W912EF-15-R-0048-0011.pdf

W68SBV51203542

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

The purpose of this amendment is to make the changes indicated in the Summary of Changes.

The proposal due date remains unchanged.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 2

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

16C. DATE SIGNED

BY 13-Oct-2015

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 W912EF-15-R-0048

X 9B. DATED (SEE ITEM 11)

28-Aug-2015

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

13-Oct-2015

CODE

USAED, WALLA WALLA - CONTRACTING DIV.

KENT R. BERNARD 201 N. THIRD AVENUE

WALLA WALLA WA 99362-1876

W912EF 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912EF-15-R-0048

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION 00010 - SOLICITATION CONTRACT FORM

The following have been added by full text:

AMENDMENT 0011

1. Revised the following Specifications (see revised Specifications for details):

a. SECTION 41 22 13.17 28 CRANES, SINGLE-GIRDER BRIDGE Revised Paragraph 1.6.2.1 Classification Revised Paragraph 1.6.2.2 Hoist Characteristics Revised Paragraph 2.2.2.1 Electric Wire-Rope Hoists Revised Paragraph 2.6.5 Stops and Bumpers Revised Paragraph 2.8.5 Hoist Motors Revised Paragraph 3.4.1.4 Hooks

(End of Summary of Changes)

Lower Mon. Navlock Downstream Gate Hoist Machinery Upgrade W912EF-15-R-0048 Amend-0011

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 22 13.17 28

CRANES, SINGLE-GIRDER BRIDGE

PART 1 GENERAL

1.1 WORKMANSHIP

1.2 REFERENCES

1.3 DEFINITIONS

1.3.1 Overhead Maintenance Crane

1.3.2 Capacity

1.3.3 Hoisting Speed

1.3.4 Rated Lift

1.3.5 Headroom

1.4 SUBMITTALS

1.5 DELIVERY AND STORAGE

1.6 SYSTEM DESCRIPTION

1.6.1 General Requirements

1.6.1.1 Materials, Equipment and Qualifications

1.6.1.2 Nameplates

1.6.1.3 Detailed Drawings

1.6.2 Design Criteria

1.6.2.1 Classification

1.6.2.2 Hoist Characteristics

1.6.2.3 Overhead Maintenance Crane Characteristics

1.6.2.4 Capacity Plates

PART 2 PRODUCTS

2.1 CONSTRUCTION TOLERANCES

2.2 ELECTRIC HOIST

2.2.1 General

2.2.2 Types of Electric Hoists

2.2.2.1 Electric Wire-Rope Hoists

2.2.3 Hoist Speed

2.2.4 Load and Motor Brakes

2.3 HOIST MECHANICAL EQUIPMENT

2.3.1 Wire-Rope Hoist

2.3.1.1 Hoist Wire Rope

2.3.1.2 Hoist-Rope Drum

2.3.1.3 Hoist Load Block and Sheaves

2.3.2 Hoist Hook Assembly

2.3.3 Hoist Gear Assembly

2.3.3.1 Gears

2.3.3.2 Gear Shafts

2.3.3.3 Gear Train Assembly

2.3.4 Hoist Bearings

2.3.4.1 Antifriction Bearings

2.3.4.2 Factory Sealed Bearings

2.3.5 Hoist Lubrication

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2.3.6 Hoist Frame and Housing

2.3.7 Hoist Paint Finish

2.3.8 Hoist Overload

2.4 TROLLEYS

2.4.1 Paint

2.4.2 Wheels

2.4.2.1 Load Distribution

2.4.2.2 Design and Type

2.4.2.3 Bearings

2.4.3 Side Plates, Pins, and Axles

2.4.3.1 Side Plates

2.4.3.2 Pins and Axles

2.4.4 Gearing

2.4.4.1 Gears

2.4.4.2 Drive Pinions

2.4.5 Safety Hangers or Lugs

2.5 TROLLEY TYPE

2.5.1 Hand Driven Trolleys

2.6 BRIDGE STRUCTURAL ITEMS

2.6.1 Bolts, Nuts, and Washers

2.6.2 Bridge Girders

2.6.3 End Ties and Bridge Girder End Connections

2.6.4 Bridge End Trucks

2.6.5 Stops and Bumpers

2.7 BRIDGE MECHANICAL EQUIPMENT

2.7.1 Bridge Drives

2.7.2 Bridge Crane Gear Assembly

2.7.2.1 Gears

2.7.2.2 Gear Shafts

2.7.3 Bridge Wheels

2.7.3.1 Wheels

2.7.3.2 Bearings

2.8 ELECTRICAL

2.8.1 Power Supply

2.8.1.1 Hoist Incoming Power Supply

2.8.2 Motor Controller

2.8.2.1 Enclosure for Mounting

2.8.3 Pushbutton Remote Control

2.8.4 Hoist Limit Switches

2.8.5 Hoist Motors

2.8.6 Motor Brake

2.8.7 Conduit and Wire

2.8.7.1 Conduit

2.8.7.2 Wire

2.9 OVERHEAD MAINTENANCE CRANE OPERATING AND MAINTENANCE INSTRUCTIONS

PART 3 EXECUTION

3.1 ERECTION

3.1.1 General

3.1.2 Pull Wires

3.1.3 Changes in Direction of Runs

3.1.4 Liquid Tight Flexible Conduit

3.1.5 Exposed Raceways

3.1.6 Termination at Sheet Metal Boxes

3.1.7 Grounding of Conduit System

3.1.8 Coordination

3.1.9 Cutting and Threading

3.1.10 Thread Compound

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3.1.11 Bends

3.1.12 Supports

3.1.13 Outlet Boxes as Part of Conduit System

3.2 WIRE AND CABLE INSTALLATION

3.2.1 General

3.2.2 Wiring Provisions

3.2.3 Conductor Identification

3.2.4 Bends

3.2.5 Splices

3.2.6 Installation

3.3 ON-SITE ELECTRIFICATION SYSTEM TESTS

3.4 ACCEPTANCE TESTING

3.4.1 Acceptance Test

3.4.1.1 Test Sequence

3.4.1.2 Test Data

3.4.1.3 Equipment Monitoring

3.4.1.4 Hooks

3.4.2 No-Load Testing

3.4.2.1 Hoist Operating and Limit Switch Test

3.4.2.2 Trolley and Bridge Travel

3.4.2.3 Hoist Loss of Power No-Load Test

3.4.3 Load Test

3.4.3.1 Hoist

3.5 MANUFACTURER'S SERVICES

3.6 FIELD TRAINING

-- End of Section Table of Contents --

SECTION 41 22 13.17 28

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SECTION 41 22 13.17 28

CRANES, SINGLE-GIRDER BRIDGE

PART 1 GENERAL

1.1 WORKMANSHIP

All work shall be completed in a thorough and workmanlike manner and shall conform to the best modern practice in the class of work regardless of any omission in the drawings and specifications.

1.2 REFERENCES

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

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 9 (1990; R 2000) Load Ratings and Fatigue Life for Ball Bearings

ABMA 11 (1990; R 1999) Load Ratings and Fatigue Life for Roller Bearings

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 9005 (1994; Rev. D) Industrial Gear Lubrication

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 348 (2000) Structural Joints Using ASTM A 325 or A 490 Bolts

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI C80.1 (1994) Rigid Steel Conduit - Zinc Coated

ANSI C119.1 (1986, R 1997) Electric Connectors - Sealed Insulated Underground Connector Systems Rated 600 Volts

ASTM INTERNATIONAL (ASTM)

ASTM A325 (2014) Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi Minimum Tensile Strength

ASTM A 490 (2002) Structural Bolts, Alloy Steel, Heat-Treated, 150 ksi Minimum Tensile Strength

ASTM B 633 (1998e1) Electrodeposited Coatings of Zinc on Iron and Steel

SECTION 41 22 13.17 28

ASTM E 10 (2001) Brinell Hardness of Metallic Materials

ASME INTERNATIONAL (ASME)

ASME HST-4 (1999) Overhead Electric Wire Rope Hoists

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

FS RR-W-410 (Rev D; Am 1) Wire Rope and Strand

CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA)

CMAA 74 (2000) Top Running and Under Running, Single Girder Electric Overhead Traveling Cranes Utilizing Under Running Trolley Hoist

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 6 (1993; R 2011) Enclosures

NEMA WC 3 (1992; Rev 1 1994) Rubber-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 (2014; AMD 1 2013; Errata 1 2013; AMD 2 2013; Errata 2 2013; AMD 3 2014; Errata 3 2014) National Electrical Code

UNDERWRITERS LABORATORIES (UL)

UL 50 (1995; Rev thru Nov 1999) Enclosures for Electrical Equipment

UL 486C (2000; R 2002) Splicing Wire Connectors

1.3 DEFINITIONS

1.3.1 Overhead Maintenance Crane

The overhead maintenance crane shall consist of a single girder bridge with manual chain drive to move the crane East and West along tracks on the tower corbels, a manual chain driven trolley that positions the hoist in the North and South directions, and a motorized vertical hoist with control pendant that can raise loads from the navigation lock deck level up into the tower.

1.3.2 Capacity

Capacity shall mean the rated load in pounds, or tons of 2,000 pounds each, specified by the manufacturer for the overhead maintenance crane and marked plainly on both sides of the single girder and load block so as to be clearly legible. In determining the applied load, the weight of the handling devices shall be included.

1.3.3 Hoisting Speed

Hoisting speed shall mean the velocity in feet per minute at which the hoist will lift the rated load. Actual lifting speed shall be within plus or minus 10 percent of the manufacturer's rating.

1.3.4 Rated Lift

Rated lift shall mean the distance between the upper and lower elevations of travel of the load block.

1.3.5 Headroom

Headroom shall be measured with the load hook in the highest position with full load which is the distance between the saddle of the load hook and the following points:

a. The bottom of the beam when S-shape runways are used.

b. The top of the bottom flange for all flat, wheel-bearing flange surfaces.

1.4 SUBMITTALS

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

submittals having an "I" designation are for information only. When used, a designation following the "G" or "I" 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-02 Shop Drawings

Detailed Drawings; G, ME

Detailed drawings as specified.

SD-03 Product Data

Hoist Hook Assembly

Heat Treatment

Record of hook material and any heat treatment performed shall be submitted and shall be stamped on the hook shank or documented in certification papers furnished with the hooks.

Materials, Equipment and Qualifications

A complete list of equipment and materials, including manufacturer's descriptive data and technical literature, performance charts and curves, catalog cuts, and installation instructions shall be submitted. Diagrams, instructions, and other sheets proposed for posting shall be submitted.

Hoist

Manufacturer's catalog data shall be submitted showing the equipment and accessories to be provided. Diagrams, instructions, and other sheets proposed for posting shall be submitted.

Electric Hoists; G, EL/ME

Trolleys; G, ME

Wiring; G, EL

Contact Conductors; G, EL

Hoist Controls; G, EL

Overcurrent Protection; G, EL

Grounding; G, EL

SD-05 Design Data

Structural Items; G, ST

Technical analysis of all structural features shall be submitted. Structural features include, but are not limited to the bridge, trolley, rail, and rail clips. Structural features shall meet CMAA 74 standards.

CONSTRUCTION TOLERANCES; G, ST

SD-06 Test Reports

Electrification System Tests; G, EL

Results of electrification system tests shall be submitted.

Acceptance Testing; G, EL

Test reports in booklet form shall be submitted showing all field tests performed to adjust each component and all field tests performed to prove compliance with the specified performance criteria, upon completion and testing of the installed system.

The report shall include the information as required by paragraph

ACCEPTANCE TESTING.

SD-07 Certificates

Hoist; G, ME

Certification shall be submitted attesting that each hoist, hoist trolley, girder, and hoist control has been factory tested for rated load capacity and operation, and that each hoist complies with the requirements specified.

Motor Controller; G, EL

Certification shall be submitted attesting that electric hoists, electric trolleys, wiring, contact conductors, controls, overcurrent protection, and grounding conform to NFPA 70 and to UL standards. The label or listing with reexamination by the UL will be accepted as evidence that the materials conform to this requirement and to NFPA 70. Certification shall be submitted attesting that each hoist, hoist trolley and girder,and hoist control has been factory tested for rated load capacity and operation, and that each hoist complies with the requirements specified.

Hoist Overload; G, ME

SD-10 Operation and Maintenance Data

Overhead Maintenance Crane Operating and Maintenance Instructions;

G, ME

1.5 DELIVERY AND STORAGE

Equipment delivered shall be placed in indoor storage, protected from the weather, humidity and temperature variations, dirt and dust, or other contaminants.

1.6 SYSTEM DESCRIPTION

1.6.1 General Requirements

1.6.1.1 Materials, Equipment and Qualifications

Materials and equipment shall be standard products of manufacturers regularly engaged in the fabrication of cranes and hoists and shall essentially duplicate items which have been in satisfactory use for at least 2 years prior to bid opening. The crane and hoist manufacturer shall have a minimum of 10 years of specialized experience in designing and manufacturing the type of equipment specified herein. Any company licensed by a crane and hoist manufacturer to manufacture cranes and hoists bearing their name shall have the design and components approved by the licensor prior to submission to the Government for approval.

1.6.1.2 Nameplates

Each major component of equipment shall have the manufacturer's name, address, type or style, model or catalog number, and serial number on a metal plate secured to the equipment.

1.6.1.3 Detailed Drawings

The Contractor shall submit detailed drawings containing complete wiring and schematic diagrams and any other details required to demonstrate that the system has been coordinated and will properly function as a unit.

Drawings shall show proposed layout, anchorage of equipment and appurtenances, and equipment relationship to other parts of the work including clearances for maintenance and operation.

1.6.2 Design Criteria

The overhead maintenance crane shall be designed to meet CMAA 74 standards, including all structural, mechanical, and electrical equipment.

The overhead maintenance crane shall be designed to operate in the spaces and match the runway dimensions and rails indicated. The hook coverage and hook vertical travel shall not be less than that indicated. The overhead maintenance crane shall be able to clear the roof hatch opening.

1.6.2.1 Classification

a. The overhead maintenance crane shall be designed and constructed to CMAA 74 Class D,C, H4 duty service requirements for operation in indoor nonhazardous environment.

b. The hoist shall be designed and constructed to ASME HST-4, Class H4, service requirements for operation in nonhazardous environment.

1.6.2.2 Hoist Characteristics

Hoist shall be an electric-wire-rope hoist of type, class, control, suspension, lift, and operating characteristics specified. Each hoist shall have the capacity, lift-height, suspension, power source, and operating characteristics indicated and as follows:

a. Hoist capacity shall be 5 tons derated to 3.5 tons.

b. Hoist shall be a standard lift with a minimum lift of 7170 feet, +/- 1 foot.

c. The hoist shall be mounted with a hand geared trolley unit.

d. The hoist and overhead maintenance crane suspension shall provide headroom such that the hook saddle at high hook is at Elevation

617.24 or higher and North-South travel is limited by the tower walls not the corbels.

e. Components of the hoist shall be designed and constructed for safety of operation and durability of components. Replacement parts shall be interchangeable and readily accessible.

f. Hoist shall be supplied with a load hook, with cast in tram marks for measuring throat deformation.

1.6.2.3 Overhead Maintenance Crane Characteristics

The overhead maintenance crane shall be top running single-girder overhead traveling crane utilizing an underrunning trolley hoist running on the bottom flanges of the single girder bridge. Overhead maintenance crane travel shall be provided by a manual hand geared system.

1.6.2.4 Capacity Plates

Two capacity plates shall be provided, one for each side of the bridge girder. Each plate shall be lettered to indicate the total rated hoisting capacity of the crane. All lettering shall be of sufficient size to be easily read from the floor. Each lower load block shall be marked with the overhead maintenance crane rated capacity.

PART 2 PRODUCTS

2.1 CONSTRUCTION TOLERANCES

The Contractor shall become familiar with all details of the work and verify all dimensions in the field so that the corbel, overhead maintenance crane and crane rails shall be properly located within the tolerances and the allowable rail adjustment recommended by the crane manufacturer. The Contractor shall submit drawings of the existing conditions showing how the

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2.2 ELECTRIC HOIST

2.2.1 General

Electric hoist shall be Yale Model number CEW5X71GT16S2 with modified headroom for corbel clearance, or approved equal. Electric hoist shall be of capacity, lift, type, suspension, headroom, and materials specified.

Each unit shall be factory wired and ready for operation. Load-carrying parts of the hoist and overhead maintenance crane shall be designed so that the calculated static stress of the material, based on the rated capacity, will not exceed 20 percent of the average theoretical strength of the material. Each hoist shall be factory lubricated and shall be complete and ready for operation with the specified hoist controls and accessories.

2.2.2 Types of Electric Hoists

2.2.2.1 Electric Wire-Rope Hoists

Electric wire-rope hoists shall be equipped with the specified standard wire-rope and hook assembly with no corroding or sparking requirements.

2.2.3 Hoist Speed

Each electric wire-rope hoist speed shall be double speed with the higher speed in the range of 15 to 25 feet per minute and the lower speed in the range of 5 to 10 feet per minute.

2.2.4 Load and Motor Brakes

Load brake shall be a totally enclosed, automatic, mechanical-type brake with a hardened-steel, Weston-type ratchet and pawl mechanism that will hold the capacity load of the hoist at any point when the motor is stopped. Motor brakes are specified in paragraph MOTOR BRAKE.

2.3 HOIST MECHANICAL EQUIPMENT

2.3.1 Wire-Rope Hoist

2.3.1.1 Hoist Wire Rope

Wire rope for standard applications shall be extra flexible, preformed, extra improved or improved plow steel, 6 by 37 fiber core sealed construction wire conforming to FS RR-W-410, Type I, Class 3.

Wire rope shall be anchored to drum or dead end. Anchoring shall be of captive type, easily detached for changing and repair. Wire rope shall have a factor of safety of not less than 5, based on the minimum ultimate tensile strength of the material.

2.3.1.2 Hoist-Rope Drum

Wire-rope drum shall be hardened steel or special grade alloy ductile iron. Minimum diameter of the drum shall be 20 times the diameter of the hoisting rope for hoists with a capacity of 2,000 pounds or less and 24

SECTION 41 22 13.17 28

times the diameter of the hoisting rope for hoists over 2,000-pound capacity. Drum shall have accurate, machine-cut grooves, cut to full depth of wire-rope diameter, with rounded corners of dimension as required for the specified lift. In addition, the drum shall have not less than two complete turns of rope around it when the hook is in its lowest position.

Groove diameter and pitch centers shall be 1/32 inch greater than diameter of rope. Drum shall be flanged at each end and shall have enclosed tops and sides to preclude cable binding and jamming. Cable reeving shall be arranged for single or double reeving.

2.3.1.3 Hoist Load Block and Sheaves

The cable load block shall be an enclosed, safety type that will shroud the sheave and protect the operator. The sheave assembly shall be mounted on a steel axle and carried on sealed, prelubricated antifriction bearings.

Wire-rope sheaves shall be machine-grooved, hardened steel, or cast iron with chilled groove surfaces. The pitch diameter for running sheaves shall be not less than 18 times the diameter of the wire rope, and the diameter of the idler and equalizer sheaves shall be not less than 16 times the diameter of the rope used.

2.3.2 Hoist Hook Assembly

a. Hooks and hook swivels shall be heat-treated alloy steel forgings.

Yokes, crossheads, and bars shall be of suitable strength steel or cast iron. The Contractor shall submit data on heat treatment as specified in the Submittals paragraph.

b. Hook assembly shall be carried on antifriction bearings to permit free swivel under rated capacity load without twisting wire. Each hook shall have a spring-loaded safety latch. Each hook assembly shall include a machined and threaded shaft and swivel locknut with an effective locking device to prevent nut from backing off.

2.3.3 Hoist Gear Assembly

2.3.3.1 Gears

Gears shall be spur, helical, spiral, or bevel-type, accurately machined, and conforming to AGMA standards for this type of service.

2.3.3.2 Gear Shafts

Gear shafts shall be manufactured from high-carbon steel or alloy steel, machined and ground for accurate fit, and splined for fitting to the mating gear.

2.3.3.3 Gear Train Assembly

Gear train assembly shall be totally enclosed in the hoist frame casting and shall operate in a sealed oil bath. Frame casting shall be provided with lubrication fittings and inspection ports.

2.3.4 Hoist Bearings

2.3.4.1 Antifriction Bearings

Bearings in the hoist mechanism shall be antifriction bearings.

2.3.4.2 Factory Sealed Bearings

Sprocket bearings, motor bearings, and load-block bearings shall be prelubricated factory sealed bearings.

2.3.5 Hoist Lubrication

Adequate lubrication shall be provided for moving parts of the hoist and trolley and for filling, draining, and checking the level of the lubricant. Lubricant shall be designed for use in an ambient temperature of 54 to 109 degrees F. Hoist reduction gearing, load brake, and trolley wheel gears with electric motor drive shall operate in an oil bath.

Lubrication and mechanism housing shall prevent leaking and shall prevent lubricant from coming into contact with electric motors and equipment.

Lubricant shall conform to AGMA 9005.

2.3.6 Hoist Frame and Housing

Operating parts of the hoist shall be mounted and enclosed in a sealed, factory-painted metal frame of malleable iron, cast steel, welded steel, or aluminum. Welded or bolted frames shall carry loads on the fabricated pieces. Welds or bolts shall be used only to hold the fabricated parts in position.

2.3.7 Hoist Paint Finish

Each hoist and accessory shall receive a factory-applied paint finish.

Hooks shall not be painted.

2.3.8 Hoist Overload

The Contractor shall provide a factory installed hoist overload device system rated at 3.5 tons. Contractor shall provide certification of manufacturers test.

2.4 TROLLEYS

2.4.1 Paint

Each trolley assembly shall be factory-painted, designed specifically for use with the specified hoist, and shall be furnished by the hoist manufacturer. Paint finish shall be the same type and quality specified for the hoist.

2.4.2 Wheels

2.4.2.1 Load Distribution

Each trolley assembly shall have not less than four wheels. Sufficient wheels shall be provided to properly distribute the load.

2.4.2.2 Design and Type

Wheels shall be single-flange type manufactured from forged alloy steel with machined, hardened treads and flanges, or high-strength cast or nodular iron with machined flanges and treads, chill-hardened not less than 1/16 inch deep. Manually driven, trolley-wheel treads shall be hardened to not less than Brinell hardness No. 245 as defined in ASTM E 10. Wheels shall be designed to operate on sloped or flat flange I-beams.

2.4.2.3 Bearings

Trolley wheels shall be carried on sealed, permanently lubricated, antifriction bearings designed for axial and thrust loading. Bearings shall conform to the applicable requirements of ABMA 9 and ABMA 11.

Bearings shall have an L-10 life of 3,000 hours or more, as defined by ABMA 9 or ABMA 11 as applicable.

2.4.3 Side Plates, Pins, and Axles

2.4.3.1 Side Plates

Side plates shall be fabricated from structural-quality rolled-steel plate milled to the required profile with integral bosses where necessary to support equalizing pins; side plates shall be fitted with steel end bumpers.

2.4.3.2 Pins and Axles

Equalizing pins and axles shall be heat-treated alloy steel, machined and finish ground to the required size.

2.4.4 Gearing

2.4.4.1 Gears

Gears shall be cut from heat-treated alloy steel accurately machined into spur, helical, and pinion gears, conforming to AGMA standards for this type of service.

2.4.4.2 Drive Pinions

Drive pinions shall be carburized alloy steel, malleable iron, or bronze, with cut or cast teeth, conforming to AGMA standards for this type of service.

2.4.5 Safety Hangers or Lugs

Safety hangers or lugs shall be steel and shall be integral with, or fastened to, each hoist frame or to trolley frame. They shall ride free above the bottom flange of the beam. Hanger shall be of sufficient capacity to hold the hoist, fully loaded, in the I-beam in case of wheel or axle failure. Safety factor of each part of trolley assembly shall be not less than 5, based on the ultimate strength of the material used.

2.5 TROLLEY TYPE

2.5.1 Hand Driven Trolleys

Trolley shall be a hand geared type conforming to the applicable requirements of CMAA 74 and the requirements specified.

2.6 BRIDGE STRUCTURAL ITEMS

2.6.1 Bolts, Nuts, and Washers

Bolts, nuts, and washers shall conform to ASTM A325 bolts. High-strength bolted connections shall conform to the requirements of AISC 348, except that ASTM A 490 bolts shall not be used. No galvanized bolts shall be used.

2.6.2 Bridge Girders

Bridge girders shall be welded structural steel box sections, wide-flange beams, standard I-Beams, reinforced beams or sections fabricated from rolled plates and shapes.

2.6.3 End Ties and Bridge Girder End Connections

Horizontal gusset plates shall be provided at the elevation of the top and bottom end tie flanges for connection to girder ends. End connections shall be made using high-strength bolts. Body-bound bolts fitted in drilled and reamed holes shall be used to maintain the crane square.

2.6.4 Bridge End Trucks

End trucks shall be fabricated from structural steel providing a rigid structure and shall be of the rotating or fixed-axle type. Jacking pads shall be provided for removal of wheel assemblies. A means shall be provided to prevent the overhead maintenance crane from dropping more than one inch in case of axle failure.

2.6.5 Stops and Bumpers

Overhead maintenance crane runways and bridge girders shall be fitted with structural steel end stops. Bridge end trucks and trolley frames shall be fitted with shock-absorbing, spring or hydraulic type bumpers capable of decelerating and stopping the bridge and/or trolley within the limits stated by OSHA and Material Handling Industry (MHI) CMAA. Trolley end stops shall be of sufficient strength to withstand the impact of a fully loaded trolley moving at expected hand driven travel speed.

2.7 BRIDGE MECHANICAL EQUIPMENT

2.7.1 Bridge Drives

Bridge drives shall consist of hand driving through a suitable reduction unit or units to the wheels located at each end of the bridge.

2.7.2 Bridge Crane Gear Assembly

2.7.2.1 Gears

Gears shall be spur, helical, spiral, or bevel type, accurately machined, and conforming to AGMA standards for this type of service.

2.7.2.2 Gear Shafts

Gear shafts shall be manufactured from high-carbon steel or alloy steel, machined and ground for accurate fit, and splined for fitting to the mating gear.

2.7.3 Bridge Wheels

2.7.3.1 Wheels

The wheels shall be made of rolled or forged steel. The wheel treads and flanges shall be rim toughened to between 320 and 370 Brinell hardness number. Bridge wheels shall be double-flanged.

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2.7.3.2 Bearings

Wheels shall be carried on sealed, permanently lubricated, antifriction bearings designed for axial and thrust loading. Bearings shall conform to the applicable requirements of the ABMA 9 or ABMA 11. Bearings shall have an L-10 life of 3,000 hours or more, as defined by ABMA 9or ABMA 11 as applicable.

2.8 ELECTRICAL

Materials and installation, including electrical wiring, Contact Conductors, controls, overcurrent protection, and grounding shall meet the requirements of NFPA 70 and applicable UL and NEMA standards and specified requirements.

2.8.1 Power Supply

Electrical power for operation of the overhead maintenance crane hoist will be supplied from the nominal 480 volt, 3 phase, 60-Hz alternating-current (a-c) power distribution system.

2.8.1.1 Hoist Incoming Power Supply

a. Festoon Conductors - Power shall be brought to the overhead maintenance crane by means of a "Festoon" system consisting of flexible power cable supported by cable trolleys running on a steel messenger cable, an I-beam rail, or a channel. The power cable shall be Type G, 167 degree F, 600-volt insulation and heavy-duty neoprene or chlorosulfonated polyethylene jacket.

Polyvinyl chloride compounds will not be permitted. The cable shall be sized as required by NFPA 70. The cable shall conform to the applicable requirements of NEMA WC 3, Part 7, and shall have class H or class K stranding. Cable conductors shall be terminated at both ends with terminal lugs on terminal blocks in terminal boxes. Cable ends shall have strain relief devices to protect the cable terminations.

2.8.2 Motor Controller

Motor controller shall be a reversing-type magnetic starter with thermal-overload protection, molded case circuit breaker, and control transformer operated by a pushbutton control station. Controller and control station shall be mechanically or electrically interlocked to preclude possibility of operating opposing control circuits simultaneously.

2.8.2.1 Enclosure for Mounting

Motor controller shall be mounted in either a gasketed cast metal or sheet metal enclosure, as required or noted, with hinged door conforming to the requirements of UL 50. Motor controller enclosures, complying with NEMA ICS 6, shall be NEMA, Type 4.

2.8.3 Pushbutton Remote Control

The hoist shall have a pendant style, pushbutton remote controller. The controller shall be a full-guarded, momentary-contact, pushbutton type with each button clearly marked to indicate its function. The remote controller shall control Start, Stop, Up, and Down movements. The pushbuttons shall return to the off (normally open contacts) position when pressure is released by operator. The controller shall be operated at a height ergonomically suited for a worker standing on the tower floor.

2.8.4 Hoist Limit Switches

Adjustable upper-limit switch shall be provided to prevent overtravel of the hook or load block in the hoisting direction. Limit switch shall be arranged to stop the hoist motor and apply the motor brake before reaching the uppermost safe limit of travel. In case of hook overtravel, the motor shall automatically and momentarily be reversed. Adjustable lower-limit switch shall be provided to stop the hoist motor and apply the motor brake when the load hook reaches a predetermined lower limit.

2.8.5 Hoist Motors

Hoist motor shall be a high-starting torque, high-slip, 30-minute time rated, reversible electric motor specifically designed for hoist duty and capable of operating at the specified duty class, capacity, and speed. The motor shall be 480-volts, 3-phase, 60-hertz and horsepower as recommended by manufacturer for capacity and lift speed of hoist. The hoist motors shall be provided with Class B, and motor enclosures shall be totally enclosed, nonventilated (TENV). Enclosure shall be fitted with a UL-approved drain and breather and shall be certified and labeled in accordance with UL 674, Class 1, Groups C and D.NEMA Class B, totally enclosed, fan cooled motors (TEFC).

2.8.6 Motor Brake

Motor brake shall be an externally adjustable, electrically operated mechanical single- or multiple-friction disk brake that shall apply automatically when the power is off. The brake shall be capable of holding 125 percent of the rated load from any operating speed. The brake shall hold a static load equal to 150 percent of the rated capacity of the overhead maintenance crane.

2.8.7 Conduit and Wire

2.8.7.1 Conduit

Conduit between feeder enclosure and disconnect switches and fixed control stations shall be zinc-coated rigid-steel conduit, couplings, elbows, bends, and nipples conforming to ANSI C80.1. Zinc coating shall be an electrodeposited coating conforming to ASTM B 633.

2.8.7.2 Wire

Building wire for use in conduits, raceways, and wireways in wet or dry locations shall be single-conductor, 600-volt, heat- and moisture-resistant Type RHW or THW with a maximum temperature rating of 75 degrees C, or cross-linked thermosetting, polyethylene insulation with a temperature rating of 90 degrees C. Polyvinyl chloride compounds will not be permitted in jacketing material.

2.9 OVERHEAD MAINTENANCE CRANE OPERATING AND MAINTENANCE INSTRUCTIONS

Copies of operation manuals shall be furnished for the equipment furnished as specified in section 01 33 00 SUBMITTAL PROCEDURES. Operation manuals shall detail the step-by-step procedures required for system startup, operation, and shutdown. Operation manuals shall include the

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manufacturer's name, model number, parts list, and brief description of all equipment and their operating features. Operation manuals shall include an overall description of the system describing any unique features that may need special attention. Maintenance manuals shall list routine maintenance procedures, possible breakdowns and repairs, and troubleshooting guides.

Maintenance manuals shall include a spare parts list of manufacturers recommended spare parts that should be maintained onsite and any long lead time items should be clearly identified. Maintenance manuals shall contain replacement part numbers for the entire assembly. Operation manuals shall be included in the preliminary, draft, and final combined O&M Manuals see section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA.

PART 3 EXECUTION

3.1 ERECTION

Erection shall be in accordance with the manufacturer's instructions.

3.1.1 General

The conduit (and tubing) installation shall be made in accordance with these specifications, the National Electrical Code, and as shown on the drawings and shall include all rigid and flexible conduits, and all necessary fittings. Care shall be taken to maintain electrical continuity of the conduit system to provide a safe ground path for fault currents by tightening each coupling and connection in the conduit system as tightly as possible.

3.1.2 Pull Wires

A pull wire shall be inserted in each empty raceway if the raceway is more than 50 feet in length and contains more than the equivalent of two 90-degree bends, or where the raceway is more than 150 feet in length. The pull wire shall be of No. 14 AWG zinc-coated steel, or of plastic having not less than 200-pound tensile strength. Not less than 10 inches of slack shall be left at each end of the pull wire.

3.1.3 Changes in Direction of Runs

Changes in direction of runs shall be made with symmetrical bends or cast-metal fittings. Field-made bends and offsets shall be made with an approved hickey or conduit-bending machine. Crushed or deformed raceways shall not be installed. Trapped raceways in damp and wet locations shall be avoided where possible. Lodgment of plaster, dirt, or trash in raceways, boxes, fittings and equipment shall be prevented during the course of construction. Clogged raceways shall be cleared of obstructions or shall be replaced.

3.1.4 Liquid Tight Flexible Conduit

The Contractor shall utilize liquid tight flexible steel conduit for the final connection to devices. Separate ground conductor shall be provided by the Contractor in liquid tight flexible conduits that do not have an internal copper bonding conductor included by the manufacturer.

3.1.5 Exposed Raceways

Raceways shall be installed parallel or perpendicular to structural members or intersections of vertical planes.

3.1.6 Termination at Sheet Metal Boxes

Unless conduit hubs are provided, conduit shall be securely fastened to sheet metal boxes and cabinets with a locknut on both inside and outside and terminated with an insulated ground bushing bonded as required in paragraph: Grounding of Conduit System. The conduit shall be of such length that when a bushing is screwed tight against the end of the conduit, no appreciable space will be left between bushing and locknut. The locknuts shall be tightened against the box without deforming the box.

3.1.7 Grounding of Conduit System

The entire metallic conduit system shall be electrically continuous and bonding jumpers shall be used across all expansion fittings and between conduits entering and leaving electrical utility vaults and panelboards and cabinets. Insulated ground bushings shall be used to bond metallic conduits. Where breaks occur in the metallic conduit system due to installation of PVC conduit, a ground conductor shall be installed in the plastic conduit to provide the bonding noted above.

3.1.8 Coordination

The conduit shall be installed in the most direct and workmanlike manner so that interference between piping, ducts, conduit, mechanical, electrical, and structural features will be avoided. The Contractor shall carefully examine previously installed work prior to developing layout and installation plans for conduit and accessories to determine that installation can be made without interference with other work.

3.1.9 Cutting and Threading

All cuts shall be made with a hacksaw or a cutter-type tool approved for this use. Roller-type pipe cutters shall not be used on conduits. All cuts shall be square and the conduit opening shall not be constricted.

After cutting and threading, conduit ends shall be reamed to remove burrs, and the entire conduit shall be thoroughly cleaned to remove all cuttings, dirt and oil from its interior. Threads shall be clean-cut. No running threads will be permitted. Except in wet locations or where a watertight conduit system is required, three-piece unions/couplings (Erickson type fittings) may be used where standard couplings cannot be used.

3.1.10 Thread Compound

Conduit joints and connections shall be made watertight and rustproof.

An identified conductive, oxidation preventing, copper based thread compound shall be applied in accordance with NEC Article 300-6. Each threaded joint shall be thoroughly cleaned to remove all cutting oil before the compound is applied. The compound used shall not insulate the joint.

3.1.11 Bends

Conduit bends shall comply with Table 346-10 of the National Electrical Code. Factory elbows may be used in lieu of field bends.

3.1.12 Supports

Metallic conduits and tubing,and the support system to which they are attached, shall be securely and rigidly fastened in place to prevent vertical and horizontal movement at intervals of not more than 10 feet and within 3 feet of boxes, cabinets, and fittings, with approved pipe straps, wall brackets, conduit clamps, conduit hangers, threaded C-clamps, beam clamps, or ceiling trapeze. Loads and supports shall be coordinated with supporting structure to prevent damage or deformation to the structure.

Attachment shall be by machine screws, welded threaded studs, heat-treated or spring-steel-tension clamps on steel work. Nail-type nylon anchors or threaded studs driven in by a powder charge and provided with lock washers and nuts may be used in lieu of expansion bolts or machine screws.

Raceways or pipe straps shall not be welded to steel structures. Holes drilled for support anchors, but not used, shall be filled. In partitions of light steel construction, sheet-metal screws may be used. Raceways shall not be supported using wire or nylon ties. Raceways shall be independently supported from the structure. Upper raceways shall not be used as a means of support for lower raceways. Supporting means shall not be shared between electrical raceways and mechanical piping or ducts.

Conduits shall be fastened to sheet-metal boxes and cabinets with two locknuts where required by NFPA 70, where insulating bushings are used, and where bushings cannot be brought into firm contact with the box; otherwise, a single locknut and bushing may be used.

3.1.13 Outlet Boxes as Part of Conduit System

The Contractor shall be responsible for furnishing and installing junction and pull boxes, complete with covers, in the wiring or raceway systems wherever required for pulling of wires, making connections, and mounting of devices or fixtures. When a pull box or special fitting is required to make a short radius bend to reach an outlet box, such pull box or fitting shall be furnished as part of the conduit installation even if not so indicated on the contract drawings. Outlet boxes shall comply with the Paragraph: OUTLETS.

3.2 WIRE AND CABLE INSTALLATION

3.2.1 General

All wire and cable shall be provided in accordance with these specifications, the National Electrical Code Requirements and with the details and notes as shown on the drawings. The Contractor shall be responsible for determining the actual length required to make an installation without splices. The Contractor shall furnish all necessary materials, tools and equipment required for proper handling and installation of wire and cable. Except spares as indicated, each wire and cable shall be connected to the associated equipment at both ends and shall be continuous and without splices between the equipment termination points.

Wire and cable shall be pulled in a manner which will preclude damage to the conductor insulation or jacket. Any cable or conductor damaged during installation shall be removed and replaced with equivalent cable or conductor at no additional cost to the Government. Installation of wire and cable shall include installation of all supporting devices and all terminations required to complete the circuits. Watertight connectors shall be provided for cables entering junction boxes, cabinets, switchgear and conduit where shown on the drawings or required by the Contracting Officer. Bushings shall be provided where indicated or required for cable passage and shall be of the insulating type. Where wire and cable is installed in existing conduits, the Contractor shall be responsible for cleaning out such conduits prior to installation of conductors. To insure that no protrusions remain on the inside of the conduit, a lead covered mandrel, painted white, or similar indicating device, shall be pulled through the conduit in the presence of the Contracting Officer's Representative.

3.2.2 Wiring Provisions

These wiring provisions shall apply to control wiring installed during installation of equipment and during manufacture of Contractor-furnished equipment. Where not installed in wiring channels or ducts, the wiring shall be formed into compact groups suitably bound together and properly supported. Nylon, self-locking adjustable cable ties will be acceptable for binding. Bindings and supports shall not cause damage or cold flow to the insulation, nor shall they contain sharp edges due to cutting off excess tie material. Groups of exposed wires shall be run straight horizontally or vertically, with short radius right angle bends. All wiring leaving a panel shall be brought out to a unit control terminal board. There shall be no splices in the wiring, and, except as specifically permitted in paragraph: Splices, all connections shall be made at terminal studs or terminal blocks. Wire termination shall be in accordance with paragraph: Terminations.

3.2.3 Conductor Identification

Conductor identification shall be provided within each enclosure where a tap, splice, or termination is made.

(1) Control Wiring

Control wiring shall be identified at both its termination and point of origin with permanent PVC slip-on wire markers or heat shrink polyolefin sleeves with machine printed labeling. Hand lettering or marking is not acceptable. Identification labels shall conform with approved shop drawings or, where applicable, contract drawings.

(2) Phase Conductors

Phase conductors shall have color-coded insulation or shall be marked with electrical tape of the required color half-lapped for at least a 2-inch length within 6-inches of the end of the conductor. The color of the insulation of the ungrounded conductors of different voltage systems shall be as follows:

208/120 volt, 3-phase: black, red, and blue.

480/277 volt, 3-phase: orange, yellow, and brown.

120/240 volt, single phase: black and red.

3.2.4 Bends

The minimum radius to which an insulated conductor larger than No. 8 AWG or a multiple-conductor cable may be bent, without specific approval, whether permanently or temporarily during installation, shall be 10 times the diameter over the outer coverings. In these instances where this radius is not possible, approval of the Contracting Officer will be required for bends of less than 10 diameters.

3.2.5 Splices

Splices will be permitted only where shown on the drawings, or with written approval from the Contracting Officer. All splices shall be made in accessible cabinets, boxes, or outlets and shall comply with UL 486C. No splices will be allowed inside conduits. Splices shall be Type II (crimp or compression) insulated to match the wire or conductor insulation.

Splices in circuits with stranded wire shall be Type II (crimp or compression) and insulated to match the wire or conductor insulation. All splices in wet locations shall be sealed type conforming to ANSI C119.1 or shall be waterproofed by a sealant filled, thick wall, heat shrinkable, thermo-setting tubing or by pouring a thermosetting resin into a mold that surrounds the joined conductors.

3.2.6 Installation

All boxes shall be straight and true with horizontal or vertical structural lines. Boxes shall be installed in a rigid and satisfactory manner and shall be supported by bar hangers in frame construction or shall be fastened directly with wood screws on wood, with bolts and expansion shields on concrete, and with machine screws, or welded threaded studs on steelwork. Threaded studs driven in by a low velocity powder charge and provided with lockwashers and nuts are acceptable in lieu of screws, expansion shields, or machine screws.

3.3 ON-SITE ELECTRIFICATION SYSTEM TESTS

Electrification system shall be given continuity and insulation tests after the installation has been completed but before equipment is energized.

Contractor shall provide necessary test equipment, labor, and personnel to perform the tests as specified. Electrification system equipment shall be completely isolated from all extraneous electrical connections. Substation and switchboard feeder breakers, circuit breakers in panelboards, and other disconnecting devices shall be used to isolate the equipment under test.

Insulation tests on equipment and wiring shall be conducted using a 1,000-volt, insulation-testing instrument. Readings shall be recorded every minute and until three equal and consecutive readings are obtained.

The resistance between phase conductors and between phase conductors and ground shall be not less than 1 megohm. Test data shall be recorded and shall include megohm readings versus time. Final acceptance shall depend upon satisfactory performance under test. Electrification system shall not be energized until recorded test data of the electrification system tests are approved.

3.4 ACCEPTANCE TESTING

Acceptance testing shall comply with the following paragraphs.

3.4.1 Acceptance Test

The Contractor shall provide all personnel necessary to conduct the tests including but not limited to operators, riggers, rigging gear, and test weights. Testing shall be performed in the presence of Contracting Officer. The Contractor shall notify the Contracting Officer 7 days prior to testing operations.

3.4.1.1 Test Sequence

The equipment shall be tested according to the applicable paragraphs of this procedure in the sequence provided.

3.4.1.2 Test Data

Operating and startup current measurements shall be recorded for electrical equipment (motors and coils) using appropriate instrumentation. Speed measurements shall be recorded.