SOW-Bombardier 600 Series Painting.pdf

Flight Program Operations Reagan National Airport FAA Hangar 6 Washington, DC 20001

Federal Aviation Administration

Attachment 1

FEDERAL AVIATION ADMINISTRATION

AVIATION SYSTEM STANDARDS

FLIGHT PROGRAM OPERATIONS

STATEMENT OF WORK (SOW)

for

BOMBARDIER 600 SERIES

CL-601 & CL-604

AIRCRAFT PAINTING

February 15, 2018

Statement of Work Painting of Challenger CL-601 & CL-604

February 15, 2018

Revision History No. Date Author Description 1 February 15, 2018 Reid/Foreman Rev. 01—Original release

STATEMENT OF WORK

Bombardier Challenger CL-601 &CL-604

Prime and Painting

1.0 Introduction:

The Flight Program Operations, Systems Integration Sub-team (AJW-3131) has a requirement to paint strip, water break clean, skin brighten, Alodine treat, prime and paint FAA’s three (3) Bombardier Challenger CL-601 and one (1) Challenger 604 Flight Inspection aircraft. in accordance with the Statement of Work. The Contractor is required to furnish all facilities, labor, supervision, materials and equipment to paint strip, water break clean, skin brighten, Alodine treat, prime and paint FAA’s Bombardier Challenger 601/604 aircraft.

The FAA Flight Program Operations Aircraft Fleet is required to operate as a Federal Aviation Regulation Part 135 Air Operator. As such, Flight Program Operations (FAA) must comply with the requirements dictated by these regulations. FAA’s Air Operator certificate RU3A249N no longer requires the painting of our aircraft to be accomplished by a FAA certificated Repair Station. However, this requirement is not just for painting of the aircraft, but also includes the repair or replacement of any items, panels, seals, of areas of corrosion found during the painting process. These fixes are covered by the Over and Above contract line item and are to be processed in accordance with the contract terms and will require CO approval prior to repair or replacement work being started. As such, all work being performed on the aircraft must be documented and signed for by a FAA certificated mechanic/technician with an Airframe and Powerplant (A&P) rating. Therefore, the prime contractor must also provide a copy of the Air Agency Certificate, Repair Station documentation with their initial technical proposal.

As such, the contractor will provide the name of the specific individuals named must be under a drug testing program acceptable to the FAA and meet our program requirements per our General Maintenance Manual TI 4100.24. The same applies to the inspector performing the Required Inspection Item (RII) tasks. The FAA’s Quality Team will evaluate, approve and authorize the two submitted individuals (A&P Mechanic/Technician and A&P RII Inspector), including performing a Facility Capability Audit.

2.0 Applicable Documents

MIL-Spec 969 or equivalent

FAA Drawing ES-0001-101 (CL-601/CL-604 Paint Scheme) – 08/29/2017-

FLIGHT PROGRAM OPERATIONS Challenger CL-601 Aircraft Maintenance Manual (AMM) T.I. 4109.2

FLIGHT PROGRAM OPERATIONS Challenger CL-601 Structural Repair Manual

(SRM) T.I. 4109.3

FLIGHT PROGRAM OPERATIONS Challenger CL-604 Aircraft Maintenance Manual (AMM) T.I. 4102.2

FLIGHT PROGRAM OPERATIONS Challenger CL-604 Structural Repair Manual

(SRM) T.I. 4102.3

General Maintenance Manual (GMM) T.I. 4100.24

3.0 Requirement

The Contractor shall perform the work listed below in accordance with the terms, conditions and provisions set forth herein.

3.1. Furnish all facilities, labor, supervision, materials and equipment to paint, strip, water break clean, skin brighten, Alodine treat, prime, and paint FAA's Challenger CL- 601/604 aircraft.

3.1.1 The contractor must provide to the FAA both names, resume, and license documentation of the individuals that will perform as the contractor’s A&P Mechanic/Technician and A&P RII Inspector. Documentation must demonstrate that both individuals’ ratings are current.

3.2 Arrival Inspection

(a) Inspect the aircraft prior to stripping and/or painting upon arrival for any evidence of damage. Areas inspected should include flight controls, fuselage skin, leading edges, composites, antennas, de-icier boots, windshields and windows. The Contracting Officers Representative (COR) will identify to the contractor the name of a Flight Program Operations Quality Control Inspector that shall be present for all arrival inspections. The Contractor is responsible for annotating all discrepancies and submitting the documentation to the Flight Program Operations Quality Control Inspector/COR prior to starting work.

(b) Components that are removed for recovering/refurbishment must be inspected for serviceability. The attach points must be inspected for serviceability and if required, repaired in accordance with the FAA’s Challenger CL-601 Aircraft Maintenance Manual (AMM) T.I. 4109.2 and/or Structural Repair Manual (SRM) T.I.

4109.3, Challenger CL-604 AMM T.I. 4102.2 and/or SRM T.I. 4102.3 as applicable, prior to reinstalling the removed component. Hardware that is worn or has degraded plating must be replaced with new hardware.

(c) Over and above work – If after initial inspections, as stated above, additional damage needing repair is found that have estimated cost that are over and above the minor repairs as stated in paragraphs (a) and (b) above, the contractor, in accordance with the Contract Section H, Clause H.(TBD) Contract Orders for Over-And- Above Task and Procedures, shall identify the damage needing repair and shall contact the CO and COR prior to any work being started. If directed by the CO, the contractor shall develop the Rough order of magnitude cost proposal for the task proposal as required under the Contract Section H.

Upon acceptance by the FAA Contracting Officer, a written authorization will be issued to the contractor to perform the required work to make the required repair to the aircraft.

3.3. Flight Controls

Flight Controls will be removed, stripped, painted, and balanced in accordance with the aircraft’s current maintenance instructions using the Challenger CL-601 Aircraft Maintenance Manuals (AMM) T.I. 4109.2, and Structural Repair Manual (SRM) T.I. 4109.3 or CL-604 Aircraft Maintenance Manuals (AMM) T.I. 4102.2, and Structural Repair Manual (SRM) T.I. 4102.3. The Contractor’s Inspector will need Required Inspection Item (RII) authorization per FLIGHT PROGRAM OPERATIONS’s General Maintenance Manual (GMM) T.I. 4100.24, (AJW-3471) to complete RII for the removal and reinstallation of the flight controls.

3.4. Replace aerodynamic sealer as required.

As required, apply aerodynamic sealer to fuselage seams and rivets, wing top and bottom seams and rivets, as well as lower pylon seams and rivets per Challenger CL- 601 Aircraft Maintenance Manuals (AMM) T.I. 4109.2, and Structural Repair Manual (SRM) T.I. 4109.3 or CL-604 Aircraft Maintenance Manuals (AMM) T.I. 4102.2, and Structural Repair Manual (SRM) T.I. 4102.3.

3.5. Paint Strip Specifications

All areas not requiring stripping (composites, antennas, de-icer boots, windows, etc.)

and special areas as directed by the Contracting Officer or the Contracting Officer’s Representative will be masked.

Masking tape must be applied by such workmanship that penetration will be prevented, not only during application of the paint remover, but also during the wash down process.

Any damage resulting during the process of paint stripping, including but not limited to faulty masking, shall be the sole responsibility of the Contractor.

The Contractor shall not use wax-based materials for masking.

Plug all antenna and beacon mounting holes when removed and all other openings wherein paint strip materials may become trapped.

All material used in the stripping process shall comply with manufacturer’s specifications and be approved by the Contracting Officer or the COR. Prior to the start of work, submit to the Contracting Officer a copy of the materials and procedures contemplated.

The approval or disapproval will be provided to the contractor in writing from the Contracting Officer.

Remove from the exterior of the aircraft, any painted-on material for catwalk areas, such as anti-slip surfaces, all existing paint, whether it be enamel, modified epoxy, lacquer, primer, polyurethane or other painting substance, including the removal of all decals and identification marks.

Wash down all paint stripped areas, remove all paint debris and any deposit of paint remover, leaving all original surfaces of the aircraft in a clean condition and free of all foreign substances. Prior to painting of the airplane, the Contractor shall inspect all paint surfaces which have been paint stripped to remove any evidence of paint debris, paint strip residue, film, stains or etc. Final cleaning should produce a water break free surface capable of supporting a continuous film of water for 30 seconds prior to separating.

At the time of delivery, the FAA COR will identify areas that should not be stripped (i.e.

wheel and flap wells) but these designated areas will require cleaning and top-coat.

The composite areas or surfaces will be identified in the FAA’s Challenger CL-601 Aircraft Maintenance Manual (AMM) T.I. 4109.2, or CL-604 AMM T.I. 4102.2 as applicable and will also not be stripped.

CAUTION: Do not use stripper of any type for removing paint from fiberglass, nylon or composite surfaces. Paint must be removed from these surfaces with fine sandpaper, using care not to sand into the material.

3.6 Preparation and Application of Alodine to Aircraft Surfaces

The contractor will use the procedures and material specified in the FAA’s Challenger CL-601 Aircraft Maintenance Manual (AMM) T.I. 4109.2 or CL-604 Aircraft Maintenance Manual AMM T.I. 4102.2 as applicable. If the FAA’s Challenger CL-601 Maintenance Manual (AMM) T.I. 4109.2 or CL-604 AMM T.I. 4102.2 as applicable does not specify procedures or material the contractor will provide a copy of their procedures to the FAA Contracting Officer for approval.

Clear Alodine is to be used on all surfaces that are to be unpainted.

Protect windows and ferrous parts (steel fastener heads included). All glass windows must be thoroughly protected. Standard protection is two layers of heavy masking paper secured at window edges with duct tape, one layer of oven aluminum foil with aluminum foil tape (MIL-Spec 969 or equivalent). Observe the Manufacturer’s caution pertaining to electrothermal windshields.

Alodine to be applied in accordance with manufacturer's specifications.

3.7. Paint Design.

3.7.1 CL-601 Paint Scheme Drawing – August 29, 2017 and CL-604 Paint Scheme Drawing – January 21, 2018 Revision 1, February 14, 2018.

The aircraft by tail code will be painted as shown in Appendix A-CL-601-N85, N85, N87 and Appendix B-CL-604 –N88 to this Statement of Work. Submit Final Dimensions paint scheme layout drawings to the Contracting Officer for approval prior to starting the first aircraft for Appendix A, and first aircraft under Appendix B. Contractor shall provide electronic copies of the Final Dimensioned Paint Scheme in accordance with Contract Data Requirements List (CDRL A001).

3.8 Additional Notes

(a) Contractor shall not use power sanding equipment, metal scrapers, or wire brushes for primer/paint removal during stripping. Orbital power sanders and/or hand sanding is acceptable to scuff or smooth primer coats only. If such sanding should penetrate to skin surface, these areas are to be re-alodined and primed.

(b) Contractor shall furnish adequate scaffolding and work stands to avoid walking or standing on freshly alodined, primed, or top coated surfaces.

(c) Contractor shall maintain a certified quality control program to ensure 100 percent coverage of all work accomplished on FAA aircraft.

(d) Contractor shall replace all required operational and safety decals, placards and markings (SOW Addendum A-1).

(e) Contractor shall apply intermediate filler primer prior to painting.

(f) Paint shall comply with lightning strike protection requirements of 14 CFR Part 25.954 and in particular, FAA Advisory Circular AC20-53. Reference FAA Airworthiness Directive AD85-14-04, Amendment 39-5087.

(g) AOA placards shall be removed prior to application of basecoat color and properly reapplied at completion of paint detail.

(h) Contractor shall not strip or paint undercarriage.

(i) Contractor shall not strip or paint external antennas.

(j) Contractor shall not strip fiberglass components – scuff sand and top coat with materials specified in the CL-601 Paint Scheme Drawing or an equivalent material approved by the Contracting Officers Representative.

(k) Contractor shall paint nose/main landing gear wheel well areas.

(l) Contractor shall paint inboard and outboard flap vanes at rub areas with Teflon paint or install erosion tape.

(m) Contractor shall paint fuselage frame structure around entry door opening, inside of entry door/stairs/frame, inside/frame of equipment bay door, inside/frame of baggage door, inside/outside/frame of nose/main landing gear doors, inside/frame of thrust reversers and non-brightwork areas of engine core cowls and engine inlets.

(n) Contractor shall polish all bright work, including, but not limited to the APU shield, wing leading edges, stabilizer leading edges, engine inlet leading edges, bright-work areas of engine core cowl and engine exhaust nozzle fairing.

(o) Contractor shall apply erosion tape on nose avionics door leading edges, wing tip leading edges, antenna leading edges (as applicable), flap fairing leading edges, nose landing gear door leading edges and main landing gear door leading edges.

(p) Contractor shall install 3M Erosion Boots on winglets and Mylar radome boot on nose radome.

(q) Contractor shall polish entry door hinge, radome latches, avionics door latches, access panel latches, core cowl latches, access and service door hinges, kidney panel surrounds and entry door hand rails.

(r) Contractor shall pressurize aircraft to 4 PSI and check for leaks.

3.9. Work Schedule

The FAA will provide a minimum of 4 weeks prior notification of delivering the aircraft for painting. All aircraft should be completed within the term stated in the contract for delivery if no discrepancies, additional work, or change orders are found and/or approved. The FAA will not have more than one aircraft in for painting at the same time.

3.10 Commercial Warranty

The contractor agrees that the supplies or services furnished under this contract shall be covered by the most favorable commercial warranties the Contractor extends to any customer for such supplies or services, and the rights and remedies provided herein are in addition to and do not limit any rights afforded to the Government by any other clause of this contract. The minimum acceptable warranty is 1200 hours or 12 months which ever occurs first. The manufacturers/supplier commercial warranty shall apply to supplies utilized in the performance of this contract, and a minimum acceptable warranty for installation labor is 60 days. The contractor shall furnish four (4) copies of the warranty applicable to the supplies or services to the COR.

4.0 Definitions

A&P - Airframe and Powerplant Certificate AMM - Aircraft Maintenance Manual CDRL - Contract Data Requirements List CO - Contracting Officer COR- Contracting Officer Representative FAA - Federal Aviation Administration FLIGHT PROGRAM OPERATIONS - Flight Inspection Services GMM - General Maintenance Manual RII - Required Inspection Item SRM - Structural Inspection and Repair Manual

5.0 Program Management

(a) The Contractor shall designate a Program Manager (PM) who shall be the central point of contact for the Contracting Officer (CO) and Contracting Officer’s Representative (COR) on all matters pertaining to the total contract effort as described in this Statement of Work and specifications. The PM shall be prepared at all times, given reasonable notice, to present and discuss with the FAA the status of contract activities. The contractor will provide the FAA with a preliminary Program Management Plan with their Technical Proposal which is due by the closing date and time set by the SIR. The Technical Plans and Specifications shall be provided as a separate document and not included in the contractor’s cost proposal. (CDRL-P001)

(b) A Post Award Conference/Preliminary Design Review will be held at the contractor’s facility approximately 20 days after contract award to discuss the various contract requirements, Plans, Statement of Work, Paint Specifications, over and above procedures, preliminary Dimensioned Paint Scheme drawings, and delivery of first aircraft to vendor for paint. Upon arrival of the first aircraft there will be a final design review to make sure all parties agree on contract plans, requirements, specifications, and paint scheme.

SOW ADDENDUM A-1

ADDENDUM and CHANGE NOTES To

Paint Scheme Specification dated June 23, 2017

Paint Mask – Available from Moody Aergraphics- These masks from this contractor are no longer required as they were found to be unacceptable for this application. Contractor shall submit for review (in accordance with CDRL A001 submission) their own masks and templates.

Standard Bombardier placard design – The FAA Aircraft have been modified so a standard Bombardier placard design will not be accurate. Placard designs need to be submitted with information provided with CDRL-A001 for FAA approval. All placards shall be painted on and clear coat applied for durability.