A.02.16_Specifications_Amendment_0005.pdf

Lower Snake River Roller Chain Supply W912EF19R0015 Amend-0005

SECTION TABLE OF CONTENTS

DIVISION 05 - METALS

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METALWORK FABRICATION - ROLLER CHAIN COMPONENTS

PART 1 GENERAL

1.1 DESCRIPTION

1.2 REFERENCES

1.3 SUBMITTALS

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS AND STANDARD METAL ARTICLES

2.2 HEAT TREATMENT PROCEDURE

2.3 CERTIFICATIONS

2.4 ROLLER CHAIN COMPONENTS

2.4.1 Rollers

2.4.2 Roller Shafts

2.4.3 Side Bars Modified Side Bars and Master Links

2.4.4 Retaining Rings

PART 3 EXECUTION

3.1 FABRICATION AND WORKMANSHIP

3.1.1 Machine Work

3.1.1.1 Finished Surfaces

3.1.2 Cleaning of Corrosion-Resisting Steel

3.2 QUALITY CONTROL SYSTEM

3.3 TESTING AND TEST REPORTS

3.3.1 Crack Test

3.3.2 Hardness Tests

3.3.3 Surface Roughness Test

3.3.4 Dimensional Tolerance

3.4 SHIPMENT AND STORAGE MACHINED COMPONENTS

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METALWORK FABRICATION - ROLLER CHAIN COMPONENTS

PART 1 GENERAL

1.1 DESCRIPTION

This SECTION specifies the requirements for materials and fabrication of headgate roller chain components.

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 A 276 (2002) Stainless Steel Bars and Shapes

ASTM A 484/A 484M (2000) General Requirements for Stainless Steel Bars, Billets, and Forgings

ASTM A 564/A 564M (2002a) Hot-Rolled and Cold-Finished Age-Hardening Stainless Steel Bars and Shapes

ASTM A 380 (2006) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A 693 (2003) Standard Specification for Precipitation-Hardening Stainless and Heat-Resisting Steel Plate, Sheet, and Strip

ASME INTERNATIONAL (ASME)

ASME B18.27 1999) Tapered and Reduced Cross Section Retaining Rings (Inch Series)

ASME B4.1 (1967; R 2004) Preferred Limits and Fits for Cylindrical Parts

ASME B46.1 (2002) Surface Texture (Surface Roughness, Waviness and Lay)

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only.

Designation following the "G" or "I" designation identifies the office that will review the submittal for the Government. Submit in accordance with SECTION 01 33 00 SUBMITTAL PROCEDURES:

The submittals shall be submitted in two packages:

(1) Prefabrication - SD-02 Shop Drawings, SD-03 Product Data, and SD-07 Material certifications

(2) Post-fabrication - SD-06 Test Reports, SD-07 Independent lab test certification

SD-02 Shop Drawings

Shop Fabrication Drawings ; G ME Contractor shall submit detail shop fabrication drawings for metalwork and machine work, prior to fabrication. Elements of fabricated items inadvertently omitted on contract drawings shall be detailed by the Contractor and indicated on the detailed drawings.

SD-03 Product Data

Shop Fabricated Metal Items ; G ME Lists of materials, and records which identify the disposition of approved certified material for each fabricated item shall be submitted for approval and approved prior to fabrication of the components.

Heat Treatment Procedure ; I ME Procedure shall identify heat treatment process and applicable standards. Submitted prior to fabrication of rollers.

SD-04 Samples

Roller chain components ; G ME The Contractor shall furnish a sample consisting of two rollers, two roller shafts with retaining rings, and four side bars to the Government for approval prior to the fabrication of the remaining components. The sample shall be submitted with documentation required in SD-06 Test Reports and SD-07 Certificates. The sample shall conform to the specifications of volume 1 of the contract drawings and be shipped to:

Lower Monumental Project Office ATTN: Chief, Technical Section P.O. Box 10 5520 Devils Canyon Road Kahlotus, WA 99335.

The sample will not be returned.

SD-06 Test Reports

Shop Fabricated Metal Items ; G ME Materials tests reports and analysis shall be submitted for approval prior to shipment of items.

Quality Control Reports ; I ME Reports form Contractor's quality control system. Shall be submitted prior to shipment of items.

SD-07 Certificates

Material Certifications ; I ME Certifications from mill shall be submitted for all chain component materials prior to commencing fabrication.

Independent Lab Test Certification ; I ME Test report from independent testing laboratory.

PART 2 PRODUCTS

2.1 MISCELLANEOUS METALS AND STANDARD METAL ARTICLES

Miscellaneous shop fabricated metal items shall conform to the respective specifications and other designated requirements. Sizes shall be as specified or shown. Where material requirements are not specified, materials furnished shall be suitable for the intended use and shall be subject to approval. The Contractor shall prepare and submit for approval shop fabrication drawings for all chain components prior to the start of work. All stainless steel components shall be pacified after final heat treatment and machining in accordance with ASTM A 380 .

2.2 HEAT TREATMENT PROCEDURE

The procedure shall identify heat treatment process when applicable for item and applicable standards. The procedure shall be submitted prior to fabrication of components.

2.3 CERTIFICATIONS

Where material is specified, the Contractor shall submit mill material certifications report for raw materials.

2.4 ROLLER CHAIN COMPONENTS

All components shall have "pacified" treatment after final machining and heat process in accordance with ASTM A 380 .

2.4.1 Rollers

Rollers shall be ASTM A 564/A 564M , UNS S17400 Type 630 or S45000 Type XM-25, age-hardened heat treated to obtain a Brinell hardness range of 331 minimum to 401 maximum. Heat treatment of rollers shall not commence until the heat treatment procedure is submitted. Roller outer surface shall be cold-finished per ASTM A 484/A 484M , Class C or hot-rolled and machine-finished to meet tolerances specified. Roller inner hole shall be bored and reamed to meet 63 micro-inch finish requirements.

2.4.2 Roller Shafts

Roller shafts shall be "Nitronic 60" or ASTM A 276 , UNS S21800, Condition A, minimum Brinell hardness 205, with 63 micro-inch cold ground finished.

Retaining ring groove shall be machined per manufacture's dimensions and tolerances.

2.4.3 Side Bars Modified Side Bars and Master Links

Shall be ASTM A 276 , UNS S30400 Condition A, cold-finished per ASTM A 484/A 484M , Class C or hot rolled and machine-finish to meet tolerances specified.

2.4.4 Retaining Rings

Retaining rings for roller shafts and links shall be corrosion-resistant stainless steel ASTM A 693 -03, S15700 Condition RH950 , conforming to ASME B18.27 -NA4 "heavy duty" external series type with nominal shaft size as shown on the contract drawings. Retaining rings shall be provided from a manufacturer that has least 5 years of experience in the fabrication of industrial retaining rings.

PART 3 EXECUTION

3.1 FABRICATION AND WORKMANSHIP

Workmanship shall be of the highest grade and in accordance with the best modern practices to conform with the specifications for the item of work being furnished.

3.1.1 Machine Work

Tolerances, allowances and gauges for metal fits between plain, non-threaded, cylindrical parts shall conform to ASME B4.1 for the class of fit shown or required unless otherwise shown on approved detail drawings. Where fits are not shown they shall be suitable as approved.

Tolerances for machine-finished surfaces designated by non-decimal dimensions shall be within 1/64 inch . Sufficient machining stock shall be allowed on placing pads to ensure true surfaces of solid material.

Finished contact or bearing surfaces shall be true and exact to secure full contact. Journal surfaces shall be polished and all surfaces shall be finished with sufficient smoothness and accuracy to ensure proper operation when assembled.

3.1.1.1 Finished Surfaces

Surface finishes indicated or specified shall be in accordance with ASME B46.1 . Values of required roughness heights are arithmetical average deviations expressed in micro-inches . These values are maximum. Lesser degrees will be satisfactory unless otherwise indicated. Compliance with surface requirements shall be determined by sense of feel and visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1 . Values of roughness width and waviness height shall be consistent with the general type of finish specified by roughness height. Where the finish is not indicated or specified it shall be that which is most suitable for the particular surface, provide the class of fit required and be indicated on the detail drawings by a symbol which conforms to ASME B46.1 when machine finishing is provided. Flaws such as scratches, ridges, holes, peaks, cracks or checks which will make the part unsuitable for the intended use will be cause for rejection.

3.1.2 Cleaning of Corrosion-Resisting Steel

Oil, paint and other foreign substances shall be removed from corrosion-resisting steel surfaces after fabrication. Cleaning shall be done by vapor degreasing or by the use of cleaners of the alkaline, emulsion or solvent type. After the surfaces have been cleaned they shall be given a final rinsing with clean water followed by a 24 hour period during which the surfaces are intermittently wet with clean water and then

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allowed to dry for the purpose of inspecting the clean surfaces. The surfaces shall be visually inspected for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust or other forms of contamination. If evidence of foreign substance exist the surface shall be cleaned in accordance with the applicable provisions of ASTM A 380 .

The proposed method of treatment shall be furnished for approval. After treatment the surfaces shall be visually reinspected. Brushes used to remove foreign substances shall have only stainless steel or nonmetallic bristles. Any contamination occurring subsequent to the initial cleaning shall be removed by one or more of the methods indicated above.

3.2 QUALITY CONTROL SYSTEM

The Contractor/manufacturer shall utilize a quality control system to insure all supplied components meet all specifications and requirements.

The Contractor shall submit Quality Control Reports for Government approval prior to shipment of components.

3.3 TESTING AND TEST REPORTS

The Contractor shall be responsible for all labor, materials, and costs associated with testing. A sample of three (3) percent of all machined components shall be randomly selected from each " lot " for examination and testing by an independent certified testing laboratory. A "lot" is defined as each part type from each manufacturer.

An independent lab test certification report shall identify component tested, specification, measured property, pass/fail, name of laboratory, equipment used, and submitted for review. Failure of a sample component will result in the rejection of that entire lot. Errors or defects disclosed shall be remedied by the Contractor at no additional cost to the Government and the batch shall be retested. The Contractor shall be responsible for cost of retesting. The following tests shall be performed on each sample.

3.3.1 Crack Test

Items shall be free of cracks as determined by dye penetrant inspection tests.

3.3.2 Hardness Tests

Each sample shall be tested for Brinell hardness and compared to applicable standard.

3.3.3 Surface Roughness Test

Contractor shall test surface requirements by comparing sample to roughness comparison specimen as per ASME B46.1 .

3.3.4 Dimensional Tolerance

Dimensional tolerances shall be compared to components specified requirements.

3.4 SHIPMENT AND STORAGE MACHINED COMPONENTS

Machined surfaces shall be thoroughly cleaned of foreign matter. All finished surfaces shall be protected by suitable means. Assembled and

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unassembled components shall be oiled and wrapped in moisture-resistant packaging or protected by other approved means. All components manufactured shall be packaged shipped in pallet crates suitable for forklift warehouse storage.

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3.1.2 Cleaning of Corrosion-Resisting Steel

3.4 SHIPMENT AND STORAGE MACHINED COMPONENTS