STATEMENT OF WORK (SOW)

LARGE COMPONENT BEAD BLAST BOOTH

WITH PRE-ENGINEERED METAL BUILDING

UNITED STATES AIR FORCE

OGDEN AIR LOGISTICS COMPLEX (OO-ALC)

09 MARCH 2026

1. DESCRIPTION OF REQUIREMENT

1.1. Provide a complete and turn-key design, construction, and installation of a new corrosion control facility at the 309th Aerospace Maintenance and Regeneration Group (AMARG), located within a controlled area of Davis-Monthan Air Force Base (DMAFB), Arizona. The primary function is the corrosion control of Aerospace Ground Equipment (AGE) and other ferrous related items. The media blast booth will be housed within a fully enclosed Pre-Engineered Metal Building (PEMB) that also provides a separated maintenance support operations area (MX Ops Area). The entire facility shall be constructed on a currently unimproved site located North of Building 7213 (the Small Paint Booth), see appendix “A”.

1.2. The performing contractor is responsible for providing all management, professional services, labor, materials, and equipment to deliver a fully functional and operational facility. The scope includes, but is not limited to, the following key tasks:

1.2.1. Site Investigation and Design Development: Perform and bear all costs for all necessary preliminary and pre-construction investigations to develop the unimproved site. These investigations shall include, but are not limited to, geotechnical analysis, utility location and capacity assessment, environmental assessment, and topographical surveys. The Contractor shall be responsible for developing a complete design package, which shall be stamped and certified by the appropriate licensed Professional Engineer(s) registered in the State of Arizona.

1.2.2. Plastic Media Blast Booth: Furnish, install, and commission a complete, stand-alone system. The system must be appropriately sized for various AGE and include a full floor media recovery system, a dust collection system that meets all hazardous location requirements, and all associated controls and safety features.

1.2.3. PEMB: Design, furnish, and erect a new, permanent, weather-tight metal building to fully enclose the blast booth and provide a separate maintenance area. The structure must be fully compliant with all architectural and engineering standards outlined in the DMAFB Design Compatibility Guidelines.

1.2.4. Utilities and Site Work: Identify, design, and construct all supporting utility infrastructure; electrical, water, sanitary sewer, etc. This includes all site work, foundations, grading, drainage, and paving necessary to support the new facility.

1.3. GENERAL DESIGN REQUIREMENTS

1.3.1. Applicable guidance, regulations, & standards. As the Designer of Record, the Contractor is solely responsible for the research, identification, and compliance with all federal, state, local, and Department of Defense guidance, regulations, and standards. This includes, but is not limited to, all Unified Facilities Criteria (UFC), Air Force Instructions (AFI), National Fire Protection Association (NFPA) codes, and the Davis-Monthan AFB Design Compatibility Guidelines. The list provided in Appendix C is a baseline and is not exhaustive; the Contractor is responsible for adherence to all applicable regulations regardless of whether they are listed. In case of conflicting requirements, the most stringent regulation shall govern. The Contractor’s licensed Professional Engineer of Record shall assume full professional liability for the final constructed facility's compliance with all such governing criteria.

1.4. COTS PREFERENCE AND JUSTIFICATION

1.4.1. Requirement: The design shall prioritize and implement Commercial Off-The- Shelf (COTS) or modified-COTS solutions for all components and assemblies.

1.4.2. Non-COTS Justification and Analysis: Proposing a Non-COTS (custom fabricated) component or assembly is permissible only when it can be definitively proven that a COTS or Modified-COTS solution is incapable of meeting mandatory performance specifications. In such cases, the Contractor shall submit a formal Non- COTS Justification Report for each proposed item, demonstrating the following:

1.4.2.1. Analysis of Alternatives (AoA): Documented market research and analysis proving that no fewer than three (3) viable COTS or Modified-COTS alternatives can meet the government's minimum performance requirements as stated in this SOW. The AoA must detail why each alternative considered is technically insufficient.

1.4.2.2. Life Cycle Cost Analysis (LCCA): A comprehensive LCCA comparing the proposed Non-COTS item against the closest COTS alternative (even if deemed insufficient). The LCCA must be calculated over the 40-year engineered lifespan of the PEMB (as stated in 3.1.3) and shall include, at a minimum: initial acquisition and fabrication costs, installation, projected energy consumption, scheduled preventative.

1.4.3. The Contractor shall maintain a COTS Determination and Justification Log. This log must be submitted with each design stage (30%, 60%, 90%) and must accompany each Non-COTS Justification Report (CDRL A008) provided to the AMARG Contracting Officer (CO), Contracting Officer Representative (COR), and Project Manager(s) (PMs) for review and written approval prior to any procurement. The log shall include the minimum following fields:

1.4.3.1. Component Name

1.4.3.2. Required Performance Specification(s)

1.4.3.3. COTS Alternative(s) Considered (if any)

1.4.3.4. Justification for Non-COTS Selection (including specific reasons why

COTS alternatives were unsuitable)

1.4.3.5. Cost Comparison

1.4.3.6. Approval: All Non-COTS selections require prior written approval from the CO.

1.5. CONTROL SYSTEM, INTERFACE, AND CYBERSECURITY REQUIREMENTS

1.5.1. System Software and Licensing. All software for the Programmable Logic

Controller (PLC) and Human Machine Interface (HMI) shall utilize commercially supported platforms. The Contractor shall deliver all software, including the full developer/integrator suite, on physical media (e.g., USB drive, CD/DVD) along with all license keys. The Contractor shall provide a perpetual, transferable, enterprise-level license registered directly to the "309th AMARG, Davis-Monthan AFB," not to the contractor. The Government shall be provided all factory-default administrator-level credentials and permissions. If any software is custom developed it must be provided on physical media.

1.5.2. Human Machine Interface (HMI): The HMI shall provide unrestricted, real-time, read/write access to all operational setpoints, sensor readings, alarm thresholds, calibration tables, and control logic timers within the PLC. The HMI shall feature a Government-configurable, role-based access control system with, at a minimum, three tiers: Operator, Maintainer, and Administrator.

1.5.3. Cybersecurity and Authority to Operate (ATO), if applicable: The control system is a Facility-Related Control System and shall be designed, installed, and documented to achieve a formal Authority to Operate (ATO) from the cognizant Davis-Monthan AFB authorizing official. The Contractor shall be responsible for developing the full Risk Management Framework (RMF) package in accordance with UFC 4-010-06, Cybersecurity of Facility-Related Control Systems, and DoDI

8510.01. The system must meet, at a minimum, the security controls for Impact Level 2 (IL2), unless a higher level is specified by the Government.

1.5.3.1. The Hardware/Software list required in section 1.5.1 shall be delivered as a comprehensive Hardware/Software/Firmware Bill of Materials (BOM), formatted for use in the RMF process.

1.5.3.2. The Contractor shall perform all required security scans and remediate all findings at their own expense to ensure the system is capable of receiving an ATO prior to project turnover.

2. INVESTIGATION, PREPARATION, AND UTILITY DESIGN

REQUIREMENTS

2.1. GENERAL SITE RESPONSIBILITY: The project site, located behind building 7213 as shown in Appendix A, is an unimproved area. The Contractor shall be solely responsible for all activities required to deliver a fully prepared and serviced site that meets all performance requirements of this SOW. This includes, but is not limited to, all investigation, design, engineering, permitting, and construction for site preparation and all utility systems.

2.2. DESIGN AND INVESTIGATION PREREQUISITES: As the initial phase of this turn-key effort, the Contractor, acting as the Designer of Record, shall perform and bear the full cost of all preliminary and pre-construction design services necessary to develop the unimproved project site. The Contractor is solely responsible for any unforeseen conditions that a comprehensive investigation would have revealed. These services shall include, but are not limited to:

2.2.1. A comprehensive topographical and boundary survey of the project site.

2.2.2. A complete geotechnical investigation, including soil borings, soil analysis, and providing foundation design recommendations in a formal report.

2.2.3. A thorough utility investigation to identify, locate (including depth), and assess the condition and available capacity of all existing utilities required for the facility (e.g., electrical, water, sanitary sewer, storm sewer, and communications). This includes identifying precise tie-in points.

2.2.4. An environmental site assessment to identify any potential environmental hazards or constraints.

2.2.5. Development of a comprehensive site plan that adheres to the DMAFB Design Compatibility Guidelines, detailing grading, drainage, utility routing, paving, force protection measures, and landscaping.

2.3. GEOTECHNICAL AND TOPOGRAPHICAL INVESTIGATION: The Contractor shall perform a comprehensive geotechnical investigation of the site in accordance with UFC 3-220-01, Geotechnical Engineering. The Contractor shall also perform a full topographical survey. The results of these investigations, including soil borings, soil classification, bearing capacity, and site grading requirements, shall be documented in a formal Site Investigation Report (SIR) (CDRL A002). The SIR shall be used as the basis of design for all foundations and earthwork and must be stamped by a licensed professional Civil or Geotechnical Engineer.

2.4. UTILITY SYSTEM DESIGN (CDRL A006): The Contractor shall conduct a comprehensive report of all existing base utility systems and determine their capacity to support the full build-out of this facility (i.e., the initial blast booth, the MX Ops Area, and the installation of a future blast booth of like size/capability within the MX Ops Area). This report shall include, at a minimum:

2.4.1. Electrical: Load testing of the nearest substation and feeders to verify capacity, voltage, phase, frequency, and amperage for the total project calculated load, and future expansion.

2.4.2. Water: Flow and pressure testing at the proposed tie-in point to verify adequacy for the required fire suppression systems and any process water needs.

2.4.3. Sewer: Investigation of existing sanitary sewer lines to determine capacity, invert elevations, and routing for the required connections.

2.4.4. Stormwater: Existing site topography and the location, capacity, and condition of the nearest storm drainage infrastructure (e.g., storm sewers, catch basins, retention ponds, or natural drainage channels).

2.5. UTILITY IMPROVEMENT DESIGN, VERIFICATION, AND COSTING: Based on Section 2.4 results, the Contractor shall design all necessary upgrades or new utility infrastructure. Any information or drawings of existing base utility systems provided by the Government are for reference purposes only. The Contractor is solely responsible for all field investigation and verification of existing utility conditions, including but not limited to locations, depths, sizes, materials, and available capacity at proposed points of connection. The final design shall extend from the verified point of connection to the facility. The cost for all identified and verified utility improvements shall be included as a firm-fixed price within the Contractor's total bid price. No claims for additional cost or time will be considered due to discrepancies between Government-provided reference drawings and actual field conditions.

2.5.1. The Contractor's firm-fixed-price shall be all-inclusive for delivering a fully serviced facility. This responsibility is absolute and not contingent upon the findings of the Contractor's own preliminary utility analysis. A failure by the Contractor to correctly forecast the required utility upgrades during the design phase shall not be considered a change in scope nor basis to claim additional compensation or time.

3. EXTERNAL STRUCTURE(S)

This section defines the requirements for the external structure or structures that will house the plastic media blast booth and associated facilities. The external structure shall be a Pre- Engineered Metal Building (PEMB) designed for modularity and ease of expansion.

3.1. GENERAL REQUIREMENTS

3.1.1. The external structure(s) shall meet all applicable building codes and Air Force design requirements.

3.1.2. Expandable: The PEMB shall be designed for modularity, allowing for future expansion with minimal disruption.

3.1.3. Durability: The PEMB shall be durable and resistant to weather, pests, and fire.

The expected engineered lifespan of the PEMB shall be 40 years.

3.1.4. Aesthetics: The PEMB shall have an aesthetically pleasing appearance that is consistent with Davis Monthan Base Design Guide.

3.2. DIMENSIONS AND ORIENTATION

3.2.1. The PEMB shall be sized to accommodate the blast booth, all support/mechanical equipment, and the MX Ops Area as defined in Section 4 (Blast Booth and Supporting Equipment) & Section 5 (Maintenance Operations Area). The PEMB orientation shall ensure that the blast booth entrance door faces South (as shown in Appendix A).

3.2.2. All blasting equipment, including the blast booth and supporting equipment listed in Section 4 shall be consolidated and located on the East side of PEMB structure.

3.2.3. The MX Ops Area shall be on the west side of PEMB.

3.2.4. Demising Wall and Environmental Separation:

3.2.4.1. Fire Barrier: The blast operations area (East PEMB) and the MX Ops Area (West PEMB) shall be separated by a continuous, full height demising wall assembly. This assembly shall be designed and constructed as a 2-hour fire barrier in accordance with UFC 3-600-01 Fire Protection Engineering for Facilities, and the International Building Code (IBC).

3.2.4.2. Penetration Sealing: All penetrations through this fire barrier—including but not limited to conduits, pipes, and ductwork—shall be sealed with a UL-listed, 2-hour rated firestopping system appropriate for the specific type and size of the penetration.

3.2.4.3. In addition to the fire rating, this demising wall shall be designed and constructed as a continuous air barrier. To achieve this, all joints, seams, and junctions in the demising wall assembly—including but not limited to wall-to-floor, wall-to-wall, and wall-to-roof/deck connections—shall be continuously sealed on both sides with a permanent, flexible, non-hardening sealant prior to the installation of final finishes. The assembly shall achieve a maximum air leakage rate of 0.04 cfm/ft² at 75 Pa (1.57 psf) of pressure differential when tested. The Contractor shall be responsible for performing and documenting this pressure test across the barrier after installation of all services but before final finishes are applied. Any failure to meet the specified air leakage rate shall require the Contractor to identify and remediate all leak paths at their sole expense. The purpose of this requirement is to ensure no migration of hazardous dust or media from the "dirty" (East) side to the "clean" (West) side of the facility. The wall assembly's design must account for the positive pressurization of the clean spaces as specified in Sections 4.2.3 and 5.4.3.

3.3. MATERIALS

3.3.1. The PEMB shall be constructed of high-quality metal materials that are appropriate for the intended use and environment and meet all applicable code requirements.

3.3.2. The frame shall be constructed of structural steel.

3.3.3. The PEMB shall be insulated to meet climate control requirements in Section 4 and Section 5.

3.4. DOORS AND WINDOWS

3.4.1. The PEMB shall include all necessary doors and windows for access / ventilation and shall meet all applicable code requirements.

3.4.2. Equipment Doors: The PEMB shall include doors that are sized to ensure that the largest sized support equipment may be moved out of the structure for maintenance, replacement, or repair. The contractor shall provide dimensions of the largest piece of equipment that will be housed in this structure and ensure that exterior doors / openings are sized accordingly.

3.4.3. Doors: The PEMB shall include doors for personnel and equipment access in accordance with NFPA 101 life safety code and applicable occupancy group.

3.5. EXTERIOR FINISH

3.5.1. Requirement: The exterior of the PEMB shall be finished to provide a durable and aesthetically pleasing appearance that blends in with the surrounding structures.

3.5.2. Color: The main exterior color shall be consistent with the color of adjacent structures. Exterior color samples shall be submitted to 355 Civil Engineering for approval. There shall be exterior accents that match as closely as possible per DMAFB Building Design Guide; this includes gutters, downspouts, doors / framing.

Color samples shall also be verified and approved by 355 Civil Engineering, prior to manufacturing and delivery.

3.5.3. Coatings: All structural steel shall be uniformly coated for corrosion resistance.

Roof and wall panels shall be galvanized and painted.

3.6. STRUCTURAL DESIGN AND ENGINEERING

3.6.1. Designer of Record: The Contractor's structural engineer shall be the Structural

Engineer of Record (SEOR) for the project. The SEOR shall be licensed in the state of Arizona and shall be responsible for the complete design and performance of the PEMB and its foundation.

3.6.2. Governing Standards and Design Loads: The structural design shall comply with all applicable codes and standards, with UFC 1-200-01, General Building Requirements, taking precedence. The design shall incorporate, at a minimum, the following criteria:

3.6.2.1. UFC 3-301-01, Structural Engineering: general structural design.

3.6.2.2. Wind Loads: Per UFC 3-301-01, calculated for a 120-mph nominal design wind speed, Exposure Category C, and a Risk Category III structure. The explicit use of "Aircraft Hangar Wind Loads" shall be evaluated by the SEOR for applicability and the most stringent condition applied.

3.6.2.3. Seismic Design: Site Soil Class D shall be used as a baseline, to be confirmed or revised by the Geotechnical Investigation required in Section 2.2 & 2.3.

3.6.2.4. Snow Load: 30 PSF Ground Snow Load, with drifts and unbalanced loads calculated per UFC 3-301-01 and ASCE 7-22.

3.6.3. Collateral and Suspended Loads: The structural design, including all frames, purlins, and girts, must support all specified collateral loads. As part of the 60% design submittal, the Contractor shall provide a Comprehensive Collateral Load Plan (CDRL A007). This plan shall include a scaled framing plan showing the precise location, weight, and structural attachment method for every piece of ceiling-mounted equipment, including but not limited to: fire suppression piping (filled with water), dry chemical fire suppression if applicable, fall arrest systems if applicable (including dynamic fall loads), HVAC units, all lighting fixtures, High Volume Low Speed (HVLS) fans, and any associated ductwork or cable trays.

3.6.4. PEMB Manufacturer Integration: The Contractor is responsible for ensuring that all loads and design requirements are fully integrated into the PEMB manufacturer's design and fabrication drawings (CDRL A001). All PEMB shop drawings must bear the stamp of the PEMB manufacturer's engineer as well as the review and approval stamp of the project's SEOR before submission to the government.

3.7. THERMAL PERFORMANCE

3.7.1. The PEMB insulation system shall be designed and installed to meet the prescriptive R-value or U-factor requirements for Climate Zone 2B (Tucson, AZ) as defined in ASHRAE 90.1 and UFC 1-200-02, High Performance and Sustainable Building Requirements. The insulation system shall ensure the HVAC systems can efficiently maintain the specified temperature ranges in Sections 4 and 5.

3.7.2. Insulation: To ensure long-term durability and prevent contamination from insulation fibers, a non-fibrous, puncture resistant, insulation system is preferred.

Contractor to propose the most cost-effective system that meets this intent, while complying with IBC and NFPA standards.

3.8. PROVISIONS FOR FUTURE EXPANSION. The design shall incorporate specific, tangible provisions for future expansion. The Contractor shall identify the 'West' wall of the MX Ops Area as the 'Expansion Wall' in all design submittals.

3.8.1. Structural Provisions: The structural design of the Expansion Wall shall be engineered to be no-load-bearing regarding the primary building frame, allowing for the future removal of wall panels and girts without compromising the structural integrity of the initial facility.

3.8.2. Utility Provisions: The Contractor shall provide capped utility stub-outs, sized to support a duplicated facility load, at the Expansion Wall. This shall include, at a minimum, a capped water line for the future fire suppression system and appropriately sized, capped electrical conduit stub-outs from the main switchgear.

The design must include isolation valves and breakers to allow for future tie-in without disruption to the initial facility.

3.8.3. Foundation Provisions: The foundation design shall extend beyond the Expansion Wall to form a footing for the future structure or shall be designed with engineered connection points (e.g., rebar dowels) to allow for a monolithic pour with the future foundation. All foundation drawings must clearly detail this provision.

3.8.4. Deliverables: The Contractor shall include a dedicated 'Future Expansion Plan' section within the 60% design submittal that details all structural, utility, and foundation provisions with calculations and drawings (CDRL A001).

3.9. PERSONNEL EGRESS

3.9.1. Provide exits or exit access doors around the entire perimeter of the PEMB to meet UFC 3-600-01, the NFPA 101 Life Safety Code and all other applicable personnel egress references.

3.9.2. Personnel egress shall be compliant with Americans with Disabilities Act (ADA) Standards for Accessible Design that apply to Government construction.

3.9.3. Exterior personnel doors shall be covered by awnings in accordance with OSHA 29 Code of Federal Regulations (CFR) 1910 and shall be designed for protection from falling objects and to prevent snow or ice accumulation. Exterior personnel doors shall be weatherproof and comprise of a minimum of 16-gauge metal with a U value of 0.50 or better.

3.9.4. Doors shall follow the keying and hardware requirements in Attachment F of the DMAFB Facility Design Guide, as applicable. Door cutouts shall be finished, framed, weatherproof, and corrosion resistant.

3.10. STORMWATER MANAGEMENT

3.10.1. Integrated Site Drainage Plan: Based on the investigation in Section 2, the

Contractor shall design and construct a complete, integrated stormwater management system for the entire site of operations. This system shall comply with UFC 3-201-01, Civil Engineering, and all applicable base and local environmental regulations. The design shall, at a minimum:

3.10.1.1. Incorporate the building's roof drainage system (gutters and downspouts).

3.10.1.2. Include site grading, swales, catch basins, culverts, and any necessary underground piping to ensure positive drainage away from the facility foundation and prevent ponding or erosion anywhere on and off the site.

3.10.1.3. Manage stormwater for a 10-year storm event, at a minimum.

3.10.1.4. Include the development of a Stormwater Pollution Prevention Plan

(SWPPP) for the construction phase, if required by local regulations.

3.10.2. The complete Stormwater Management design, including all calculations and grading plans, shall be stamped by the Contractor's licensed Professional Civil Engineer and included in the design submittals.

3.11. FIRE PROTECTION

3.11.1. The PEMB shall include a complete fire protection system compliant with all applicable codes, including UFC 3-600-01 and relevant NFPA standards. The Contractor shall perform and submit a formal Fire Protection Hazard Analysis as part of the 30% design submittal. This analysis will determine the specific system requirements (e.g., sprinkler type, coverage density, fire alarm integration). The final level and type of fire protection must be reviewed and approved in writing by the Davis-Monthan AFB Fire Department during the design review process. The Contractor is responsible for coordinating and documenting this approval.

3.11.2. Fire suppression system shall be approved by a licensed professional engineer, registered in any of the 50 United States as well as an NFPA Certified Fire Protection Specialist (CFPS).

3.11.3. The fire suppression system shall be tested IAW NFPA 409 Chapter 12 Section

12.5.9. Testing required by NFPA 409 Chapter 12 Section 11 shall also be performed as applicable to initial installation. Passing results shall be supplied to the GPE prior to acceptance.

3.12. LIGHTNING PROTECTION SYSTEM (LPS):

3.12.1. The LPS, if required, shall be designed and installed in accordance with AFMAN 32-1065, UFC 3-575-01, NEC, and NFPA 780.

3.12.2. Building ground systems shall be interconnected at a common accessible point in accordance with applicable regulations, including NFPA 780 Section 4.14.5 and Gap Analysis.

3.12.3. The system shall be installed by a contractor with an Underwriters Laboratories (UL) Lightning Protection Master Certification (LPMC).

3.12.4. The LPS design shall be approved by a licensed professional engineer, registered in any of the 50 United States.

3.12.5. Inspection and Acceptance:

3.12.5.1. The LPS be inspected prior to acceptance, by a commercial third-party inspector, whose sole work is lightning protection.

3.12.5.2. The system shall be certified by this third-party inspector in accordance with AFMAN 32-1065 and NFPA 780 (in that priority order).

3.13. ELECTRICAL

3.13.1. Contractor shall use appropriate NEMA rated enclosures for exterior and/or interior environments as applicable.

3.13.2. Provide an NEC compliant power interruption panel suitable for lock out/tag out

IAW OSHA regulations for blast booth equipment.

3.14. LIGHTING

3.14.1. Internal overhead lighting shall be Solid-state lighting (SSL) Light Emitting

Diode (LED), and installed IAW UFC 3-530-01, DMAFB Facility Design Guide and lighting levels per Illuminating Engineering Society (IES) recommendations with the following exceptions:

3.14.2. LED lighting shall be no more than 4100K at Color Rendering Index (CRI).

3.14.3. A photometric lighting plan shall be submitted to the GPE for approval through the design process (IAW para 6.3.1.).

3.14.4. Illumination of egress, emergency lighting, and egress markings shall be installed

IAW NFPA 101 Section 40.2.8, 40.2.9, and 40.2.10.

3.14.5. Exit signs shall be the photo-luminescent type. Exit signs shall be connected to the emergency lighting inverter or provided with emergency battery units.

3.14.6. Interior lights shall be controlled via a combination of occupancy sensors, vacancy sensors, photocells, time clocks, and/or switches.

3.14.7. Exterior lighting to be installed IAW UFC 3-530-01, UFC 4-010-01, and DM

Building Design Guide.

3.14.8. Exterior lighting shall be LED building-mounted fixtures installed over personnel egress. This includes any external utility or compressor rooms. No standalone light posts should be installed.

3.14.9. Exterior lighting shall be installed to illuminate the surrounding area and any disturbances to existing light coverage or shadowing caused by the PEMB.

4. BLAST BOOTH AND SUPPORTING EQUIPMENT (EAST PEMB)

This section defines the requirements for the blast booth support equipment / spaces of blast operations within the east side of the external structure, including locker rooms, transition area, observation room, and the equipment / storage room. All support facilities and spaces shall comply with applicable building codes, Air Force design requirements, and all applicable codes and regulations listed in Appendix C.

4.1. GENERAL REQUIREMENTS

4.1.1. Contamination Control Zone Designations: The entire blast operations facility shall be designed, constructed, and designated according to the three-zone "Cold/Warm/Hot" contamination control concept as detailed in UFC 4-211-02 figure 2-5 CLEAN-DIRTY Schematic (see Appendix “E”). The Contractor shall use this official nomenclature in all design documents, drawings, operational procedures, and signage. The zones are defined as follows:

4.1.1.1. Cold Zone (Clean Area): An area free from contamination where no Personal Protective Equipment (PPE) is required. This zone includes the Clean Locker Room, Administrative / Break Areas (if applicable), and the Observation Area. It shall be the area of highest relative air pressure.

4.1.1.2. Warm Zone (Contamination Reduction Corridor): A transition area between the Cold and Hot zones where personnel don off contaminated PPE.

This zone includes the Dirty Locker Room, Respirator Cleaning Station, Transition Areas, and an Air Lock / Air Shower. It shall be maintained at a negative pressure relative to the Cold Zone.

4.1.1.3. Hot Zone (Exclusion Zone): This zone consists of the blast booth where hazardous operations occur and contamination is generated. Full PPE is required and shall be the area of most negative relative air pressure.

4.1.2. Layout: Support facilities and spaces shall be designed to eliminate the potential for blast booth media and dust migration and ensure proper workflow.

4.1.3. Finishes: All blast support and transition spaces shall have durable, easy-to-clean, wipeable, industrial level finishes. No carpet is permitted.

4.1.4. Fire Safety: The blast booth, mechanical areas, and support spaces shall include fire protection measures (e.g., fire sprinklers, fire-rated walls) as required by applicable codes and standards.

4.2. HVAC AND CONTAMINATION CONTROL

4.2.1. Climate Control: All ancillary spaces shall be climate controlled to maintain a target setpoint temperature between 60°F and 80°F.

4.2.2. Climate controls shall be localized / not connected to a network.

4.2.3. Contamination Control via Pressure Differential: The HVAC system shall be designed to create a cascading pressure differential to ensure airflow is always from cleaner areas to dirtier areas, preventing the migration of dust and contaminants.

The design shall adhere to the principles outlined in UFC 4-211-02 “CLEAN- DIRTY” schematic, Blast-Resistant Design and the ACGIH Industrial Ventilation:

A Manual of Recommended Practice. The pressure hierarchy shall be, at a minimum:

4.2.3.1. Cold / Clean Spaces (Highest Pressure): The Clean Locker Room and Observation Area shall be maintained at a positive pressure relative to all adjacent spaces.

4.2.3.2. Warm / Transition Spaces (Intermediate Pressure): The Dirty Locker Room and Transition Area shall be maintained at a negative pressure relative to the clean spaces, but a positive pressure relative to the blast enclosure.

4.2.3.3. Hot / Dirty Spaces (Most Negative Pressure): The blast enclosure itself shall be maintained at a negative pressure relative to all adjacent spaces, ensuring maximum containment.

4.2.4. Verification: The Contractor's certified Test and Balance reports must include a detailed matrix of differential pressure readings between all adjacent Cold, Warm, and Hot spaces to prove this cascading relationship has been achieved.

4.3. COLD, WARM, AND HOT AREAS

4.3.1. Configuration Approval. The Contractor shall be responsible for formally presenting the proposed layout of all Cold, Warm, and Hot areas to the Government's designated Bioenvironmental Engineering and Occupational Safety representatives during the 30% Concept Design stage. The Contractor shall document and incorporate all requirements from these stakeholders into the design.

Written, signed approval of the final layout from both stakeholder offices must be obtained by the Contractor and submitted as a condition for the Government's approval of the 60% Preliminary Design submittal.

4.4. OBSERVATION ROOM (COLD AREA) SHALL:

4.4.1. Prevent entry or migration of blast dust.

4.4.2. Be sized to accommodate 2 personnel.

4.4.3. Have window sized for unobstructed view of the entire blast booth work area.

4.4.4. Have a window made of safety glass protected by a screen per OSHA 1910.94.

4.4.5. Be isolated from noise generated by the blast booth / equipment to a sustained level lower than 85 dBA during blast operations.

4.4.6. Provide access to all blast system and ventilation system controls and monitoring via the PLC/HMI.

4.4.7. Shall have full system emergency stop.

4.4.8. Shall have blast booth lighting controls.

4.5. CLEAN LOCKER ROOM (COLD AREA) SHALL:

4.5.1. Serve as the sole entrance into the Warm Area (Dirty Locker Room).

4.5.2. Be sized to accommodate a maximum of 4 personnel and have a minimum area of

200 square feet.

4.5.3. Contain four (4) lockers for storage of employees’ personal items. Lockers will be stacked two high, lockable, with 18 inches of depth minimum.

4.5.4. Have Contractor installed supply cabinets for the storage of clean blast coveralls, gloves, and Tyvek suits.

4.5.5. Have two (2) seating benches, minimum length of 42 inches, and permanently mounted to flooring.

4.6. DIRTY LOCKER ROOM (WARM AREA) SHALL:

4.6.1. Be sized to accommodate a maximum of 4 personnel and have a minimum area of

200 square feet.

4.6.2. Contain four (4) lockers for storage of employees’ personal items. Lockers will be stacked two high, lockable, with 18 inches of depth minimum.

4.6.3. Include space for government provided containers to collect contaminated PPE.

4.6.4. Have electrical outlets for use of a HEPA vacuum.

4.6.5. Have a culinary water source for a two basin sink that is sized large enough for hand and respirator washing. Basin sink will drain to the sanitary sewer, and all plumbing systems shall be installed IAW UFC 3-420-01.

4.7. AIR LOCK / AIR SHOWER (WARM AREA) SHALL:

4.7.1. Be provided for initial decontamination of employees who will transition to / from the blast booth (Hot Area) and Dirty Locker Room (Warm Area).

4.7.2. Be designed and implemented per NIOSH requirements and offer the best efficiency and efficacy of dust removal and filtration.

4.7.3. Be designed for ease of maintenance, specifically HEPA filter(s) changes.

4.8. TRANSITION AREA (WARM AREA) SHALL:

4.8.1. Have electrical outlets for HEPA vacuum.

4.8.2. Have indicator lights at booth entrance, showing status of blast enclosure (blast system enabled, hoses active/in use).

4.9. BLAST EQUIPMENT ROOM

4.9.1. An equipment area shall be provided for media reclaim, recovery, and blast equipment.

4.9.2. Blast equipment shall be designed to not leak or permit the migration of media or dust into the equipment area or Cold Areas.

4.9.3. External access via a roll-up door and a man door. Equipment / Storage doors shall be sized to ensure that the maintenance, replacement, or repair of the equipment can be easily accomplished in and out of the room(s). The contractor shall provide dimensions of the largest piece of equipment that will be housed and ensure that the door is sized accordingly.

4.9.4. Shall have basic temperature control, ventilation, and/or insulation to prevent overheating (at or below 90°F) that is independent from ancillary personnel areas HVAC. Contractor to recommend most economical solution.

4.9.5. Shall have space to store 2 pallets of clean blast media barrels.

4.10. MECHANICAL/ELECTRICAL ROOM

4.10.1. A weatherproof compressor and electrical room shall be provided.

4.10.2. Size: The rooms shall be sized appropriately to accommodate all necessary electrical and compressor equipment.

4.10.3. Access: The rooms shall have secure access with lockable doors and provide external access for maintenance actions. Doors shall be sized to ensure that the maintenance, replacement, or repair of the equipment can be easily accomplished.

The contractor shall provide dimensions of the largest piece of equipment that will be housed in this room and ensure that the door is sized accordingly.

4.11. COMPRESSED AIR SOURCE

4.11.1. The contractor shall be responsible for providing a compressed air source that is sufficient for the blast booth and all associated equipment for 8 hours of continuous blast booth operations.

4.11.2. Air needs to be dried to prevent issues with the blast media.

4.11.3. All compressed air tanks shall have auto drains installed to prevent buildup of condensate, oil, and/or corrosion. Contractor to recommend a permissible and most economical solution for drain condensate collection and/or disposal (i.e. sanitary sewer, other).

4.12. BREATHING AIR

4.12.1. The Contractor shall design, furnish, and install a complete, standalone, and compliant Grade D Breathing Air System. This system shall be designed in strict accordance with OSHA 29 CFR 1910.134, Respiratory Protection, and the referenced CGA G-7.1 standard. The system must be fully independent of the shop / process compressed air system.

4.12.2. Source and Filtration: The breathing air compressor shall be of a type specifically designed for respiratory protection (e.g., oil-less or with multi-stage filtration for oil removal). The compressor's air intake shall be located in a clean, outdoor area, demonstrably free from vehicle exhaust or other atmospheric contaminants. The system shall include all necessary filtration, drying, and purification stages to ensure the final air quality at the point of attachment meets or exceeds Grade D requirements under all operating conditions.

4.12.3. Continuous Monitoring and Alarms: The system shall be equipped with continuous in-line monitoring for Carbon Monoxide (CO). The CO monitor shall be the specified Invertech CAM-900. The system shall also incorporate alarms for high temperature and/or CO that are both audible and visual inside the blast booth and at the Observation Area HMI. The system must be configured to automatically shut down the breathing air supply and prevent use if a high-CO or high-temperature condition is detected.

4.12.4. Third-Party Verification and Certification: Upon completion of installation and prior to final acceptance, the Contractor shall engage a certified, independent, third-party testing laboratory to sample and test the breathing air from each connection point (CDRL A009). The Contractor shall provide the Government with a formal Certificate of Analysis from this laboratory certifying that the air delivered at each point meets or exceeds CGA G-7.1 Grade D specifications (CDRL A009). This testing and certification shall be performed at the Contractor's expense.

4.12.5. Breathing air couplings must not be compatible with outlets for no respirable worksite air or other gas systems. There should be multiple connection ports for airline respirator hoses to allow worker mobility.

4.13. ELECTRICAL

4.13.1. Sufficient to run all blast, recovery, reclaim, ventilation, and other equipment.

4.14. BLAST ENCLOSURE (Hot Area)

4.14.1. Shall comply with but not limited to T.O. 1-1-8, UFCs, all applicable building codes, Air Force design requirements, and applicable codes and regulations are listed in Appendix C.

4.14.2. Expected Workload for Blast Enclosure Table:

AMARG AGE

Category Equipment Dimension Tallest B-2 Maintenance Stand 17 ft lowered Widest B-52 Tow Bar 12.5 ft Heaviest 4100 R& I Trailer 3,190 lbs.

4.14.3. Combustible Dust Hazard Compliance. The plastic media used in this facility is a recognized combustible dust. As such, the blast enclosure, dust collector, and all associated ventilation and reclaim ductwork shall be designed, installed, and protected in strict accordance with NFPA 652 Standard on the Fundamentals of Combustible Dust, and NFPA 654 Standard for the Prevention of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids. As a component of the 30% design submittal, the Contractor shall provide a formal Dust Hazard Analysis (DHA) as required by NFPA 652. This DHA shall inform the design of all required explosion protection and mitigation systems (e.g., explosion venting, suppression, or containment) which must be approved by the Davis-Monthan AFB Fire Department as part of the overall Fire Protection Hazard Analysis (per Section 3.11).

4.14.4. Floor Load Capacity: The blast booth floor shall be designed to support the weight of the heaviest configuration of AGE that will be used in the booth. The heaviest AGE is defined as the 4100 Engine Trailer (~3,190lbs).

4.14.4.1. Verification: The Contractor shall provide calculations demonstrating that the blast booth floor meets the specified load capacity. The calculations shall include the weight and footprint of the 4100 Engine Trailer.

4.14.5. Construction:

4.14.5.1. Structure will be delivered with most of the fabrication and assembly being accomplished at the factory and much of the installation shall be accomplished from the ground level.

4.14.5.2. May be integrated or an insert of the PEMB

4.14.6. Size:

4.14.6.1. The blast booth interior volume shall be sized to fit various sizes of Aerospace Ground Equipment that is listed in para 4.14.2.

4.14.6.2. Internal Dimensions:

4.14.6.2.1. Height: 20 ft

4.14.6.2.2. Width: 20 ft

4.14.6.2.3. Depth: 40 ft

4.14.6.3. Must be able to accommodate the following:

4.14.6.3.1. Tallest AGE: B-2 at 17’

4.14.6.3.2. Heaviest AGE: 3,190 lbs.

4.14.7. Walls for enclosure:

4.14.7.1. Sealed to prevent media/dust migration to surrounding areas

4.14.7.2. Walls need to be abrasion resistant

4.14.7.3. Sound damping material shall be installed on the exterior of blast booth walls to ensure noise levels are lower than 85 dBA during blast operations.

4.14.7.4. If integrated, then insulated appropriately

4.14.8. Lighting:

4.14.8.1. LED lighting on the walls and the ceiling appropriate for a blast environment, at a minimum Class 2 Div 1 or higher as required based on Fire Department classification of the space.

4.14.8.2. Minimum lighting is ~ 70-foot candles at 2’6” above the floor.

4.14.9. Utility Hookups:

4.14.9.1. Air connections should have a shut off valve at the wall connection point.

4.14.9.2. Air connections shall be managed by regulators to adjust pressure.

4.14.10. Compressed Air / Shop Air

4.14.10.1. 100 PSI.

4.14.10.2. Four (4) minimum connections.

4.14.10.3. Connection Type: DeVILBISS Quick Disconnect -High Flow Ball and

Ring Lock Type.

4.14.11. Breathing Air Connections

4.14.11.1. Minimum of four (4) connections.

4.14.11.2. Breathing Air Couplets must not be compatible with outlets of non-breathing worksite air or other gases.

4.14.11.3. Connection Type: 3M Twist Lock (Shrader), Automatic Connect system.

4.14.11.4. Carbon Monoxide Monitor is required to ensure safe and compliant respirator program and shall be the Invertech CAM-900.

4.14.12. Notification System:

4.14.12.1. Breathing air system alarm.

4.14.12.2. Fire alarm.

4.14.12.3. Door alarm while in operation.

4.14.13. Doorways/Openings:

4.14.13.1. Sealed to prevent dust escape or migration.

4.14.14. Main Blast Door:

4.14.14.1. Sized to ensure fitment of tallest / widest AGE equipment.

4.14.14.2. Sealed to prevent dust escape, and ingress of outside moisture / dirt.

4.14.14.3. May be integrated in PEMB (preferred) or as an insert.

4.14.14.4. Door will be facing south towards wrap around road as shown in

Appendix A.

4.14.15. Grounding:

4.14.15.1. Static Dissipation: The entire blast enclosure, including the operator and all equipment, shall be treated as a static-controlled area. The Contractor shall provide a complete static control system that includes, at a minimum conductive or static-dissipative blast hoses designed to prevent static charge accumulation.

4.14.15.2. Two (2) grounding points on / near centerline.

4.14.15.3. All blasting equipment and components being blasted shall be properly electrically grounded in accordance with TO 00-25-172.

4.14.15.4. Floor gates access panels should be located outside of the booth, where possible.

4.14.15.5. The blast booth must meet fire egress requirements per UFC 3-600-01.

4.14.15.6. Noise level within appropriate OSHA levels in and around the booth and support facilities & spaces.

4.15. BLAST EQUIPMENT

4.15.1. This section details the requirements for all equipment used in the plastic media blast process. The equipment shall be designed for maintainability and reliability, ensuring consistent and efficient performance. The blast equipment shall be capable of effectively removing paint, primer, and corrosion from AGE without damaging the underlying material. Blast booth shall utilize Type V media (Acrylic Plastic) with a 3.5MOH hardness defined in the Technical Order 1-1-8.

4.15.2. General Requirements:

4.15.2.1. All blast equipment shall be designed and constructed to meet all applicable safety standards.

4.15.2.2. Air Quality: Air shall be dried and filtered appropriately to prevent issues with the blast media or equipment.

4.15.2.3. Abrasion Resistance: All system transfer ducting shall be able to withstand abrasion from media.

4.15.2.4. Ergonomics and Noise Reduction: Blast equipment shall be designed with noise reduction technology and ergonomics to promote the reduction of user fatigue and safety.

4.15.3. Blast Equipment Requirements

4.15.3.1. System shall have two (2) independent blast pots capable of blasting continuously for 15 minutes with no interruptions.

4.15.3.2. The blast pots shall have capability to operate with media flow enabled or disabled (supplying compressed air only to the nozzle), selected for each pot independently from the Observation Room HMI or at the nozzle deadman trigger.

4.15.3.3. The blast pot pressure and the media feed rates shall be changeable for the individual blast pots, controlled from the Observation Room HMI using a supervisor-only pass code.

4.15.3.4. The blast pots shall be able to provide a calibrated and adjustable media flow rate between 0-15lbs/min with 0.1lb/min accuracy minimum, using an AccuFlow media metering valve, or equivalent.

4.15.3.5. The blast pots shall operate at a calibrated and adjustable pot pressure which provides 10-60 PSI at the blast nozzle with 2 PSI accuracy minimum.

4.15.4. Blast Hardware:

4.15.4.1. Nozzle- Marco #8 or equivalent.

4.15.4.2. Triggers – standard deadman trigger.

4.15.4.3. Media flow/air flow switch at nozzle.

4.15.4.4. Hoses (Main and whip hose), sized to reach the full interior space, with room to move vertically as needed.

4.15.4.5. Hoses shall be of a static-dissipative or conductive construction suitable for plastic media applications to prevent static charge buildup.

4.15.5. Media Reclaim Equipment

4.15.5.1. Requirement: Blast Booth shall utilize a pneumatic full floor media recovery system.

4.15.5.2. The media reclaim equipment shall be capable of efficiently and effectively reclaiming and cleaning used blast media for reuse.

4.15.5.3. Performance: The system shall be capable of processing and storing sufficient media to supply clean media to two (2) blast pots operating simultaneously for two (2) consecutive 8-hour shifts.

4.15.5.4. PLC Control: Equipment start/stop, appropriate adjustments, and monitoring shall be performed by the PLC/HMI in Observation Area.

4.15.5.5. Waste Management: The waste generated during the reclamation of the media shall be consolidated into a single waste stream into a waste collection system that is independent of the booth ventilation system. Waste shall be consolidated into a palletized 55-gallon open head steel drum with bolt ring.

4.15.5.6. System Transfer: All system transfer ducting should be able to withstand abrasion from the blast media.

4.15.6. Hopper Equipment Requirements (All):

4.15.6.1. Include a minimum of two (2) media storage hoppers including a dirty and clean hopper.

4.15.6.2. Include sensors to detect media capacities, to automate the start / stop of reclaiming and recovery equipment as needed, to keep the hoppers full. Hopper media levels shall be displayed in the Observation Room PLC.

4.15.6.3. Include sight windows to visually observe media levels.

4.15.6.4. Designed to prevent media bridging.

4.15.6.5. Designed to feed all blast pots evenly.

4.15.6.6. Self-feeding.

4.15.6.7. Include media shut off valves for maintenance.

4.15.7. Media Cleaning:

4.15.7.1. Timing adjusted from main HMI.

4.15.7.2. Ionizer to reduce static in media.

4.15.7.3. Vibratory classifier to sort media based on size.

4.15.7.4. Dense particle separator to sort media based on density.

4.15.7.5. Quality: The reclaim system shall clean media to meet the standards in TO

1-1-8, paragraph 2.12.12.

4.15.7.6. Anti-static fluid sprayer to treat reclaimed media (if required / optional)

4.15.7.6.1. Accessible refill point.

4.15.7.6.2. Applied only when the media is flowing.

4.15.7.6.3. Capability to adjust the amount of fluid sprayed.

4.15.7.7. Loading of new media; special reload mode to speed recovery of new media (floor gate control option)

4.16. BLAST BOOTH VENTILATION EQUIPMENT SHALL:

4.16.1. Provide a sufficient volume of ventilation air to maintain an average minimum cross-draft velocity of 100 FPM across the entire operational cross-section of the blast enclosure (OSHA 29 CFR 1910.94). The system shall be balanced to ensure airflow is laminar and without dead spots.

4.16.1.1. Ventilation Performance: Provide certified test and balance reports demonstrating that the blast enclosure meets the specified average cross-draft velocity of 100 FPM and the negative pressure requirements (per Section 4.2.3). Velocity readings shall be taken on a grid pattern as prescribed by the ACGIH Industrial Ventilation manual to verify uniform flow.

4.16.2. Produce negative pressure to minimize dust migration.

4.16.3. Maintain temperature…