Amendment 0002 TechSpecs 20R0004.pdf

HLD Powerhouse Intake Gantry Crane Controls Upgrade W912EF20R0004 Amend-0002

PROJECT TABLE OF CONTENTS

DI VI SI ON 00 - PROCUREMENT AND CONTRACTI NG REQUI REMENTS

00 01 15.00 28 LIST OF DRAWINGS

DI VI SI ON 01 - GENERAL REQUI REMENTS

01 00 00.00 28 GENERAL REQUIREMENTS

01 11 00.00 28 SUMMARY OF WORK

01 11 01.00 28 SUPPLEMENTARY REQUIREMENTS

01 14 00.10 28 PROJECT SITE RESTRICTIONS

01 14 00.90 28 INTEGRATING ANTITERRORISM (AT) AND OPERATIONS SECURITY

(OPSEC)

01 22 00.00 28 MEASUREMENT AND PAYMENT

01 32 01.00 28 PROJECT SCHEDULE

01 33 00 SUBMITTAL PROCEDURES

01 35 29.10 28 GOVERNMENTAL SAFETY REQUIREMENTS

01 42 00 SOURCES FOR REFERENCE PUBLICATIONS

01 45 01.00 28 RESIDENT MANAGEMENT SYSTEM CONTRACTOR MODE (RMS CM)

01 45 04.00 28 CONTRACTOR QUALITY CONTROL

01 51 00.00 28 TEMPORARY UTILITIES

01 55 10.00 28 CONTRACTOR WORK, ACCESS AND STORAGE AREAS

01 57 20.00 28 ENVIRONMENTAL PROTECTION

01 78 00.00 28 CLOSEOUT SUBMITTALS

01 78 23.00 28 OPERATION AND MAINTENANCE DATA

DI VI SI ON 02 - EXI STI NG CONDI TI ONS

02 83 33.12 28 LEAD BASED PAINT (LBP) REMOVAL AND DISPOSAL

DI VI SI ON 05 - METALS

05 05 23.17 26 STEEL WELDING AND FABRICATION

05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS

DI VI SI ON 09 - FI NI SHES

09 97 02.10 26 PAINTING: STEEL STRUCTURES

DI VI SI ON 26 - ELECTRI CAL

26 05 00.00 26 BASIC ELECTRICAL MATERIALS AND METHODS

DI VI SI ON 41 - MATERI AL PROCESSI NG AND HANDLI NG EQUI PMENT

41 01 20.16 26 GANTRY CRANE DATA, SPARE PARTS, TESTING, AND TRAINING

41 01 20.17 26 GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION

41 01 20.18 26 GANTRY CRANE ELECTRICAL REHABILITATION

41 01 20.19 26 GANTRY CRANE STRUCTURAL APPURTENANCES

41 01 20.75 26 BELOW-THE-HOOK LIFTING DEVICES INSPECTION AND

CERTIFICATION

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PROJECT TABLE OF CONTENTS Page 2

SECTION TABLE OF CONTENTS

DIVISION 00 - PROCUREMENT AND CONTRACTING REQUIREMENTS

SECTION 00 01 15.00 28

LIST OF DRAWINGS

PART 1 GENERAL

1.1 SUMMARY

1.2 CONTRACT DRAWINGS

1.2.1 Use Of Government Prepared Contract CAD Electronic Files

1.3 RESOURCE DRAWINGS (R)

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DOCUMENT 00 01 15.00 28

SECTION 00 01 15.00 28

LIST OF DRAWINGS

PART 1 GENERAL

1.1 SUMMARY

This section lists the drawings for the project pursuant to contract clause "DFARS 252.236-7001, Contract Drawings, Maps and Specifications."

1.2 CONTRACT DRAWINGS

Contract drawings are as follows:

FILE NUMBER SHEET

NUMBER

TITLE Revision Date

GENERAL

IHP-1.29-0/1 G-001 PROJECT LOCATION &

VICINITY MAP

IHP-1.29-0/2 G-002 INDEX OF CONTRACT DRAWINGS

IHP-1.29-0/3 G-003 INDEX OF RESOURCE DRAWINGS

IHP-1.29-0/4 G-004 INDEX OF RESOURCE DRAWINGS

IHP-1.29-0/5 G-005 GENERAL NOTES & LEGEND

IHP-1.29-0/6 G-101 CONTRACTOR STAGING & WORK

AREAS

STRUCTURAL

IHP-1.29-5-1/1 S-101 MAIN TROLLEY FALL

PROTECTION, TOOL HOIST, &

MISCELLANEOUS INSTALL

IHP-1.29-5-1/2 S-102 AUXILARY TROLLEY FALL

PROTECTION, TOOL HOIST, &

MISCELLANEOUS INSTALL

IHP-1.29-5-1/3 S-201 NORTH ELEVATION FALL

PROTECTION, TOOL HOISTS,

& MISCELLANEOUS INSTALL

IHP-1.29-5-1/4 S-202 SOUTH ELEVATION FALL

PROTECTION, TOOL HOISTS,

& MISCELLANEOUS INSTALL

MECHANICAL

IHP-1.29-3-1/1 MD101 MAIN TROLLEY ASSEMBLY

REMOVAL

IHP-1.29-3-1/2 MD102 AUXILIARY TROLLEY

ASSEMBLY REMOVAL

IHP-1.29-3-1/3 MD103 GANTRY TRAVEL TRUCK

REMOVAL

IHP-1.29-3-1/4 M-101 MAIN TROLLEY ASSEMBLY

INSTALL

IHP-1.29-3-1/5 M-102 AUXILIARY TROLLEY

ASSEMBLY INSTALL

IHP-1.29-3-1/6 M-103 GANTRY TRAVEL TRUCK

INSTALL

IHP-1.29-3-1/7 M-501 HOIST SHEAR BLOCKS INSTALL

ELECTRICAL

IHP-1.29-6-1A0/1 ED101 CRANE OVERHEAD TROLLEY

LINE REMOVAL

IHP-1.29-6-1A0/2 ED102 OPERATOR CABS LAYOUT

REMOVAL

IHP-1.29-6-1A0/3 ED103 CONTROL HOUSE LAYOUT

REMOVAL

IHP-1.29-6-1A22/1 ED610 THREE LINE DIAGRAM

REMOVAL SHEET 1

IHP-1.29-6-1A22/2 ED611 THREE LINE DIAGRAM

REMOVAL SHEET 2

IHP-1.29-6-1A0/4 E-101 CRANE OVERHEAD TROLLEY

LINE INSTALL

IHP-1.29-6-1A0/5 E-102 OPERATOR CABS LAYOUT

INSTALL

IHP-1.29-6-1A0/6 E-103 CONTROL HOUSE LAYOUT

INSTALL

IHP-1.29-6-1A0/7 E-501 UPSTREAM OPERATOR'S CHAIR

DETAIL INSTALL

IHP-1.29-6-1A0/8 E-502 DOWNSTREAM OPERATOR'S

CHAIR DETAIL INSTALL

IHP-1.29-6-1A0/9 E-503 CRANE AND TUGGER HOIST

RADIO CONTROLS DETAIL

IHP-1.29-6-1A0/10 E-504 UPSTREAM CAB HUMAN

MACHINE INTERFACE (HMI)

DISPLAY DETAIL

IHP-1.29-6-1A0/11 E-505 DOWNSTREAM CAB HUMAN

MACHINE INTERFACE (HMI)

DISPLAY DETAIL

IHP-1.29-6-1A0/12 E-506 GROUND LEVEL AND CONTROL

HOUSE HUMAN MACHINE

INTERFACE (HMI) DISPLAY

DETAIL

IHP-1.29-6-1A0/13 E-507 HUMAN MACHINE INTERFACE

(HMI)VARIABLE FREQUENCY

DRIVE SCREEEN DISPLAY

DETAIL

IHP-1.29-6-1A0/14 E-508 HUMAN MACHINE INTERFACE

(HMI)VARIABLE FREQUENCY

DRIVE SCREEEN DISPLAY

DETAIL

IHP-1.29-6-1A0/15 E-509 HUMAN MACHINE INTERFACE

(HMI)VARIABLE FREQUENCY

DRIVE SCREEEN DISPLAY

DETAIL

IHP-1.29-6-1A0/16 E-510 HUMAN MACHINE INTERFACE

(HMI)VARIABLE FREQUENCY

DRIVE SCREEEN DISPLAY

DETAIL

IHP-1.29-6-1A0/17 E-511 HUMAN MACHINE INTERFACE

(HMI)VARIABLE FREQUENCY

DRIVE SCREEEN DISPLAY

DETAIL

IHP-1.29-6-1A22/3 E-610 THREE LINE DIAGRAM

INSTALL SHEET 1

IHP-1.29-6-1A22/4 E-611 THREE LINE DIAGRAM

INSTALL SHEET 2

1.2.1 Use Of Government Prepared Contract CAD Electronic Files

a. Contract CAD drawing files requests by the Contractor will be granted only when the Contractor is planning to use the electronic CAD files for creating shop drawings.

b. No For Information Only drawings are available on CAD.

c. The Contractor assumes all risks associated in using electronic CAD drawings.

d. Electronic copies of CAD drawings are only available in Bentley MicroStation format.

e. The contract drawings shall govern if there are any discrepancies between the electronic copy and the contract drawing. The Contractor shall promptly notify the Contracting Officer of any discrepancies.

The Government will not be responsible to correct the electronic CAD drawing.

1.3 FOR INFORMATION ONLY DRAWINGS (FIO) RESOURCE DRAWINGS (R)

These FIO drawings are included with the drawings for information. The Government does not warrant the accuracy of the FIO drawings. The Government recommends that the Contractor verify the accuracy of FIO drawings.

FIO drawings are as follows: These R drawings are included with the drawings for information only. The Government does not warrant the accuracy of the R drawings. The Government recommends that the Contractor verify the accuracy of R drawings.

Resource (R) drawings are as follows:

FILE NUMBER SHEET

NUMBER

TITLE Revision Date

6148 9 R-001 POWERHOUSE STRUCTURAL STEEL TROLLEY

DEAD END STRUCTURE, TEMPORARY END

WALL BEAMS (UNIT 3)

6148 9W R-002 POWERHOUSE STRUCTURAL STEEL TROLLEY

DEAD END STRUCTURE, TEMPORARY END

WALL BEAMS (UNIT)

A-15360 R-003 MAIN HOIST DRUM DETAIL 39 P.D. 1

1/4" DIAMETER ROPE

A-15362 R-004 MAIN HOIST DRUM DETAIL 39 P.D. 1

1/4" DIAMETER ROPE

DOCUMENT 00 01 15.00 28

A-15363 R-005 ACTUATING HOIST DRUM & DRUM SHAFT

DETAIL 15 3/4P.D. 5/8" DIAMETER ROPE

A-15364 R-006 ACTUATING HOIST DRUM & DRUM SHAFT

DETAIL 15 3/4P.D. 5/8" DIAMETER ROPE

A-15365 R-007 DRUM GEAR & PINION DETAIL

A-15366 R-008 DRUM PILLOW BLOCK ASSEMBLY & DETAILS

22218 BEARING

A-15367 R-009 DRUM PILLOW BLOCK ASSEMBLY & DETAILS

22222 BEARING

A-15371 R-010 MAIN HOIST LOWER BLOCK FRAME

A-15372 R-011 LOWER BLOCK ASSEMBLY & DETAILS

A-15373 R-012 AUXILIARY HOIST DRUM DETAIL 44"

PITCH DIAMETER 5/8 " ROPE DIAMETER

A-15374 R-013 TROLLEY DRIVE & IDLER WHEEL SHAFTS &

WHEEL DETAILS

A-15375 R-014 TROLLEY WHEEL BEARING RETAINER &

COVER PLATES

A-15376 R-015 TROLLEY DRIVE & IDLER WHEEL ASSEMBLY

A-15377 R-016 AUXILIARY HOIST DRUM DETAIL 44"

PITCH DIAMETER 5/8 " ROPE DIAMETER

A-15378 R-017 HOUSE AUXILIARY HOIST

A-15379 R-018 BRIDGE WHEEL, BEARING RETAINER, &

WHEEL COVER DETAILS

A-15380 R-019 AUXILIARY DRUM GEAR, PINION, ROPE

CLAMP, & SHAFT ADAPTER 15 & 2 TON

HOIST

A-15381 R-020 AUXILIARY HOIST MISCELLANEOUS

DETAILS 15 & 2 TON HOIST

A-15383 R-021 AUXILIARY TROLLEY DRIVER & IDLER

WHEEL ASSEMBLY 15" DIAMETER WHEELS

A-15385 R-022 AUXILIARY HOIST MISCELLANEOUS

DETAILS 15 & 2 TON HOIST

A-15386 R-023 AUXILIARY LOWER BLOCK MISC.ELLANEOUS

DETAILS 15 & 2 TON HOIST

A-15387 R-024 AUXILIARY LOWER BLOCK MISCELLANEOUS

DETAILS 15 & 2 TON HOIST

A-15388 R-025 AUXILIARY LOWER BLOCK ASSEMBLY 15/2

TON HOIST 5/8" DIAMETER ROPE

A-15389 R-026 AUXILIARY TROLLEY BUFFER SUPPORT &

GUARD DETAILS

A-15390 R-027 AUXILIARY TROLLEY ASSEMBLY 30 TON

RATING

A-15392 R-028 AUXILIARY TROLLEY LOAD CELL ASSEMBLY

& DETAILS

A-15393 SH 1 R-029 UPSTREAM SILL 111 TON INTAKE GANTRY

CRANE

A-15393 SH 2 R-030 UPSTREAM SILL 111 TON INTAKE GANTRY

CRANE

A-15394 R-031 DOWNSTREAM LEG DETAIL

A-15395 R-032 UPSTREAM LEG DETAIL

A-15396 R-033 AUX. ILIARY TROLLEY SUPPORT BEAM

A-15397 R-034 MAIN TROLLEY GIRDER DETAIL

A-15398 R-035 TOP TIE BEAM

A-15399 R-036 AUXILIARY GIRDER END TIE BEAM

A-15400 R-037 100 TON INTAKE GANTRY CRANE HOUSE

MAIN HOIST

A-15401 R-038 BRACING DETAILS & ARRANGEMENT

A-15402 R-039 AUXILIARY TROLLEY GIRDER DETAIL

A-15403 R-040 HOIST CASE SHAFT DETAILS

A-15404 SH 1 R-041 MAIN HOIST ASSEMBLY 111/15 TON CAP

PLAN VIEW

A-15404 SH 2 R-042 MAIN HOIST ASSEMBLY 111/15 TON CAP

ELEVATION VIEWS

A-15405 R-043 TROLLEY DRIVE ASSEMBLY 111 TON CAP

A-15406 R-044 MAIN HOIST ASSEMBLY 111 TON CAP

A-15407 R-045 GANTRY DRIVE TORQUE ARM DETAILS

A-15408 R-046 GANTRY DRIVE WHEEL ASSEMBLY

A-15409 R-047 ACTUATING HOIST ASSEMBLY & DETAILS

15 TON CAP

A-15410 SH 1 R-048 DOWNSTREAM SILL 111 TON INTAKE

GANRTY CRANE

A-15410 SH 2 R-049 DOWNSTREAM SILL 111 TON INTAKE

GANRTY CRANE

A-15410 SH 3 R-050 CONTROL HOUSE MOUNTING DETAIL

(DOWNSTREAM SILL)

A-15411 SH 1 R-051 AUXILIARY TROLLEY FRAME FAB

A-15411 SH 2 R-052 AUXILIARY TROLLEY FRAME FAB

A-15411 SH 3 R-053 AUXILIARY TROLLEY FRAME FAB

A-15412 R-054 AUXILIARY TROLLEY FRAME MACHINING

A-15413 R-055 AUXILIARY TROLLEY FRAME EXTENSION

A-15414 R-056 AUXILIARY TROLLEY WALKWAY FABRICATION

A-15415 R-057 GANTRY DRIVE GEAR & PINION DETAIL

A-15416 R-058 GANRTY DRIVE WHEEL & PINION SHAFT

DETAIL

A-15417 R-059 GANTRY DRIVE PINION SHAFT BEARING

CAP DETAILS

A-15418 R-060 GANTRY DRIVE BASE DETAIL

A-15419 R-061 GANTRY TRUCK FRAME DETAIL

A-15422 R-062 AUXILIARY TROLLEY DETAILS

A-15423 R-063 AUXILIARY TROLLEY DETAILS

A-15424 R-064 DRUM GEAR GUARD AUXILIARY HOIST 30

TON RATING

A-15425 R-065 AUXILIARY TROLLEY HOIST ASSEMBLY 30

TON RATING

A-15426 SH 1 R-066 MAIN TROLLEY FRAME FABRICATION DWG.

PLAN & ELEVATION VIEWS

A-15426 SH 2 R-067 MAIN TROLLEY FRAME BOTTOM VIEW &

DETAILS

A-15426 SH 3 R-068 MAIN TROLLEY FRAME DETAILS

A-15426 SH 4 R-069 TROLLEY FRAME DETAILS

A-15427 R-070 MAIN TROLLEY FRAME MACHINING DRAWING

A-15428 R-071 GANTRY TRUCK ASSEMBLY

A-15429 R-072 GANTRY TRUCK ASSEMBLY

A-15430 R-073 COUPLING LIST

A-15431 R-074 AUXILIARY TROLLEY DRIVE ASSEMBLY W/

DETAILS 30 TON HOIST

A-15432 R-075 MAIN HOIST DRUM GEAR GUARD

A-15433 R-076 MAIN TROLLEY DRIVE DRIP PAN &

COUPLING GUARD DETAILS

A-15434 R-077 MAIN TROLLEY BRAKE GUARD DETAILS

A-15437 R-078 AUXILIARY TROLLEY LIMIT SWITCH

ASSEMBLY & BUMPER STOP LOCATION 30

TON HOIST

A-15438 R-079 MAIN HOIST EQUALIZER ASSEMBLY DETAILS

A-15439 R-080 MAIN TROLLEY LIMIT SWITCH BUFFER &

RAIL SWEEP ASSEMBLY & DETAILS

A-15440 R-081 MAIN HOIST & ACTUATING HOIST REEVING

ACTUATING HOIST DEAD END ASSEMBLY

A-15441 R-082 WHEEL / GEAR GUARD RAIL SWEEP &

COUPLING GUARD DETAILS

A-15442 R-083 MAIN GIRDER HANDRAIL DETAILS

A-15443 R-084 MAIN GIRGER HANDRAIL & W'WAY DETAILS

ELEVATION 66'-1 3/4 66'-2 1/4

BOARDING SIDE

A-15445 R-085 AUXILIARY TROLLEY UPPER LIMIT SWITCH

ASSEMBLY

A-15446 SH 1 R-086 AUXILIARY GIRDER W'WAY ARRANGEMENT &

DETAILS (BOARDING SIDE)

A-15446 SH 2 R-087 AUXILIARY GIRDER W'WAY ARRANGEMENT &

DETAILS (BOARDING SIDE) ELEV. 37'-8

A-15447 SH 1 R-088 AUXILIARY GIRDER W'WAY ARRANGEMENT &

DETAILS ELEVATION 37'-8

A-15447 SH 2 R-089 AUXILIARY GIRDER W'WAY DETAILS

A-15448 R-090 WALKWAY DETAIL ELEVATION 37'-8"

(AUXILIARY GIRDER AT UPSTREAM LEG)

A-15449 R-091 CONTROL HOUSE 100 TON GANTRY CRANE

A-15450 SH 1 R-092 MAIN TROLLEY FRAME EXTENSIONS &

WALKWAY

A-15450 SH 2 R-093 MAIN TROLLEY WALKWAY STAIRS

A-15451 R-094 ACTUATING LOWER BLOCK ASSEMBLY 15

TON HOIST 5/8 DIAMETER ROPE

A-15452 R-095 ACTUATING LOWER BLOCK MISCELLANEOUS

DETAILS 15 TON HOIST

A-15453 R-096 SIGNS

A-15455 R-097 MAIN TROLLEY POWER TRACK

A-15456 R-098 AUXILIARY TROLLEY POWER TRACK

A-15457 R-099 LADDER DETAIL ELEVATION 51'-8 TO

66'-1 3/4 (LANDING TO MAIN HOIST

GIRDER DOWNSTREAM LEG)

A-15458 R-100 LADDER DETAIL ELEVATION 37'-8 TO

51'-8 (AUXILIARY GRIDER WALKWAY UP

TO LANDING)

A-15459 R-101 LANDING DETAIL ELEVATION 51'-8

(ACCESS TO MAIN TROLLEY)

A-15460 R-102 MOMORAIL HOIST FESTOON ASSEMBLY

A-15461 R-103 AUXILIARY GIRDER RESTRAINT LUGS

A-15462 R-104 LADDER DETAIL ELEVATION 29'-8 TO

9'-8 (UP TO MAINLINE ACCESS)

A-15463 R-105 LADDER DETAIL ELEVATION 37'-8 TO

29'-8 (MAINLINE ACCESS TO AUXILIARY

GIRDER W'WAY)

A-15464 R-106 AUXILIARY GIRDER ACCESS PLATEFORM

DETAIL ELEVATION 37'-8 (ELEC

HSE/GANTRY SILL TO AUX GIRDER W'WAY)

A-15465 R-107 PLATFORM DETAIL ELEVATION 37'-8 (AUX

TROLLEY GIRDER TO MOMORAIL HOIST

MAINT. PLATFORM)

A-15466 R-108 LADDER DETAIL ELEVATION 37'-8 TO

32'-10 1/4 (AUX GIRDER TO MONORAIL

HOIST MAINT. PLATFORM)

A-15467 R-109 MAINTENANCE PLATFORM DETAIL

ELEVATION 32-10 1/4 (AUX TROLLEY

MONORAIL HOIST)

A-15468 R-110 CAB ACCESS W'WAY DETAIL ELEVATION

37'-8 (CAB ACCESS AT UPSTREAM LEG)

A-15470 R-111 1/2 TON AIR WINCH ASSEMBLY

A-15476 R-112 BOLT LIST

A15477 R-113 CRANE ACCESS PLATFORM DETAIL

ELEVATION. 9'-3 3/16 (CRANE ACCESS)

A-15478 R-114 BOARDING/ELEC HOUSE PLATEFORM DETAIL

ELEVATION 9'-3 3/16 (CRANE ACCESS)

A-15479 R-115 ELECTRICAL HOUSE PLATFORM DETAIL

ELEVATION 9'-3 3/16 (ELECTRICAL

HOUSE ACCESS)

A-15480 R-116 BOARDING LADDER DETAIL GROUND

ELEVATION 0 TO 9'-3 3/16 (CRANE

ACCESS)

A-15481 R-117 CRANE LIGHT MOUNTING ASSEMBLY

A-15482 R-118 ERECTION DWG & MATCHMARKS 111 TON

INTAKE GANTRY CRANE

A-15483 R-119 MONORAIL HOIST LIMIT SWITCH ASSEMBLY

& DETAILS

A-15485 R-120 CAB ACCESS LADDER DETAIL ELEVATION

37'-8 DOWN TO CAB

A-15486 R-121 STORAGE BOX 60 CUBIC FEET

A-15491 SH 1 R-122 OPERATOR'S CAB DETAIL (TRASH RAKE)

A-15491 SH 2 R-123 WALL DETAILS (TRASH RAKE)

A-15491 SH 3 R-124 OPERATOR'S CAB DETAIL (TRASH RAKE)

A-15492 SH 1 R-125 OPERATOR'S CAB DETAIL (ALL HOISTS)

A-15492 SH 2 R-126 WALL DETAILS (ALL HOISTS)

A-15492 SH 3 R-127 OPERATOR'S CAB DETAIL (ALL HOISTS)

A-15494 R-128 CAB ACCESS PLATFORM DETAILS

ELEVATION 27'-6

A-15495 SH 1 R-129 OPERATOR'S CAB ASSEMBLY (TRASH RAKE)

A-15495 SH 2 R-130 OPERATOR'S CAB ASSEMBLY (TRASH RAKE)

A-15496 SH 1 R-131 OPERATOR'S CAB ASSEMBLY (ALL HOISTS)

A-15496 SH 2 R-132 OPERATOR'S CAB ASSEMBLY (ALL HOISTS)

A-15498 R-133 SHIPPING DIMENSIONS & WEIGHTS 111

TON INTAKE GANTRY CRANE

A-15499 R-134 COLLECTOR MOUNT

A-15502 R-135 AUXILIARY TROLLEY HANDRAIL AUXILIARY

TROLLEY GIRDER

EA-2438 SH I R-136 TITLE & INDEX

EA-2438 SH II R-137 100 TON INTAKE GANTRY CRANE NOTES &

MACHINE DATA

EA-2438 SH 1 R-138 100 TON INTAKE GANTRY CRANE POWER

DISTRIBUTION ELEMENTARY

EA-2438 SH 2 R-139 100 TON INTAKE GANTRY CRANE POWER

DISTRIBUTION ELEMENTARY

EA-2438 SH 3 R-140 100 TON INTAKE GANTRY CRANE

CONVENIENCE OUTLETS, LIGHTING, &

SPACE HEATER ELEMENTARY DIAGRAMS

EA-2438 SH 4 R-141 100 TON INTAKE GANTRY CRANE LOUVER,

ANTI-COLLISION, PLC DISTRIBUTION

ELEMENTARY DIAGRAMS

EA-2438 SH 5 R-142 100 TON INTAKE GANTRY CRANE MAIN

CONTROL ELEMENTARY DIAGRAM

EA-2438 SH 6 R-143 100 TON INTAKE GANTRY CRANE MAIN

HOIST CONTROL ELEMENTARY DIAGRAM

EA-2438 SH 7 R-144 100 TON INTAKE GANTRY CRANE MAIN

HOIST CONTROL ELEMENTARY DIAGRAM

EA-2438 SH 8 R-145 100 TON INTAKE GANTRY CRANE MAIN

HOIST CONTROL ELEMENTARY DIAGRAM

EA-2438 SH 9 R-146 ACTUATING HOIST CONTROL ELEMENTARY

EA-2438 SH 10 R-147 ACTUATING HOIST CONTROL ELEMENTARY

EA-2438 SH 11 R-148 ACTUATING HOIST CONTROL ELEMENTARY

EA-2438 SH 12 R-149 MAIN TROLLEY CONTROL ELEMENTARY

EA-2438 SH 13 R-150 MAIN TROLLEY CONTROL ELEMENTARY

EA-2438 SH 14 R-151 MAIN TROLLEY CONTROL ELEMENTARY

EA-2438 SH 15 R-152 AUXILIARY HOIST 1 CONTROL ELEMENTARY

EA-2438 SH 16 R-153 AUXILIARY HOIST 1 CONTROL ELEMENTARY

EA-2438 SH 17 R-154 AUXILIARY HOIST 1 CONTROL ELEMENTARY

EA-2438 SH 18 R-155 AUXILIARY HOIST 2 CONTROL ELEMENTARY

EA-2438 SH 19 R-156 AUXILIARY HOIST 2 CONTROL ELEMENTARY

EA-2438 SH 20 R-157 AUXILIARY HOIST 2 CONTROL ELEMENTARY

EA-2438 SH 21 R-158 MONORAIL HOIST & TROLLEY CONTROL

ELEMENTARY

EA-2438 SH 22 R-159 MONORAIL HOIST & TROLLEY MOTOR

ELEMENTARY

EA-2438 SH 23 R-160 AUXILIARY TROLLEY CONTROL ELEMENTARY

EA-2438 SH 24 R-161 AUXILIARY TROLLEY CONTROL ELEMENTARY

EA-2438 SH 25 R-162 AUXILIARY TROLLEY CONTROL ELEMENTARY

EA-2438 SH 26 R-163 GANTRY CONTROL ELEMENTARY

EA-2438 SH 27 R-164 GANTRY CONTROL ELEMENTARY

EA-2438 SH 28 R-165 GANTRY CONTROL ELEMENTARY

EA-2438 SH 29 R-166 MAIN & AUXILIARY WEIGHT SYSTEMS

ELEMENTARY

EA-2439 SH 1 R-167 PANEL LAYOUT & WIRING

EA-2439 SH 2 R-168 PANEL LAYOUT & WIRING

EA-2439 SH 3 R-169 MP1-1 GANTRY PANEL WIRING

EA-2439 SH 4 R-170 MP1-1 GANTRY PANEL WIRING

EA-2439 SH 5 R-171 MP1-2 PLC PANEL WIRING

EA-2439 SH 6 R-172 MP1-2 PLC PANEL WIRING

EA-2439 SH 7 R-173 MP1-3 MAIN POWER & CONTROL PANEL

WIRING

EA-2439 SH 8 R-174 MP1-3 MAIN POWER & CONTROL PANEL

WIRING

EA-2439 SH 9 R-175 MP2-1 MAIN & AUX. TROLEY PANEL WIRING

EA-2439 SH 10 R-176 MP2-1 MAIN & AUXILIARY TROLEY PANEL

WIRING

EA-2439 SH 11 R-177 MP2-2 AUXILIARY HOIST 1 & 2 PANEL

WIRING

EA-2439 SH 12 R-178 MP2-2 AUXILIARY HOIST 1 & 2 PANEL

WIRING

EA-2439 SH 13 R-179 MP2-3 MAIN & ACTUATOR HOIST PANEL

WIRING

EA-2439 SH 14 R-180 MP2-3 MAIN & ACTUATOR HOIST PANEL

WIRING

EA-2439 SH 15 R-181 COLLISION AVOIDANCE TRANSMIT &

WEIGHT DISPLAY PANELS

EA-2439 SH 16 R-182 JUNCTION BOX TERMINAL BLOCKS

EA-2439 SH 17 R-183 JUNCTION BOX TERMINAL BLOCKS

EA-2439 SH 18 R-184 UPSTREAM & DOWNSTREAM CHAIR CONSOLES

EA-2439 SH 19 R-185 DOWNSTREAM CHAIR CONSOLES

EA-2439 SH 20 R-186 UPSTREAM CHAIR CONSOLES

EA-2440 SH 1 R-187 INTERCONNECTION (CAB)

EA-2440 SH 2 R-188 INTERCONNECTION (CAB)

EA-2440 SH 3 R-189 INTERCONNECTION (CAB)

EA-2440 SH 4 R-190 INTERCONNECTION (ELECTRICAL CONTROL

HOUSE)

EA-2440 SH 5 R-191 INTERCONNECTION (ELECTRICAL CONTROL

HOUSE)

EA-2440 SH 6 R-192 INTERCONNECTION (ELECTRICAL CONTROL

HOUSE)

EA-2440 SH 7 R-193 INTERCONNECTION (ELECTRICAL CONTROL

HOUSE)

EA-2440 SH 8 R-194 INTERCONNECTION (GANTRY)

EA-2440 SH 9 R-195 INTERCONNECTION (GANTRY)

EA-2440 SH 10 R-196 INTERCONNECTION (GANTRY)

EA-2440 SH 11 R-197 INTERCONNECTION (GANTRY)

EA-2440 SH 12 R-198 INTERCONNECTION (MAIN TROLLEY)

EA-2440 SH 13 R-199 INTERCONNECTION (MAIN TROLLEY)

EA-2440 SH 14 R-200 INTERCONNECTION (AUXILIARY TROLLEY)

EA-2440 SH 15 R-201 INTERCONNECTION (AUXILIARY TROLLEY)

EA-2440 SH 16 R-202 INTERCONNECTION (AUXILIARY TROLLEY)

EA-2440 SH 17 R-203 INTERCONNECTION (AUXILIARY TROLLEY /

AUXILIARY TROLLEY MONORAIL)

EA-2440 SH 18 R-204 INTERCONNECTION (MP1 & MP2 SUBPANEL

INTERCONNECTION)

EA-2441 SH 1 R-205 MAIN TROLLEY POWER TRACK & MONORAIL

TROLLEY FESTOON

EA-2441 SH 2 R-206 AUXILIARY TROLLEY NORTH AND SOUTH

POWER TRACK

EA-2445 SH 1 R-207 GANTRY NORTH ELEVATION CONDUIT LAYOUT

EA-2445 SH 2 R-208 GANTRY WEST ELEVATION CONDUIT LAYOUT

EA-2445 SH 3 R-209 GANTRY SOUTH ELEVATION CONDUIT LAYOUT

EA-2445 SH 4 R-210 GANTRY CONDUIT LAYOUT (AUXILIARY

TROLLEY LEVEL)

EA-2445 SH 5 R-211 GANTRY CONDUIT LAYOUT (MAIN TROLLEY

LEVEL)

EA-2445 SH 6 R-212 AUXILIARY TROLLEY CONDUIT LAYOUT

EA-2445 SH 7 R-213 MAIN TROLLEY CONDUIT LAYOUT

EA-2445 SH 8 R-214 GANTRY TRUCK CONDUIT LAYOUT

EA-2445 SH 9 R-215 CONDUIT LAYOUT DETAILS

EA-2445 SH 10 R-216 CONTROL HOUSE POWER & CONTROL CONDUIT

EA-2445 SH 11 R-217 CONDUIT DETAIL DRAWINGS (FROM SHEET

1)

EA-2445 SH 12 R-218 CONDUIT DETAIL DRAWINGS (FROM SHEET

2)

EA-2445 SH 13 R-219 CONDUIT DETAIL DRAWINGS (FROM SHEET

3)

EA-2446 SH 1 R-220 ELECTRICAL EQUIPMENT LIGHTING LAYOUT

EA-2446 SH 2 R-221 ELECTRICAL EQUIPMENT GANTRY LAYOUT

EA-2446 SH 3 R-222 ELECTRICAL EQUIPMENT MAIN TROLLEY

LAYOUT

EA-2446 SH 4 R-223 ELECTRICAL EQUIPMENT AUX. TROLLEY

LAYOUT

EA-2446 SH 5 R-224 ELECTRICAL EQUIPMENT GANTRY TRUCK

LAYOUT

IHP-1.1-5-0/2 R-225 TROLLEY DEAD END STRUCTURE

IHP-1.1-6-1A11/2 R-226 MISCELLANEOUS INSTALLATIONS SHEET 1

IHP-1.14-4-2/1 R-227 GENERAL NOTES

IHP-1.14-4-2/2 R-228 INTAKE DECK PLAN EL. 453.00 EXISTING

CONDITIONS

IHP-1.14-4-2/3 R-229 INTAKE DECK PLAN EL. 453.00 MODIFIED

CONDITION

IHP-1.14-4-2/4 R-230 PEDESTAL & MISCELLANEOUS METAL

DETAILS

IHP-1.14-4-2/5 R-231 GUY CABLE INSTALLATION

IHP-1.14-6-1A11/3 R-232 CRANE FEEDER INSTALLATION SHEET 3

PA-1905 R-233 CLEARANCE DRAWING 100 TON INTAKE

GANTRY CRANE

SKF-57-1238 R-234 MOUNTING ARRANGEMENTS ON POLES FOR

ICE HARBOR LOCK AND DAM

IHP-5.3-3-4/63 R-235 STS HANDLING EQUIPMENT LIFTING BEAM

ASSEMBLY

IHP-5.3-3-4/69 R-236 STS HANDLING EQUIPMENT LATCHING

ASSEMBLY

IHP-5.3-3-4/72 R-237 STS HANDLING EQUIPMENT LOWER BEAM

WELDMENT SHT 1

IHP-5.3-3-4/74 R-238 STS HANDLING EQUIPMENT LOWER BEAM

WELDMENT SHT 3

IHP-5.3-3-4/75 R-239 STS HANDLING EQUIPMENT LOWER BEAM

WELDMENT SHT 4

IHP-5.3-3-4-76 R-240 STS HANDLING EQUIPMENT LOWER BEAM

DETAILS SHT 1

IHP-5.3-3-4/77 R-241 STS HANDLING EQUIPMENT LOWER BEAM

DETAILS SHT 2

91-47-54 R-242 STS HANDLING EQUIPMENT LIFTING BEAM

ASSEMBLY

91-47-69 R-243 STS HANDLING EQUIPMENT LOWER BEAM,

TEMPORARY MODIFICATION

IHP-1-5-2/36 R-244 LIFTING BEAM AND INTAKE BULKHEAD

MOFIFICATION LIFTING BEAM

MODIFICATIONS

IHP-1-3-2/2 R-245 TRASH RACK AND INTAKE BULKHEAD

LIFTING BEAM

IHP-1-3-2/39 R-246 INTAKE TRASH RAKE ASSY

IHP-1-3-2/40 R-247 INTAKE TRASH RAKE FRAME DETAILS

IHP-1-3-2/41 R-248 INTAKE TRASH RAKE BED & MISC DETAILS

IHP-1-3-2/42 R-249 INTAKE TRASH RAKE MISC DETAILS

IHP-9-3-2/40 R-250 INTAKE TRASH RAKE FULL RAKE DETAIL

825-64 R-251 STS HANDLING EQUIPMENT - UPPER BEAM

WELDMENT

IHP-5.3-3-4/64 R-252 STS HANDLING EQUIPMENT - UPPER BEAM

WELDMENT

[] HLD-SKET-119 [] R-253 MAIN UNITS 1-3 INTAKE GATE LIFTING

BRACKET[TO COMPLETE: LIFTING LINKS

AND BRACKETS]

HLD-SKET-120 R-254 MAIN UNITS 4-6 INTAKE GATE LIFTING

BRACKET

825-67 R-255 STS HANDLING EQUIPMENT PINS & LINKS

IHP-5.3-3-4/67 R-256 STS HANDLING EQUIPMENT PINS & LINKS

-- End of Document --

DOCUMENT 00 01 15.00 28

THIS PAGE INTENTIONALLY LEFT BLANK

SECTION TABLE OF CONTENTS

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT

SECTION 41 01 20.17 26

GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

1.2 REFERENCES

1.3 SUBMITTALS

1.4 DESIGN CRITERIA

1.4.1 General

1.4.2 Data, Capacities, Speeds, and Travel

1.4.3 Design

1.4.4 Loading

1.4.4.1 General

1.4.5 Unit Stresses

1.4.5.1 Structural Components

1.4.5.2 Bolts

1.4.5.3 Welds

1.4.5.4 Detailing Requirements

1.4.5.5 Mechanical Parts of the Crane

1.4.5.6 Fatigue Design

1.4.5.7 Wire Rope Stresses

1.4.6 Use of Cast Iron

1.4.7 Connections

1.4.7.1 Shop and Field Connections

1.4.7.2 Welded Connections

1.4.7.3 Bolted Connections

1.5 SUBMISSION OF CRANE DESIGN DATA

1.5.1 General

1.5.1.1 Drawing Index

1.5.1.2 Bill of Materials/Schedule of Equipment

1.5.1.3 Drawings

1.5.1.3.1 Detailed Shop Drawings

1.5.1.4 Product Data

1.5.1.4.1 General

1.5.1.4.2 Type of Equipment and Quality

1.5.1.5 Design Calculations

1.5.1.5.1 Finite Element Analysis (FEA)

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor Prepared Drawings

1.7 FIELD MEASUREMENTS

1.8 REHABILITATION PROCEDURE

PART 2 PRODUCTS

2.1 LUBRICANTS

2.1.1 General

2.1.2 Gear Grease

2.1.3 New Lubricating Oil

2.1.4 New Grease

2.2 WIRE ROPE FOR AUXILIARY HOISTS AND ACTUATING HOIST

2.3 TOOL HOISTS

SECTION 41 01 20.17 26

2.3.1 General

2.3.2 Hoist

2.3.3 Tool Hoist Wire Rope Lubricant

2.3.4 Wall Mounted Cantilever Jib

2.4 DESICCANT BREATHERS FOR ALL GEARBOXES

2.5 SHAFT COUPLINGS

2.5.1 General

2.5.2 Configuration

2.6 BEARINGS

2.6.1 General

2.6.2 Anti-Friction

2.7 BIRD SCREENS FOR EXPANDED MAIN HOIST WIRE ROPE SLOTS

PART 3 EXECUTION

3.1 CLEANUP AND REMOVAL

3.1.1 Cleanup

3.1.1.1 Cleanup - Environmental Considerations

3.1.2 Removal

3.2 INITIAL PRE-WORK INSPECTION PROCEDURE

3.2.1 General

3.2.2 Open Gear Pre-Work Inspection

3.2.3 Speed Reducer Pre-Work Inspection

3.2.4 In-Service Speed Reducer Oil Test Report

3.2.5 Hoist Machinery Bearings Pre-Work Inspection

3.2.6 Hoist Machinery Bolt Torque Pre-Work Inspection Report

3.3 HOISTS

3.3.1 General

3.3.2 Auxiliary and Actuating Hoist Drums

3.3.3 Shear Blocks

3.3.4 Load Cells

3.3.5 Shaft Couplings

3.4 SPEED REDUCERS

3.5 MAIN TROLLEY AND AUXILIARY TROLLEY DRIVES

3.6 GANTRY DRIVES

3.7 STORM BRAKES

3.8 TUGGER HOISTS

3.9 SHAFT ALIGNMENT

3.10 DYNAMIC BALANCING OF MACHINERY

3.11 TOOL HOIST INSTALLATION AND TESTING

3.11.1 General

3.11.2 Operation Test

3.11.3 Load Test

3.11.4 Testing Report

3.12 MOUNTING BASES

3.12.1 Hoist Bases

3.12.2 Trolley Drive Bases

3.12.3 Gantry Drive Bases

3.13 MISCELLANEOUS ITEMS

3.14 NAMEPLATES AND CAPACITY PLATES

3.14.1 Crane Nameplates

3.14.2 Warning Labels

-- End of Section Table of Contents --

SECTION 41 01 20.17 26

SECTION 41 01 20.17 26

GANTRY CRANE MECHANICAL AND STRUCTURAL REHABILITATION

PART 1 GENERAL

1.1 DESCRIPTION OF WORK

This SECTION covers the mechanical and structural work for the rehabilitation of the 111-ton capacity intake gantry crane at Ice Harbor Dam. Design all new, replaced, or modified systems and components of the crane and submit computations and drawings as stated in Paragraph "Submittals" below. Furnish detailed shop drawings showing all details required to fabricate and install new or modified mechanical and structural equipment. Contractor is responsible for any changes in material or quality which are necessary for products to conform with these specifications while maintaining clearances, fits, and alignment with existing equipment. No items may be considered purely replace-in-kind;

product data submittals, calculations, and drawings are required for all new components or modifications.

1.2 REFERENCES

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

AMERICAN BEARING MANUFACTURERS ASSOCIATION (ABMA)

ABMA 8.2 (1999) Ball and Roller Bearing Mounting Accessories, Inch Design

ABMA 19.1 (1987; R 1999) Tapered Roller Bearings - Radial Metric Design

ABMA 19.2 (1994; R 1999) Tapered Roller Bearings - Radial Inch Design

ABMA 20 (1996) Radial Bearings of Ball, Cylindrical Roller and Spherical Roller Types Metric Design

AMERICAN GEAR MANUFACTURERS ASSOCIATION (AGMA)

AGMA 9005 (2002e) Industrial Gear Lubrication

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 (2017) Steel Construction Manual

ASME INTERNATIONAL (ASME)

ASME B30.2 (2017) Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)

ASME B30.16 (2017) Overhead Underhung and Stationary Hoists

ASTM INTERNATIONAL (ASTM)

ASTM A36/A36M (2014) Standard Specification for Carbon Structural Steel

ASTM A572/A572M (2015) Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel

ASTM A992/A992M (2011; R 2015) Standard Specification for Structural Steel Shapes

ASTM D 445 (2006) Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and the Calculation of Dynamic Viscosity)

ASTM D 664 (2007) Standard Test Method for Acid Number of Petroleum Products by Potentiometric Titration

ASTM D 2509 (2003; R 2008) Standard Test Method for Measurement of Load-Carrying Capacity of Lubricating Grease (Timken Method)

ASTM D 4425 (2009) Standard Test Method for Oil Separation From Lubricating Grease by Centrifuging (Koppers Method)

ASTM D 4950 (2008) Standard Classification and Specification for Automotive Service Greases

ASTM D 5185 Determination of Additive Elements, Wear Metals, and Contaminants in Used Lubricating Oils and Determination of Selected Elements in Base Oils by Inductively Coupled Plasma Atomic Emission Spectrometry (ICP-AES)

ASTM D 6304 (2007) Standard Test Method for Determination of Water in Petroleum Products, Lubricating Oils, and Additives by Coulometric Karl Fischer Titration

ASTM E1571 (2011) Standard Practice for Electromagnetic Examination of Ferromagnetic Steel Wire Rope

AMERICAN WELDING SOCIETY (AWS)

AWS D1.1/D1.1M (2015) Structural Welding Code - Steel

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 4406 (1999) Hydraulic Fluid Power - Fluids -

Method for Coding the Level of Contamination by Solid Particles - Second Edition

ISO 11171 (1999; Corrigendum 1 2001) Hydraulic Fluid Power - Calibration of Automatic Particle Counters for Liquids - First Edition

U.S. GENERAL SERVICES ADMINISTRATION (GSA)

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

1.3 SUBMITTALS

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

submittals having an "I" designation are for information only. A designation following the "G" or "I" 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

Submit the following submittals within the timeframe specified in the respective paragraphs that define the requirements of each submittal.

Initial Pre-Work Inspection Procedure ; G, HDC

Field Measurements ; G, HDC

Rehabilitation Procedure ; G, HDC

Tool Hoist Testing Plan ; G, HDC

SD-02 Shop Drawings

Submit shop drawings with Crane Design Data design package submittals under SD-05 Design Data.

SD-03 Product Data

Submit product data with Crane Design Data design package submittals under SD-05 Design Data.

Lubricants ; G, HDC Submit 30 days prior to initial inspection.

Shaft Couplings ; G, HDC

Desiccant Breathers ; G, HDC

Gantry Reducer Bearings ; G, HDC

Tool Hoist Product Information ; G, HDC

SD-05 Design Data

Submit the following submittals within the timeframe specified in the respective paragraphs that define the requirements of each submittal.

Crane Design Data ; G, HDC

Bolt Tension Chart ; G, HDC

Design Package Submittals ; G, HDC

Cantilever Jib Analysis ; G, HDC

Tool Hoist Design Data ; G, HDC

SD-06 Test Reports

Wire Rope Magnetic Flux Leakage Test Results (prior to installation) ; G, HDC

Tool Hoist Test Report ; G, HDC

Speed Reducer Pre-Work Inspection Report ; G, HDC

Open Gear Pre-Work Inspection Report ; G, HDC

Hoist Machinery Bolt Torque Pre-Work Inspection Report ; G, HDC

Hoist Machinery Bearings Pre-Work Inspection Report ; G, HDC

In-Service Speed Reducer Oil Test Report ; G, HDC

Shaft Alignment Report ; G, HDC

Balance Quality Report ; G, HDC

Dynamic Balancing Report ; G, HDC

SD-07 Certificates

Wire Rope Certificates ; G, HDC

Registered Professional Mechanical Engineer ; G, HDC

Registered Professional Structural Engineer ; G, HDC

SD-11 Closeout Submittals

Final Approved Versions of Contractor Prepared Drawings ; G, HDC

Final Calculations ; G, HDC

1.4 DESIGN CRITERIA

1.4.1 General

Perform all rehabilitation work as specified and shown.

If there are conflicts between design criteria listed here and listed in referenced documents, the most conservative approaches govern.

1.4.2 Data, Capacities, Speeds, and Travel

Data, capacities, travel distances, and rated speeds of the crane are as per Section 41 01 20.16 26 CRANE DATA, SPARE PARTS, TESTING, AND TRAINING.

1.4.3 Design

The contract drawings indicate the general arrangement and outline of the gantry and other pertinent features. Furnish the detailed design in conformity with the design criteria and other requirements specified herein. Submit design calculations and detailed shop drawings as per the requirements in Paragraph "Submission of Crane Design Data" and in accordance with the requirements of Section 01 33 00 SUBMITTAL PROCEDURES.

1.4.4 Loading

1.4.4.1 General

Base the design loads and speeds on the rated capacities specified in Section 41 01 20.16 26 CRANE DATA, SPARE PARTS, TESTING, AND TRAINING.

For the purpose of design of structural and mechanical parts, loads resulting from the maximum torque of the motors are defined as 200 percent of the rated full-load torque of the motor.

1.4.5 Unit Stresses

1.4.5.1 Structural Components

Allowable stresses in structural parts (except bolts and welds) for new or modified structural components are defined as the lesser of 45% of the yield or 75% of AISC 325 allowable stresses for ASTM A36/A36M, ASTM A992/A992M or ASTM A572/A572M grade 50 steel. Allowable stresses in structural parts not carrying primary loads must be designed to 100% of AISC 325 allowable stresses.

1.4.5.2 Bolts

Allowable stresses in bolts must be no more than 75% of AISC 325 allowable stresses. Allowable stresses in structural bolts not connecting members carrying primary loads must be designed to 100% of AISC 325 allowable stresses.

1.4.5.3 Welds

Design welded joints in accordance with the applicable provisions of AWS D1.1/D1.1M , except that allowable stresses in welds must be no more than 75% of AISC 325 allowable stresses. For designs where fatigue must be considered, allowable stresses must be the lesser of 75% of AISC 325 allowable stresses or the allowable stresses based on fatigue design provisions. Allowable stresses in welds not connecting members carrying primary loads must be designed to no more than 100% of AISC 325 allowable stresses.

1.4.5.4 Detailing Requirements

The detailing of structural components and connections must conform to the requirements of AISC 325 .

1.4.5.5 Mechanical Parts of the Crane

Design new or modified mechanical parts of the crane for rated load, with a factor of safety of 5 based on the ultimate strength of the materials, provided that each part or component, excluding wire rope, must be proportioned to withstand the stresses produced by the maximum torque of the motors with resultant stresses not exceeding 75 percent of the yield point of the materials involved.

1.4.5.6 Fatigue Design

Fatigue design must be addressed for conditions resulting in high numbers of load cycles inclusive excessive vibration. Use stress concentration factors where applicable. Reduce allowable stresses to compensate for repeated cycles of loading as necessary. For ancillary features, provide bracing and support such that excessive vibration does not occur during normal crane usage.

1.4.5.7 Wire Rope Stresses

For hoisting ropes, the maximum stress resulting from the rated load must be used and must take into consideration the overall efficiency of the hoist tackle in the blocks, wire rope fittings/connections/sockets, and other parts. The stresses must not be greater than 1/5 the nominal breaking strength of the rope. In addition, the rope tension resulting from the maximum torque of the motor selected must not exceed 0.7 of the nominal breaking strength of the rope.

1.4.6 Use of Cast Iron

Cast iron of a class less than 30 must not be used for any parts of the crane except for counterweights. Cast iron of class 30 or higher may be used for gear cases. Brake shoes and brake wheels must conform to materials specified in Section 41 01 20.18 26 GANTRY CRANE ELECTRICAL

REHABILITATION.

1.4.7 Connections

1.4.7.1 Shop and Field Connections

Accomplish all connections by either welding or bolting. Riveted connections are not permitted. For connections fabricated complete in the shop, design welded connections at all locations practicable. For connections which must be completed in the field, provide bolted connections. Field welding will not be accepted without written approval from the KO, with the exception of field welding required to install new shear blocks as shown and specified. Avoid combining welds and bolts in the same connection. When bolts are used in combination with welds, bolts should not be considered as sharing loads in combination with the welds and the welds should be designed to carry the entire load. Connections that are welded to one member and bolted to another are permitted.

1.4.7.2 Welded Connections

Design welded connections in accordance with the applicable provisions of AWS D1.1/D1.1M , except that allowable unit stresses in paragraph "Unit Stresses" apply.

1.4.7.3 Bolted Connections

Design of bolted connections in accordance with Section 05 05 23.17 26

STEEL WELDING AND FABRICATION, 05 50 04.00 26 METALS: MATERIALS, PRODUCTS,

AND MISCELLANEOUS ITEMS and as follows:

a. Machine bolts or fitted bolts must be used for assembly connections on machine parts, frames, attaching machine parts, and similar items.

b. Utilize structural bolts as defined in section 05 50 04.00 26 METALS: MATERIALS, PRODUCTS, AND MISCELLANEOUS ITEMS for structural bolted connections carrying primary loads, guardrails, gates, and similar structural items.

c. For all bolted connections, provide installation (torque) requirements in the design documents and on the shop drawings.

d. Coupling bolted joints must be assembled per manufacturer's instructions with manufacturer-supplied or recommended hardware.

1.5 SUBMISSION OF CRANE DESIGN DATA

1.5.1 General

Submit Crane Design Data . Crane Design Data must be approved prior to procurement of associated materials and equipment. Crane Design Data must be submitted for each major crane component or system of components and must include the following items which are described in the following sub-paragraphs of same title:

a. Drawing Index

b. Bill of Materials/Schedule of Equipment

c. Drawings

d. Product Data

e. Design Calculations

Crane Design Data for a complete crane rehabilitation must be submitted in a logical order with the major components submitted first and the lesser components submitted afterwards. Examples of Crane Components or Systems include, but are not limited to those listed below:

1. Tugger Hoists

2. Tool Hoists on Wall Mounted Jib Booms with Winches

3. Shear Blocks

4. Storm Brakes

5. Wire Rope

6. Speed Reducer Breather Installation

7. Lubricants, Flushing, and Lubrication

8. Gantry Drive Rehabilitation (Including Storm Brakes)

All submittals for Crane Design Data must be uniquely categorized into Design Package Submittals and must be named based off the Crane Components or Systems. For example: "Crane Design Data - Tugger Hoists". A list of proposed design package submittals with schedule of submittal dates must be submitted no later than 30 calendar days after receipt of notice to proceed.

All mechanical computations and drawings submitted as part of the Crane Design Data must be stamped and signed by a registered professional mechanical engineer who has done the design himself/herself or supervised and reviewed work if done by other engineers.

All structural computations and drawings submitted as part of the Crane Design Data must be stamped and signed by a registered professional structural engineer who is either licensed as a structural engineer and who has done the design himself/herself or supervised and reviewed work if done by other engineers.

Crane design data must be submitted no later than 90 calendar days prior to the 'crane taken out of service date' specified in FAR Clause 52.211-10.

1.5.1.1 Drawing Index

Submit an index for each drawing set submitted. The index must be part of the accompanying drawing set, having a title block, border, and sheet number compatible with the drawing set.

1.5.1.2 Bill of Materials/Schedule of Equipment

Bill of materials or parts lists must be included on the drawings, consisting of descriptive name (e.g. "new main hoist machinery base"), total quantity, manufacturer, part number, material type, size, and weight of item or equipment; or bill of materials must be drawings that are part of the drawing set, having a title block, border, and sheet number compatible with the drawing set. Bill of materials must provide a cross reference between manufacturer data and shop drawings.

1.5.1.3 Drawings

Submit design drawings for a complete crane rehabilitation for each major system and/or component for each crane as a whole. Drawings must be easily readable in half size format. Weights of items must be included on the drawings. Show assembly views and all details required for a complete crane rehabilitation, including but not being limited to layout and installation of all machinery. Each drawings which labels components with numbers from a Bill of Materials on a separate drawing must have a note referencing the drawing number of that Bill of Materials. Drawings must include detailed locations of all drilling required in structural members. Provide detailed drawings of any replaced components. Label components with descriptive names (e.g. "Auxiliary Trolley Tool Hoist Reinforcement"). Reference drawings used in the development of the Contractor prepared drawings must be noted on the drawing by listing the FIOResource drawing sheet number, file number, the manufacturer's drawing number, and reference drawing title. The use of reference drawings in lieu of providing new drawings will not be acceptable.

1.5.1.3.1 Detailed Shop Drawings

Detailed shop drawings must be submitted for approval prior to fabrication of all components. Drawings for individual components must reference an assembly drawing of the entire crane which shows clearances where pertinent. Each component must be labeled with an appropriate descriptive name (e.g. "Main Hoist Gear-Side Drum Bearing Stand"). When detailed drawings are submitted, they must be submitted with arrangement drawings and bill of materials/parts lists. Detail drawings for metalwork and machine work must include catalog cuts, templates, fabrication and assembly details and type, grade and class of material as appropriate.

1.5.1.4 Product Data

1.5.1.4.1 General

Submit complete descriptive literature and specifications of each product

SECTION 41 01 20.17 26

or system of products provided for a complete crane rehabilitation, (including but not being limited to the items listed in the submittal article). Product data literature must include legible manufacturer's cut sheets and data sheets to clearly indicate physical construction, operation, mechanical and structural characteristics and associated hardware, as applicable. For sheets with extraneous data, clearly indicate which data applies, such as by crossing out non-applicable models and circling the correct options. Include manufacturer's catalog numbers and designations, and clearly cross-reference with shop drawings as appropriate. Product data submitted for approval must clearly show conformance with these specifications, including, but not being limited to product manufacturers' declarations of conformance to applicable technical standards. Product data will be used for supporting approval of components shown or listed on the drawings. Approval of items for which product data is submitted will be by approving the design package submittal, including the relevant calculations together with relevant drawings and product data.

1.5.1.4.2 Type of Equipment and Quality

Materials and equipment must be of the type normally furnished for crane applications and service and must be the standard, unmodified, products of manufacturers specializing in the production of this type of equipment as evidenced by the existence of previously published catalog data.

Equipment and materials for the same, similar, or allied services must be of the same manufacturer and type, and when of the same rating, must be interchangeable. Materials and equipment must be new and unused.

Defective equipment or equipment damaged in the course of installation must be replaced or repaired as approved by the Contracting Officer (KO).

1.5.1.5 Design Calculations

Design calculations for new, replaced, and modified mechanical and structural components must be submitted for approval. Design calculations for new/replaced/modified components (or system of components) must be submitted concurrently with the drawings and product data specific to the designed component (or system of components). Calculations must include an introductory narrative paragraph describing the methodology for the analysis including the failure theories used and/or the codes and standards referenced, a list of assumptions made, equations, specified efficiencies, limits, factors of safety, component ratings, sources of values used, free body diagrams, or sketches of each load case.

Calculations must show that the rehabilitated crane meets the capacities and speeds as listed in Section 41 01 20.16 26 GANTRY CRANE DATA, SPARE

PARTS, TESTING, AND TRAINING.

1.5.1.5.1 Finite Element Analysis (FEA)

When FEA data is submitted, it must be submitted in addition to, not instead of, the design calculations defined in the previous paragraph.

Present FEA in report format. FEA report must include clear indication of all load scenarios, visual and narrative description of load location and application, boundary conditions / fixtures, global mesh attributes, detailed mesh attributes where mesh refinement is required, reasoning for mesh refinement, verification that actual material is consistent with material used in the model, narrative explanation of any peak stresses noted, and narrative explanation of any peak deflections noted. Submit electronic files for any FEA performed (in the FEA software file type).

Accompany any FEA data submitted with sample written calculations that support the FEA analysis.

1.6 FINAL APPROVED VERSIONS OF CONTRACTOR PREPARED DRAWINGS AND FINAL

CALCULATIONS

1.6.1 Final Approved Versions of Contractor Prepared Drawings

Final Approved Versions of Contractor Prepared Drawings for the Intake Gantry Crane must be submitted. Final approved versions of Contractor prepared drawings must be submitted in accordance with Section 01 78 00.00 28 CLOSEOUT SUBMITTALS. Contractor prepared drawings must be updated if there are any outstanding comments. Modifications to approved Contractor prepared drawings made during fabrication and installation must be immediately recorded for inclusion into final versions of Contractor prepared drawings. A set of 11 by 17 inch final approved versions of Contractor prepared drawings must be inserted in the Operation and Maintenance Manuals, see Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA for requirements on the O&M manuals.

1.6.2 Final Calculations

Final Calculations must be submitted and approved prior to start of acceptance testing. All design calculations must be assembled with a table of contents and submitted for review to verify that all calculations have been assembled and to verify that they have incorporated all outstanding comments and changes to the design. When final calculations are submitted, each section must include reference to submittals where that section was approved with a "B" code or better. They must be called "Final Calculations." Upon approval of the final calculations, they must be inserted as a separate section in the Operation and Maintenance Manuals, see Section 01 78 23.00 28 OPERATION AND MAINTENANCE DATA for requirements on the O&M manuals. Submit one electronic copy, in the form of a bookmarked, page-numbered PDF on a marked DVD.

1.7 FIELD MEASUREMENTS

Field verify all elevations, dimensions, deck clearances and coordinates of existing features indicated on the contract drawings that affect the specified work. Before performing any design work, Contractor must become familiar with all details of the work, verify all dimensions in the field, and submit a letter describing the results of this verification including discrepancies to the KO. See contract drawings for identification of crane clearances, deck clearances, and dimensions to field measure (list of dimensions and clearances to field verify is not all inclusive).

1.8 REHABILITATION PROCEDURE

Submit a complete rehabilitation procedure for all work done on this job for approval before any work will be allowed to start. The procedure must include, but not be limited to the following:

a. Step-by-step rehabilitation procedure.

b. Schedule and sequence of work.

c. Types of equipment used on site, such as work platforms, cranes, and scissor lifts, for example.

d. Methods of removing and reinstalling components, including but not limited to main hoist drums and trolleys, if applicable.

e. Work area restrictions.

All components that can be fabricated and/or assembled prior to removing the crane from service must be furnished prior to the commencement of on-site work.

See Section 01 35 29.10 28 GOVERNMENT SAFETY PROCEDURES for the requirements on safety precautions during the rehabilitation.

PART 2 PRODUCTS

2.1 LUBRICANTS

2.1.1 General

For new and existing equipment, lubrication must be provided for gear trains and gear- or grid-type couplings, and other mechanical operating parts. The Government will provide lubricating oil for the existing speed reducers as detailed in paragraph 2.1.3 SPEED REDUCERS. Submit product data for approval for all lubricants to be replaced on the crane that are not provided by the Government. At a minimum, submit product data for lubrication for the following equipment:

- wire rope, for tool hoists, auxiliary hoists, and actuating hoist

- all gantry drive open gears

- all hoist open gears

- all replaced couplings

Lubricants must be acceptable to equipment manufacturers and must be compatible with lubricants already in use on the crane.

2.1.2 Gear Grease

Grease lubrication must be provided for all open gears.

For hoist open gears, trolley and gantry drive gears, lubricants must be compatible with what is currently used at the Project unless otherwise specified. The Project currently uses high film strength Chevron open gear grease.

2.1.3 New Lubricating Oil

New speed reducer lubricating oil will be provided by the Government for use by the Contractor to fill the speed reducers once inspection and flushing have been completed. Existing lubrication oil for the speed reducer is Chevron Meropa EP 150 gear oil.

2.1.4 New Grease

a. General purpose grease must be NLGI No. 2 high temperature Lithium complex type meeting the highest performance categories of ASTM D 4950 Automotive Grease Classification System, GC-LB. The grease must provide extreme pressure (EP) performance and be rated for high Timken O.K. load of 70 pounds minimum per ASTM D 2509 . The mineral oil viscosity must be 400 cSt at 40 degrees C and 24.3 cSt at 100 degrees C. The general purpose grease must be proven through thorough grease compatibility testing submitted for approval to be compatible with what is currently in use, unless otherwise approved by the COR.

b. Gear- or grid type couplings must use grease that is highly resistant to separation, with high viscosity and low bleed rates.

Minimum specifications include viscosity of 715 cSt at 40 degrees C and 38 cSt at 100 degrees C, NLGI Grade as recommended by coupling manufacturer, Timken extreme pressure (EP) O.K. Load of 40 pounds per ASTM D 2509 . Centrifugal separation must be K36s 2/24 maximum per ASTM D 4425 . Existing couplings must be cleaned of old grease before packing with new.