412213.30 underhung bridge cranes.pdf

F5W61607 Combined Support Maintenance Shop - Phase II Ohio Army National Guard Rev. 0 Defense Supply Center Columbus, Ohio 30 January 2009 Bid Final

UNDERHUNG BRIDGE CRANES 412213.30 -1

SECTION 412213.30 – UNDERHUNG BRIDGE CRANES

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specifications, apply to this Section.

1.2 SUMMARY

A. This Section includes the following:

1. Underhung patented track bridge crane 2H6.

B. System shall be a modular design permitting expansion or relocation and include:

1. Hanger assemblies.

2. Hoist trolleys.

3. End trucks.

4. Festoon trolleys.

5. Festoon clamps.

6. End stop bumpers.

7. Universal bumper.

8. Stack section.

9. Flat cable.

C. Related Sections:

1. Section 051200 "Structural Steel Framing" for additional information about the steel products associated with this work.

1.3 SUBMITTALS

A. Product Data: Include rated capacities; shipping, installed, and operating (loaded) weights; furnished specialties; and accessories.

B. Shop Drawings: Prepared by or under the supervision of a qualified professional engineer detailing fabrication and assembly of cranes, as well as procedures and diagrams.

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1. For installed products indicated to comply with design loads, include structural analysis data signed and sealed by a professional engineer registered in the state of Ohio.

C. Product Certificates: For each type of crane, signed by product manufacturer. Submit a copy of load test certification from the Crane Manufacturer.

D. Welding certificates.

E. Field quality-control test reports.

F. Operation and Maintenance Data: For cranes to include in emergency, operation, and maintenance manuals. In addition to items specified in Section 01782 "Operation and Maintenance Data."

1.4 QUALITY ASSURANCE

A. Installer Qualifications: An authorized representative of crane manufacturer for installation and maintenance of units required for this Project.

1. Maintenance Proximity: Not more than 2 hours' normal travel time from Installer's place of business to Project site.

2. Installer's responsibilities include fabricating and installing cranes and providing professional engineering services needed to assume engineering responsibility.

3. Engineering Responsibility: Preparation of data for cranes, including Shop Drawings, based on testing and engineering analysis of manufacturer's standard units in assemblies similar to those indicated for this Project.

B. Manufacturer Qualifications: A qualified manufacturer with a minimum of 10 years in the field of manufacturing bridge cranes. Provide list of five projects similar in scope, with names of Architects, Contractors, with the years and locations of installations.

C. Welding: Qualify procedures and personnel according to AWS D1.1, "Structural Welding Code--Steel D1.3, "Structural Welding Code--Sheet Steel D1.4, and "Structural Welding Code--Reinforcing Steel."

D. Regulatory Requirements: Fabricate and label crane to comply with applicable safety and electrical codes.

E. Certificates: Submit Overload Test Certificate stating that the crane design load is based on rated capacity plus 15% for weight of hoist and trolley and an additional 25% for impact or a total design capacity of 1.4 (at speeds up to 50 fpm.)

F. Preinstallation Conference: Conduct conference at Project site. Review methods and procedures related to cranes including, but not limited to, the following:

1. Review structural load limitations.

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2. Review and finalize construction schedule and verify availability of materials, Installer's personnel, equipment, and facilities needed to make progress and avoid delays.

3. Review required certifying procedures.

1.5 COORDINATION

A. Coordinate delivery of crane with Installer and Contracting Officer.

B. Consult user on hook/adapter, and hoist speed prior to submission of product data and shop drawings.

1.6 WARRANTY

A. Warranty: Manufacturer's standard form in which manufacturer agrees to repair or replace components of cranes and electrical controls that fail due to materials or workmanship within specified warranty period.

1. Failures include, but are not limited to, the following:

a. Structural failures.

b. Faulty operation of electronic controls.

c. Deterioration of metals, metal finishes, and other materials.

B. Crane manufacturer shall guarantee the cranes and hoist against all defects on material and workmanship for a period of one year after date of substantial completion.

PART 2 - PRODUCTS

2.1 MANUFACTURER

A. Basis-of-Design: The design and performance for the cranes is based on products by the following manufacturer. Subject to compliance with requirements, provide products by an approved manufacturer that complies with the specification requirements.

1. Manufacturer: Underhung Patented Track Bridge Cranes by Cleveland Tramrail/Gorbel Corporation.

a. Contact Information: Gorbel, Inc., 600 Fishers Run, P.O. Box 593, Fishers, NY 14453, telephone 585-924-6262.

2. Or comparable product by one of the following or equivalent:

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a. Spanco, Inc., Morgantown Business Park, 604 Hemlock Road, Morgantown, PA 10543, telephone 610-286-7200.

b. EMH, Inc., 550 Crane Drive Liverpool Industrial Park, Valley City, OH 44280, telephone 330-220-8600.

2.2 BRIDGE CRANE – NUMBER 2H6 (Rebuild Area)

A. Provide free standing crane as follows:

1. Capacity: 2 tons.

2. Span: Approximately 33 feet. Refer to drawings.

3. Travel: Approximately 50 feet. Refer to drawings.

4. Min. Hook Travel Distance: Floor to 10 feet.

5. Speed: 2-speed vertical; manual trolley and bridge; maximum hoist speed 20 fpm with full load.

6. Manual trolley and bridge.

7. Controls: Pendant type.

2.3 CRANES, GENERAL

A. Cranes shall be complete systems including rails, bridges trolleys, drives, electrification bars, hoists, electrical panels, controls, and pendant controllers.

B. Bridge cranes, bridges, and trolleys shall comply with ANSI MH27.1 Specifications for Patented Track Underhung Cranes and Monorail Systems” Duty Service Classification C (Moderate Service).

C. Hoists shall comply with ASME HST-4 "Performance Standard for Overhead Electric Wire Rope Hoists” service classification “H3."

D. Safety: Comply with mandatory and advisory safety requirements of ASME B30.11, ASME 30.16, 29 CFR 1910.147, 29 CFR 1910.179, 29 CFR 1910.306, and all applicable provisions of 29 CFR 1910, Title 8, Subchapter 7 and all applicable requirements of the State of Ohio.

E. Provide complete system with the following components and restrictions:

1. Spans and travel shall be as shown on the Drawings. Spans and travel shown on equipment schedules are approximate.

2. Hook heights shall be as shown on the Equipment Schedule.

3. Flush mounted hanger assemblies with beam clips or clamps. Drilling or welding support beams is prohibited.

4. Stops at end of rails.

5. Runway electrification: Flat festoon cable carried by adequate number of festoon trolleys.

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6. Hoist shall be electrically powered with variable frequency drives (VFDs) permitting operation at very slow speed and adjustment of maximum speed, up to specified maximum speed, in the control panel.

7. Hoist: Provide with mechanical load brake capable of holding rated load stationary for extended periods of time.

8. Bridge and trolley shall be manually movable with force required to move the load not more than one one-hundredth of load. (A 1,000 lb load shall require no more than 10 lb of force to move it.)

9. Hoist shall be pendant controlled:

2.4 ELECTRICAL DESIGN

A. Design, selection, rating and installation of the electrical portions of the crane and its accessories shall conform to the requirements of NEMA ICS 3, ASME HST-4 and NFPA 70, and other requirements specified. The crane manufacturer shall furnish and install all electrical equipment on the crane, including motor, electrically released brakes, switches, controllers, panels, operation station, wiring system, cables, conduits and bridge-to-trolley electrification, the runaway electrification and wiring to the junction box indicated. Provide NEMA Type 12, and defined by NEMA 250, enclosures for controls.

2.5 HOISTING ROPES

A. FS RR-W-410. Hoisting ropes shall be 6 by 37 class construction, improved or extra improved plow steel, with an independent wire rope core. Maximum hoisting rope fleet angles shall be 4 degrees for drums and 4.75 degrees for sheaves. Hoisting rope end connections, other than drum connections, shall be speltered sockets with forged steel terminals. Provide proof of wire rope breaking strength. Provide wire rope minimum safety factory of 5 to 1 based on the ratio of actual minimum wire rope breaking load to the calculated load on rope when hoist is assumed loaded to rated capacity. Certification from rope manufacturer, verifying provided wire roping breaking strength, shall be submitted to Contracting Officer and approved prior to final acceptance of hoist. No paint or coatings shall be allowed on the wire rope. Minimum length of the wire rope shall enable the load hook to operate through its full hook lift range and still have a minimum of two full wraps of wire rope around the rope drum.

2.6 MOTORS

A. AISC 348 NEMA MG 1. Provide single speed AC squirrel cage induction type motors for the hoist. Motor insulation shall be Class F. Provide totally enclosed non-ventilated (TENV) motor enclosure.

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2.7 FINISHES, GENERAL

A. Finish: Manufacturer's standard color paint applied to factory-assembled and -tested cranes before shipping.

1. Provide touch-up paint from manufacturer in colors matching delivered equipment.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine substrates and conditions, with Installer present, for compliance with requirements for installation tolerances and other conditions affecting performance of work.

B. Proceed with installation only after unsatisfactory conditions have been corrected.

3.2 INSTALLATION, GENERAL

A. Shop assemble cranes and crane components to the maximum extent to facilitate erection and minimize field labor. Size each assembly so that it can be transported by common carrier without disassembly insofar as shipping clearances are concerned.

Protect parts and equipment delivered to the site from weather, damage, abuse and loss of identification. Ensure that the cranes are erected without initial stresses, forced or improvised fits, misalignments, stress-raising welds and rough burrs.

Solvent-clean wire ropes to remove all preservative and grease-lubricant in accordance with wire ropes manufacturer's recommendations prior to reeling. Erect crane within 30 days of the initial delivery of components. After the crane is erected, clean and retouch damaged painted surface.

B. Crane manufacturer shall provide supervisory erection service.

3.3 FIELD QUALITY CONTROL

A. Post-Erection Inspection: After erection, the Contractor and the Contracting Officer shall jointly inspect the crane bridge and hoist systems and components to determine compliance with specifications and approved submittals. Contractor shall notify Contracting Officer 14 days prior to the inspection. Provide a report of the inspection indicating the crane is considered ready for operational tests.

B. Operational Tests: Provide operation tests for each crane unit. After erection and inspection, test the hoist, bridge, and trolley as specified. Perform the 125 percent rated load test with the bridge and trolley located to obtain maximum loads on the

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bridge and runway girders. Test the system in service to determine that each component of the system operates as specified, is properly installed and adjusted, and is free from defects in material, manufacture, installation and workmanship.

Rectify all deficiencies disclosed by testing and retest the system or component to prove the crane is operational. Contractor shall furnish test loads/rigging, operating personnel, instruments and other apparatus necessary to conduct field tests on each crane.

C. Test Data: Record test date on appropriate test record forms suitable for retention for the life of the cranes. Record operating and startup current measurements for electrical equipment (motors and coils) using appropriate instrumentation, such as clamp-on ammeters. Compare recorded values with design specifications or manufacturer's recommended values; abnormal differences, those greater than 10 percent from manufacturer's or design values, shall be justified or appropriate adjustments performed. In addition, high temperatures or abnormal operation of any equipment or machinery shall be noted, investigated and corrected. Record hoist, trolley and bridge speeds during each test cycle.

D. Test Hook: Measure hook for hook throat spread before and after load test. Establish a throat dimension base measurement by installing two tram points and measuring the distance between these tram points, plus or minus 1/64-inch. Record this base dimension. Measure the distance between tram points before and after load test. An increase in the throat opening by more than 5 percent from the base measurement shall be cause for rejection.

E. No-Load Test: Raise and lower the hook through the full range of normal travel at rated speed for three complete cycles. Raise and lower the hook, testing other speeds of the crane. Verify proper operation of hoist limit switches.

F. Load Tests: Perform for each crane. Perform the following tests, as specified, with test loads of 50, 100 and 125 percent of rated load. If the hoist is equipped with an overload limit device, disconnect it to allow the hoist to lift the test load. Proof test the overload limit device after it is reconnected. Submit a copy of load test certification from the Crane Manufacture.

1. Static Load: 125 percent only. Check entire structure, holding brake and hoisting components as follows: Raise the test load approximately one foot.

Hold the load for 10 minutes. Rotate the load and hook to check bearing operation. Observe lowering that may occur indicating a weakness in the structure or malfunction of hoisting components or brakes.

2. Dynamic Load Tests: Raise and lower and test load through the full lift range.

Lower the load to the floor, wait 5 minutes, then raise and lower the load through two more cycles. As a minimum, operate in each speed for each test load. In addition, the dynamic test of load sequence number 2 (100 percent of rated load) shall be repeated for 10 cycles at rated speed, in order to demonstrate proper operation and repeatability of all functions without component overheating or malfunction. Completely stop the machinery at least once in each direction during each cycle to ensure proper brake operation. The

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hoist shall not be stopped for more than 15 seconds prior to commencing the next cycle.

3. Hoist Load Brake (at 125 percent only): Raise test load approximately 5 feet.

With the hoist controller in the neutral position, release by hand the holding brake. The load brake should hold the test load. Again with the holding brake in the released position start the test load down (first point) and return the controller to the "off" position as the test load lowers. The load brake should prevent the test load from accelerating.

4. Hoist Loss of Power Test (at 125 percent only): Raise the test load to approximately 8 feet. While slowly lowering the test load (first point), disconnect the crane's power source. Verify that the test load does not lower and that the brake is set.

3.4 DEMONSTRATION

A. Engage a factory-authorized service representative to train Government's maintenance personnel to adjust, operate, and maintain cranes and controls. Make training arrangements through Contracting Officer.

END OF SECTION 412213.30