Section_C _Revision_1_Description_Speciification.pdf

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SECTION C (Revision 1)

DESCRIPTION/SPECIFICATIONS

1. 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 Testing and Materials (ASTM).

A 27 (2013) Standard Specification for Steel Castings, Carbon, for General Application

A 148 (2015) Standard Specification for Steel Castings, High Strength, for Structural Purposes

A 276 (2016) Standard Specification for Stainless Steel

Bars and Shapes

A 492 (1995; R 2013) Standard Specification for Stainless Steel Rope Wire

A 582 (2012; E 2012) Standard Specification for Free-

Machining Stainless Steel Bars

A 751 (2014) Standard Test Methods, Practices, and

Terminology for Chemical Analysis of Steel Products

A 903 (1999; R 2012; E 2016) Standard Specification for steel Castings, Surface Acceptance Standards, Magnetic Particle and Liquid Penetrant Inspection

A 931 (2008; R 2013) Standard Test Method for Tension

Testing of Wire Ropes and Strand

B 505 (2014) Standard Specification for Copper Alloy

Continuous Castings

B 843 (2013) Standard Specification for Magnesium Alloy

Anodes for Cathodic Protection

E 165 (2009) Standard Practice for Liquid Penetrant Examination for General Industry

F 468 (2015; E 2016) Standard Specification for Nonferrous

Bolts, Hex Cap Screws, Socket Head Cap Screws, and Studs for General Use

U.S. General Services Administration (GSA).

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

Wire Rope Technical Board (WRTB).

WRTB (2005) Wire Rope User’s Manual

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2. SCOPE. The Contractor shall furnish all labor, materials, plant, and equipment required to fabricate and deliver, the wire rope assemblies, as specified herein and shown on the contract drawings. Wire rope assemblies will be installed by others.

3. SUBMITTALS. Government Approval is required for submittals with a “GA” designation; submittals having an “FIO” designation are for information only.

Submittals required by this section of the Technical Specifications include, but are not necessarily limited to:

3.1 Data.

3.1.1 Material, Size, Type, Construction, Strength, and

properties of the wire rope used for the rope assemblies. GA

3.1.2 Pre-Stretching Procedure. GA

3.1.3 End Termination Attachment Method. The Contractor shall submit, for approval, complete data on the zinc material used for speltering.

GA

3.1.4 Wire Rope Manufacturer’s Qualifications Statement. The

Contractor shall submit a complete list of previous projects completed using flat wire rope of similar size and load rating. The list shall include the purpose of the rope, the end customer, and the date of manufacture. GA

3.1.5 Quality Control Plan. The Contractor shall submit its

Quality Control Plan. FIO

3.1.6 Work/Fabrication Schedule. The Contractor shall submit its Work/Fabrication Schedule. FIO

3.2 Reports.

3.2.1 Tension Testing. Rope tension test report. GA

3.2.2 Attaching and Proof Loading Termination. Proof load of

terminations test report and measured rope lengths. GA

3.2.3 Wire Strength and Ductility. Wire strength and ductility test results. GA

3.2.4 Pre-forming. Verification of pre-forming test results. GA

3.2.5 Socket Non-Destructive Testing. Socket non-destructive

testing results. GA

3.3 Certificates.

3.3.1 Wire Rope Size, Material, Construction and Certified

Breaking Strength. GA

3.3.2 Type of Wire Rope. Wire material certification for all wire used in rope, along with copies of any in-house QA tests done on purchased products. GA

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3.3.3 Warranty. Submit signed copies or the manufacturer’s

warranty of a 1 year warranty for all materials and services provided under this section.

3.4 Drawings.

3.4.1 Shop Drawings. GA. Submit complete shop drawings of flat wire rope assemblies, including new sockets prior to fabrication of any components. Shop drawings shall indicate complete details of all materials, tolerances, as-cast dimensions, heat treatments, finishes, fits and machining processes, as applicable, for each part.

4. WIRE ROPE MANUFACTURER’S QUALIFICATIONS. The wire rope material and the fabrication of the wire rope shall be the standard product and procedure of a manufacturer regularly engaged in the manufacture of wire rope of this type, size and breaking strength, and shall essentially duplicate products having been in satisfactory use for at least 10 years prior to bid opening.

5. CONTRACTOR QUALITY CONTROL. The Contractor shall follow a standard and pre-established Quality Control Plan for all operations involved with the manufacture, fabrication, inspection and testing of all of the wire rope assemblies required under this contract. This Quality Control Plan shall include ordering of the required wire, inspection and testing of wire supplied, assembly/fabrication of the required quantity of flat wire rope, pretensioning of the flat wire rope, cutting of flat wire rope sections, socketing operations, proof testing, final measurements, inspections and preparations for shipment and delivery including reeling operations. This plan shall include all required documentation required to insure that the requirements of this contract are met. The plan shall address what steps the Contractor shall institute if any defective materials or manufacturing processes are encountered at any point during this contract. The Quality Control Plan shall include documentation on the frequency of calibration of measuring devices used during the manufacture, testing and measurement of the wire rope assemblies required by this contract. The Contactor shall designate, in writing, a Quality Control Manager for all of the operations including documentation and records required to meet the requirements of the Quality Control Plan.

6. WORK/FABRICATION SCHEDULE. Within 10 business days after Notice to Proceed, the Contractor shall submit to the Contracting Officer a work/fabrication schedule. The schedule shall include dates for major milestones in the production of the wire rope assemblies. These milestones shall include, but not be limited to the following: receive component wire rope necessary for flat wire rope production, fabricate flat wire rope, pre-stretch flat wire rope, tension test flat wire rope, attach sockets, proof load flat wire rope assemblies, prepare flat wire rope assemblies for shipment, delivery of flat wire rope assemblies. Changes to the submitted work/fabrication schedule shall be submitted in writing to the Contracting Officer.

6.1 Pre-Fabrication Meeting. Prior to fabrication and after delivery of all pre-fabrication submittals. The Contractor shall coordinate a pre-fabrication meeting with the Government to discuss all pre-fabrication submittals, including work/fabrication schedule.

7. FLAT WIRE ROPE AND SOCKETS.

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7.1 General. The Contractor shall furnish flat wire ropes with new sockets at both ends, as indicated on drawing M-1. Each flat wire rope assembly shall be of the length indicated on the drawings and shall include all appurtenances as shown in the drawings. All like assemblies (Gate 1 Assemblies and Gate 2 Assemblies) shall be manufactured into flat wire rope by the same crew. This will insure that each set of flat wire rope assemblies will not contain any inconsistencies inherent with the flat wire rope manufacturing process. The quantities of each flat wire rope assembly shall be as follows.

Gate 1 – 2 Assemblies

Gate 2 – 2 Assemblies

7.2 Wire Rope Test Results and Certification. The Contractor shall submit the following certificates prior to fabrication of the flat wire rope.

7.2.1 Manufacturer of Stainless Steel Wire and Wire Rope Strands will provide Test results for Chemical Composition of the stainless steel (S 30200

– UNS Designation) that meet ASTM A492 – these test results will be what is commonly refer to as being “Certified Mill Certification’s” or ladle analysis

(ASTM A751).

7.2.2 Manufacturer of Stainless Steel Wire and Wire Rope Strands will provide Tensile Strength test results for the individual wire(s) in the wire rope for the wire strand diameters and for the 302 Stainless Steel wires that meet TABLE 2 of ASTM A492.

7.3 Sockets. The Contractor shall furnish the sockets, as shown on the contract drawings, for the fabrication of wire rope assemblies. The drum sockets shall be cast in accordance with ASTM A148, grade as shown on drawings. The gate sockets shall be cast in accordance with ASTM A27, grade as shown on drawings. The castings shall be manufactured to the final finished dimensions shown on the contract drawings, in accordance with the standard industry practice for “as cast” tolerances. Castings that are warped, distorted, or not within the tolerances will be rejected. The structure of the metal in the castings shall be homogenous and free from nonmetallic inclusions. Each casting shall bear the mark number shown on the contract drawings, unless waived in writing by the Contracting Officer. All repairs to a casting shall meet the requirements of the applicable ASTM.

7.3.1 Miscellaneous Socket Components. The materials for the

miscellaneous socket components shall be in accordance with the following standards:

Component Material Magnesium Anode ASTM B843, Grade AZ63C

Eye Bolt ASTM A276, Type 440C (110/65) Spanner Nut ASTM A276, Type 440C (110/65)

Bronze Bushing ASTM B505, Alloy C93200 Gate Pin ASTM A582, Type 416 (110/85) Cap Screw ASTM F468, Alloy 400

Retaining Ring Stainless Steel

7.4 Type of Wire Rope. The wire rope shall be of the following type:

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Component Rope Configuration: 4 x 19 Construction.

Number of Component Ropes per Flat Wire Rope: 10 Lay: Alternating left - right.

Flat Wire Rope Size: 1/2” x 4-1/2” Nominal (3/4” x 5” actual).

Finish: plain.

Material: AISI 302 stainless.

Pre-formed: yes.

Minimum Breaking Strength (Flat Wire Rope): 181,500 lbs.

Serving-type: Double.

NOTE: The drum that the flat wire rope passes over has a maximum width of 5.25”; therefore, it is critical that the finished dimension of the flat wire rope matches that given as the “actual” width for the 1/2” x 4-1/2” “nominal” flat wire rope.

7.5 Pre-Stretching. The manufacturer shall pre-stretch the flat wire ropes prior to attaching the final end terminations. This shall be done by subjecting them to three cycles at 40 percent of its nominal strength. The 40 percent loads shall be held for 5 minutes with 5 percent loads for 5 minutes between cycles.

7.6 Wire Strength and Ductility. The Manufacturer shall perform testing in accordance with FS RR-W-410 to verify wire strength and ductility.

7.7 Pre-forming. The component wire ropes shall be pre-formed, and the

Manufacturer shall perform testing in accordance with FS RR-W-410 to verify pre-forming.

7.8 Weld Distribution. Wire joints in any strand shall not be closer than 18 inches in any strand. Welding is the only approved method of wire joints.

7.9 Lubrication. The rope strands shall be lubricated with a clear lubricant at the time of manufacture.

7.10 Tension Testing. A tension test shall be performed to verify the component wire ropes, when woven into the flat wire rope, will meet the required minimum breaking force. Two rope samples from each production run shall be tested to failure. The test shall be performed using suitable tension testing equipment and by qualified personnel, both furnished by the Contractor. The rope samples shall be cut to no less than 3 feet of length.

The test will not be considered valid if the failure occurs less than 2 inches from either socket or holding mechanism, unless it meets or exceeds the minimum breaking force. Relative speed between the machine heads shall not exceed 1 inch per minute. Load test certificates shall be furnished for each production run of wire rope.

7.11 Attaching and Proof Loading Terminations. The manufacturer shall attach the end terminations after pre-stretching the flat wire rope. The sockets shall be attached such that the orientation of the sockets shall be as shown in the attachments under load. The end termination attachments shall be zinc speltered in accordance with industry standards and the Wire Rope User’s Manual. During the speltering process, a minimum of 5 feet of free and straight length of flat wire rope shall be present below the base of the socket. After their attachment, the flat wire rope assemblies shall be proof

C-6 loaded at 40 percent of nominal strength of the rope. Length of the flat wire ropes shall be measured to the nearest 1/16 inch at the proof load.

7.12 Wire Rope Assembly Documentation and Marking. Each flat wire rope assembly shall be assigned a unique identification. The designations shall be: GATE 1 #(1-2) and GATE 2 #(1-2). The following information shall be documented and supplied to the Contracting Officer in a neat and orderly document for each assembly: strand configuration, nominal dimensions (thickness and width), measured finished dimensions (thickness and width) to the nearest 1/16”, material, measured length under proof load to the nearest 1/16”, and minimum breaking force from tension test. Along with the documentation, each flat wire rope assembly shall have the following information etched on the gate sockets (Mark No. 862-6-3): flat wire rope assembly unique identification and measured length under proof load.

8. FABRICATION INSPECTION. The Contractor shall be prepared to accommodate up to three representatives of the Contracting Officer to witness the various manufacturing processes for the flat wire rope assemblies. At a minimum: a site visit will be made to witness the flat wire rope fabrication, socket attachment, and proof load testing to include measured flat wire rope assembly lengths. A minimum of 7 calendar days notice will be provided by the Contractor to witness the various manufacturing or testing processes for the flat wire rope assemblies.

9. PREPARATION FOR SHIPMENT. Prior to shipment from the fabricator’s plant, the Contractor shall prepare all assemblies for shipment as described herein.

The wire rope assemblies shall be neatly coiled and bound or wound on wood spools in the same direction as they were bent during manufacturing. The coils or spools shall be covered for protection from rain, snow, and road spatter during shipping. Wire rope assemblies shall be packaged in a way that the sets of assemblies are not intermixed. Only assemblies of the same set shall be packaged on a pallet. Pallets shall be of sufficient size and strength to permit safe loading and unloading without causing any kinking or other adverse bending. All materials shall be protected from abrasion or contact damage in shipping. Pallets shall not be stacked without sufficient supports to prevent contact of wire rope with an adjacent pallet. Each pallet shall be marked with the proper assembly designation (as specified in paragraph 7.12), quantity, assembly length, and shipping weight, as well as the fabricator’s name, address, contract number, and telephone number. All markings shall be in the English language with letters at least one-inch in height. A packing list, sealed in a moisture-proof envelope, shall be attached to each pallet.

10. DELIVERY. The completed wire rope assemblies shall be delivered to Mark Twain Lake Generation Building, across the street from the Mark Twain Lake Project Office, 20642 Highway J, Monroe City, MO. Government personnel and equipment will be available to assist in unloading, the Contractor will be responsible for coordinating unloading requirements with point of contact and providing equipment that is needed and not owned by the Government. All work performed with respect to unloading or delivering of the completed assemblies at Mark Twain Lake shall occur between the hours of 0700 and 1600 local time, Monday through Friday. Point of Contact for delivery and unloading shall be Mr. Curtis Meisner (573-735-4843) or Mr. Travis Arch (573-735-4843).

11. INSPECTION. Upon delivery to the Government, preliminary inspections of the flat wire rope assemblies shall be completed upon offloading to determine if damages occurred during transport or offloading. Final inspections shall

C-7 be performed at the Reregulation Dam just prior to installation. For the final inspection, the flat wire rope shall be inspected for dings, kinks or other damage. The flat wire rope assemblies will be separated from each other and extended straight to allow complete inspection of the wire rope assemblies over their entire length. The Contractor shall have a qualified representative at the site during this inspection. If a deficiency is noted during installation, the Contractor shall be responsible for providing information regarding serviceability and/or repair within 7 calendar days from date Contractor is notified of discovery of deficiency.

12. ANTI-TERRORISM/OPERATIONAL SECURITY REQUIREMENTS. The following applies to all contractor and/or sub-contractor personnel that will be on USACE property at any time during the duration of the contract.

12.1 iWATCH Training. The contractor and all associated sub-contractors shall review the attached "Contractor iWATCH Training" slides. This locally developed training will be used to inform employees of the types of behavior to watch for and instruct employees to report suspicious activity to the security representative or law enforcement entity.

12.2 Pre-Screen Candidates Using E-Verify. The Contractor must pre-screen personnel using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The contractor must ensure that personnel have two valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system.

END OF SECTION C