ABDR Trailer SOW.docx

Aircraft Battle Damage Repair Trailers Statement of Work 24 February 2021

PURPOSE

Deliver designs and one prototype of a mobile Aircraft Battle Damage Repair (ABDR) War Reserve Materiel (WRM) Trailer capable of long term sustainment in harsh weather environments along with all maintenance data necessary for lifetime sustainment.

BACKGROUND

Our forces rapidly deploy to repair battle damaged aircraft across 10 different airframes: A-10, B-1, B-52, C-130, E/KC-135s, C-5, E-3, F-15, F-16 and F-22 aircraft. To support these forces, the ABDR Technical Support Office (TSO) sustains 60 WRM trailers worldwide. These trailers contain non-hazardous tooling and parts required for execution of these repairs.

CURRENT STATE

The ABDR WRM Trailers, otherwise known as War Wagons, are built on top of old demilitarized MHU-12 and MHU-141 ammo trailers. Provisions were added to house tool cabinets and sheet metal in order to support the ABDR mission. Through attrition, new aircraft have dictated additional tooling be added in order to support changing mission requirements, for which we no longer have space to expand or alter due to space and weight constraints. Trailers are stored in facilities ranging from fully enclosed supply buildings, to open ended hangar storage, but deployed to Forward Operating Bases, and improvised landing locations outside, in order to support mission requirements.

JUSTIFICATION

The Aircraft Battle Damage Repair program is currently operating with WRM trailers that are slowly deteriorating in condition. Salt-water and sand locations, paired with long term storage have slowly done their toll on overall lifespan. Additionally, added tool requirements have trailer useable weights reaching their maximum intended limits.

REQUIREMENT

The ABDR program office requires engineering of a WRM Tool and Equipment Trailer prototype to be designed. Design of the trailer must meet the following requirements at a minimum.

· Be Air Transportability Test Loading Activity (ATTLA) certified and meet or exceed the following Military Standards (MIL-STD) for airlift on all cargo variants of C-130, C-17 and C-5 aircraft:

· MIL-STD-209 Interface Standard For Lifting And Tiedown Provisions

· MIL-STD-810 Environmental Engineering Considerations And Laboratory

· MIL-STD-1366 Interface Standard For Transportability Criteria

· MIL-STD-1791 Designing For Internal Aerial Delivery In Fixed Wing Aircraft

· Must not exceed height of 102 inches and width of 99 inches

· Maximum weight for Air Transport (Gross Vehicle Weight) 8,500 lbs (requires sleeper shoring). 8500 lbs is the weight limit of the trailer fully stocked with its contents.

· Axle Limits: Front – 3,160 lbs. (requires sleeper shoring)

· Axle Limits: Rear – 5,710 lbs. (requires sleeper shoring)

· Have a Shipping Dataplate Placard permanently affixed to the exterior of the Trailer identifying shipping information as identified in MIL-STD-209 and conform to Federal Specification A-A-50271.

· LED lighting to illuminate drawers (Centrally Powered via 110/120V NEMA 5-15 plug, not operated by batteries) Luminosity: the LED lighting is required to be bright enough for personnel to identify fine writing in small tools for accuracy.

· Material storage

· Sheetmetal comes in 4 foot by 8 foot pieces, we can cut these down to 4 foot by 4 foot

· We store up to 20 sheets of sheetmetal at a thickness of .125” per sheet.

· Storage area needs to be evenly divided into individual bays (10 bays) to prevent materiel cross contamination

· 2 cabinets at 5 ft high x 5 ft wide x 3 ft deep with the maximum amount of drawers allowed to maximize area.

· 1 cabinet at 4 ft high x 2 ft wide x 2 ft deep with the maximum amount of drawers allowed to maximize area.

· 8 foot metal tubing/extrusion storage area

· Must be towable with a parking brake system that will withstand a 15 degree incline. Testing for confirmation is required.

· Must be able to be towable at a minimum of 15 mph.

· Tow bar must be able to be removed and stored on trailer

· Towed by both pintle hook and standard tow hitch ball

· Durable enough for both on and off road conditions in austere locations

· Spare tire and necessary tire change equipment enclosed on trailer. Spare tire will be air-filled.

· Environmental Resistance. Testing for confirmation is required.

· All storage locations must be weather proofed to prevent water entrapment

· Weather proof will apply when closed for storage.

· Withstand temperature ranges from -50 to +150 degrees Fahrenheit

· Humidity ranges from 0 to 100%

· Withstand extreme wet (snow and rain) as well as sandy environments.

· Sandy environments will be encountered and trailers exposed 24/7 when used in Area of Responsibility (AOR) operations.

· Electrical Availability

· 120 VAC / 60 Hz / 50 AMP standard male and female outlets.

· Externally mounted female outlet(s) required for electrical input. Power will be supplied by external generator and connected via extension cord(s). Not required to provide generator.

· 4 External mounted male outlets required for powering external devices with plug-in covers.

· 4 each 50’ electrical extension cords attached inside the trailer on a reel assembly utilized for quick deployment of cord.

· Internal wiring to accommodate connections and provide power for LED lighting system.

· Pneumatic Connections

· 4 each 50’ pneumatic hoses attached inside the trailer, on a reel assembly, utilized for quick deployment of hose.

· Work Stations

· Minimum of two work tables that extend from the trailer with supporting legs

· Dimensions of work tables will be based on the size of the trailer relative to how the contractor can incorporate at least two tables as part of the design. Intent is to maximize available space, which contractor will have to determine.

· Removable vice

· LED lighting. Luminosity needs to be bright enough for personnel to be able to execute highly precise actions, such as cutting metal sheets to specific dimensions during nighttime operations with minimal surrounding light other than what is being provided by the trailer.

· Area for metal working equipment (throat-less shear and metal bending brake)

· No need for an air compressor or vacuum pump to be added for composite repairs

· Servicing

· Expect 30 year service life

· All operating instructions, service manuals and maintenance manuals containing inspection requirements, lubrication schedule, illustrated parts breakdown, shipping documentation, and final dimensions, which are referenced in the Requirements section as MIL-STDs.

With the exception of the above requirements we invite any design ideas that will increase the capability of these assets. Our desired end state is to have a mobile, self-sustained tool and working platform to increase our capabilities during a war time scenario.

Design will have a minimum of three design reviews completed with the ABDR program office prior to and after prototype delivery, in order to verify usability of the final product; these reviews consist of an Initial Design Review, Pre-Production Design Review and a Post-Production Design Review. Design reviews can be sent to the contracting office via email where we then can coordinate teleconferences with the contractor for in-depth discussions. All testing will be performed by the contractor under the supervision of ABDR certified personnel to allow for immediate feedback. The USAF ABDR Program office will retain the rights to the final drawing package after the final design has been accepted to maintain product uniformity and avoid design deviation should circumstances dictate further procurement of trailers and initial contractor is unable to deliver.

DELIVERABLES

- ABDR WRM Trailer Design Blueprints

- All Source Documentation (Operation, Maintenance, Parts Breakdown, Service, Shipping, Storage) in the form of a commercial manual developed by the contractor.

- Prototype Trailer