Updated Specs - BAR Spillway Gate Chains Fabrication_Amdnt 0003_24JUN24.pdf

Solicitation No. W912P5-24-B-0005

Amendment No. 0003

I. CHANGES TO TECHNICAL SPECIFICATIONS.

a. Section 35 01 41 “ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND

DAMS” Paragraph 2.2.4 “Spare Parts” has been updated.

II. CHANGES TO PLANS.

a. Drawings “Q9-M-101”, “Q9-M-102”, and “Q9-M-103”, “Bill of Materials” table has been updated.

b. Drawing Q9-M-102, Note 1 has been updated.

-- END OF AMENDMENT NO. 0003 TECHNICAL CHANGES --

Spillway Gates Chain Replacement Barkley Dam W912P5-24-B-0005 Amendment 003 Kuttawa, KY

SECTION TABLE OF CONTENTS

DIVISION 35 - WATERWAY AND MARINE CONSTRUCTION

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

PART 1 GENERAL

1.1 SCOPE

1.2 REFERENCES

1.3 SUBMITTALS

1.4 QUALITY ASSURANCE

1.4.1 Manufacturer and Assembler

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Delivery Location

1.5.2 Certified Test Reports

1.5.3 Delivery, Storage and Handling of Equipment

1.5.3.1 Packaging

1.5.3.2 Shipping, Preservation, and Storage

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Equipment Submittal Data

2.2 ENGINEERED CHAIN

2.2.1 Materials

2.2.2 Coating

2.2.3 Hardness

2.2.4 Spare Parts

2.3 SAFETY CHAIN ASSEMBLY

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 General

3.1.2 Material

3.1.3 Dimensional Tolerances for Structural Work

3.2 FABRICATION SCHEDULE

3.3 MACHINE WORK

3.3.1 Finished Surfaces

3.3.2 Unfinished Surfaces

3.3.3 Pin Holes

3.4 NONDESTRUCTIVE EXAMINATION

3.4.1 NDT Agency Requirements

3.4.2 Nondestructive Testing (NDT) for Flaws

3.5 QUALITY CONTROL

3.5.1 Hardness Testing

3.5.2 Ultrasonic Testing

3.5.2.1 Ultrasonic Testing Agency Requirements

3.5.2.2 Material Non-Destructive Testing

3.5.3 Engineered Chain Component Acceptance Test

3.5.4 Chain Pre-Load Test

SECTION 35 01 41.00 10 Page 1

3.5.5 Shop Inspections

3.5.6 Internal Inspections Reports

3.5.7 Packaging

3.6 MISCELLANEOUS PROVISIONS

3.6.1 Cleaning of Corrosion-Resisting Steel

3.7 CLEANING

3.7.1 Cleaning

3.8 WEIGHING

3.9 AS-BUILT DRAWINGS

-- End of Section Table of Contents --

SECTION 35 01 41.00 10 Page 2

35 01 41.00 10

ELECTROMECHANICAL OPERATING MACHINERY FOR LOCKS AND DAMS

PART 1 GENERAL

1.1 SCOPE

The contractor must provide all labor, material and equipment necessary to fabricate, assemble and deliver Barkley Dam Spillway Gate Lifting Chains in accordance with these specifications and contract drawings. See Section 01 20 00 PRICE AND PAYMENT PROCEDURES for a description on how the contract is separated by base and option work. Installation will be performed by others.

The following components are to be fabricated. Quantities listed are per gate. See Section 01 20 00 PRICE AND PAYMENT PROCEDURES for the number of gates required per the base and each option.

a. End Side Bar, Mk. 55/31-1, Qty. 8

b. Side Bar, Mk. 55/31-2, Qty. 616

c. Short Pin, Mk. 55/31-3, Qty. 10

d. Normal Pin, Mk. 55/31-4, Qty. 134

e. Rack Pin, Mk. 55/31-5, Qty. 12

f. Bottom Pin, Mk. 55/31-6, Qty. 2

g. Spacer Sleeve, Mk. 55/31-7, Qty. 156

h. Collar, Mk. 55/31-8, Qty. 268

i. Racking Collar, Mk. 55/31-9, Qty. 24

j. Spacer Washer, Mk. 55/31-10, Qty. 4

k. Spacer Washer, Mk. 55/31-11, Qty. 4

l. Washer, Mk. 55/31-12, Qty. 936

m. Washer, Mk. 55/31-13, Qty. 16

o. Retainer Ring, Mk. 55/31-14, Qty. 312

p. Retainer Ring, Mk. 55/31-15, Qty. 4

q. Link Plate, Mk. 55/31-16, Qty. 4

r. Grease Fitting, Mk. 55/31-17, Qty. 316

1.2 REFERENCES

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

AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)

ASNT SNT-TC-1A (2020) Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B46.1 (2020) Surface Texture, Surface Roughness, Waviness and Lay

SECTION 35 01 41.00 10 Page 3

ASTM INTERNATIONAL (ASTM)

ASTM A380/A380M (2017) Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems

ASTM A578/A578M (2007; R 2012) Standard Specification for Straight-Beam Ultrasonic Examination of Rolled Steel Plates for Special Applications

ASTM B36/B36M (2023) Standard Specification for Brass Plate, Sheet, Strip, and Rolled Bar

ASTM B505/B505M (2018) Standard Specification for Copper Alloy Continuous Castings

ASTM D3951 (2018) Commercial Packaging

ASTM D92 (2018) Standard Test Method for Flash and Fire Points by Cleveland Open Cup Tester

ASTM E114 (2015) Standard Practice for Ultrasonic Pulse-Echo Straight-Beam Contact Testing

ASTM E165/E165M (2018) Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E709 (2021) Standard Guide for Magnetic Particle Testing

1.3 SUBMITTALS

Government approval is required for submittals with a "G" or "S" classification. Submittals not having a "G" or "S" classification are for information only. When used, a code following the "G" classification 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 Pre-Fabrication Submittals

Fabrication Schedule; G

Certified Test Reports

SD-02 Shop Drawings

Detail Drawings; G , ECD-E

As-Built Drawings; G

SD-03 Product Data

Coating; G, ECD-M

SD-05 Design Data

Weight of Components

SECTION 35 01 41.00 10 Page 4

SD-06 Test Reports

Hardness Testing; G, ECD-M

Ultrasonic Testing; G, ECD-M

Inspection Reports; G

Chain Pre-Load Test Report; G, ECD-M

SD-07 Certificates

Equipment Manufacturer's and Fabricator's Qualifications; G

Nondestructive Examination Certification; G

1.4 QUALITY ASSURANCE

1.4.1 Manufacturer and Assembler

Manufacturing and assembly of the engineered chains must be performed by a Contractor and fabrication company that has been normally and regularly engaged in the fabrication of engineered chain in similar size over the preceding five (5) years. Changes to the dimensions shown on the drawings for the engineered chain requires written approval from the Contracting Officer. Submit Equipment Manufacturer's and Fabricator's Qualifications showing evidence and years of experience for each of the equipment manufacturers and fabricators. Identify any certifications, standards, and/or professional organizations the manufacturers comply with or are members of.

1.5 DELIVERY, STORAGE, AND HANDLING

1.5.1 Delivery Location

Upon completion of fabrication, testing, at the Contracting Officers direction, and a two weeks notice prior to delivery, deliver specified equipment to :

8439 US Hwy 62 W Kuttawa, KY 42055 Attn: Jamie Holt, Power Plant Superintendent Phone: 270-362-8159 E-mail: jamie.t.holt@usace.army.mil

1.5.2 Certified Test Reports

Submit reports of tests, inspections, and verifications of all materials used under this contract approved by the Government before fabrication begins. Reports must include all mill chemistry, heat treatment, mechanical testing, hardness, etc. information

1.5.3 Delivery, Storage and Handling of Equipment

Protect equipment and components from corrosion, deformation, and other types of damage. Store items in enclosed and secured areas free from contact with soil. Provide moisture proof weather protection for all equipment stored in outdoor locations. Transport, handle and store all equipment in accordance with the manufacturer's written instructions.

SECTION 35 01 41.00 10 Page 5

Remove and replace damaged items with new items.

Contractor must ship the engineered chains in three sections.

1.5.3.1 Packaging

Provide equipment and subassemblies with adequate protective pads, supports, and blocking. Securely restrain equipment and subassemblies to prevent distortion or damage to the painted surfaces in transit. Any loss or damage during shipment, including damage to the painted surfaces, is the responsibility of the Contractor. Replace or repair lost or damaged items without cost to the Government. Coat all parts with a rust preventative, wrap in heavy-duty plastic, and securely contain in wooden crates. Clearly mark each crate with its contents (including contract number and Corps mark number) on the outside, with a non-ferrous metal tag, engraved with the contents, and secured to the crate with non-ferrous screws. Provide a means for inspection of the crate's contents without destroying the crate. Pack all accessories and spare parts separately in containers plainly marked "ACCESSORIES ONLY," or "SPARE PARTS ONLY."

Package each spare part or spare part assembly in a durable treated wooden crate with metallic, plastic or suitable outer shell for weathertight protection and with provisions for handling and long-term storage (60 months). Provide and deliver the component and assembly spare parts as delineated on the drawings. Place a separate packing list, listing the contents of each crate, in a moisture-proof envelope securely fastened to the outside of the crate. Standard commercial packaging in accordance with ASTM D3951 is acceptable except where a different method or standard of packaging is specified.

1.5.3.2 Shipping, Preservation, and Storage

Provide all packing, crating, e.g., necessary to ensure safe shipment of equipment. The crates become the property of the Government. Fill or protect the equipment with the necessary fluids, coatings, and/or preservatives to maintain in a stable condition without corrosion, deterioration, or degradation for an extended period of storage of up to 12 months. Protect stored equipment from the weather, humidity, temperature variation, dirt and dust, or other contaminants.

PART 2 PRODUCTS

2.1 EQUIPMENT

2.1.1 Equipment Submittal Data

Submit Equipment Data and Detail Drawings for hoisting chains, equipment dimensional drawings, assembly drawings, catalog cuts, and material data and shop drawings showing arrangement, proposed and final shop test procedures and data sheets for approval. Provide all details of fabrication and assembly to include shipping and long term storage instructions. Shop drawings lacking this information will be rejected.

Approval of the material submitted in no way relieves the Contractor from the responsibility of complying with the requirements of the specifications as to the suitability and quality of materials and workmanship and other essential characteristics of the spillway gate chains.

Submit drawings, catalogs, and design data necessary to clearly show the details of any changes proposed in conformity with the requirements of this specification. Equipment, materials, and articles of construction installed or used without such approval will be at the risk of subsequent

SECTION 35 01 41.00 10 Page 6 rejection.

2.2 ENGINEERED CHAIN

2.2.1 Materials

End Side Bars (Mk. 55/31-1), Side Bars (Mk. 55/31-2), Short Pins (Mk.

55/31-3), Normal Pins (Mk. 55/31-4), Rack Pins (Mk. 55/31-5), Bottom Pin (Mk. 55/31-6), Spacer Sleeves (Mk. 55/31-7), Collars (Mk. 55/31-8), Racking Collar (Mk. 55/31-9), Spacer Washers (Mk. 55/31-10), Spacer Washers (Mk. 55/31-11), Link Plates (Mk. 55/31-16) - ASTM A29/ A29M, AISI 4140

Washers (Mk. 55/31-12), Washers (Mk. 55/31-13) - ASTM B36/ B36M UNS C22000 Hal f Har d or ASTM B505/ B505M UNS C93200

Ret ai ner Ri ngs ( Mk. 55/ 31- 14) , Ret ai ner Ri ngs ( Mk. 55/ 31- 15) - The r et ai ner r i ng mat er i al shal l be ASTM A29/ A29M, AI SI 4140, wi t h a BHN of 440- 480. The r et ai ner r i ng desi gn may be al t er ed t o f i t a manuf act ur er ' s st andar d r et ai ni ng r i ng. Rect angul ar wi r e, r ound wi r e, or mul t i pl e- t ur n const r uct i on r et ai ni ng r i ngs may be accept abl e. Submi t r et ai ni ng r i ng manuf act ur er ' s cat al og and engi neer i ng dat a t o demonst r at e t hat i t mat ches t he st r engt h of t he desi gn shown on t he cont r act dr awi ngs. Submi t manuf act ur er ' s dat a i ncl udi ng r i ng di mensi ons, i nst al l at i on i nst r uct i ons, and r ecommended r i ng gr oove di mensi ons. The Cont r act or i s r esponsi bl e t o make t he appr opr i at e pi n det ai l changes f or any ot her appr oved r et ai ni ng r i ng used.

Grease Fitting (Mk. 55/31-17) - Steel with Zinc Plating

2.2.2 Coating

After fabrication and before assembly, the chain components must be coated with a grease conforming to the specifications below:

Flash Point (COC) - ASTM D92 - 250°F min.

Congealing Point - ASTM D938 - 125-160

Penetration - ASTM D937 - 140-195

Phenols - 1 ppm max.

Total Heavy Metals - 1 ppm max

Salt Spray - 20 mils - 10+ years

After assembly, inject grease through grease ports until visible between the chain links. Submit coating system for approval.

2.2.3 Hardness

Contractor shall abide by the hardness values shown on the contract drawings.

2.2.4 Spare Parts

Sets of sidebars must be matched sets. See paragraph "Engineered Chain

SECTION 35 01 41.00 10 Page 7

Fabrication"

Item Mark Number Total Spares

End Side Bars 55/31-1 One set (four total)

Side Bars 55/31-2 Three hundred and eight

Short Pins 55/31-3 Five

Normal Pins 55/31-4 Sixty Seven

Rack Pins 55/31-5 Six

Bottom Pin 55/31-6 One

Spacer Sleeve 55/31-7 Seventy Eight

Collar 55/31-8 One Hundred Thirty Four

Racking Collar 55/31-9 Twelve

Spacer Washer 55/31-10 Two

Spacer Washer 55/31-11 Two

Washer 55/31-12 Four Hundred Sixty Eight

Washer 55/31-13 Eight

Retainer Ring 55/31-14 One Hundred Fifty Six

Retainer Ring 55/31-15 Two

Link Plate 55/31-16 Two

Grease Fitting 55/31-17 One Hundred Fifty Eight

Enough spare parts must be included in the opt i on 1 of t he cont r act to complete one chain assembly. Spare parts must not be assembled; ship individually.

2.3 SAFETY CHAIN ASSEMBLY

The components of the safety chain assembly are shown for reference. The contractor may submit manufacturer standard chain.

The safety chain shall be equivalent to grade 100, zinc-plated alloy steel. Links shall be 3/4 inch in diameter and have a minimum working load of 35,000 pounds. Submit safety chain components with the detail drawings.

PART 3 EXECUTION

3.1 FABRICATION

3.1.1 General

Chain sidebars may be cut by wat er j et cut t i ng or mechanically guided or

SECTION 35 01 41.00 10 Page 8 hand guided torches provided an accurate profile with a smooth surface free from cracks and notches is obtained. Cuts must be ground, or machined to sound metal, to the finished dimensions shown. Chain sidebars must be cut from mill stock plate or bar stock thickness. Both surfaces must be machined or surface ground true over approximately 75 percent of the surface area and all subsequent machining operations will be referenced from these surfaces. Thickness tolerances must be as shown on the contract drawings.

Sidebar plates must be bored in sets of four, protected and stored in these sets prior to assembly. Alternative methods for boring of sidebar plates can be used with approval from the Contract Officer's Representative (COR).

3.1.2 Material

Material must be straight before being laid off or worked. If straightening is necessary, straighten by methods that do not impair or alter the metal. Sharp kinks, bends, or overcuts of material are cause for rejection of the material. Material with welds will not be accepted except where welding is specified, indicated, or otherwise approved.

Flame cutting of material is not allowed. Shearing must be accurately done and all portions of the work neatly finished. Corners must be square and true unless otherwise indicated.

3.1.3 Dimensional Tolerances for Structural Work

The overall dimensions of an assembled structural unit must be within the tolerances indicated on the drawings or as specified for the item of work. Where tolerances are not specified in other sections of these specifications or shown, a variation of 1/32 inch is permissible in the overall length of component members with both ends milled and component members without milled ends must not deviate from the dimensions shown by not more than 1/16 inch for members 30 feet or less in length and by not more than 1/8 inch for members over 30 feet in length.

3.2 FABRICATION SCHEDULE

The Contractor must submit a fabrication schedule for approval. The schedule must detail time frames required for material purchases, fabrication, inspection, disassembly and shipping.

3.3 MACHINE WORK

3.3.1 Finished Surfaces

a. Surface finishes indicated or specified herein, must be in accordance with ASME B46.1 . Determine compliance with specified surface by sense of feel and by visual inspection of the work compared to Roughness Comparison Specimens in accordance with the provisions of ASME B46.1 .

Values of roughness width and waviness height are not specified but must be consistent with the general type of finish specified by roughness height. Flaws such as scratches, ridges, holes, peaks, cracks, or checks which will make the part unsuitable for the intended use are cause for rejection.

b. Where the finish is not indicated or specified, the type of finish is that which is most suitable for the particular surface and provides the class of fit required. Maximum surface roughness of any surface is

SECTION 35 01 41.00 10 Page 9

250 micro-inch. Indicate surfaces to be machine finished by symbols which conform to ASME B46.1 .

3.3.2 Unfinished Surfaces

In so far as practicable, lay out all work to secure proper matching of adjoining unfinished surfaces. Where there is a large discrepancy between adjoining unfinished surfaces, chip and grind smooth or machine to secure proper alignment. Unfinished surfaces must be true to the lines and dimensions indicated and must be chipped or ground free of all projections and rough spots. Fill depressions or holes not affecting the strength or usefulness of the parts in a manner approved by the Contracting Officer.

3.3.3 Pin Holes

Pin holes must be bored true to gages, smooth, straight, and at right angles to the axis of the member. Perform the boring after the member is securely fastened in position.

3.4 NONDESTRUCTIVE EXAMINATION

3.4.1 NDT Agency Requirements

Conduct NDT examinations using a testing agency adequately equipped and competent to perform such services or using suitable equipment and qualified personnel. In either case, provide written approval of the examination procedures and perform the examination tests in the presence of the Contracting Officer. Persons performing the NDT examination must be qualified for the specific procedure used in accordance with ASNT SNT-TC-1A . Submit nondestructive examination certification of qualified persons, procedures and equipment performing or used for nondestructive testing.

3.4.2 Nondestructive Testing (NDT) for Flaws

For all components to be furnished ultrasonically scan a quantity representing approximately 10 percent of the total supplied quantity for internal defects as specified. The Contracting Officer will select parts to be examined at random. Notify the Government two weeks prior to when the lots are available for specimen selection. Flawed specimens (excessive inclusion size, out-of-tolerance dimension or hardness, or excessive surface roughness) are subject to rejection.

3.5 QUALITY CONTROL

3.5.1 Hardness Testing

The Contractor must make, in addition to the quantities shown on the drawings and listed as spare parts, one additional end side bar, side bar, short pin, normal pin, and rack pin for the purposes of hardness testing.

Tests must be performed by an independent laboratory. The laboratory must cut the samples by means that will not disturb the as found hardness of the components. These tests and analyses must be performed and certified at the Contractor's expense.

Hardness readings must be taken through cross sections of side bars at the pin holes and midpoints of pitch diameters. Cross sections at the pin holes must be along the length and width of side bars. Readings must be taken at the edges of the cross section and midpoints of the cross

SECTION 35 01 41.00 10 Page 10 sections. For pins, cross sections must be made at mid length. Readings must be taken at the center and near the edges. All components, pins and sidebars, must be hardness tested on outside surfaces in addition to cross sections. Testing of surface hardness must be performed before painting or other coating systems are applied. The har dness at t he cent er of t he pi n must not be bel ow 340 BHN.

The Contractor must provide to the Government a report documenting through digital photographs and detailed descriptions of the results found. The report must include:

a. Findings related to hardness testing.

b. Descriptions of the test methods and equipment used.

3.5.2 Ultrasonic Testing

The quantity of sidebars, end sidebars, center rollers, collar rollers, long pins, intermediate pins and short pins must be ultrasonically tested for internal defects at the location of fabrication prior to assembly and shipping to the project site. Lots from which parts to be tested are selected must consist of at least 10% of the total quantity of each type of part furnished per shipment. Parts to be examined must be selected at random by a representative of the Contracting Officer. The Contractor must notify the Contracting Officer’s representative two weeks prior to when the lots are available for specimen selection. If a significant flaw as specified (such as discontinuities, voids, or delamination) is detected with certainty in any part of a shipment lot, the entire shipment lot of that part will be rejected. Only after additional testing of the part, for the entire shipment lot, has been performed to the satisfaction of the Contracting Officer’s representative will the part be accepted.

Sidebars, end sidebars, link plates, center rollers and collar rollers must be ultrasonically tested in the machined and hardened state in accordance with ASTM A578/A578M . Specimens with inclusion (defect) size greater than 0.10 inch in any direction must be rejected.

Short pins, intermediate pins and long pins tested must have ends finished to 125 micro-inches or smoother to allow axial direction ultrasound scans. Pins must be ultrasonically tested in accordance with ASTM E114.

Specimens with inclusion (defect) size greater than 0.10 inch in any direction must be rejected.

3.5.2.1 Ultrasonic Testing Agency Requirements

The ultrasonic testing must be conducted by an independent commercial testing agency adequately equipped and competent to perform such services or by the contractor using suitable equipment and qualified personnel. In either case, written approval of the examination procedures will be required. The examination tests must be made in the presence of the Contracting Officer’s representative. Only individuals qualified for NDT Level II may perform this ultrasonic examination.

3.5.2.2 Material Non-Destructive Testing

When doubt exists as to the soundness of any material part such part may be subjected to any form of nondestructive testing determined by the COR.

This may include magnetic particle examination in accordance with ASTM E709, dye penetrant in accordance with ASTM E165/E165M , Ultrasonic test in

SECTION 35 01 41.00 10 Page 11 accordance with ASTM E114, X-ray, gamma ray or any other test that will thoroughly investigate the part in question. The cost of such investigation will be borne by the Government. Any defects will be cause for rejection and rejected parts must be replaced and tested at the Contractor's expense.

3.5.3 Engineered Chain Component Acceptance Test

The following acceptance test measurements must be made by the Contractor in the presence of the COR on the initial chain components. The quantites listed in the table below is a minimum and do not restrict the Government the right to inspect additional components. The Contractor must be prepared that any individual part may be identified for sampling and testing. All readings taken from the sample must be within the specified tolerance. Any components that fail the tolerance test will make the entire quantity subject to rejection. It is recognized that not all of a given sample set may be available at one time at one place. More than one testing date may be required. The dates of the test must be coordinated by the Contractor with the COR. Similar tests may be performed on the remaining chains to be fabricated at the discretion of the COR.

Item (Notes) Mark Number Measured and Record Parameters Number of Samples Tested (1)

End Side Bar (4)

55/31-1 IDPB, Pitch, Width, Finish, Side Finish, BHN

Side Bar (4) 55/31-2 IDPB, Pitch, Width, Finish, Side Finish, BHN

Short Pin (2) 55/31-3 OD, BHN (6), Finish, ODRRG 2

Normal Pin (2) 55/31-4 OD, BHN (6), Finish, ODRRG 2

Rack Pin (2) 55/31-5 OD, BHN (6), Finish, ODRRG 1

Bottom Pin (2) 55/31-6 OD, BHN (6), Finish, ODRRG 1

Spacer Sleeve (3)

55/31-7 ID, OD, BHN (6), Width, Finish 1

Collar (3) 55/31-8 ID, OD, BHN (6), Width, Finish 1

Racking Collar (3)

55/31-9 ID, OD, BHN (6), Width, Finish 1

Spacer Washer 55/31-10 IDPB, Width 1

Washer 55/31-12 IDPB, Width 1

Retainer Ring 55/31-14 IDPB, Width 1

SECTION 35 01 41.00 10 Page 12

Item (Notes) Mark Number Measured and Record Parameters Number of Samples Tested (1)

Link Plate 55/31-16 IDPB, OD, Width, IDSCPB 1

Legend:

OD = Outside Diameter ID = Inside Diameter BHN = Brinell Hardness Number FINISH = Surface Finish ODRRG = Outside Diameter of Retainer Ring Groove IDPB = Inside Diameter Pin Bores IDSCPB = Inside Diameter Safety Chain Pin Bore

Notes:

(1) The Contractor must be prepared that any individual part may be identified for sampling and testing.

(2) Pins (short, normal, and rack): Take three diameter readings per selected pin within the bearing interface region.

(3) Center sleeve, end collar, and racking collar: Measure inside diameter of installed bearing (one measurement per bore), outside diameter of roller/collar and width of roller/collar. Take three surface hardness readings per selected roller/collar.

(4) Sidebar: Measure both assembled bearing inside diameters (one measurement per bore). Measure pitch tolerance derived from bearing edge to edge measurements, both faces of sidebar.

(5) See Paragraph 3.2.7 "Hardness Testing".

(6) Chain Assembly: Measure overall length of assembled chain and clearances between parts within an individual pin link assembly.

3.5.4 Chain Pre-Load Test

Each full chain length shall be matched in pairs. The assembled chain pitch shall be 12 inches within a tolerance of +/- 0.005 inches to ensure that each side bar of any link will have equal bearing under load and the links matched so that the total accumulative length of the full length of chain will not vary more than 1/4-inch with its matching chain. The matching of the two chains for equal length shall be determined by subjecting each chain to an initial load of 5,000 pounds; each match pair of chains shall be tagged or marked at the factory for ease of identification. The lengths of groups of any ten links shall not vary more than 1/32-inch from that shown on the drawings.

Submit a Chain Pre-Load Test Report that indicates the results of the test. The report should include but is not limited to a description of how the test is performed, the total length of each chain, photographs of the test, the identification system for matching chain pairs, and the

SECTION 35 01 41.00 10 Page 13 corrective action if a chain is found out of tolerance. Notify the Government two weeks prior to this test.

3.5.5 Shop Inspections

The engineering chain acceptance test shall be performed just prior to delivery of the lifting chains. An intermediate inspection of the fabrication of the lifting chains will also be coordinated between the contractor and the Government.

The Contracting Officer, assistants, and other agents of the Government shall at all times have full and unrestricted access for inspection to all places of manufacture where equipment or materials are being made or prepared for use under this contract.

3.5.6 Internal Inspections Reports

The contractor must submit all internal inspection reports of the fabricated components prior to asssembly.

3.5.7 Packaging

The equipment must be packed in a manner acceptable to preserve the condition of the equipment as it left the fabricator's shop. The packaging must clearly identify the contents and weight of the package.

The maximum length of any package must not exceed 15'. The maximum weight of any individual package must not exceed 4,500 lbs. Loose items such as bolts and screws must be packaged together in a single package. All transportation, delivery and storage costs must be included in the bid price.

3.6 MISCELLANEOUS PROVISIONS

3.6.1 Cleaning of Corrosion-Resisting Steel

After fabrication, remove oil, paint, and other foreign substances from corrosion-resisting steel surfaces. Clean by vapor degreasing or by the use of cleaners of the alkaline, emulsion, or solvent type. After the surfaces have been cleaned, final rinse with clean water followed by a 24 hour period during which the surfaces are intermittently wet with clean water and then allowed to dry for the purpose of inspecting the clean surfaces. Visually inspect the surfaces for evidence of paint, oil, grease, welding slag, heat treatment scale, iron rust, or other forms of contamination. If evidence of foreign substance exists, clean the surface in accordance with the applicable provisions of ASTM A380/A380M . Submit the proposed method of treatment. After treatment visually reinspect the surfaces. Brushes used to remove foreign substances must have only stainless steel or nonmetallic bristles. Remove any contamination occurring subsequent to the initial cleaning by one or more of the methods indicated above.

3.7 CLEANING

3.7.1 Cleaning

Remove all loose rust, dirt, moisture, grease or other contaminants from surface. Power-tool clean in accordance with SSPC SP 3 or hand-tool clean in accordance with SSPC SP 2. For more severe environments, dry abrasive blast in accordance with SSPC 7/NACE No.4. Water blasting is also

SECTION 35 01 41.00 10 Page 14 acceptable.

3.8 WEIGHING

After fabrication and before assembly, each component of the engineered chain must be weighed, and the contractor must provide the Government with the weight of components. The weight each of component must be listed below each perspective item's detail in the as-built drawings.

3.9 AS-BUILT DRAWINGS

Upon completion of the work under this contract, the Contractor must furnish a complete set of As-Built drawings in DGN or DWG and pdf formats as finally approved.

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2.3 SAFETY CHAIN ASSEMBLY