AMEND 2 SPECIFICATIONS DOCUMENT - 2019452564 KNB MARINE CONSTR.pdf

Marine Construction and Repairs, KNB, Kuwait 2019452564

SECTION TABLE OF CONTENTS

DIVISION 01 - GENERAL REQUIREMENTS

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SUMMARY OF WORK REVISED BY AMENDMENT NO. 0002

PART 1 GENERAL

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SECTION 01 11 00

SUMMARY OF WORK

REVISED BY AMENDMENT NO. 0002

PART 1 GENERAL

1.1 GENERAL PROJECT DESCRIPTION

This project involves various inspections, construction, repairs, upgrades, and certifications to the ship lift and rail transfer yard at Kuwait Naval Base (KNB). The ship lift coordinates with the rail transfer yard to provide a means to safely transport vessels from the water to locations throughout the drydock areas. In this manner, the components function as a fully-integrated system, where the ship lift moves a vessel vertically, and a tow vehicle moves a vessel horizontally as needed to transport it throughout the drydock area. The scope of the project includes upgrades and repairs to the entire system, including but not limited to the following primary elements: ship lift structure, ship lift piers, rail transfer yard, drydock areas, transfer carriages, boat carriages and cradles, transportation equipment, and associated utility systems.

1.2 Existing Ship Lift and Adjacent Piers

The existing ship lift is a steel structure with wooden decking and a 4-rail section extending the length of the deck. It is situated between adjacent concrete piers, where the ship lift hoists and capstans are located. The hoists raise and lower the ship lift structure via a series of capstans, sheaves, and cables. The concrete piers on either side of the ship lift have steel structures, catwalks, and railings beneath the pier surface to allow access for operations and maintenance. The depth of the harbor area directly below the ship lift is designed to be coordinated with the ship lift to allow for complete lowering at design conditions and while moving the design vessel.

The ship lift is raised or lowered with (18) hoists, each rated for a capacity of 244 tons.

1.3 Eastern Dry Dock

The eastern dry dock includes six (6) 2-rail sections installed in concrete foundations for ship storage and maintenance. There also is a single 4-rail section installed in concrete foundations at the southern end of the eastern dry dock. This 4-rail section aligns with that of the ship lift deck and serves to transition the rail system from the ship lift to the transfer yard.

1.4 Western Dry Dock

The western dry dock includes six (6) 4-rail sections installed in concrete foundations, including two that extend inside and the length of an existing maintenance hangar, three immediately to the south of the maintenance hangar, and one that is longer and located at the southern end of the current dry dock. There is also a single rail installed in concrete foundations along the maintenance hangar door that allows the door to travel. Part of this project includes an expansion of this western dry

SECTION 01 11 00 Page 2 dock towards the south in order to install another (seventh) 4-rail section to provide additional space for vessel maintenance and storage.

1.5 Transfer Yard and Transfer Carriages

The transfer yard is located between the eastern and western dry docks and serves to move vessels horizontally in the north-south direction; whereas, the dry dock rails move vessels horizontally in the east-west direction.

The transfer yard has a surface elevation that is lower than the adjacent dry dock areas to allow for steel-framed and wooden-decked transfer carriages to traverse it while carrying vessels along the length of the transfer yard.

The transfer yard has a series of rails installed in concrete foundations that are oriented perpendicular to the rails in the drydock areas. The transfer carriages have wheels located to coordinate with the transfer yard rails, but they also contain a 4-rail line along the length of the carriages (parallel to the dry dock rails) installed at the level of the wooden deck.

There are two transfer carriages (primary and secondary). The primary transfer carriage extends the entire length of the transfer yard and currently utilizes a layout with seventeen (17) rails the length of the transfer yard. The secondary transfer carriage is located only at the southern end of the transfer yard, where it becomes wider along the western side. It currently utilizes a layout with eight (8) rails. As part of the proposed western dry dock expansion, the entire transfer yard must be extended towards the south a coordinating distance.

The transfer carriages are constructed of a steel frame and wooden decking and a 4-rail line extending the length of each carriage. Elevation, rail spacing, etc. must be coordinated to accommodate seamless and safe vessel movement from one drydock to another. Furthermore, the transfer yard surface must accommodate movement of the tow vehicle that pushes or pulls the transfer carriage along its length (i.e., the tow vehicle must be able to maneuver and traverse the transfer yard as required). At the same time, the transfer carriages must accommodate the same tow vehicle to push or pull vessels across the length of the transfer carriage.

1.6 Boat Cradles

The existing transfer equipment system uses several types and sizes of boat cradles (wheeled assemblies which support vessels during transfer). There are three basic typical types of boat cradles, labelled as types 107B, 107C, and 107D on existing as-built drawings dated 2-11-94 and labelled DRG. NO. CW/RR/SL-2250-107B, CW/RR/SL-2250-107C, and CW/RR/SL-2250-107D.

These drawings are included as Appendix A.

1.7 Tow Vehicle

There is an existing tow vehicle that connects to the transfer carriages or boat cradles via a specially designed head connector that is coordinated with the other system components. The tow vehicle and all components must support a minimum towing capacity of 40 tons.

1.8 Utility Systems

There are existing utility systems that extend underground and provide water, compressed air, and electrical power in various underground utility boxes throughout the drydock areas. Systems have varying levels of

SECTION 01 11 00 Page 3 functionality, with deterioration and damage anticipated at the utility boxes, within the distribution network within the drydock areas, and within the service network outside of the drydock areas. As-built drawings is provided as Appendix B.

PART 2 SCOPE

2.1 Project Scope

The scope of work items listed in this section are intended to convey the general nature of the various elements of work to be performed. This section is not intended to provide an exhaustive listing of all work to be performed or all technical specifications. The Technical Requirements section (01 80 00.12 10) must be consulted for more detailed technical requirements and information.

2.2 Existing Ship Lift and Adjacent Piers

2.2.1 Ship Lift Steel Structure

The existing ship lift steel structure will require disconnection and removal in order to perform the following repair items: full cleaning and surface preparation, detailed structural inspection and report, and structural steel coatings. The structural steel inspection report must detail the lifting capacity of the system and all required repairs to achieve a capacity of no less than 3488 tons. The structural steel inspection report must be submitted in a timeframe to allow the Government a review and approval period of no less than sixty (60) calendar days without impact to the project schedule.

In addition to the ship lift structure, the steel pilings and structure for the adjacent concrete piers must be cleaned, prepared, and recoated.

2.2.2 Ship Lift Lower Sheave Housings

All of the lower sheave housings must be replaced with a cartridge-type unit that will allow for future maintenance and replacement without the need to completely remove the ship lift structure.

2.2.3 Ship Lift Rails and Wood Planks

All of the rail lines and attachments, including anchor bolts, clips, nuts, etc., on the ship lift must be replaced entirely. Sizes, layout, and orientation must match existing and coordinate with all other components of the ship lift and transfer yard system.

All wood decking and fasteners must be replaced. Size, thickness, layout, and orientation of pieces must match existing and coordinate with all other components of the ship lift system.

2.2.4 Ship Lift Pier Catwalk and Railings

The catwalks, fall protection railings, and ladders under the ship lift piers must be removed and replaced entirely. Walk surface, handrail, and ladder materials shall be constructed and/or protected to provide the same estimated life expectancy as required for all other elements of the design.

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2.2.5 Ship Lift Bottom Dredging

While the ship lift steel structure is removed, the harbor immediately beneath the ship lift must be surveyed and dredged as required to provide full vertical movement of the ship lift structure. The area shall be over-dredged by a minimum of 1m, and a final, post-dredge bathymetric survey of the immediate area of the ship lift must be provided by the Contractor to verify compliance.

The Contractor shall assume that the volume of dredged material required (including over-dredge) will be no more than one (1) m of depth for the entire area of the ship lift.

The Contractor shall perform a bathymetric in-survey prior to any dredging work and shall provide an acceptable report to the Government to verify the total dredging requirement. The Contractor shall provide for no less than twenty-eight (28) days for the Government to review the bathymetric in-survey report prior to mobilization of any equipment to perform dredging operations.

2.2.6 Ship Lift Hoist Housings

All of the ship lift hoist housings, located on the concrete piers adjacent to the ship lift, must be cleaned, treated, and coated. This requirement applies to the concrete foundations and the steel housings.

2.2.7 Capstans

The four (4) existing capstans are to be replaced with new equipment to match the existing functionality. In addition, two (2) new capstans are to be installed in locations identified to match the other new ones. All accessories including control stations, cable guide assemblies, and cleats must be replaced and/or added to provide fully functioning systems. The Contractor also must procure and install 500 m of ¾" diameter ship towing rope and install it on the new capstans at the direction of the Contracting Officer's Representative.

2.2.8 Miscellaneous Ship Lift Repairs

The following other miscellaneous repairs are to be made to the ship lift, adjacent concrete piers, and/or adjacent concrete spider crane quay wall.

2.2.8.1 Concrete Pier Repairs

The Contractor is to patch all damaged or spalled areas of concrete beam, decking, or other structural member within the piers adjacent to the ship lift.

2.2.8.2 Infill Concrete Pier Face Recesses

The Contractor is to prepare and infill with concrete all of the recesses in the concrete pier faces at the piers adjacent to the ship lift.

2.2.8.3 Spider Crane Quay Wall Repairs

The Contractor is to prepare and patch all damaged or spalled areas of concrete along the spider crane quay wall to the north of the ship lift area.

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2.2.8.4 Replace Chain Rails

The Contractor is to remove and replace in kind all chain rails and stanchions located on the ship lift or adjacent piers.

2.2.8.5 Cleats

The Contractor is to remove and replace in kind all cleats on the ship lift or adjacent piers. Furthermore, the Contractor is to furnish and install four (4) additional cleats in locations noted in the contract documents or as directed by the Government.

2.2.8.6 Manholes

The Contractor is to remove and replace in kind all manholes and frames located in the piers adjacent to the ship lift.

2.3 Eastern Dry Dock Repairs

All of the rail lines and attachments (including anchor bolts and clips), bituminous filler material around rails, shims, etc. must be removed entirely to expose concrete foundations. New rails and attachment hardware must be installed. Sizes, layout, and orientation must match existing and coordinate with all other components of the ship lift and transfer yard system.

Existing bituminous filler material installed within the concrete recesses and around the existing rails is not to be replaced. Instead, the concrete recesses are to be left clean after installation of the new rail systems, and the Contractor is to design and install moveable steel crossing surfaces that fit over the concrete recesses and provide a surface across which vehicles may travel at locations where shown in the Technical Requirements. Furthermore, the tow vehicle and head connector towing bar wheel bases must be designed to avoid conflict with or riding on railings and/or concrete recesses.

North-south oriented sections of rail on the east side of the Eastern Dry Dock, adjacent to the ship lift, are to be removed and the recesses filled with concrete. Furthermore, the concrete surface in that area is to be surveyed and leveled as required to provide a continuous, smooth surface and allow for proper drainage.

2.4 Western Dry Dock Repairs

All of the rail lines and attachments (including anchor bolts and clips), bituminous filler material around rails, shims, etc. must be removed entirely to expose concrete foundations. Sizes, layout, and orientation must match existing and coordinate with all other components of the ship lift and transfer yard system.

Existing bituminous filler material installed within the concrete recesses and around the existing rails is not to be replaced. Instead, the concrete recesses are to be left clean after installation of the new rail systems, and the Contractor is to design and install moveable steel crossing surfaces that fit over the concrete recesses and provide a surface across which vehicles may travel at locations where shown in the Technical Requirements. Furthermore, the tow vehicle and head connector towing bar wheel bases must be designed to avoid conflict with or riding on railings and/or concrete recesses.

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The rail system supporting the door for the maintenance hangar within the Western Dry Dock also must be replaced.

2.5 Western Dry Dock Expansion

The work at the Western Dry Dock includes optional expansion of the Western Dry Dock towards the south, and all incidental or related work required to complete this, in order to provide one additional set of four (4) rails as shown.

2.6 Transfer Yard and Transfer Carriages

2.6.1 Transfer Yard Repairs

All of the rail lines and attachments (including anchor bolts and clips), bituminous filler material around rails, shims, etc. must be removed entirely to expose concrete foundations. Sizes, layout, and orientation must match existing and coordinate with all other components of the ship lift and transfer yard system.

All miscellaneous vegetation and debris shall be removed, and the areas between rails shall be graded to drain away from the rails and foundations. The Contractor also shall propose and install a solution to collect and dispose of excess stormwater within the transfer pit, particularly at the north end of the pit.

All areas of concrete retaining wall around the transfer pit shall be inspected and repaired as required. The Contractor shall include an assumed quantity of 4.0 square meters (0.4 cubic meters) of repair.

Steel armor plates at the pit walls, where drydock areas transition to the transfer pit, are to be installed to protect the edge of concrete at all areas where they are not currently installed.

2.6.2 Transfer Carriages

The Contractor is to design, furnish, and fabricate new primary and secondary transfer carriage structures to match the existing and coordinate with the new installation. The transfer carriages are to be wheeled steel structures with wooden plank decks and a set of four (4) rails. Transfer carriage design (size, orientation, height, structural capacity, etc.) must be designed to coordinate as an integral component of the ship lift and transfer yard system.

The transfer carriage structures and driving surfaces must include reinforced travel paths to support the tow vehicle to avoid damage to the carriage structure or decking from routine use.

2.7 Transfer Yard Expansion

The work at the Transfer Yard includes expansion of the Transfer Yard towards the south as required to accommodate the optional expansion of the Western Dry Dock.

2.8 Boat Cradles

The Contractor shall design, furnish, and fabricate new boat cradles of the quantities and types as noted below. Basis of design for items are as

SECTION 01 11 00 Page 7 noted on as-built drawings dated 2-11-94 and labelled DRG. NO.

CW/RR/SL-2250-107B, CW/RR/SL-2250-107C, and CW/RR/SL-2250-107D. As-built drawings are provided in Appendix A. Provide the following quantities:

DRG. NO. CW/RR/SL-2250-107B:

Keel Block Cradle - (200) Keel Block Cradle Connector (detail 6A) - (205) Bilge Block Cradle Connector (detail 6B) - (55) Main Connectors - (2)

DRG. NO. CW/RR/SL-2250-107C:

Bilge Block Cradle - (50)

DRG. NO. CW/RR/SL-2250-107D:

50 Ton Capacity Small Craft Cradle - (30)

2.9 Tow Vehicle

The Contractor shall procure a tow vehicle designed to coordinate with and serve as an integral member of the ship lift and rail transfer yard system. The tow vehicle shall conform to all aspects of the Technical Requirements including but not limited to a towing capacity of no less than 40 tons and available service through a local vendor within Kuwait. The Contractor shall coordinate the tow vehicle to operate with the other components of the ship lift and rail transfer yard system, including but not limited to the primary and secondary transfer carriages, boat cradles, and tow bars. The system shall be designed so the tow vehicle wheels must not travel along rails (including transfer carriage rails) or foundation recesses for rails. However, tow vehicle wheels may have to cross rails or recesses perpendicularly at locations.

2.10 Utility Systems

Utility systems (water, compressed air, and electrical power) shall be replaced entirely within the project limits and as designated within the Technical Requirements. New installations shall be in kind, with same size, capacity, orientation, etc. except as may be required by other directives within the Technical Requirements. The limit of new utility installation will be tie-in to existing systems where noted in the Technical Requirements.

New utility systems are to be provided to areas where shown in the Technical Requirements including but not limited to new capstans and in support of the proposed Western Dry Dock and Transfer Yard expansion.

2.11 Third Party International Certification

The End User previously maintained a Certificate of Inspection and Load Testing for the ship lift through Lloyd's Register (LR). Upon acceptance of the work, the Contractor shall provide a valid Certificate of Inspection and Load Testing from a certified classification society firm. The Certificate shall be valid for no less than one year from the date of acceptance by the Government. The Certificate shall be issued on behalf of the End User so that the End User may assume responsibility for re-certification.

The Certificate shall cover all portions of the ship lift, drydock areas, and transfer yard, as well as all transfer carriages, boat cradles, and towing appliances. All inspections and certifications shall be performed

SECTION 01 11 00 Page 8 in accordance with the most relevant rules or codes published by the classification society, most current edition(s) at time of contract award.

All work, inspections, and certifications shall be performed or provided in such a way as to provide a system-wide capacity of no less than 3488 tons.

The End User previously maintained a Certificate of Inspection and Load Testing for the ship lift through Lloyd's Register (LR). Upon acceptance of the work, the Contractor shall provide a valid Certificate of Inspection and Load Testing from LR. The Certificate shall be valid for no less than one year from the date of acceptance by the Government. The Certificate shall be issued on behalf of the End User so that the End User may assume responsibility for re-certification.

The Certificate provided by LR shall cover all portions of the ship lift, drydock areas, and transfer yard, as well as all transfer carriages, boat cradles, and towing appliances. All inspections and certifications shall be performed in accordance with LR Code for Lifting Appliances in a Marine Environment, most current edition at time of contract award. All work, inspections, and certifications shall be performed or provided in such a way as to provide a system-wide capacity of no less than 3488 tons.

2.12 Miscellaneous Equipment and Spare Parts

The Contractor shall furnish one Pressure Washer Machine and one Air Compressor as per specifications in the Technical Requirements.

The Contractor shall furnish all spare parts in new and un-used condition as specified in the Technical Requirements. Spare parts include but may not be limited to the following:

a. 600 hard wood blocks with dimensions 120cm x 30cm x 30cm.

b. 5,000 soft wood blocks with dimensions 120cm x 30cm x 10cm.

c. 20% (of each size) spare wooden planks or blocks for the primary and secondary transfer carriages, including required fasteners.

d. 20% (of each size) spare wooden planks or blocks for the Ship Lift platform, including required fasteners.

e. 20% (of each size/item) spare wheels, clamps, bolts, nuts, and consumable items for the primary and secondary transfer carriages.

f. 10% spare parts for all rails (spare rail material for 10% of the total length installed).

g. 20% spare parts for all rail accessory and attachment items.

h. A two-year supply of all spare parts required for the end user to fully perform regularly-scheduled maintenance for all mechanical items.

PART 3 - EXECUTION

3.1 CONTRACTOR'S INSPECTIONS

Prior to beginning work, the contractor is required to inspect and assess the condition of all items to remain, noting any instances where the scope of the project as stated is in disagreement with the assessment, if applicable. If the survey indicates any issues with the condition (such as distress, deterioration, or disrepair) of any system element requiring work beyond the scope of the project as detailed in the Contract Documents, then the Contractor must notify the Contracting Officer prior to proceeding with the work.

After work is completed, a final inspection and third party certification is required to demonstrate that new rail lines, systems, and equipment have

SECTION 01 11 00 Page 9 been installed properly and can acceptably accommodate movement of the design vessel throughout the facility.

3.2 PHASING AND CONSTRAINTS

The users of this facility have a requirement that the project be phased such that operations may continue during construction to the greatest degree possible. For instance, the dry dock area construction should be performed while the transfer pit remains in operation, if at all possible). As part of their construction schedule, the Contractor must provide a phasing plan which clearly indicates which areas will be out of service at which times. The phasing plan is subject to reviewby and coordination with the End User.

ATTACHMENTS

APPENDIX A -- AS-BUILT DRAWINGS

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