SECTION 41 2213.13

BRIDGE CRANES

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LANL MASTER SPECIFICATION

This template must be edited for each project.  In doing so, specifier
must add job-specific requirements.  Brackets are used in the text to
indicate designer choices or locations where text must be supplied by
the designer.  Once the choice is made or text supplied, remove the
brackets.  The specifications must also be edited to delete
specification requirements for processes, items, or designs that are not
included in the project \-- and specifier's notes such as these.  To
seek a variance from requirements in the specifications that are
applicable, contact the Engineering Standards Manual
[Mechanical](http://engstandards.lanl.gov/engrman/6mech/htmls/mechnew2.htm)
and/or
[Structural](http://engstandards.lanl.gov/engrman/5struc/htmls/strucnew2.htm)
POC. Please contact POC with suggestions for improvement as well.\
\
When assembling a specification package, include applicable
specifications from all Divisions, especially Division 1, General
Requirements.\
\
Specification developed for ML-4 projects.  For ML-1, 2, and 3
applications, additional requirements and independent reviews should be
added if increased confidence in procurement or execution is desired;
see ESM Chapter 1 Section Z10 Specifications and Quality sections.\
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1.  GENERAL

    1.  SECTION INCLUDES

        A.  Provide, install and test a top running overhead bridge
            crane.

    2.  DESCRIPTION

        A.  Provide a \[ \] -Ton CMAA Service Class \[ D \] Bridge
            Crane.

    3.  SUBMITTALS

        A.  Submit the following in accordance with Section 01 3300,
            Submittal Procedures:

            1.  Certificates:

                a.  Certification of previous crane installations,
                    including name and address of project and owner.

                b.  Certifications for structural steel, fasteners,
                    hooks, wire rope, forgings and castings.

                c.  Certifications for all electrical and mechanical
                    components stating manufacturer and type.

                d.  Certification of required inspection and load
                    testing.

                e.  Welder certifications for all welders who will
                    perform work on the crane system. Certify welders in
                    accordance with AWS.

            2.  Manufacturer\'s installation instructions.

            3.  Performance Data: Provide Quality Assurance Plan in
                accordance with PART 3, Section 3.5.

            4.  Shop drawings:

                a.  Structural steel fabrication drawings showing
                    structural members and their connections.

                b.  Crane arrangement drawings (Plans, Sections and
                    Elevations) showing the location of structural
                    members, bridge and trolley equipment, travel of
                    hook and work platforms. Include clearances, lifting
                    lengths, maximum crane wheel loads and simultaneous
                    trolley wheel loads.

                c.  Bridge, bridge dive and hoist arrangement drawings
                    (Plans, Section and Elevations) showing the
                    arrangement of the bridge, bridge drive, and hoist.
                    Include equipment (gears, shafts, wheels, couplings,
                    bearings, drum, blocks, rope reeving, framing,
                    festooned conductors, trolleys, brakes, and
                    machinery) dimensions and weight. Also, include
                    description (as applicable, rating for horsepower,
                    time, rpm, temperature, torque, amperes, current
                    characteristics, model and size number) of motors
                    couplings, brakes, limit switches, and similar
                    parts.

                d.  Electrical drawings of the electrical equipment and
                    wiring diagrams, showing and identifying electrical
                    equipment and schematically showing connections and
                    interconnections of panels and equipment. Include
                    manufacturer\'s name, model number and rating. Also,
                    include hook-speed/hook-load curves (hoisting and
                    lowering) or motor-speed/ torque and current curves
                    for controllers for hoist motor, and motor-speed/
                    torque and current curves for controllers for
                    trolley and bridge travel.

            5.  Operation and maintenance data indicating the following:

                a.  Name, address and telephone number of nearest
                    authorized service facilities and parts distributor.

                b.  Parts lists.

                c.  Recommended spare parts.

                d.  Lubrication requirements and list of lubricants
                    including acceptable substitutes.

                e.  Maintenance requirements and schedules for all
                    equipment.

                f.  Safety procedures.

                g.  Proper operation of all equipment.

                h.  Routine maintenance procedures.

                i.  Assembly drawings and descriptive literature.

                j.  Wiring schematics.

            6.  Written 24 month parts and labor warranty. Repair or
                replace defective materials and workmanship of the crane
                during the warranty period. The warranty will begin at
                the time of final acceptance of the installation by
                LANL.

                a.  Defective Material and Workmanship is defined to
                    include:

-   Performance below required minimums.

-   Abnormal wear considering intensity of use.

-   Systems not maintainable or accessible for required maintenance.

-   Unsafe conditions.

-   Counterfeit parts.

    1.  QUALITY ASSURANCE

        A.  Design and fabricate bridge crane in accordance with the
            recommendations of ANSI B30.20, CMAA Specification No. 70,
            OSHA 29 CFR Part 1910, NEC (NFPA 70), Article 610, and the
            requirements specified herein.

        B.  Manufacturer\'s Qualifications: A firm regularly engaged in
            the manufacturer of major components for cranes of the type
            specified for this project. The new assembly will duplicate
            equipment that has been in satisfactory use for a period of
            at least 3 years.

        C.  The installer will be a manufacturer\'s representative
            having experience installing the type of equipment supplied.

        D.  Temporary use of the crane for construction purposes or
            during the construction period will not be permitted without
            written permission from LANL. In the event permission is
            given, the Subcontractor will assume full responsibility for
            protection and maintenance of equipment. All hoisting
            equipment used in this fashion will be fully load tested,
            inspected, and accepted by LANL as a fully functional unit
            prior to use. Expense for this testing will be paid for by
            the Subcontractor. Hoisting equipment will be fully
            inspected after temporary use period has ended. Equipment
            damaged or worn beyond use will be replaced by the
            Subcontractor. Preventative maintenance required by the
            equipment manufacturer during this temporary use period will
            be performed and paid for by the subcontractor.

2.  PRODUCTS

    1.  PRODUCT OPTIONS AND SUBSTITUTIONS

        A.  Comply with Section 01 2500, Substitution Procedures.

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    1.  MATERIALS AND CONSTRUCTION

        A.  Manufacturers:

            1.  Harnischfeger P&H.

            2.  Whiting Corp.

            3.  Acco/Wright.

        B.  The crane will be located \[ inside a building \] at an
            altitude of \[ 7500 \] feet above sea level with \[ 15 \]
            degree F minimum, \[ 65 \] degree F normal, and \[ 100 \]
            degree F maximum temperatures, \[ free from dust, moisture,
            corrosive fumes \]. The crane will be operated by \[ LANL
            technicians and not by skilled crane operators \].

        C.  Operational Requirements:

            1.  Rated Load:

                a.  Main Hoist: \[ \] tons.

                b.  Auxiliary Hoist \[ \] tons.

            2.  Approximate Span: \[ \] feet \[ \] inches.

            3.  Required hook lift:

                a.  Main Hoist: \[ \] feet \[ \] inches.

                b.  Auxiliary Hoist: \[ \] feet \[ \] inches.

            4.  Approximate length of Runway: \[ \] feet \[ \] inches.

            5.  Service Information: CMAA Service Class \[ \].

            6.  Travel Speeds:

                a.  Main hoist \[ \] fpm maximum.

Control: variable frequency, stepless.

b.  Auxillary hoist \[ \] fpm maximum.

Control: variable frequency, stepless.

c.  Bridge \[ \] fpm maximum.

Control: variable frequency, stepless.

d.  Trolley \[ \] fpm maximum.

Control: variable frequency, stepless.

7.  Hoist Coverage:

    a.  Provide for coverage of floor area, except for coverage within
        \[ \] from building side walls and \[ \] from end walls.

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D.  General Requirements:

    1.  Arrange mechanical and electrical equipment on the bridge to
        permit easy and convenient access to all components requiring
        periodic maintenance, replacement or adjustment from the work
        platform.

    2.  Provide moving parts, shafts, etc., with covers to guard against
        accidental injury or risk of injury to the operator in
        accordance with OSHA. Install hinged and hatched protective
        covers in such a manner as to simplify access to the covered
        parts for maintenance and repair.

    3.  Clean and paint with 1 coat (1.5 mil) of primer and 2 finish
        coats (3.0 mil) exposed metal surfaces, except contact surfaces
        between moving parts, wire rope and hook(s). Use manufacturer\'s
        standard paint. Touch-up all damaged areas after installation
        with same brand and color of paint.

    4.  On underside of bridge crane paint directional arrows to
        correspond to the labeling of push buttons on the pendant
        control. Paint directional arrows with a size (6 inch minimum),
        style, and color to be visible from any position of the control
        pendant.

    5.  Provide a motion warning system consisting of a pulsating horn
        and signal lights. Control the horn at the pendant controller
        with \"hold-to-operate\" type control. Mount blue rotating
        beacon lights in a prominent location on the bridge and trolley
        to signal when the crane is in motion. The signal lights shall
        remain on when crane is in operation.

    6.  Do not use lead based paint.

    7.  Do not use asbestos in brakes or any other component.

E.  Structural Requirements:

    1.  Provide structural steel conforming to the requirements of ASTM
        A36 or other types of steel as selected by the manufacturer and
        approved by LANL.

    2.  Provide high strength bolts conforming to ASTM A325.

    3.  Provide welding designs and procedures that conform to AWS
        D14.1, Specification for Welding Industrial and Mill Cranes,
        with the exception of Section 705, which will be in accordance
        with crane and manufacturers standard tolerances for deviation
        from specified camber and sweep.

    4.  Design girders to carry the full rated load of the crane without
        undue vertical or lateral deflection or vibration in accordance
        with requirements of CMAA 70.

        a.  Provide bridge crane consist of 2 girders carried by end
            trucks. Provide girders of welded construction with built-up
            box section or reinforced wide flange beams.

        b.  Notch girder at each end and install seat welded to the
            girder to provide a connection to end trucks. Connect end
            trucks with high strength bolts to prevent crane skewing on
            the tracks.

        c.  Provide ASCE standard rails. Fasten or weld rails to top
            member of each girder to provide a track for the trolley.
            Weld steel stops near the end of each girder to engage
            bumpers on the trolley to prevent it leaving the bridge.

    5.  Construct end truck of structural steel sections and steel
        plates forming a box section, reinforced to provide a rigid
        structure with openings at each end for mounting of truck
        wheels. Precision bore end trucks to provide accurate alignment
        of wheel bearing assemblies. Provide end truck with a wheel base
        of a minimum of 1/7 of the span of the bridge. Provide end truck
        with 1 wheel in each end truck geared for use with the bridge
        drive. Include as part of the end truck the drive wheels,
        carries wheels and wheel gear protecting guards. Design the
        truck so that in case of a wheel or axle failure, the drop of
        the load will be limited to one inch. Make all end truck to
        bridge connections with high strength bolts. Provide squaring
        marks between the bridge girders and end trucks to facilitate
        erection. Provide end trucks with rubber bumpers on all 4
        corners. Provide rail sweeps of rubber or equal on all 4
        corners.

    6.  Provide a trolley frame built up from structural steel sections
        welded together to form a rigid one-piece frame adequately
        braced to ensure proper alignment of trolley wheels. Provide
        trolley end stops with a height equal to or greater than the
        radius of the trolley wheels. Provide rail sweeps of rubber or
        equal on trolley frame for sweeping rails in both directions.

    7.  Install a \[ 36 \] -inch-wide work platform and handrails
        running the full length of the bridge. Mount the platform on the
        \[ \] side of the bridge. Construct the work platform in
        accordance with CMAA 70 and OSHA requirements.

    8.  Provide wire mesh partitions between the toe plate and
        intermediate rails of the outboard handrails and both end
        handrails. Construct partitions of 10 gage steel wire panels,
        woven into 1 1/2 inch diamond mesh. Weld partitions to support
        members.

F.  Mechanical Requirements:

    1.  Provide stationary type bridge and trolley wheel axles with
        wheel mounted midway between axle bearings. Provide wheel axles
        with mounting nuts for bearing adjustment. Design wheel mounting
        so that an axle wheel can be removed without disturbing other
        truck elements or their alignment.

    2.  Provide double flange type steel bridge and trolley wheels with
        treads hardened to 275 Brinell. Provide drive wheels with a
        tolerance of 0.01 inches between wheel diameters.

    3.  Provide bridge end truck unit drives that are totally enclosed
        with all gearing operating in oil-tight casing. Provide
        horizontally split gear cases. Provide bridge drive consisting
        of individual electric motor driving gear reduction units direct
        coupled to driving wheel in the end trucks. Provide bridge drive
        units with a brake and controlled from pendant control.

    4.  Provide trolley drive mechanisms that consist of an electric
        motor driving through gear reduction unit flexibly coupled to
        the trolley drive wheel axles. Gearing, except the final
        reduction at wheels, shall run in oil or be splash lubricated.

    5.  Hoisting Machinery:

        a.  Provide hoist with a HMI rating of H-3 and capable of
            holding 150 percent of rated load. Provide hoisting
            machinery consisting of an electric motor driving through
            gear reductions to a winding drum. Do not use trolley drive
            motor as the hoist motor. Mount gears in the reduction unit
            on short shafts and support gears between bearings. Connect
            the drum gear to the hub of the rope drum by keyed type
            connection. Encase gears in oil-tight housing split
            horizontally and readily accessible for maintenance. Connect
            hoist motor to the reduction unit with a flexible coupling.

        b.  Provide the rope drum with a running sheave to rope diameter
            ratio of 24 to 1. Provide idler sheaves of not less than 1/2
            the running sheaves.

        c.  Fabricate rope drums of cast iron or steel and properly
            machined for the cable used.

        d.  Groove the rope drums right and left hand to receive the
            full run of hoisting cable without overlapping. Provide
            drums of sufficient size and length so at least 2 turns of
            wire rope remains on the drum when the hook is in low
            position.

    6.  Equip hoists with an overload cutoff device. Provide a
        non-friction electro-mechanical protective device that permits
        operation of the hoist(s) within its rated capacity, but
        prevents lifting loads that could cause damage to a properly
        maintained hoist. Provide an overload cutoff that is capable of
        sensing a load greater the 105 percent, (plus 0 percent, minus 5
        percent), and interrupts the \"up\" control circuit and prevent
        the hoist from raising the load. Operation of the cutoff will
        automatically reset upon removal of the overload. Do not
        increase the hoist headroom with overload device. Configure the
        cutoff to permit easy replacement of the wire rope and permit
        the use of swaged end rope terminations.

    7.  Provide bridge brake of shoe type magnetic brake mounted
        outboard on motor shaft or motor extension shaft. Press on and
        key the brake wheel to motor shaft. Provide ample clearance for
        opening of brake and for servicing and removing brake wheel
        without disturbing motor.

    8.  Provide hoist with 2 means of braking, a hoist motor brake and a
        mechanical load brake or suitable method of electrical braking.

        a.  Provide mechanical load brake or electric braking systems to
            automatically regulate the speed during lowering to prevent
            undue acceleration. Provide load brake capable of holding
            full load independent of hoist motor brake.

        b.  Provide hoist motor brake of either direct current
            magnetically operated disc type or shoe type mounted on
            extended pinion shaft. Provide spring set brake, equally
            effective in either direction of motor rotation, and sized
            to stop motor and hold rated capacity load. Design brake to
            set automatically whenever current to motor is off.

        c.  The minimum required brake rating are as follows:

[Motor]{.underline} [Brake, Rating,]{.underline}

[Full Load Torque]{.underline}

Hoist 150 percent

Bridge 100 percent

Trolley 50 percent

9.  Provide gearing rated by AGMA standards for strength and durability
    for the service intended. Provide pinions of alloy steel and heat
    treated.

10. Provide heavy-duty, anti-friction ball or roller type bearings.
    Select bearings to give a minimum L~10~ life of 10,000 hours, per
    AFBMA - 9 based on full rated speed.

11. Provide extra flexible improved plow steel wire rope, manufactured
    for crane service. Design wire rope to have a safety factor of 5.

12. Provide loadblock with a heavy steel housing to support sheaves and
    hook. Construct hook of forged steel and support on thrust bearing.
    Provided hook with safety catch. Provide sheaves of steel having
    deep flanges and properly grooved to fit wire rope. Enclose sheaves
    by steel housing.

13. Provide sealed gear enclosures with lubrication so gears operate in
    a oil bath that provides positive splash lubrication for gears and
    gear bearings. Provide lifetime lubrications for bearings in axle,
    sheaves and drum shaft.

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G.  Electrical Requirements:

    1.  Provide 480 volt, 3 phase, 60 hertz electrical power for crane
        motors. Provide 120 volt, single phase, 60 hertz control power
        or other lower voltages approved by LANL.

    2.  Design, assemble, test, and install electrical equipment and
        wiring in accordance with the requirements of the NEC (NFPA 70),
        Article 610.

    3.  Supply power to the bridge, trolley and hoist motors with one or
        a combination of the following systems.

        a.  Conductor-Collector System: Supply power by enclosed copper
            conductors mounted on a runway track and on a trolley track
            by means of phenolic insulator blocks and conducting bar
            brackets. Provide sliding shoe type collectors that provide
            positive contact with the conductor and permit high-speed
            operation without causing damage to the system.

        b.  Festooned System: Supply power by a flat wire festooned
            system consisting of multi-conductor flat cable attached to
            trolleys supported by a rigid track.

    4.  Size conductors for 125 percent full-load nameplate current of
        the largest motor and full-load currents of all additional
        motors, but in no case less that No. 12 AWG. Do not use a
        grounded transformer circuit to eliminate one conductor in any
        crane system.

    5.  Provide motors for hoist, trolley and bridge drives designed for
        intermittent reversing crane duty in accordance with the
        applicable section(s) of NEMA MG-1. Provide totally enclosed
        non-ventilated (TENV), squirrel cage rotor, NEMA design \[ \"B\"
        \], permanently lubricated ball bearing, class \[ F \]
        insulation motors with variable frequency drive. Provide motors
        rated for full operation for \[ 30 \] minutes without exceeding
        an allowable motor temperature raise of 60 degrees C above an
        ambient temperature of 40 degrees C at 7500 feet elevation.

    6.  Provide motor controls that comply with the requirements of NEMA
        and Underwriter\'s Laboratories Inc., UL 508.

    7.  Provide an adjustable frequency drive (stepless) infinite
        variable speed control system for control of all crane motions.
        Monitor and adjust frequency and voltage of electrical power
        going to the motors with a microprocessor incorporated in the
        adjustable frequency drive control system. Control braking
        electronically with the adjustable frequency drive control
        system. Equip the adjustable frequency drive control system with
        self-diagnostics that monitor the electrical and electronic
        components of the control system and motors.

    8.  Control crane motions from the floor by 1 pendant control
        station. Arrange the pendant control station by functionally
        grouping buttons or as shown on the Drawings. Provide a pendant
        not to exceed \[ 4 \] inches in width or depth.

        a.  Provide control buttons, except as noted below, with
            elevated ring type guards with recessed push buttons.

        b.  Provide push buttons of spring return momentary contact type
            with a concave or high-friction surfaces and a positive
            sense of control actuation. Provide buttons with an
            activation force resistance of 10-40 ounces, and a
            displacement of 1/8 inch minimum.

        c.  Provide push buttons with a minimum 3/4 inch diameter.
            Separate buttons with a space of at least 1/2 inch, with 2
            inches preferred.

    9.  Permanently marked push button functions, (sticky tape is not an
        acceptable marking). Provide labels with black letters on a
        light background and upper case in style. Provide letters with a
        minimum of 1/8 inch in height.

    10. Provide the pendant station with the following special controls
        in addition to the controls required for bridge, trolley and
        hoist control:

        a.  Emergency stop function: activation disconnects the power to
            the mainline contactor. Provide an emergency stop button
            larger in size than the other control buttons, red in color
            and unguarded for rapid activation.

        b.  Reset function: activation restores power after the
            emergency Stop button has been activated.

        c.  Rotary Lockout Control Switch: disables controls when placed
            in the \"safety\" switch position.

        d.  Speed Control Potentiometer: provides infinitely variable
            speed control from zero to maximum speed for each of the
            controlled functions.

    11. Provide a pendant control station suspended and supported by a
        restraint cable from a torque reel balancer in such a manner
        that the electrical conductor does not carry the weight of the
        pendant station and so that the pendant hangs vertically.
        Provide vertical adjustment of the pendant station from 3\'-4\"
        to 7 feet above finish or operating floor. Design torque reel
        that works on the principal of a window shade, whereby the
        operator must make a deliberate motion to raise or lower the
        pendant station.

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3.  EXECUTION

    1.  FABRICATION

        A.  Fabricate the crane in accordance with approved shop
            drawings and manufacturer\'s data.

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    1.  SHIPPING

        A.  Protect, pack, identify, and ship crane components to the
            job site.

    2.  EXAMINATION

        A.  Examine and verify the areas and conditions under which the
            crane equipment is to be installed, by the manufacturer.
            Bring unsatisfactory conditions to the immediate attention
            of LANL for correction prior to any installations
            activities.

    3.  INSTALLATION

        A.  Install the crane in the location shown on the Drawings and
            in accordance with the approved shop drawings. Install the
            crane under the supervision of the manufacturer\'s
            representative.

    4.  SOURCE QUALITY CONTROL

        A.  Perform all on and off-site quality control, inspection,
            testing, and reporting in accordance with this specification
            and established quality assurance plans. Submit a Quality
            Assurance Plan prior to fabrication.

        B.  Quality Control: The manufacturer is responsible for the
            performance of all inspection requirements at the factory
            and or place of assembly (Off-site assembly only). Document
            inspections performed on the crane systems during
            fabrication in a report to LANL. Perform following
            inspections:

            1.  Inspection of Steel Castings, Hooks and Welds: Employ an
                independent testing laboratory, approved by LANL, for
                the inspection of all steel castings, hooks and welds of
                each crane system. Conform to the following frequency
                for welds, 100 percent of full penetrating, 75 percent
                of all fillet welds. Use the magnetic particle method,
                ASTM A275, for testing metal parts or other methods
                approved by LANL.

            2.  Welding: Prepare a welding procedure for all welding
                work and inspection in accordance with AWS.

            3.  Off site modifications: Provide a separate Quality Plan
                for work performed after shipment.

    5.  INSPECTION AND TESTING

        A.  Notify the LANL Subcontract Technical Representative (STR)
            at least 14 days prior to beginning any testing. LANL will
            be present during all tests.

        B.  Factory Tests: Test, prior to shipment from the factory,
            hoisting and lowering functions of all hoists (controls
            inclusive) at all speeds with no load, 50 percent and 100
            percent of the rated load capacity.

        C.  Field Test: Conduct testing under the supervision of a
            service engineer representing the manufacturer. Conduct the
            following field tests:

            1.  Operational Tests:

                a.  Test crane systems, following installation but prior
                    to acceptance, to ensure compliance with this
                    specification and the Subcontract documents. Test
                    the crane functions of hoisting and lowering,
                    operation of brakes, travel limit switches, and all
                    safety devices. Trip setting of limit switches and
                    safety devices at no-load conditions initially.
                    Conduct tests at first by hand, if practical, and
                    then under the lowest speed obtainable. Continue
                    testing until all systems are tested under no-load
                    conditions through the full range of motion and
                    speed attainable by the crane. Test crane to
                    determine that the hoists, including hooks and
                    pendants are electrically grounded during all phases
                    of hoist operation.

            2.  Overload Tests:

                a.  After the operational tests, test functions of the
                    crane systems at 125 percent of the rated load. Each
                    crane system will be operated through its complete
                    range of movements at this overloaded condition.
                    Adjust the hoist overload cutoff to 125 percent of
                    the rated load during the overload test and reset to
                    105 percent after the overload testing is complete.

        D.  Inspection: LANL will perform a formal crane inspection for
            compliance with this specification prior to final acceptance
            of the crane installation.

    6.  ADJUSTMENT AND REPAIRS

        A.  Correct any unsafe conditions disclosed by the inspection
            and tests prior to final acceptance by LANL. After
            completion of any adjustments or repairs, repeat pertinent
            field tests until the crane systems are approved by LANL.
            LANL will decide which field tests are applicable.

    7.  TRAINING

        A.  Supply to LANL an \[ 8 \] hour training session on the
            installed equipment. Cover operations and maintenance
            requirements.

END OF SECTION

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Do not delete the following reference information:

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FOR LANL USE ONLY

This project specification is based on LANL Master Specification 41 2213
Rev. 1, dated July 17, 2008.