NAVFAC Design-Build Model Request for Proposal - Child Development Center

D10 GENERAL

RFP Part 3 including the Engineering System Requirements (ESR) provide project specific requirements.  The RFP Part 4, Performance Technical Sections (PTS) provide generalized technical requirements that apply to multiple facility types and include more requirements than are applicable to any one project. Therefore, only the RFP Part 4 requirements that apply to the project and further define the RFP Part 3 project specific requirements are required.

Comply with the requirements of UFC 1-200-01, DoD Building Code.

NOTE:  All new passenger elevators must comply with ABA Standards requirements. 

D10 1.1 DESIGN GUIDANCE

Provide the design and installation in accordance with the following references.  This Performance Technical Specification (PTS) adds clarification to the fundamental requirements contained in the following Government Standards.  The general requirements of this PTS section are located in PTS Section Z10, General Performance Technical Specification.

Industry standards, codes, and Government standards referenced in the section text that are not found in the Unified Master Reference List (UMRL) in the Federal Facility Criteria (FFC) at the Whole Building Design Guide (WBDG) website, are listed below for basic designation identification.  Refer to the UMRL for full reference standard title and current document date.  Comply with the required and advisory portions of the current edition of the referenced standard at the time of contract award.

NOTE: Do not use this specification to procure cranes, monorail systems or hoist that have the following requirements;

(a) Nine (9) metric ton (10 short ton, 9072 kg, 20,000 pounds) capacity or greater;

(b) Cranes that operate in "hazardous locations" as defined in the National Electrical Code;

(c) Cranes intended for precision handling operations requiring complex or synchronized lifting;

(d) Cranes that handle hot (molten) metals or ordnance. 

(e) Cranes for special purpose service associated with servicing of nuclear reactors and related components.

Contact the Naval Facilities Engineering Command, Navy Crane Center, for assistance with equipment in these categories (See NAVCRANECEN Instruction 11450.1A).

NOTE:  This PTS Specification covers the design and construction of facility bridge cranes, girder cranes, and monorails.  Other types of cranes require a prescriptive specification to be written and placed in RFP Part 5 as a programmatic requirement.  Refer to the Whole Building Design Guide, UFGS website and/or contact the Naval Facilities Engineering Command, Navy Crane Center, to obtain other types of crane specification templates.

D10 1.1.1 Industry Standards and Codes

Although some the following references are listed in the UMRL, they are repeated here for emphasis.

References publications in this RFP that refer to the "authority having jurisdiction" must be interpreted to mean the "Contracting Officer."

AMERICAN GEAR MANUFACTURERS' ASSOCIATION (ANSI/AGMA)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

AMERICAN WELDING SOCIETY (AWS)

NATIONAL FIRE PROTECTION ASSOCIATION

RESEARCH COUNCIL ON STRUCTURAL CONNECTIONS (RCSC)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

D10 1.1.2 Government Standards

NAVAL FACILITIES ENGINEERING COMMAND (NAVFAC)

NAVAL SEA SYSTEMS COMMAND (NAVSEA)

 US NATIONAL ARCHIVES AND RECORDS - OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (NARA/ OSHA) - Code of Federal Regulations (CFR)

 U.S. DEPARTMENT OF DEFENSE (DOD) UNIFIED FACILITIES CRITERIA (UFC)

D10 1.2 PERFORMANCE VERIFICATION AND ACCEPTANCE TESTING

Provide verification of satisfactory Conveying systems performance via Performance Verification Testing, as detailed in this section of the RFP.

D10 1.2.1 Testing and Inspections for Elevators

1. Conduct all testing and inspections in the presence of both the Elevator Specialist and a NAVFAC Certified Elevator Inspector. The Elevator Inspector must complete, sign and post the results of all tests and inspection results after successful completion of inspection and testing. The Contractor is responsible for all costs involved with reinspection and retesting required to correct discrepancies discovered during testing and the subsequent retesting required, including all costs and expenses incurred by the Government Furnished Inspector.
2. Testing Materials and Instruments
   Provide testing materials and instruments required for final inspection, including a current equipment calibration certification.
3. Field Tests for Elevators
   
   In addition to the tests required by AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) A17.1 AND ASME A17.2, perform the following:
   
   (1)  Endurance Tests - Test each elevator for a period of one hour continuous run, with specified rated load in the car. Restart the one hour test period from beginning, following any shutdown or failure. During the test run, stop car at each floor in both directions of travel for standing period of 10 seconds per floor. Meet the requirements for Rated Speed, Leveling, Temperature Rise, and Motor Amperes testing specified herein throughout the duration of the Endurance test.
   
   (2)  Speed Tests - Determine actual speed of each elevator in both directions of travel with rated load and with no load in elevator car. Minimum acceptable elevator speed is the Rated speed specified.  Maximum acceptable elevator speed is 110 percent of Rated speed.
   
   (3)  Leveling Tests - Test elevator car leveling devices for landing accuracy of plus or minus 1/4-inch (6 mm) at each floor with no load in car, symmetrical load in car, and with rated load in car in both directions of travel. Car sill must be level with landing sills.
   
   (4)  Temperature Rise Tests - Determine temperature rise of elevator hoisting motor, motor-generator, exciter, and booster during full-load test run for one hour minimum. Under these conditions, maximum acceptable temperature rise must not exceed acceptable temperature rise indicated on manufacturer's data plate. Start test only when equipment is within 9 degrees F (5 degrees C) of ambient temperature.
   
   (5)  Motor Ampere Tests - Measure and record motor amperage when motor is running and elevator is lifting at rated load and speed. Measure and record motor amperage at beginning and end of Endurance test.  Test results must not exceed nameplate amperage when motor is running and elevator is lifting at rated load speed.
   
   (6)  Balance Load for Electric Elevators Tests - Perform electrical and mechanical balance load tests of car and counterweight.
   
   (7)  Automatic Shutoff Valve Tests - For hydraulic elevators, test the automatic shutoff valve twice. Once at beginning of acceptance test and again at conclusion of one-hour Endurance test to ensure consistent performance of shutoff valve, regardless of temperature of equipment and oil.
   
   (8)  Perform miscellaneous tests called for in this Section.

D10 1.2.2 Crane System and Monorail with Hoist/Trolley System Installation and Certification

Provide verification of satisfactory conveying systems performance via Inspection and Testing, as detailed in this section of the RFP. Erect and install the crane or monorail system, complete in accordance with the approved submittals and in condition to successfully perform the inspections, operational tests, and acceptance tests listed below. In addition, provide statements and certifications listed below.

a. Certification  

The following certifications are required to be submitted and approved prior to acceptance load testing.

(1)  Load Chain or Wire Rope - Submit wire rope or chain manufacturer's certification of minimum wire rope or load chain breaking force for each hoist.

(2)  Overload Test Certificate - Submit a statement that the crane or monorail system and hoist/trolley can be periodically load tested at up to 125 percent of rated load.

(3) Loss of Power Test Certificate - Submit a statement that the crane or monorail system can be subjected to loss of power testing without damage (See paragraph entitled "Load Test").

(4)  Hazardous Material Certificate - Submit a statement that the crane or monorail system contains no asbestos, lead paint, polychlorinated biphenyl's (PCB's), elemental mercury and that chromates have been avoided where feasible.

 (5)  Hook Proof Test - Submit a statement that load and suspension hooks have been proof tested and satisfy the acceptance criteria of ASME B30.10.

(6)  Welding Certifications 

 (a)  Submit a statement that all welders, welding operators, weld inspectors and welding procedures meet the requirements of AMERICAN WELDING SOCIETY (AWS) D14.1 for all work performed in manufacturing the cranes.

 (b)  Submit a statement that all welders, welding operators, weld inspectors, and welding procedures meet the requirements of AWS D1.1 for all field welds.

 (7)  Design Review by Professional Engineer - Submit a statement that non-commercial component design and any modifications to commercial products have been reviewed by a professional engineer.  Indicate on the certificate, the name, state of licensure and license number of the professional engineer.

 (8)  Crane Runway Rail - For runway rails provided as part of this contract, submit survey data and a statement that the runway rails are in accordance with the requirements of CRANE MANUFACTURERS' ASSOCIATION OF AMERICA (CMAA) 70, Table 1.4.2-1, or MH 27.1, Figure 1, as applicable.

(9) Frequency Allocation Application - Complete the technical section of the Application for Equipment Frequency Allocation, Form DD 1494, addressing the radio equipment provided, submitted by the manufacturer of the radio control equipment being furnished under this contract.

b.  Inspection and Testing

After erection, jointly inspect the crane or monorail system and associated components to determine compliance with specifications and approved submittals with representatives of the Contracting Officer and of the end user's Weight Handling Equipment (WHE) Certifying Official.  The WHE certifying official is the designated representative of the supported command empowered to designate lifting and handling equipment acceptable for use.  Provide a report of the inspection indicating the crane or monorail system is considered ready for operational tests

(1)  Operational Tests - After erection and inspection, test the crane or monorail system and hoist/trolley as specified herein.  Test the systems in service to determine that each component 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 under load to prove the system is operational.  Furnish loads for testing, operating personnel, instruments, and all other necessary apparatus.

(2)  Test Data - Record test data on appropriate test record forms suitable for retention for the life of the crane or monorail system.  Record operating and startup current measurements for electrical equipment (motors) using appropriate instrumentation (i.e., clamp-on ammeters).    In addition, note, investigate, and correct high temperatures or abnormal operation of any equipment or machinery.  Record function speeds during each test cycle.

(3)  Hook Measurement

(a)  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.  Record this base dimension.  Measure the distance between tram points after load test.  Any twist or increase in the throat opening from the base measurement will be cause for rejection.

(b)  Hook Identification - Uniquely identify each hook and nut or eye pin (and swivel eye bar as applicable) with some type of permanent marking in order to provide positive traceability to the non-destructive test report.  Mark hooks in low stress areas using low stress marking methods. 

(4)  Load and Suspension Hook Inspection - Non-Destructive Test (NDT) the entire hook, eye pin (and swivel eye bar as applicable) for defects.  No linear indications greater than 1/16 inch (1.6 mm) is the acceptance criterion.  Acceptance criteria for external hook threads may be based on the acceptance criteria in SAE standard J123.  Use magnetic particle method in accordance with NAVAL SEA SYSTEMS COMMAND (NAVSEA) Technical Publication T9074-AS-GIB-010/271 for NDT.  American Society for Testing and Materials (ASTM) A275 may be used with the following restrictions: DC yokes (including switchable AC/DC yokes used in the DC mode) and permanent magnet yokes must not be used; automatic powder blowers or any other form of forced air other than from a hand-held bulb must not be used for the application or removal of dry magnetic particles; arc strikes shall be removed; and equipment ammeters must have an accuracy of +/- 5 percent of full scale (equipment ammeter accuracy other than that stated is acceptable provided the MT procedure states that a magnetic field indicator is used to establish and verify adequate field strength for all aspects of the inspection).  For hooks of non-magnetic material, use liquid penetrant (PT) method in accordance with ASTM E 1417 or T9074-AS-GIB-010/271 for NDT.  For PT testing of hooks containing stainless steels, titanium, or nickel-based alloys, total halogens, and sulphur used in the NDT process must be controlled as specified in T9074-AS-GIB-010/271.  If NDT cannot be performed on surfaces inside small holes (e.g. hook/nut captivation roll pin holes), visually inspect those surfaces to the maximum extent practical.  Perform NDT prior to load tests.

(5). Non-Destructive Test Quality Assurance Requirements.

 (a)  The magnetic particle inspection report must include a letter from the performing vendor certifying that the vendor meets the requirements of ASTM E543.  Provide current certification, within one year of the date the NDT was performed.

(b)  In addition, include report procedures, for review, including technique sheets specific to the types, shapes, and sizes of the parts being examined (e.g., shank hook, eye hook, duplex hook, eye pin, swivel eye bar).  Describe the orientation of the hook or pin to the magnetizing equipment in the procedures.

 (c)  Indicate review by an independent Level III examiner certified in the applicable NDT method and not an employee of the NDT vendor in the procedures.

 (d)  In lieu of a., b., and c. above, state in the NDT report that non-destructive testing was performed per Crosby Quality Control Procedure No. 0120, Revision 16, and Technique Sheet No. 319N, Revision 1, or Gunnebo Johnson Quality System Procedure QSP-69, Revision A.

(6)  No-Load Test

(a)  Hoist:  Lower and raise each load hook through the hoist range.  Operate at various speeds in both directions. Operate each load hook slowly the full operating lift distance into the hoist primary limit switch or stop and verify satisfactory operation of hoist, upper limit switch or stop, and lower limit switch or stop.  Verify that a minimum of two wraps remain on the drum for wire rope hoists and that the load chain is slack on the dead end side for chain hoists when the lower limit switch is engaged.  If the hoist is equipped with slow down limits, verify proper operation during the hook travel test.  For electric or air powered hoists with primary and secondary limit switches, bypass the primary upper limit switch and check for proper operation of the backup limit switch.  For electric hoists, verify all power to hoist is removed upon actuation of backup limit switch, and the keyswitch reenergizes hoist and allows operation in the down direction only. Operate the hoist at gradually increasing speed to full speed in the up direction until the primary upper limit switch activates.  Verify that the hoist stops prior to secondary limit switch operation.  Operate the hoist at gradually increasing speed to full speed in the up direction with the primary limit switch bypassed until the secondary upper limit switch is activated.  Verify that the hoist stops prior to the load block contacting any portion of the hoist frame.  For hoists with two electromechanical brakes, remove power to the crane and observe the proper timing sequence in the application of the primary and secondary brake.

(b)  Trolley:  Operate the trolley the full length of the monorail or crane bridge rails in both directions.  Check the existence of OSHA required 2 inch side and 3 inch overhead clearances during the trolley operation check.  Operate at all various speeds in each direction.  Verify proper trolley brake operation, if equipped.  Slowly contact all trolley stops with the bumpers to verify even bumper contact and that there will be no contact between the crane and any obstruction within the crane envelope with the bumpers fully compressed. Contact the trolley stops with the bumpers at full rated speed, unpowered, and verify structural integrity and that there was no contact between the crane and any obstruction within the crane envelope with the bumpers fully compressed.

 (c)  Bridge (if equipped):  Operate the crane assembly the full length of the crane runway in both directions.  Check the existence of OSHA required 2 inch side and 3 inch overhead clearances during the bridge operation check. Operate at all available speeds in each direction.  Verify proper bridge brake operation, if equipped.  Slowly contact all bridge end stops with crane bumpers to verify even bumper contact and structural integrity and that there will be no contact between the crane and any obstruction within the crane envelope with the bumpers fully compressed. Contact the runway stops with the bumpers at full rated speed, unpowered, and verify structural integrity and that there was no contact between the crane and any obstruction within the crane envelope with the bumpers fully compressed.

(7)  Rated Load Speed Test - Test at 100 percent (plus 0 percent minus 5) of rated capacity.  If the crane is equipped with multiple trolleys that are used to achieve the rated load of the crane (e.g., two 2,000 pound trolleys which together allow for a 4,000 pound maximum capacity), then perform this bridge rated load speed test with the multiple trolleys loaded simultaneously. 

(a) With the hoist loaded to rated capacity, raise and lower the load and record maximum and minimum load speeds in each direction.  Also record the voltage and steady state motor amperage draw in both directions at maximum speed.  Verify that the hoisting and lowering speeds are provided as specified. Verify slow speed operation (if equipped).

(b) If the capacity overload limit activates during lifting of the rated load (typical of the adjustable type), verify that the drive stops and the load can only be lowered.  Bypass capacity overload device utilizing keyswitch and continue with test.

(c) With the hoist loaded to rated capacity and the load lifted a minimum distance, operate the trolley along the crane bridge, or monorail and record maximum and minimum load speeds in each direction.  Also record the steady state motor amperage draw in both directions at maximum speed.  Verify that the trolley speeds are provided as specified.  Further, verify that the trolley comes to a stop from maximum speed in each direction within a distance (in feet) equal to 10 percent of rated capacity high speed (in feet per minute). Verify slow speed operation (if equipped).

(d) With the hoist loaded to rated capacity and the load lifted a minimum distance, operate crane bridge (if equipped) along the crane runway and record maximum and minimum load speeds in each direction.  Also record the steady state motor amperage draw in both directions at maximum speed.  Verify that the bridge speeds are provided as specified.  Further, verify that the crane bridge comes to a stop from maximum speed in each direction within a distance (in feet) equal to 10 percent of rated capacity high speed (in feet per minute). Verify slow speed operation (if equipped).

(e) With the hoist loaded to rated capacity and the load lifted a minimum distance, operate the swing function (if equipped) at maximum and minimum radius and record maximum and minimum load speeds in each direction.  If swing function is powered, record the steady state motor amperage draw in both directions at maximum speed.  Verify that the swing speeds are provided as specified.  Further, verify that the boom comes to a stop and retains its position. Verify slow speed operation (if equipped).

(8)  Rated Load Deflection Test - Test at 100 Percent (plus 0 percent minus 5) of rated capacity.

 (a) With the unloaded trolley moved to one end of the bridge or monorail, measure the height of a point near the midpoint of a bridge crane, near the midpoint of the longest unsupported length of a monorail.

(b) With the hoist loaded to rated capacity, move the trolley to the midpoint of the bridge, midpoint of the longest unsupported length of a monorail.  Repeat the measurement taken in step a.  Record the difference between the measurements taken in step a. and step b.

 (c) Verify that the difference recorded in step b. is less than 1/888 of the span for top running and cambered underunning girder bridge cranes, 1/600 of the span for uncambered underrunning bridge cranes, 1/450 of the longest unsupported length for monorails. Patented track deflection may not exceed 1.25 inch regardless of span.

 (d) For bridge cranes, move the unloaded bridge crane over a runway structural support, move the trolley to the opposite end of the bridge, and measure the height of a point near the midpoint of the longest unsupported length of runway.  Hoist a load at rated capacity a minimum distance, move the trolley to the end of the bridge nearest the structural support, and travel the bridge to the midpoint of the longest unsupported length of runway.  Repeat the measurement. Record the difference between the measurements.  Verify that the difference is less than 1/450 of the unsupported span length for patented rail and underrunning runways, or 1/600 of the longest unsupported length for top running rolled shape runways.  Patented track deflection may not exceed 1.25 inch regardless of span.

(9)  Load Test - Test at 125 Percent (plus 0 percent minus 5) of rated capacity.  If the crane is equipped with multiple hoists or trolleys that are used to achieve the rated load of the crane (e.g., two 2,000 pound trolleys which together allow for a 4,000 pound maximum capacity), then perform these tests with the multiple hoists or trolleys loaded simultaneously. During load testing, only lift the test load a minimum height as necessary to perform the specified tests.

(a)  If the capacity overload limit activates during lifting of the test load (typical of the adjustable type), verify that the drive stops and the load can only be lowered.  Bypass capacity overload device utilizing keyswitch and continue with test

(b) Hoist Static Test:  Raise test load approximately 12 inches (300 mm) above the floor and hold for 10 minutes.  Rotate load and hook 360 degrees clockwise and counter-clockwise to check bearing operation.  Observe for load lowering that may occur indicating possible malfunction of hoisting components or brakes.  Lower the test load to the floor until the hoist line is slack.

 (c) Hoist Dynamic Test:  Raise the test load using all available speeds. Lower the load back to the floor using all speeds.  Visually observe smooth control and acceleration/deceleration between speeds.  Stop the test load at least once while hoisting and once while lowering at highest speed and observe that the brake stops and holds the load. Repeat the above cycle for at least 15 minutes.

(d)  Load Brake Test (for powered hoists equipped with mechanical load brake and single holding brake): 

1. Raise test load no more than 5 feet (1.5 meters).  With the hoist controller in the neutral position, release the holding brake.  The load brake must hold the test load. 

2. Raise test load the minimum amount to perform the following test.  Again, with the holding brake in the released position, start the test load down slowly and return the controller to the neutral position as the test load lowers.  The load brake must stop and hold the test load.

3. Document the method used to release the holding brake.  Brake release method must be recorded to enable repeating that method during later periodic load testing by the end user.  Methods of releasing the holding brake vary from hoist to hoist depending upon the design of the brake and hoist and must be specified by the crane manufacturer prior to testing. 

(e)  Trolley:  With test load hoisted to a minimum height, operate the trolley the full distance of the monorail or crane bridge in both directions using slow speed.  Verify satisfactory operation.  Verify proper brake operation, if equipped.

(f)  Bridge (if equipped):  With test load hoisted to a minimum height and the trolley at one end of the bridge, operate the crane assembly the full length of the crane runway.  Move the trolley to the opposite end of the bridge, then operate the crane assembly the full length of the crane runway in the opposite direction.  Verify satisfactory operation and that bridge trucks move without binding.  Verify proper brake operation, if equipped. 

(g)  Loss of Power Test:  Raise the test load approximately 3 feet (900 mm) and while lowering test load, disconnect main power to hoist and return the hoist controller to neutral.  Load must stop.  Repeat the test for the trolley, bridge and swing functions, as applicable. 

c.  Field Test Reports.

NOTE:  The brake adjustment record form is available at the https://portal.navfac.navy.mil/portal/page/portal/NAVFAC/NAVFAC_WW_PP/NAVFAC_NCC_PP under the Downloads page.

(1)  Brake Adjustment Records.  Provide a brake adjustment record for each brake on the crane or monorail system that contains the adjusted air gap, measured brake lining thickness, measured torque spring length, as well as the manufacturer provided range of acceptable measurement for each.  Submit the brake adjustment records on the official form, which can be obtained from the Contracting Officer upon request.

(2)  Field Test Record.  Upon successful completion of all testing, submit a copy of the completed test record and all test data.

(3)  After the crane has passed the acceptance test, complete a control system parameter record for the crane including all control system parameters, and explanation of their functions, and their final settings.  Designate each control system parameter as either used or unused.

D10 1.3 DESIGN SUBMITTALS

Provide design submittals in accordance with PTS Section Z10, General Performance Technical Specifications, Part 2 Section 01 33 10.05 20, Design Submittal Procedures, Facilities Criteria (FC) 1-300-09N, Navy and Marine Corps Design Procedures, UFC 3-101-01, Architecture and UFC 3-301-01, Structural Engineering.  Provide design submittals that include the following items:

a. Elevators and Weight Handling Equipment (WHE):

(1)  Drawings.  Show the design of the track beam system, including weight handling equipment curves and switches, principal dimensions, details of structural connections, all component details, and electrical one-line diagrams.  Show clearances between elevator and/ or crane structure and building and identify interferences. Provide weight handling equipment wheel load diagrams and hook configuration.

 (2)  Specification. Provide edited version(s) of the UFGS elevator and weight handling equipment specification(s) that are applicable to this project. Edit the UFGS's in accordance with restrictions of RFP Part 4 - PTS Section Z10 and refer to Part 2 Section 01 33 10.05 20, Design Submittal Procedures for format and further specification requirements. Do not add or delete requirements to the UFGS for weight handling equipment unless specifically approved by Navy Crane Center.  Edit UFGS for weight handling equipment only to add project specific information such as capacity and hook height.  Submit the applicable UFGS as a part of the Contractor originated design submittal, DO NOT submit RFP Part 4 - D10 as part of the design submittal.

 If this RFP includes a type of elevator and weight handling equipment that is not covered in this D10 PTS Section and is specified in a Prescriptive Specification located RFP Part 5, include this Prescriptive Specification in the Contractor's design submittal without modification. 

(3) Catalog Cuts.  Include catalog cuts in addition to the UFGS sections for all major components.  Mark and highlight all catalog cuts to identify all the specific components that are applicable to the project.

D10 1.4 CONSTRUCTION SUBMITTALS

NOTE:  Coordinate with PM and CM who will provide approval or surveillance of the elevator and crane construction drawings and designate who has that responsibility in Part 2 Section 01 33 00.05 20, Construction Submittal Procedures.

Submit construction submittals in accordance with PTS section Z10, General Performance Technical Specifications.  In addition to the Z10 requirements, the Designer of Record (DOR) will approve the following construction submittals as a minimum:

a.  Construction Submittals for Vertical Transportation Equipment (VTE)

(1)  Elevator Construction Submittals 

In addition to the submittal requirements of ASME A17.1, provide the following submittals:

Detail drawings must include dimensioned layouts in plan and elevation showing the arrangement of elevator equipment, accessories, supporting systems, anchorage of equipment and anchorage forces from seismic, gravity, impact, etc. loads, clearances for maintenance and operation; and details on hoistway, doors and frames, operation and signal stations, controllers, motors, guide rails and brackets, and points of interface with normal power, fire alarm system, HVAC or exhaust systems, and interface with emergency power systems. Drawings must show any revised building electrical system required to make supplied elevator system function as specified. Drawings must contain complete wiring diagrams showing electrical connections and other details required to demonstrate sequence of operations and functions of system devices. Drawings must include the appropriate sizing of electrical protective devices, which are frequently different from National Electrical Code standard sizes.

Submit one set of wiring diagrams in plastic or glass cover, framed and mounted in elevator machine room. Deliver other sets to Contracting Officer. Coded diagrams are not acceptable unless adequately identified.

(2)  Construction Submittals for Facility Electronic Operation and Maintenance Support Information (eOMSI): 

Submit final submittals for eOMSI Submittal.  After approval by the DOR and sign-offs by the elevator inspector, assimilate construction submittals into the OMSI manuals required under Part 2 Section 01 78 24.00 20, Facility Data Workbook (FDW).

b. Construction Submittals for Weight Handling Equipment (WHE):

(1) Drawings.  Submit to DOR for approval, the construction submittal and drawings described below.  After DOR approval submit to the Government for approval or surveillance as required in Part 2 Section 01 33 00.05 20, Construction Submittal Procedures.  Manufacturer's catalog data will suffice for standard commercial products. Each assembly and subassembly drawing must include an integral Bill of Materials or must be followed by a consecutively numbered drawing with the applicable Bill of Materials.

(a)  General Arrangement Drawings.  Show in plan, elevation and end view the crane or monorail system assembly and each major component, including runways for underrunning cranes to demonstrate proper interface with the facility building. Show all major features including: clearances, lifts, speeds, hook approaches (on all sides), maximum wheel loads (without impact), electrical or pneumatic power supply, and general locations of components such as: hoists, trolleys, brakes, motors, speed reducers, and control panels (including size).  Indicate torque value or tightening method (e.g. turn of the nut) for bolts on the drawing. In addition, show estimated weights for major components (girders, trolleys, runway beams, control panels and end trucks) and the completely assembled crane.  Provide approximate locations of center of gravity and location of lifting points for completely assembled crane and for each major component with the design drawings. 

(b)  Structural Drawings.  Show fabrication details including all weldments, fastener joints, structural components, and list of materials for fabricated crane girders (including end stops), fabricated trolleys and fabricated end trucks on these drawings. Specify the type of structural bolted connection (i.e. slip critical, snug-tightened, or pretensioned) on the drawing.  

(c)  Mechanical Drawings.  Show the layout of mechanical equipment on cranes and monorail systems on the drawings, in particular drive arrangements (including assembled components). On pneumatically powered cranes, show the layout of pneumatic equipment, including control panel enclosures, motors, brakes, limit switches, piping and valves on the drawings.  The drawings must also include:

 1.   Complete schematic diagram of pneumatic systems with narrative of any special description of operation. All components shown on schematics must have labels that correspond to the nameplates that will be on the crane. Pipe material and size must be included.

2.  Rating and types of over-pressure protective devices.

3. Complete assembly diagrams including a component material list.  Show on the drawings the layout of pneumatic equipment on the crane including: motors, brakes, limit switches, conduits, and piping systems.

(d)  Electrical Drawings.  Show the layout of electrical equipment on cranes and monorail systems, including control panel enclosures, motors, brakes, limit switches, conduits, disconnects, and conductor systems on the drawings.  The drawings must also include:

 1.   Complete schematic diagram with narrative of any special description of operation. All components shown on schematics must have labels that correspond to the nameplates that will be on the crane. Wiring type, size, and temperature ratings must be included on schematic diagrams. Remove all optional equipment not included in this project from the schematic diagrams.

2.  Motor nameplate data (including all information called for in NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) 70, Section 430.7 (A) items 1 through 7)

3. Rating and types of over-current protective devices.

4.  Complete assembly (wiring) diagrams including a component material list.  Show on the drawings, the layout of electrical equipment on the crane, including control panel enclosures, motors, brakes, limit switches, conduits, and conductor systems.

5.   Layout diagrams showing component placement in control panel enclosures.

 (2)  Product Data.  Provide manufacturer's catalog data for all major components of cranes and monorail systems.  Mark-up or supplement the catalog cuts with additional sheets to clearly identify the model or size, selected options, features, and/or modifications to demonstrate compliance with specification requirements.  Catalog cuts which show modifications beyond the standard options and all supplemental pages must bear original signatures and dates of the equipment manufacturer's authorized representative.  Clearly identify the item on the catalog cuts and each supplemental sheet to which it applies.

(a)  Structural Product Data.  Submit product data for Bridge End Trucks, Trolley Frame, Patented Track, Runway and Bridge Rails and Support System, and End Stops.

 (b)  Mechanical Product Data.  Submit product data for Speed Reducers, Brakes (including electrical information), Bearings, Couplings, Load Blocks, Hoist/Trolley (if procured as a packaged unit), Hose Reels, Oilers, Pressure Regulators and Bumpers.

 (c)  Electrical Product Data.  Submit product data for Variable Frequency Drives, Motors, Electrical Enclosures, Runway Electrification and Collectors, Limit Switches, Bridge to Trolley Electrification, Pendant or Radio Control Station, Warning and Pilot Devices, Disconnect Switches, and Fuses and Circuit breakers.

(3)  Design Data.  Provide calculations that demonstrate compliance with all design requirements.  Design data will not be approved if their evaluation/review is dependent on data or information not previously approved.  List and define all variables at the beginning of each calculation section; variables must be in accordance with required references.  Include sufficient information in the design data, so that they may be approved without reference to detail (shop) drawings.

When there is one hoist on one monorail system, the monorail system rated capacity and the hoist rated capacity will be equal.  When there is more than one hoist on the monorail system, the rated capacity of the monorail track beam system must be designed equal to the sum of the two hoists rated capacities. An exception to this is that if the two hoists are separated by positive track beam stops and distance so that the track beam is strength-wise essentially two independent track beam systems.

 (a) Structural Calculations.  Submit calculations verifying the sizing of any track, track suspension device and additional supports, which are not the runway or monorail system manufacturer's standard cataloged product. Include support reactions and recommended method of connecting/attaching the support.  Provide calculations verifying compliance with Section 3 of CMAA No.70 or No. 74 or Section 6 of MH 27.1.  In addition to Load Cases 1 and 2 of CMAA No. 70 and 74, the following load combinations are also required in the crane design calculations:

 1. CMAA Case 3: Test Loads.  The crane will be periodically tested up to 125% of rated capacity.  Combined stresses for the following load combinations must be calculated to ensure structural adequacy during testing:

DL (DLF_B) + TL (DLF_T) + LL (1 + HLF) + IFD + SK

 Test Loads (Stress Level 3).  In this calculation use LL = 1.25 x rated capacity.  Do not consider the test and extraordinary loads in the fatigue analysis. Formula abbreviations correspond to principal loads as defined in CMAA #70 and 74, Section 3.3.  The subscripts T and B refer to trolley and bridge, respectively.

 2. CMAA Case 4:  Seismic Load.  Provide seismic analysis in accordance with AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE) 7-05.  Consider loading condition in an event while the crane is operating at rated capacity without lowering or dropping the load. 

 3. Calculations verifying design of runway and bridge rail stops and bumpers in accordance with the dynamic requirements of Association for Iron and Steel Technology (AIST) TR-06.

 4. For cranes that operate outdoor without wind protection, calculations determining the wind speed that will cause the crane travel, trolley, and rotate functions to drive through the brake with the brakes set, and, for rail mounted or wheel mounted cranes, the wind speed that will cause the crane to slide on the rail or runway surface with the brakes set.

(b)  Mechanical Calculations. Calculations verifying compliance with Section 4 of CMAA #70, regardless of crane type, for any non-commercial items.

 (c)  Electrical Calculations

1. Minimum required horsepower for each drive motor - Motor power rating must be based upon the formulae given in CMAA #70 regardless of crane type.  For hoist motor sizing calculations, the factor "Kc" must not be less than 1.0. For bridge and trolley drive motor sizing calculations, the factor "E" must be the published gear reducer efficiency ratings. For the bridge drive the minimum acceleration rate must be 4 seconds and 2 seconds for simulated plugging (deceleration). For the trolley drive the minimum acceleration rate must be 3 seconds and 1.5 seconds for simulated plugging.  Calculations are not required for packaged hoists, but packaged hoists must still meet acceleration and deceleration requirements.

2. Overcurrent protection.

3. Conductor sizing and Conduit fill calculations (using tables from NFPA 70, Chapter 9 or manufacturer's data sheets).

4. Protective device coordination study showing proper coordination for any overcurrent devices that have the same rating as another overcurrent device upstream

5. Transformer sizing.

6. Drive controller sizing for hoist motors.

               
(4)  Facility Electronic Operation and Maintenance Data, Documents, and Training Information.  Submit the WHE's operation and maintenance data, document, and training information to be incorporated in the Part 2 Section 01 78 24.00 20, Facility Data Workbook (FDW) submittal.  Make a copy of the eOMSI submittal available at the acceptance test.  Include in the eOMSI submittal a table of contents, operation instructions, preventive maintenance instructions including maintenance, training materials, and programming instructions for the adjustable frequency drives, parts information, a drawing list, design drawings, lubrication drawing supply list, catalog cuts, photographs as needed to explain maintenance or repair procedures, and calculations.  Provide maintenance instructions to include recommended maintenance procedures and component manufacturer's installation and maintenance manuals and lubrication instructions.  Include detailed crane operating and safety instructions in the operating instructions.  Parts information must include information on purchased sub-assemblies and components, including manufacturer's original part number, and detailed drawings of Contractor-designed parts.  Break-out the parts information into the smallest replacement part.

(5)  Provide onsite training for unique critical job skills associated with the crane or attachments 

(6)  Field Test Reports. Submit a copy of all Field Reports.