SECTION_14_6400_BRIDGE_CRANES.docx

PART 1 GENERAL

1.1 SECTION INCLUDES

SECTION 14 6400 BRIDGE CRANES

BRIDGE CRANES

14 6400 - 2

A. Maintenance Bay CMAA Class C bridge crane complete system including runway beams, crane rails and clips, bridge beam, end trucks, hoist, trolley and operating system.

B. Materials and labor for complete installation.

C. Sequencing and coordination of work with other disciplines.

1.2 REFERENCES

A. CMAA No. 74 - Crane Manufacturers Association of America.

B. ASME Crane Standards, B30 Series.

C. ASME HST-4-1999 (R 2010), "Performance Standard for Overhead Electric Wire Rope Hoists".

D. NEMA - National Electric Manufacturers Association.

E. NEC - National Electric Code.

F. OSHA - Occupational Safety and Health Administration.

G. HMI - Hoist Manufacturers Institute.

H. AISC - American Institute of Steel Construction.

I. AWS - American Welding Society.

1.3 SYSTEM DESCRIPTION

A. One Maintenance Bay bridge crane with the following features:

1. Double-girder, top running, bridge crane

2. Four-ton capacity; three-ton main hoist plus one-ton auxiliary hoist.

3. 57-foot-8-inch span.

4. 100 feet/minute traveling +/- speed.

5. C-track power festoon.

6. Wireless Radio Pushbutton Control with receiver.

7. Three-ton electric wire rope main hoist.

a. 16'-0" +/- available lift with variable and/or 2-Speed Motors (Low-Speed 2-3 FPM, High-Speed 15-30 FPM +/- speed lift operation)

b. Motor driven trolley with 65 feet/minute +/- speed and brake.

c. True vertical lift type hoist.

8. One-ton electric wire rope auxiliary hoist.

a. 15'-10" +/- available lift with variable and/or 2-Speed Motors (Low-Speed 2-3 FPM, High-Speed 15-30 FPM +/- speed lift operation.

b. Motor driven trolley with 65 feet/minute +/- speed and brake.

c. True vertical lift type hoist.

9. 4-bar enclosed mainline electrification for 83 foot long runway.

a. Includes: conductor bars, power feeds, mounting brackets, hangars, end caps, and connecting tool.

10. Runway beams.

a. Includes: channel cap, splice plates, end stops and attachment hardware.

b. Runway beams with varying lengths up to 30 foot spans. Runway beams supported at locations indicated on the drawings by bolting to new columns and anchored to the existing structure as shown.

B. Installation, mechanical and electrical hookup of above equipment.

1.4 DESIGN REQUIREMENTS

A. Runway beams, complete with connections to the building structural system, and any required splices shall be designed, supplied, and erected by the Contractor as shown in the drawings. Runway beam design including sizing and all connections shall be per CMAA.

B. All equipment furnished under this section shall comply in all respects with the requirements of OSHA, the standards of the Crane Manufacturers Association of America (CMAA), the Hoist Manufacturer's Institute (HMI), and Air Force Occupational Safety and Health Standards (AFOSH 91-46).

1.5 SUBMITTALS

A. Contractor shall submit an AF form 3000 along each material submittal.

B. Product Data: Provide manufacturers catalog data confirming rated capacity, equipment speeds, horsepower electrical requirements, and component sizes and dimensions.

C. Shop Drawings

1. Each submittal shall be complete in all respects, incorporating all information and data listed herein and all additional information required for evaluation of the proposed equipment's compliance with the Contract Documents. Partial, incomplete or illegible submissions will be returned to the Contractor without review for resubmission.

2. Shop drawings shall include but not be limited to:

a. Equipment specifications and data sheets identifying all materials used and methods of fabrication.

b. Complete assembly, layout and installation of drawings with clearly marked dimensions.

c. Manufacturer's installation and startup instructions.

d. Weights of all component parts, assembled weight of units and approximate total shipping weight.

e. Example equipment nameplate data sheet.

f. Interconnecting ladder-type wiring diagrams for power and control wiring required for final connections. Clearly differentiate between portions of wiring that are factory installed and portions to be field installed.

g. List of recommended spare parts.

D. Certificates: Certify that products of this section meet or exceed specified requirements. Provide factory test certificates.

E. Factory testing and inspection certificates.

F. Operation and maintenance manuals.

G. Manufacturer's instructions.

H. Installation, testing and commissioning certificates.

I. List of manufacturers and model numbers.

J. Special tools list.

K. List with a minimum of four manufacturers' standard lubricants, which may be used interchangeably for each type of lubricant required.

L. Warranty: Submit manufacturer warranty and ensure that forms have been completed in Contracting Officer's name and registered with manufacturer.

1.6 QUALITY ASSURANCE

A. Manufacturer shall be regularly engaged in the business of designing, building, and repairing bridge cranes of the type specified in this Section. All bridge crane components and appurtenances furnished for this contract shall be designed, coordinated, and supplied by a single supplier. The Contractor shall be responsible for ensuring the proper components are incorporated in the package and that the requirements of other specification sections are satisfied.

B. Products Requiring Electrical Connection: Listed and classified by UL as suitable for the purpose specified and indicated.

1.7 DELIVERY, STORAGE, AND PROTECTION

A. Units shall be packaged, shipped and stored in such a way as to prevent rust or damage.

1.8 PROJECT CONDITIONS

A. Sequence installation to ensure utility connections are achieved in an orderly and expeditious manner.

1.9 WARRANTY

A. Correct defective Work within a five year period after Date of Substantial Completion.

B. Provide one year manufacturer warranty for the complete system, including accessories and components. Each component shall be warranted by the manufacturer having unit responsibility.

1.10 EXTRA MATERIALS

A. Spare Parts and Special Tools: Spare parts and any special tools required for disassembly or maintenance shall be provided. One complete set of manufacturer's standard spare parts for each component size shall be provided. Spare parts shall be completely identified with a numerical system to facilitate parts inventory control and stocking. A separate number shall identify each part.

PART 2 PRODUCTS

2.1 MANUFACTURERS

A. Konecrane, Detroit Crane and Hoist, Columbus McKinnon Corporation, Harrington, or equal, modified to provide the specified features and to satisfy the specified operating conditions.

2.2 MATERIALS

A. Runway beams: ASTM A992 Grade 50 or ASTM A572 Grade 50.

B. Runway channel: ASTM A36 C. Crane rail: ASCE 40 D. Bridge beam: ASTM A992 Grade 50, ASTM A572 Grade 50 or ASTM A36.

E. Wire rope: Extra flexible plow steel cable for crane service.

2.3 COMPONENTS

A. Crane Bridge:

1. The crane shall be assembled and tested at the point of manufacture prior to shipment and disassembled only to the extent required to facilitate shipment and installation.

2. The rated capacity of the crane shall be the load that the crane is designed to carry as specified by the manufacturer and shown in tons on large capacity plates located on each side of the crane bridge.

3. Materials shall be free from all defects and imperfections that may affect the finished product. All parts shall be new and unused.

4. End trucks shall be fabricated from structural steel shapes and plates welded into an integral unit and in-line bored to receive the wheel axles.

5. The bridge shall be designed and fabricated as a complete integral structure with only such parts removable as required to facilitate the erection and maintenance of equipment.

6. The bridge girder shall be constructed of standard structural shapes or boxed sections, reinforced and welded as required. Connections between the girder and end trucks can be either welded or bolted after installation and squaring.

7. The end trucks shall have a minimum wheel base of 1/8 of the crane's span. Each truck will be carried on four (4) wheels running on anti-friction bearings. Wheels shall be of machined, hardened steel, single flanged compound tread wheels capable of running on ASCE 40 # rail. The end trucks will be provided with rubber bumpers at each end to engage end stops on the crane runway.

B. Bridge Drive: The crane bridge shall be driven by two drives. One located on and driving one pair of wheels on each end truck. Each drive shall consist of a drive gear reducer, a TENV, crane duty, 30-minute rated motor with class F insulation and means of braking to meet the requirements of OSHA.

C. Bridge Control Panel:

1. The bridge motion's control shall be located in a bridge-mounted NEMA 4 enclosure. The bridge control is to be provided with a mainline contactor controlled from the bridge control station and a door-mounted disconnect that turns off power to the bridge panel and drives and the hoist and trolley panel and drives before the panel door can be opened.

2. The control shall be designed and built per the National Electric Code (NEC) standards with color-coded and match-marked wires. The panel shall also meet appropriate UL standards.

D. Crane Motion Control:

1. All motions of each crane (hoists, trollies and bridge) shall be operated through a single Wireless Radio pushbutton type control. The Wireless Radio Control shall have pushbuttons for the control of each motion plus power on/off buttons:

a. Hoist - up/down.

b. Trolley - left/right.

c. Bridge - forward/reverse.

d. Power - on/off.

2. Pushbutton station shall be molded contour grip type and a wall mount for storage and changing. The enclosure is to be NEMA 12. The pushbuttons shall return to the off position when the operator releases the pressure. The magnetic contactors for all motions shall be mechanically or electrically interlocked. Control voltage at the pushbutton stations shall be grounded to the hoists.

E. Crane Bridge Electrification:

1. Power and control voltage will be provided to the moving trolley and hoist through means of a festoon flat cable system. There will be separate cables for the motor power supply (line voltage) and control and these cables will be provided with separate connecting fittings and plugs. The cable connecting fittings and plugs shall be metal, not plastic and will be of the type easily repairable or modified in the field without special tools. The power and control cables will be carried from trolleys with four (4) steel wheels running in a track suspended off the bridge girder running the full length of the crane span.

2. The bridge will be provided with a main power pick-up (collector pole) and sliding shoe collectors that will contact and run in the shielded bar runway conductor system.

F. Crane Runway System:

1. Runway beams shall be provided and attached to the building framing system as noted on the drawings. The beams shall be capped or uncapped as required to achieve maximum hook lift and to handle the crane's loading (Equivalent Center Loading, ECL) at full capacity load and closest to hook approach possible. The ends of the runway beams are to be jointed together by means of bolted splices.

2. Runway power electrification shall be provided running the full length on one side of the runway. The electrification shall be of the shielded bar type supported at proper intervals to prevent sag or excessive vibration and with power feeds located to minimize voltage drop so as to provide adequate power to operate at least the hoist and one traverse motion at the extreme ends of the runway.

G. Electric Wire Rope Hoist:

1. Wire rope hoist shall meet the requirements of ASME B30.16 "Overhead Hoists". Hoist shall be heavy duty meeting H4 Service classification as defined in ANSI/ASME HST-4M "Performance Standard for Overhead Electric Wire Rope Hoists". Hoist shall meet the following requirements:

a. Frame shall be fabricated from rolled steel to form a one-piece weldment.

b. Gear case is to be machined aluminum alloy casting with sealed construction allowing the gears and load brake to operate in a bath of oil.

c. Bearings shall be high quality anti-friction type of either needle or ball design and used throughout the hoist. Bearings not considered lifetime lubricated by the manufacturer, shall be provided with a means for lubrication.

d. Hoist shall have two types of brakes: One DC electrical multiple disc motor brake spring set electrically released, and one self-adjusting Weston type mechanical load brake located in the gear case. Either brake shall have the capability of holding rated load in the event of failure of either brake system.

e. Overload devices shall be provided to prevent lifting excessive overloads. This load-limiting device shall be pre-set at the factory to disengage the hoist motor form the gearing in event of excessive overload condition. Overload device is to be located between the motor and load brake, so that the load brake will hold the load in event of overload device failure.

f. Motors shall be of high starting torque type designed specifically for hoist duty services with permanently lubricated ball bearings, rated for 30-minute duty cycle. The motor enclosure is to be totally enclosed non-ventilated, TENV. Motor insulation shall be class F minimum. If hoist is to be two-speed, it shall have a high speed to low speed ration of 3:1. Motor is to have automatic reset temperature actuated switch (TAS) in motor windings to provide motor running over current protection.

g. Gearing shall be a combination of spur and/or helical, precision cut and heat treated to ensure quiet, efficient operation. Gears shall be totally enclosed and run in a bath of oil to provide maximum lubrication. Gears are either splined or keyed to shafts.

h. Deep grooved, large diameter rope drum that helps prevent over wrap of cable for longer rope life.

i. The diameter of the rope drum shall not be less than 18 times the diameter of hoisting cable, running sheaves not less than 16 times, and idler sheaves not less than 12 times the diameter. Hoisting cable shall be 6x37 improved plow steel.

j. Geared upper and lower limit switch shall be provided that allows the upper and lower limits to be set to accommodate the application.

k. Controls to be centralized and designed per NEC standards and housed in a panel with a hinged door. The controls are to be provided with a step-down transformer within the panel that provides 120 volts power to the control circuits. Control circuit voltage to push the button station shall not exceed 120 volts. In addition, the panel shall meet appropriate UL standards.

l. All controls, including power transformer, shall be housed in a NEMA 1 enclosure mounted in an easily accessible location on the hoist. Controls shall include trolley travel and hoist raising and lowering. Motors shall be fully enclosed 30-minute duty cycle motors in a NEMA frame rated for 208 volts, 3-phase, 60 Hz power supply.

m. Motor driven trolleys shall have heavy section rolled steel side frames. The wheels shall be steel with heat-treated tread. Motor driven trolleys shall have totally enclosed non-ventilated (TENV) motors with right angle gear reducers. Trolley wheel gears and pinions shall have machined cut gear teeth. Spacer washers shall be provided for trolley adjustments to various beam sizes.

H. Electrical:

1. Electrical Characteristics:

2. Furnish and install all wiring and controls from the wall-mounted disconnect switch.

3. The sizing and selection of electric crane motors shall be the responsibility of the crane manufacturer in order to ensure complete coordination of components and to provide unit responsibility.

4. Any reference to motor size or power requirements for the crane motors contained in the Contract Documents is preliminary and shall not be relied on by the Contractor. The Contractor shall be responsible for any changes to the electrical system that may result from final sizing and selection of the crane motors by the crane manufacturer at no additional cost to the Contracting Officer.

5. All motors shall be furnished and installed under this Section. All motors shall be of the standard efficiency totally enclosed non-ventilated squirrel cage type for 208 volts, 3-phase, 60 Hz. All motors shall be of ample size and construction to carry continuously all loads which may be imposed through their full range of operation. The maximum motor loading shall not exceed the nameplate horsepower rating, exclusive of service factor.

Motor horsepower is to be determined by the crane supplier. All motors shall operate at speeds not greater than described herein.

6. Furnish and install all motors and drives specified in this Section. The Contractor shall also furnish all necessary wiring diagrams and instructions for proper wiring of equipment.

I. Spare Parts and Special Tools: Spare parts and any special tools required for disassembly or maintenance shall be provided. One complete set of manufacturer's standard spare parts for each component size shall be provided.

2.4 SHOP FINISHING

A. Except for touchup, all painting shall be done in the shop. The top-running crane bridge beams shall be primed and finish coated in accordance with Section 09900 - Paints and Coatings.

2.5 SOURCE QUALITY CONTROL AND TESTS

A. Fabrication Tolerances: Per CMMA requirements.

B. Factory tests shall be performed by the manufacturer prior to delivery in order to verify the accuracy and performance of the systems specified. The manufacturer shall certify and provide copies of the tests and warranty the equipment's performance specified in this Section. All certifications of factory tests shall be submitted to and reviewed by the Contracting Officer before the equipment is shipped.

PART 3 EXECUTION

3.1 EXAMINATION

A.

3.2 INSTALLATION

A. The Contractor shall install the complete systems in the general arrangement and where shown on the drawings and as specified. The Contractor shall install and test each complete system and each system component in strict conformance with the manufacture's written recommendations. Installation shall be performed by mechanics skilled in work of this kind.

The equipment shall be checked, aligned, and approved for start-up by the manufacture's factory trained representatives. Each system component shall be reviewed and approved by the applicable manufacturer prior to start-up of the complete system. The manufacture having unit responsibility shall arrange and coordinate such reviews between component manufacturers and the Contractor.

3.3 ERECTION TOLERANCES

A. Erection tolerances shall meet the requirements of the manufacturer and all referenced standards.

3.4 FIELD QUALITY CONTROL

A. The Contractor shall arrange and schedule testing and commissioning with the Contracting Officer.

B. After completion of installation, the bridge crane, trolley and hoist shall be completely tested to ensure compliance with the performance requirements as specified. As a minimum, testing shall be by operating the equipment through a complete lift and lowering cycle and through a complete travel of the bridge and runway or monorail beams to determine that the equipment performs smoothly and safely without failure. Verify that the crane is electrically interlocked with the cord reels. Such tests shall be carried out with the hoisting equipment loaded at 125 percent of specified capacity. After load testing, the overload limit switch is to be reset at the rated load. Any defects shall be corrected or replaced immediately by the Contractor at no expense to the Contracting Officer. All testing and the costs of all required certification shall be at the Contractor's expense.

3.5 STARTING EQUIPMENT AND SYSTEMS

A. The Contractor shall include in the Contractor's bid all costs associated with providing the services of the Manufacturer's field representative for checking, aligning, testing placing in operation, and Contracting Officer Training.

B. The Contractor shall not use cranes or hoists to perform any of the Work for this Contract without prior written authorization by the Contracting Officer. Any use of cranes or hoists by the Contractor shall be at the Contractor's risk. Any damage done to cranes or hoists by Contractor shall be repaired by Contractor at Contractor's expense.

3.6 CLEANING

A. Clean all installed materials, equipment and related areas after final installation.

END OF SECTION