A02_SOW_L24_and_L25_Culver_Valve_Wire_Rope.pdf

US Army Corps of Engineers St. Louis District

Culvert Valve Wire Ropes Lock and Dam No. 24 & No. 25

Lock & Dam 24 350 North 1st Street Clarksville, MO 63336

Lock & Dam 25 #10 Sandy Slough Winfield, MO 63389

SCOPE OF WORK AND TECHNICAL

SPECIFICATIONS

November 2017

Scope of Work

1. GENERAL. The work provided for herein consists of furnishing all plant, labor, materials, and equipment required to fabricate and deliver, the wire rope assemblies for Lock and Dam No. 24 and Lock and Dam No. 25 Culvert Valves, as specified herein and shown on the contract drawings. Wire rope assemblies will be installed by others.

2. OMISSIONS. This scope of work may duplicate or not cover all specified activities, steps, and/or procedures required to accomplish work. In case of omission, the normal industry standards, practices, specifications and/or guidelines shall prevail. In no instance shall omission be a reason to perform inferior work, produce a less than acceptable product or service, or refuse to perform an intended activity.

3. CONTRACTING OFFICER. The term "Contracting Officer" shall mean the person executing this contract on behalf of the Government, and any other officer or civilian employee who is properly designated Contracting Officer; and the term shall include, except as otherwise provided in this contract, the authorized representative of a Contracting Officer acting within the limits of their authority.

4. WARRANTY. Materials and workmanship shall be warranted by the Contractor for a period of one year from date of delivery to the Government. All replacement parts required under the warranty provisions shall be furnished by the Contractor at no additional cost to the Government.

5. PAYMENT. Payment for the wire ropes assemblies will be made at the contract amount for the applicable item shown in Section B, which price and payment shall constitute full compensation for the work specified herein and shown on the contract drawings for each item.

6. ANTITERRORISM/OPERATIONS SECURITY:

a) Access and General Protection/Security Policy and Procedures: All contractor and all associated sub-contractors employees shall comply with applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative). The contractor shall also provide all information required for background checks to meet installation/facility access requirements to be accomplished by installation Provost Marshal Office, Director of Emergency Services or Security Office. Contractor workforce must comply with all personal identity verification requirements (FAR clause 52.204-9, Personal Identity Verification of Contractor Personnel) as directed by DOD, HQDA and/or local policy. In addition to the changes otherwise authorized by the changes clause of this contract, should the Force Protection Condition (FPCON) at any installation or facility change, the Government may require changes in contractor security matters or processes.

a. Contractor and all associated sub-contractors employees shall comply with adjudication standards and procedures using the National Crime Information Center Interstate Identification Index (NCIC-III) and Terrorist Screening Database (TSDB) (Army Directive 2014-05 / AR 190-13), applicable installation, facility and area commander installation/facility access and local security policies and procedures (provided by government representative, as NCIC and TSDB are available), or, at OCONUS locations, in accordance with status of forces agreements and other theater regulations.

b) Suspicious Activity Reporting Training (e.g. iWATCH, CorpsWatch, or See Something, Say

Something): The contractor and all associated sub-contractors shall receive a brief/training (provided by the RA) on the local suspicious activity reporting program. 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 project manager, security representative or law enforcement entity. This training shall be completed within 30 calendar days of contract award and within 30 calendar days of new employees commencing performance with the results reported to the COR NLT 5 calendar days after the completion of the training.

c) All contract employees, including subcontractor employees who are not in possession of the appropriate security clearance or access privileges, will be escorted in areas where they may be exposed to classified and/or sensitive materials and/or sensitive or restricted areas.

d) Pre-screen candidates using E-Verify Program: The Contractor must pre-screen Candidates using the E-verify Program (http://www.uscis.gov/e-verify) website to meet the established employment eligibility requirements. The Vendor must ensure that the Candidate has two (2) valid forms of Government issued identification prior to enrollment to ensure the correct information is entered into the E-verify system. An initial list of verified/eligible Candidates must be provided to the COR no later than three (3) business days after the initial contract award.

a. When contracts are with individuals, the individuals will be required to complete a Form

I-9, Employment Eligibility Verification, with the designated Government representative.

This Form will be provided to the Contracting Officer and shall become part of the official contract file.

7. DRAWINGS AND SPECIFICATIONS. See attached plans and specifications listed herein for additional work performance requirements to include submittal, testing, and inspection requirements:

A. SECTION B - SUPPLIES OR SERVICES AND PRICES/COSTS

B. SECTION C - DESCRIPTION/SPECIFICATIONS

C. SECTION F - DELIVERIES OR PERFORMANCE

D. SECTION J- LIST OF ATTACHMENTS

8. GENERAL NOTE. Upon completion of work the contractor and Government shall inspect all work for functionality and operation. The contractor shall be responsible for repair or replacement of all damages or non-functioning components prior to final acceptance and repair or replacement of all damages to the work site resulting from work performed under this contract.

SECTION B

SUPPLIES OR SERVICES AND PRICES/COSTS

NOTE: Prices must be on a fixed, firm basis.

UNIT

ITEM DESCRIPTION QTY U/I PRICE AMOUNT

0001 Lock and Dam 24 Wire Ropes 16 EA _________ __________

0002 Lock and Dam 25 Wire Ropes 16 EA _________ __________

NOTE: Any Job (JB) price and payments shall constitute full compensation for all costs associated with furnishing all required components of each Bid Item, following the delivery schedule as outlined in Section F – Deliveries or Performance.

All costs for Bid Items No. 0001 and 0002 shall include, but not be limited to, wire rope fabrication, socket fabrication, socketing of wire rope assemblies, all required testing, inspection of wire rope and assemblies, preparation for shipment and delivery of final assemblies per the contract requirements.

END OF SECTION B

SECTION C

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).

A36 (2014) Standard Specification for Carbon Structural

Steel

A276 (2016a) Standard Specification for Stainless Steel

Bars and Shapes

A492 (1995; R 2013) Standard Specification for Stainless

Steel Rope Wire

A751 (2014) Standard Test Methods, Practices, and

Terminology for Chemical Analysis of Steel Products

A931 (2008; R 2013) Standard Test Method for Tension

Testing of Wire Ropes and Strand

U.S. Army Corps of Engineers (USACE).

EM 385-1-1 (2014) Safety and Health Requirements Manual

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

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; GA. The Contractor

shall submit, for approval, complete data on the material used for speltering.

3.1.4 Wire Rope Manufacturer’s Qualifications Statement; GA. The Contractor shall submit a complete list of previous projects completed within the last 24 months using 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.

3.1.5 Quality Control Plan; FIO. The Contractor shall submit its Quality Control Plan.

3.1.6 Work/Fabrication Schedule; FIO. The Contractor shall

submit its Work/Fabrication Schedule.

3.2 Reports.

3.2.1 Tension Testing; GA. Rope tension test report

3.2.2 Attaching and Proof Loading Termination; GA. Proof load of terminations test report and measured rope lengths.

3.2.3 Wire Strength and Ductility; GA. Wire strength and

ductility test results.

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

3.3 Certificates.

3.3.1 Wire Rope Size, Material, Construction and Certified

Breaking Strength; GA.

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

3.3.3 Warranty; FIO. 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 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 wire rope, pretensioning of the wire rope, cutting of 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 wire rope production, fabricate wire rope, pre-stretch wire rope, tension test wire rope, attach sockets, proof load wire rope assemblies, prepare wire rope assemblies for shipment, delivery of wire rope assemblies. Changes to the submitted work/fabrication schedule shall be submitted in writing to the Contracting Officer.

7. WIRE ROPE AND SOCKETS.

7.1 General. The Contractor shall furnish wire ropes with new sockets at both ends, as indicated on drawing M-L24-7 M-105.1. Each 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 shall be manufactured into wire rope by the same crew. This will insure that each set of wire rope assemblies will not contain any inconsistencies inherent with the wire rope manufacturing process. The quantities of each wire rope assembly shall be as follows.

Item 0001:

Lock and Dam No. 24 Length = 60’ – 6” Quantity: Eight (8) right regular lay and eight (8) left regular lay

Item 0002:

Lock and Dam No. 25 Length = 63’ – 7” Quantity: Eight (8) right regular lay and eight (8) left regular lay

7.2 Wire Rope Test Results and Certification. The Contractor shall submit the following certificates prior to fabrication of the 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 30400

– 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 304 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 in accordance with ASTM A36. The gate sockets shall be constructed of galvanized forged steel.

7.3.1 Miscellaneous Socket Components. The materials for the

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

Component Material Required

Per Assembly

Keeper Bar (B/M No. 63) ASTM A276, Type 304L Steel 1” x 1/2” x

3” 1

Socket Pin (B/M No. 30) 304 stainless steel 1 Socket Pin Washer

(B/M No. 31) 304 stainless steel 1

Socket Pin Spacer (B/M No. 32) 304 stainless steel 2

Cotter Pin (B/M No. 39) 304 Stainless Steel, 1/4” dia. x 4” long 1

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

Rope Classification: 6 x 37.

Rope Construction: 6 x 36 IWRC (Warrington-Seale).

Wire Rope Size: 1”.

Finish: plain.

Material: AISI 304 stainless.

Pre-formed: yes.

Pre-stretch: yes.

Minimum Breaking Strength 77,300 lbs.

Wire rope shall conform to the applicable requirements of FS RR-W-410 for Type I, class 3, construction 6. The wire ropes shall be shop assembled to the valve and drum connecting sockets.

7.5 Pre-Stretching. The manufacturer shall pre-stretch the 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. The manufacturer may propose a method of dynamic pre-stretching.

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. Test results shall be submitted.

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 ropes shall be furnished internally lubricated with manufacturer’s standard lubricant, but externally dry.

7.10 Tension Testing. A tension test shall be performed to verify the wire ropes 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. Submit results of rope tension testing.

7.11 Attaching and Proof Loading Terminations. The manufacturer shall attach the end terminations after pre-stretching the wire rope. The sockets shall be attached such that the orientation of the sockets shall be as shown in the attachments under load. The gate end termination attachment shall be zinc speltered in accordance with industry standards and the Wire Rope User’s Manual. The drum end termination shall be swaged in accordance with manufacturer’s instructions. After their attachment, the wire rope assemblies shall be proof loaded at 40 percent of nominal strength of the rope. Length of the wire ropes shall be measured to the nearest 1/16 inch at the proof load.

7.12 Wire Rope Assembly Documentation and Marking. Each wire rope assembly shall be assigned a unique identification. The designations shall be:

LD24 right lay (number 1 through 8) LD24 left lay (number 1 through 8) LD25 right lay (number 1 through 8) LD25 left lay (number 1 through 8)

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), material, measured length under proof load to the nearest 1/16”, and minimum breaking force from tension test. Along with the documentation, each wire rope assembly shall have the following information included on rope spool: wire rope assembly unique identification, lay configuration, 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 wire rope assemblies. At the Government’s option, a site visit will be made to witness the wire rope fabrication, socket attachment, and proof load testing to include measured 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 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 of sufficient strength to be stackable and packaged 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 shall be delivered F.O.B. destination to the following locations:

Lock and Dam No. 24 Wire Ropes (Item 0001):

Lock and Dam No. 24 350 North 1st Street Clarksville, MO 63336 POC: Ryan Lee, Lockmaster, 573-242-3524 Deliveries received Monday through Friday, 7:00 AM to 4:00 PM

Lock and Dam No. 25 Wire Ropes (Item 0002):

Lock and Dam No. 25 #10 Sandy Slough Winfield, MO 63389 POC: Tony Reis, Lockmaster, 636-566-8120 Deliveries received Monday through Friday, 7:00 AM to 4:00 PM

Technical POC for this contract will be Danny Lunsford (314-560-9470)

11. INSPECTION. Upon delivery to the Government, preliminary inspections of the wire rope assemblies shall be completed upon offloading to determine if damages occurred during transport or offloading. Final inspections shall be performed at a later date just prior to installation. For the final inspection, the wire rope shall be inspected for dings, kinks or other damage. The 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.

END OF SECTION C

SECTION F

DELIVERIES OR PERFORMANCE

1 52.211-8 III TIME OF DELIVERY (JUN 1997)--ALTERNATE III (APR 1984)

(a) The Government requires delivery to be made according to the following schedule:

REQUIRED DELIVERY SCHEDULE

ITEM NO. QUANTITY WITHIN DAYS AFTER THE

DATE OF RECEIPT OF A

WRITTEN NOTICE OF AWARD

0001 1 120 calendar days 0002 1 120 calendar days

The Government will evaluate equally, as regards time of delivery, offers that propose delivery of each quantity within the applicable delivery period specified above. Offers that propose delivery that will not clearly fall within the applicable required delivery period specified above will be considered nonresponsive and rejected. The Government reserves the right to award under either the required delivery schedule or the proposed delivery schedule, when an offeror offers an earlier delivery schedule than required above. If the offeror proposes no other delivery schedule, the required delivery schedule above will apply.

OFFEROR'S PROPOSED DELIVERY SCHEDULE

ITEM NO. QUANTITY WITHIN DAYS AFTER

DATE OF RECEIPT OF A

WRITTEN NOTICE OF AWARD

(End of clause)

2 52.247-34 F.O.B. DESTINATION (NOV 1991)

(a) The term "f.o.b. destination," as used in this clause, means--

(1) Free of expense to the Government, on board the carrier's conveyance, at a specified delivery point where the consignee's facility (plant, warehouse, store, lot, or other location to which shipment can be made) is located; and

(2) Supplies shall be delivered to the destination consignee's wharf (if destination is a port city and supplies are for export), warehouse unloading platform, or receiving dock, at the expense of the Contractor. The Government shall not be liable for any delivery, storage, demurrage, accessorial, or other charges involved before the actual delivery (or "constructive placement" as defined in carrier tariffs) of the supplies to the destination, unless such charges are caused by an act or order of the Government acting in its contractual capacity. If rail carrier is used, supplies shall be delivered to the specified unloading platform of the consignee. If motor carrier (including "piggyback") is used, supplies shall be delivered to truck tailgate at the unloading platform of the consignee, except when the supplies delivered meet the requirements of Item 568 of the National Motor Freight Classification for "heavy or bulky freight." When supplies meeting the requirements of the referenced Item 568 are delivered, unloading (including movement to the tailgate) shall be performed by the consignee, with assistance from the truck driver, if requested. If the contractor uses rail carrier or freight forwarded for less than carload shipments, the contractor shall ensure that the carrier will furnish tailgate delivery, when required, if transfer to truck is required to complete delivery to consignee.

(b) The Contractor shall--

(1)(i) Pack and mark the shipment to comply with contract specifications; or

(ii) In the absence of specifications, prepare the shipment in conformance with carrier requirements;

(2) Prepare and distribute commercial bills of lading;

(3) Deliver the shipment in good order and condition to the point of delivery specified in the contract;

(4) Be responsible for any loss of and/or damage to the goods occurring before receipt of the shipment by the consignee at the delivery point specified in the contract;

(5) Furnish a delivery schedule and designate the mode of delivering carrier; and

(6) Pay and bear all charges to the specified point of delivery.

(End of clause)

END OF SECTION F

SECTION J

LIST OF ATTACHMENTS

REFERENCE DRAWINGS

M-L24-7 M-105.1 Lock and Dam No. 24 – Mechanical – Tainter Valve

Machinery – Cable and Drum Details

End of Section J