhead Cranes Utilizing Under Running Trolley Hoist, No. 74

SECTION 41 22 23.19 Page 4 R0003

INTERNATIONAL CODE COUNCIL (ICC)

IBC (2012) International Building Code

MATERIAL HANDLING INDUSTRY OF AMERICA INC (MHIA)

MHI MH27.1 (2009) Specifications for Underhung Cranes and Monorail Systems

MHI MH27.2 (2009) Specifications for Enclosed Track Underhung Cranes and Monorail Systems

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014) National Electrical Code

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

RCSC S348 (2004) RCSC Specification for Structural Joints Using ASTM A325 or A490 Bolts

U.S. ARMY CORPS OF ENGINEERS (USACE)

EM 385-1-1 (2014) Safety and Health Requirements Manual

U.S. NATIONAL ARCHIVES AND RECORDS ADMINISTRATION (NARA)

29 CFR 1910.179 Overhead and Gantry Cranes

1.2 SYSTEM DESCRIPTION

Design and provide a rail system with air-powered trolley (or trolleys), and two non-motorized trolleys for fall restraint connections, tested and complete, ready for operation.

The powered trolleys and rail system shall be designed to utilize Chief Joseph Dam's Spider ST-17 hoist baskets and platform extensions. The non-motorized trolleys will be designed to work with the system and provide fall restraint attachement points for life safety. There shall be a rail system for each of the 19 spillway gates. Only one motorized trolley system is required, but the system shall be compatible and transfereable with all 19 rail systems.

Rail systems, hoist attachments, trolley system, non-motorized trolley fall retraints, equipment, materials, design, installation, examination, inspection, and workmanship shall conform to the applicable requirements of

NFPA 70, ASME B30.11, ASME B30.16, ASME HST-1, ASME HST-4, ASME HST-6,

MHI MH27.1,MHI MH27.2, EM 385-1-1, ASME B30.16, CMAA 74, and ANSI Z359.

Designed for frequent usage (heavy service) and for outdoor service.

Anchorage or attachment to spillway bridge is an important component of the design along with the rail and trolley systems. Observe important details and take field measurements in designing attachement and anchorage to the spillway bridge. Anchorage and attachments will need USACE approval before final design is accepted.

The system designer must analyze the spillway bridge super structure load rating following AASHTO MBE and AASHTO LRFD Bridge Design Specifications

SECTION 41 22 23.19 Page 5 R0003 with the effects of trolley system attached, and provide a load rating for the bridge with the trolley system included.

Also remove existing I-Beams in gate bays 10 and 11, removing a total of four beams.

Anticipated design and installed quantities are:

a.) Thirty-eight designed and installed I-beams to act as rail system.

b.) Designed and installed anchorage for all 38 beams.

c.) Two air powered trolleys for spider hoists and platforms.

d.) Two non-motorized trolleys for attaching fall restraints.

e.) Remove four I-beams located at spillway gates 10 and 11.

f.) Three radio control pendants for powered trolleys.

g.) One attached control pendant.

These are anticipated quantities to represent intent. The actual design may lead to variances.

See Attachment 41 22 23.19-A REFERENCE INFORMATION FOR SPILLWAY RAIL AND TROLLEY SYSTEMS following this section for additional information and reference drawings.

1.2.1 Design Data: Structural Design Calculations

Submit structural design calculations verifying the size of structural members, anchorage, structural supports (fittings, rods, brackets, foundation attachements, and components), and lifting beams for the track beam system. Include stress and loading diagrams. Design track beams (rails) to allow travel by trolley to access the full width and depth of the gates as needed. The mounting hardware, embedment, and method shall be designed, verified, and approved by a licensed registered professional structural engineer who shall affix their engineering stamp to the design drawings and calculations.

Design and stamp steel trolley support beams, connection to the concrete pit ceiling/bridge above, and all other associated items for a complete and usable installation. Design calculations shall be stamped by a registered professional engineer. Submit all structural design calculations for approval before beginning fabrication. Submit calculations with rail system design drawings including spillway bridge load rating calculations.

Analyze spillway bridge super structure load rating following AASHTO MBE and provide a load rating for the bridge with the trolley system included.

Submit additional product data for commercially procured items, including as a minimum, the following items:

Festoon System Variable Frequency Drives Bumpers End Stops Concrete Anchors and Fasteners

1.2.2 Design Requirements

Submit design drawings showing capacity and the general arrangement of the track beam (rail) system, including switches, clearances, principal dimensions, details of structural connections, details of anchorage connections, and all component details. Include complete schematic wiring

SECTION 41 22 23.19 Page 6 R0003 diagram with description of operation. Manufacturer's catalog data will suffice for items of standard manufacturer. Also submit fabrication drawings before fabrications (see Part 3).

1.2.2.1 Design Loads and Loading Criteria

The track beams (rail system) are to support a traveling scaffold system.

Each beam shall be designed to support all loads from the trolleys including the scaffolding, workers, and tools. Contractor will include wind, seismic, thermal movement, dynamic, and any other load required by code to act on the structure.

Ensure each trolley is capable to support the loads required in CMAA 74 and IBC with a safety factor of five, including but not limited to the following:

a.) The entire nominal weight of the current Spider Brand ST-17 scaffold system (both Spider hoists and connecting platforms).

Contractor and Designer shall view equipment during site visit to ensure design compatability.

b.) Two (2) Workers at 300 pounds each.

c.) Four hundred (400) pounds miscellaneous tools and equipment.

d.) Environmental loads, including but not limited to wind and seismic loads.

e.) Fall arrest loads as specified in ANSI Z359.

f.) Rails (beams) shall be designed to support all loads transmitted to it from the trolleys with a minimum safety factor of five.

1.2.2.2 Rail or Track Welding

Welding sections of rail system shall conform to AWS D1.1/D1.1M.

1.2.2.3 Trade Coordination

The Contractor is responsible for the coordination of their work with the work of all trades involved and as it relates to the spillway and operation of the spillway. Verify all quantities and dimensions that relate to fabrication of the rail system and trolley systems, and notify the Contracting Officer of any discrepancy prior to ordering the rail and trolley componenents.

1.3 SUBMITTALS

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

submittals not having a "G" designation are for information only. 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-01 Preconstruction Submittals

Erection Plan; G

SECTION 41 22 23.19 Page 7 R0003

SD-02 Shop Drawings

Rail System; G Complete schematic wiring diagram with description of operation Fabrication Drawings; G Anchorage and Attachments; G

SD-03 Product Data

Rail Track System; G Trolley; G Radio Remote Control System; G Attached Pushbutton Pendant; G Hook Proof Test; G Festoon System; G Variable Frequency Drives; G Bumpers; G End Stops; G Concrete Anchors and Fasteners; G Manufacturer's Published Tables

Manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions, and parts list.

SD-05 Design Data

Structural Design calculations; G Design Drawings; G Structural and Load Capacity calculations; G

Load and sizing calculations as specified.

SD-06 Test Reports

125 percent Rated Load test No-Load Test Post-Erection Inspection Operational Tests Rated Load Speed Test Hook NDT Report Hook Tram Measurement Anchorage Testing and Verification Plan Anchorage Test Reports

Tests and inspections reports. Magnetic particle inspection of hook and hook nut results. Hook NDT Report can mean hook or attachment point NDT report depending on design.

SD-07 Certificates

Compliance with all listed Standards Semi-Annual Overload/Safe for Testing Welder Certification Brake Settings Runway Straightness/Levelness Loss of Power Test Hook Proof Test

SECTION 41 22 23.19 Page 8 R0003

SD-10 Operation and Maintenance Data

Rail System with Trolley Systems and hoist system, all components, Data Package 3; G

Submit Data Package 3 as specified in Section 01 78 23

OPERATIONS AND MAINTENANCE MANUALS.

1.4 QUALITY ASSURANCE

1.4.1 Certificates

a. Certification that the hoist, hook, and trolley system contains no hazardous material, asbestos, cadmium, lead, elemental mercury, or PCBs.

b. Semi-Annual Overload/Safe for Testing certification that the hook and trolley system is safe to test on a semi-annual overload basis with a test load of 131.25 percent of rated capacity with no detrimental effects.

c. Certification that testing may be performed in which hook, and trolley system is subjected to a Loss of Power Test during operation with no detrimental effects.

d. Certification that the hook, and trolley system design and fabrication is in compliance with all listed standards and standard industry practices.

e. Hook Proof Test certification that the hoist hook was subjected to a minimum static load of 200 percent of rated capacity for at least 10 minutes without deformation. Hook can mean attachement point depending on design.

f. Runway Straightness/Levelness certification that the straightness, levelness, and elevation of the monorail system meet MH27.1 requirements.

g. Certification of brake settings, including the allowable range of adjustment for hoist and trolley brakes and the initial setting of each.

1.4.2 Pre-Erection Inspection

Before erection/ installation, the Contractor and the manufacturer's representative shall jointly inspect the rail (beam) system and trolley systems and components at the job site to determine compliance with specifications, designer drawings, and manufacturer's data and fabrication drawings as approved. Notify the Contracting Officer 10 days before the inspection.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Delivery and Storage

Inspect materials delivered to site for damage; unload and store with minimum handling. Store materials on-site in enclosures or under protective coverings. Protect materials not suitable for outdoor storage to prevent damage or corrosion during periods of inclement weather, including subfreezing temperatures, precipitation, and high winds. Store

SECTION 41 22 23.19 Page 9 R0003 materials susceptible to deterioration by direct sunlight under cover and avoid damage due to high temperatures. Do not store materials directly on ground. When special precautions are required, prominently and legibly stencil instructions for such precautions on outside of equipment or its crating.

1.5.2 Handling

Handle materials in such a manner as to ensure delivery to final location in undamaged condition. Make repairs to damaged materials at no cost to Government.

1.6 MAINTENANCE

Submit Rail System with Trolley Systems and hoist system, all components, Data Package 3 for the entire combined system in accordance with Section

01 78 23 OPERATION AND MAINTENANCE DATA.

PART 2 PRODUCTS

2.1 IDENTIFICATION PLATES

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. Also provide rail track beam identification plates showing the capacity of the system, legible from the spillway catwalk.

2.2 OVERHEAD RAIL SYSTEM AND TROLLEY SYSTEMS

Provide approved rail system with air powered trolley (or trolleys), and non-motorized trolleys for fall restraint connections complete, tested and ready for operation as described in Paragraph SYSTEM DESCRIPTION. The trolleys and rail system shall utilize Chief Joseph Dams Spider ST-17 hoist baskets and platform extensions. There shall be a rail system for each of the 19 spillway gates. Only one trolley system is required, but the system shall be compatible and transferable with all 19 rail systems. Rail system, hoist attachments, trolley system, equipment, materials, design, installation, examination, inspection, and workmanship shall conform to the applicable requirements of NFPA 70, ASME B30.11, ASME B30.16, ASME HST-1, ASME HST-4, ASME HST-6, MHI MH27.1, MHI MH27.2, EM 385-1-1, ASME B30.16, CMAA 74 and ANSI Z359. Design the system for frequent usage (heavy service) and for outdoor service.

2.2.1 Capacity

Provide rail system and trolley system capable to support the loads required in CMAA 74 and IBC with a factor of safety of 5, including but not limited to the following:

a. The entire nominal weight of the current Spider Brand ST-17 scaffold system. System is made of two Spiders and connecting platforms. Verify weights of the Spider System in use.

b. Two (2) Workers at 300 pounds each.

c. Four hundred (400) pounds miscellaneous equipment.

d. Environmental loads, including but not limited to wind and seismic loads.

e. Fall arrest loads as specified in ANSI Z359.

f. Rails (beams) shall be designed to support all loads transmitted to it from the trolleys with a minimum safety factor of 5.

SECTION 41 22 23.19 Page 10 R0003

2.2.2 Material and Design Requirements

Rail system and trolley systems shall include the following design requirements:

a. Powered trolleys shall include a brake and a controlled braking means and an overload limiting device.

b. Trolleys shall be compatible with all rails (beams) installed and existing Spider Hoist with connecting platforms. That is, trolleys shall have treads that are compatible with new rails (or I-beams) installed on all 19 spillway gates, and trolleys shall have attachement points compatible with current Spider Hoists and platform system in use by Chief Joseph Dam. Trolleys shall have lifting points to be installed onto rails by a crane from spillway bridge. Rail system will need to allow for frequent removal and installation of trolleys.

c. 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 each motor, motor controller, and branch circuit conductor shall all conform to the NFPA 70.

dc. Provide safety (drop) lugs or a functional equivalent on the trolley frame to prevent derailment in the event of wheel failure.

ed. The trolley systems shall be capable of general service in all weather outdoor (-18 to 38 degrees C, 0 to 100 degrees F) working conditions.

fe. Provide air powered trolley system operating on 100 psi tool air.

Provide compatible twist lock connector and hose to get from nearest compressed air system connection point to trolley festoon connection.

Provide sufficient hose length to allow trolley to travel full length of track.

gf. Provide non-motorized trolley system for fall protection connections.

2.2.3 Safety

Comply with the mandatory and advisory safety requirements of ASME B30.11, ASME B30.16,EM 385-1-1, ASME B30.23 and 29 CFR 1910.179. The Contractor is responsible for checking the proper operation and condition of safety devices, electrical components, mechanical equipment, and structural assemblies prior to installation. Immediately report any observed defective components and replace. Submit structural and load capacity calculations verifying a design safety factor of 5 to 1 to ultimate strength of weakest material (steel) used for any track suspension device, anchorage connection, or support which is not a standard cataloged product of the manufacturer.

2.3 RAIL TRACK SYSTEM

Track system shall conform to MHI MH27.1 or MHI MH27.2, except as modified and supplemented in this section, for powered hoists. Provide designed and registered proffessional engineer stamped or patented track beam sections fabricated by a manufacturer regularly engaged in production of this type of beam. The maximum allowable vertical and lateral deflection shall conform to CMAA 74, with the hoist(s) at rated load(s) and at any

SECTION 41 22 23.19 Page 11 R0003 location(s). Rail separation at joints shall not exceed 1/16 inch.

2.3.1 Quick Shutoff

Provide quick shutoff type air supply valve, readily accessible from the catwalk, and located within proximity to the rail system.

2.3.2 Track Beam System

Provide the track beam system with trolley stops at all open end locations. The stops shall retain the hoist on the track. Stops shall contact the wrap-around type trolley frame. Since trolleys will be moved from spillway to spillway, stops will be required to be removable and easily reainstalled (or have the ability to move for trolley installation).

2.3.3 Track Suspension or Track Anchorage System

Provide rail suspension and anchorage system. Design and installation of the rail track beam suspension system and anchorage system is the responsibility of the Contractor. Approval of anchorage to the dam concrete is required. Provide detail drawings and calculations of anchorage to dam for approval. Detail drawings shall include anchorage type and location.

a. Suspend the rail track beam with the manufacturer's standard cataloged suspension products. Submit manufacturer's published tables verifying the sizing of any track beam and suspension system.

b. Make bolted connections to supporting structure, excluding hanger rods, with ASTM A325 bolts, ASTM A563 nuts, and ASTM F959 load indicator washers, or ASTM F436 hardened washers or designer designated hardware or anchorage used in design and calculations. ASTM A325 bolts shall be fully pre-tensioned in accordance with RCSC S348.

c. Post installed concrete anchors shall be drill and bonded. Designer will detail installation instructions and Quality Control inspection requirements.

2.3.4 Track Beam System Materials

All structural steel used in this project shall be ASTM A992/A992M or ASTM A36/A36M. All steel bolts shall be ASTM A325 or ASTM A325M bolts with ASTM A563 or ASTM A563M nuts and ASTM F436 or ASTM F436M washers. Steel bolts, nuts, and washers shall all be corrosion resistant.

Supply the certified manufacturer's mill reports which clearly show the applicable ASTM mechanical and chemical requirements together with the actual test results for the supplied structural members and fasteners.

Structural steel shall be new steel conforming to ASTM A6/A6M.

2.4 TROLLEYS

Provide two trolley systems, one motorized trolley system for the newly installed rail system (beams) at Chief Joseph Dam, and additional non-motorized trolley system for fall protection of workers.

Motorized trolleys need to travel along the newly installed I-Beams and can be relocated from spillway rail to spillway rail system. The trolleys must only provide movement along the rail or I-beam (i.e. no vertical hoist), as

SECTION 41 22 23.19 Page 12 R0003 the existing Spider platforms contain winches. The non-motorized trolleys need to travel in tandem with the motorized trolleys to provide fall protection of workers in the platform. These trolleys are to be linked in such a way that upon failure of the motorized trolleys, these trolleys will provide fall arrest of the workers.

Trolley systems shall be capable of operating outdoors in all weather conditions from 0 to 100 degrees F. Trolley systems shall be designed to carry all loads as listed in Paragraph CAPACITY.

Trolleys shall meet ANSI/ASME B30.23 requirements for human occupancy. They are to be man-rated and capable of supporting the load and safety factor specified in Paragraph CAPACITY.

Each trolley is to have a lifting point so that it may be lifted onto rail systems by a crane.

Provide a storage container to hold and trasport the trolley and additional trolley components (hoses, etc.) while the trolley is not in use. Storage container shall be able to bear the weight of the trolley and reasonably protect it from the elements.

Also see Attachment 41 22 23.19-A "Reference Information for Spillway Rail and Trolley System" for additional information. Note: This attachment is for information only.

2.5 MOTORS

2.5.1 Trolley Motors

Trolley drive motor shall be vane motor type. Trolleys shall be capable of operating at two operating speeds. The fast speed shall be between 50 and 75 feet per minute (fpm), and the slower speed shall be between 20 and 30 fpm. If a two trolley system is used, the radio controls are to be configured to control both trolleys simultaneously, be capable of controlling all features of the trolley (multiple speeds, brakes), and shall have a minimum range of fifty (50) yards. The ability for each trolley to act independently is to be disabled.

2.6 CONTROLS

Provide control of air powered trolley from a radio remote control system and/or cord attached pushbutton pendant. Arrange pushbuttons in accordance with ASME B30.11 recommendations. Provide three radio control pendants and one cord attached push button pendant. The controls are to be configured to control both trolleys simultaneously (if two trolleys are used) and be capable of controlling all features of the trolley (multiple speeds, brakes). The radio remote controls shall have a minimum range of fifty

(50) yards. The cord attached control shall have a 50-foot long cord and have the ability to be uplugged or easily removed or installed for control. The ability for each trolley to act independently is to be disabled.

2.7 BRAKES

2.7.1 Trolley Brake

Provide trolley with a non-coasting worm drive. Trolley brake shall have a torque rating equal to or greater than 50 percent of the drive motor rated

SECTION 41 22 23.19 Page 13 R0003 torque and be adjustable from 85 percent to 100 percent of its torque rating. Equip trolley brake with a manual release. Design to permit easy access for wear, inspection and setting. The trolleys will have holding brakes to prevent moving unless under power.

2.8 LOAD BLOCK, ATTACHMENT POINT, AND HOOK

Provide attachment point or safety hook fitted with self-closing, spring loaded steel safety latch, and with hook nuts keyed to hook shanks by means of a setscrew installed in a plane parallel to the longitudinal axis of the hook shank, or by any other similar easily removable securing device to attach Spider hoists to trolley system. Provide unpainted attachment point or hook and hook nut, permanently marked with an identification number.

Clearly mark the hook and hook nut with a unique identification number corresponding to the number used in non-destructive test (NDT) reports.

Attachment point or hook shall be specifically designed to be used with Spider ST-17 hoist and platforms.

2.8.1 Non-Destructive Testing

The following requirements apply:

a. The Hook NDT Report supplier shall provide a letter certifying that the requirements of ASTM E543 are met. Hook NDT Report can be hook or attachement point NDT report depending on design.

b. The NDT supplier shall develop, and submit for review, procedures, including technique sheets specific to the types, shapes, and sizes of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye bar nut). For the magnetic particle method, the procedures shall adequately describe the orientation of the hook or nut, or pin with the magnetizing equipment.

c. These procedures shall be reviewed by a Level III examiner who is independent of the NDT supplier and is certified in the applicable NDT method.

2.8.2 Hook and Hook Nut Magnetic Particle Inspections

The hook and hook nut (or attachement point) shall be magnetic-particle inspected in compliance with ASTM E709 over the entire area in accordance with ASTM A275/A275M, with the following restrictions: Do not use DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes. Do not use automatic powder blowers or any other form of forced air other than from a hand-held bulb for the application or removal of dry magnetic particles. Remove arc strikes. Equipment ammeters shall have an accuracy of plus or minus 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the MT procedure states that a magnetic field indicator is used to establish and verify adequate field strength for the aspects of the inspection). The acceptance standard is no linear indications greater than 1/16 inch.

2.9 BEARINGS

All bearings…