Exhibit_1_-_Statement_of_Work__for_Full_Scale_Accelerated_Pavement_Testing_Machine.pdf

Office of Infrastructure Research and Development

Statement of Work

For

Full-scale Accelerated Pavement Testing Machine

1.0 Overview

This is a commercial item acquisition contract to provide Full-scale Accelerated Pavement Testing Machine. The Government will not exercise any supervision or control over the contract work the providers performing the work herein. Such work providers shall be accountable solely to the Contractor who, in turn, is responsible to the Government as defined in this Statement of Work (SOW). The Contractor shall perform to the standards herein.

1.1 Background

The Federal Highway Administration (FHWA) has operated a Pavement Test Facility (PTF) at the Turner-Fairbank Highway Research Center (TFHRC) since 1986. The PTF uses rapid pavement testing of full-scale structures to evaluate the performance and durability of both new and existing pavement materials. Recent testings have contributed to the development and verification of new specifications, designs, and test procedures for rigid and flexible pavements.

Past and potential future applications include assessing the impact of different tire or load configurations on pavement performance.

The facility simulates truck traffic with controlled loading and pavement temperatures. In only a few months, the facility’s loading machines can apply wheel loads comparable to that experienced by highway pavements under many years of service, and collect the corresponding pavement distress and performance data. TFHRC currently has two machines that allow simultaneous testing of two pavement lanes under the same ambient temperature and moisture conditions or at the same pavement age.

The current machines are Accelerated Loading Facility (ALF), manufactured by the Australian Road Research Board (ARRB). The ALF is a transportable linear full-scale accelerated loading facility which applies a rolling wheel load on a 45-ft test length of any test pavement. Figure 1 shows the two ALF machines at the PTF. The first ALF was delivered to PTF in 1986 and the second was purchased in 1993.

Figure 1. FHWA’s two ALF machines loading pavements at PTF site.

Each ALF contains an infrared heating system that provides for the precise control of pavement temperatures during testing. The ALF frame is 95-ft long and approximately 12-ft in width. Each machine is capable of applying an average of 35,000 wheel passes per week from a half-axle load ranging from 7,500 to 19,000-lbf. An electric motor provides unidirectional loading passes at constant speed programmable up to 11-mi/h.

The PTF has the capability for up to 12 testing lanes. Each full-scale test lane is 165-ft by 13-ft, and can be further divided into 4 subsites, for a total of 48 test locations on the facility grounds.

With age and wear, the current ALF machines have become less reliable and are difficult to repair some parts are not commercially available.

1.1 Objective

The objective of this contract is to provide Full-scale Accelerated Pavement Testing Machine and all control equipment to replace the current ALF machines at TFHRC.

1.2 Detailed Requirement

The Contractor shall provide all personnel, equipment, supplies, facilities, transportation, tools, materials, supervision, and other items and non-personal services necessary to deliver the required Full-scale Accelerated Pavement Testing Machine.

A Full-Scale Accelerated Pavement Testing Machine (PTM) utilizes controlled application of wheel loading to pavement structures for simulating the effects of long-term in-service loading conditions in a compressed time period.

Device Operation Specifications:

1) Shall be able to operate in a linear fixed wheel path mode.

2) Shall be able to operate in wheel path wander mode.

a. The lateral control of wheel wander shall be a minimum 1-inch increments.

b. Total allowable wander shall be a minimum of 24 inches.

i. The options for wander pattern shall be user selectable and consists of an automated, machine controlled, random pass pattern within the specified user wander range.

3) Shall allow for the test wheel to be automatically positioned anywhere within the test area.

4) Shall be able to operate in both an uni- or bi-directional mode.

5) Shall be powered solely by shore power three-phase electric power, 480V).

a. Government will provide all applicable electrical cabling and connection requirements from the PTM device to the electrical source within the limits of FHWA’s PTF.

6) Shall be able to produce and sustain gear load between 9,000 and 22,500 lbf (40 to 100 kN).

a. The loading mechanism shall be either hydraulically or pneumatically controlled

i. shall not include the use of ballast (weights) to control the range of loading.

b. Load control shall be within +/- 5% between specified and measured load.

7) Shall be able to operate at 4.0 to 6.0 mph under any gear load conditions in combination with any operational mode.

a. The speed control shall be +/- 5% limited between specified and measure speed.

8) Shall be able to maintain the desired load and speed over a test length of at least 40 feet.

9) Shall be less than or equal to 100 feet in length

10) Shall be capable of re-positioning from one test section to any other test section within PTF.

a. Re-positioning shall be able to be accomplished in less than 8 hours with 3 person crew, without use of owner-supplied heavy/specialty equipment. (Note: FHWA owns a forklift with maximum drawbar pull 10,000 lbf that could be utilized for repositioning)

11) Shall be able to operate without interruption within the specified load ranges and speed in 4-inch rutted pavement conditions

a. Interruption includes: mechanical malfunction, system malfunction, or need repositioning of the machine/frame or loading mechanism.

b. A 4-inch rut is defined as the elevation difference between the depression in the pavement rut and surrounding pavement within the test area.

12) Shall be able to operate (including controls systems) within an ambient air temperature between 15 to 120°F.

13) Shall include all operational and control systems (computer hardware, software, and related mechanical parts) necessary for both manual and automatic control of the machine.

a. The Government will provide the housing for the machine system control components.

i. the location shall be within the existing control room.

b. The PTM shall be able to be remotely controlled via an Ethernet cable connected directly to the PTM control cabinet.

14) Shall be provided with a dual 11R22.5 tires and wheel assembly as standard equipment.

a. The PTM shall also be supplied with a “super single” 425/65R22.5 tire and wheel assembly.

i. This includes all the necessary components to switch between dual and super single assemblies

b. All wheel assemblies shall meet current industry standards and be able to accommodate pressure and temperature sensors.

15) Shall have capability to apply at least 7500 loaded passes in uni-directional mode per 24 hours.

16) Shall have an environmental chamber to heat the pavement using electricity to:

a. 140°F pavement surface temperature

b. 125°F at depth of 1 inches beneath the pavement surface

17) The device shall be fabricated with commercially available standard parts (includes motors, motor controls, electrical controls, system controls and all mechanical parts.

a. All unique or specially fabricated parts shall be identified for evaluation

Device Monitoring Controls:

18) Shall be able remotely monitor and record experimental parameters; tire pressure, tire temperature, wheel load, wheel speed, wheel horizontal position, wheel vertical position, and number of geared passes and air and pavement temperatures.

a. All required software and hardware to meet these requirements shall be included.

b. System software shall be commonly available, expandable and upgradeable.

c. System hardware shall be commercially available, expandable and upgradeable.

19) Shall have a graphical user interface for all experimental parameters

a. All recorded data shall be readily exportable into Microsoft® Excel® workbook/s.

20) Shall be able to evaluate all pertinent machine function parameters leading to a system malfunction for diagnostics.

21) Shall be designed for both user-controlled and automatic (programmable) operation.

22) Shall have the ability to automatically shut down, without user intervention, at any defined limits based on any set of experimental parameters.

23) Shall have the ability to automatically shut down, without user intervention, in the event of any system malfunction.

24) Shall have the capability for remote shutoff.

25) The PTM shall have safety controls and measures

a. Include emergency shut off switches on the PTM and override controls.

Manufacturer Service/Support:

26) Shall be capable of remote diagnosis and have the ability to correct minor operational issues remotely.

27) Shall provide training for up to 5 persons at the Turner-Fairbank Highway Research Center, McLean, VA. The duration of the training must be specified. At a minimum, training shall include:

a. an overview of components and controls, electrical and mechanical system checks, assembly and set-up for different conditions, moving procedures, operation for linear and wheel wander experiments necessary for proper and safe use of the machine;

b. maintenance schedule and maintenance procedures;

c. fundamental repair procedures;

d. machine safety procedure and training

28) Shall provide a list of recommended stock of spare parts and sources from which standard parts can be obtained.

29) Shall provide a recommended servicing and maintenance schedule along with a list of consumable items and sources from which they can be obtained.

30) Shall provide a complete set of as-built drawings with accompanying parts identification and sources, and manuals describing all operational and servicing information.

31) Shall supply a two-year warranty for all mechanical parts and machine components.

a. parts covered

32) Shall include a two-year technical support plan

a. Include an outline of all technical support services that will be provided

b. Technical support response time for both remote and onsite service

33) The machine shall meet all applicable industry standards for design, construction, and operation.

34) All components used in the fabrication and operation of the machine shall meet all applicable Federal, State, and Local standards including but not limited to operational safety, environmental use, and noise.

Government Surveillance Inspections and Acceptance:

The contractor shall develop a process control plan that shall include at a minimum:

a. Final technical drawings for provisional acceptance

b. Pre-delivery testing/inspection at contractor’s facility

a. PTM operation specifications

b. System operational controls

c. Diagnostics demonststration

d. PTM re-positioning demonstration

e. PTM wheel change demonstration

c. Post delivery testing at TFHRC

a. Transportation damages

b. Fit and finish

c. PTM operation

d. PTM operational modes per specifications

e. Geared loads and accuracy per specifications

f. Speed and accuracy per specifications

g. Interruption or system shut off within the specified load ranges, speed, and 4-inch rutted pavement conditions

i. Super single tire conditions

ii. Dual tire conditions

h. Temperature shut off controls (if feasible)

i. Operational and control systems per specifications

j. Experimental parameter monitoring collection system.

k. System malfunctions

l. System malfunction protocols

m. Automatic shutdown controls and limits per the specificaions

n. Safety system and controls

o. PTM re-positioning per specification

p. PTM wheel change per specification

Optional Features:

1) Surface profiler

a. Device shall be capable of collecting longitudinal and transverse profile data at multiple locations along loading area of test section

b. Shall be capable of measuring up to 4 inches of vertical displacement over a transverse length of 6.5 feet. Measurement accuracy of +/- 1mm

2) PTM #2 – a second PTM unit

a. PTM shall be produced to the same specifications as the first unit with the following exceptions:

i. No environmental chamber

ii. Independent functionality is not required. PTM#2 can operate via the same control system as PTM#1, if possible.

3) Environmental chamber for second basic loading unit: Add an environmental chamber to the second basic loading unit that can heat the pavement using electricity to a) 140°F pavement surface temperature, and b) 125°F at depth of 1 inch beneath the pavement surface.

TECHNICAL EXHIBIT 1

DELIVERABLES SCHEDULE

This technical exhibit lists any reports or documentation that is required as a deliverable to include the frequency, # of copies, medium/format and who/where it is to be submitted. A deliverable is anything that can be physically delivered but may include non-physical things such as meeting minutes.

Deliverable Compliance Frequency

# of Copies Medium/Format Submit To

Final technical drawings

No Once within 60 days of contract award

2 copies

Electronic format Adobe PDF

COR

Review

Pre-delivery inspection report

No Once within 300 days of contract

COR

Review

Post-delivery inspection (on-site) report

No Once within 365 days of contract

COR

Review

Full-Scale Accelelrated Pavement Testing Machine and all control systems

No Once within 365 days of contract award

NA NA COR

Review