Army HD Flatcar SOW July 26_2023.docx

Statement of Work

New Heavy-Duty Chain-Tiedown Flatcars

July 2023

Office of the Secretary, U.S. Department of Transportation Volpe National Transportation Systems Center Infrastructure Engineering and Deployment

Contents

DESCRIPTION

The applicable North American Industry Classification System (NAICS) Code is 336510, Railroad Rolling Stock Manufacturing, with a small business size standard of 1,500 employees. This solicitation document and incorporated provisions and clauses are those in effect through Federal Acquisition Circular (FAC) 2005-77.

The United States Department of Transportation, Volpe National Transportation Systems Center (Volpe Center), Cambridge, MA, 02142, is seeking to design and acquire up to six (6) heavy-duty railway flatcars. All flatcar deliveries shall be FOB DESTINATION and therefore Offerors must consider any shipping costs in the CLIN price. All materiel deliveries shall be within timeframe specified in CLINs. It is noted upon delivery/acceptance for each railway flatcar the standard commercial warranty will begin. The Government intends to award one or more Firm-Fixed-Price contract(s) resulting from this solicitation, however, reserves the right to award no contract depending on the quality of quotations. The Government is NOT offering commercial contract financing terms IAW FAR Subpart 32.2 for this acquisition.

This acquisition is the first phase of larger effort to eventually acquire approximately 500 heavy-duty railway flatcars.

Design and Engineering

00200

(OPTION)

00300

(OPTION)

New Heavy-Duty Chain-Tiedown Flatcars

Chain-Tiedown Flatcar with or without container handling capability. Flatcar 1.

00500

(OPTION)

Newly Manufactured 160-ton Chain-Tiedown Flatcar with or without container handling capability. Flatcar 2.

00600

(OPTION)

Newly Manufactured 160-ton Chain-Tiedown Flatcar with or without container handling capability. Flatcar 3.

00700

(OPTION)

Newly Manufactured 160-ton Chain-Tiedown Flatcar with or without container handling capability. Flatcar 4.

00800

(OPTION)

Newly Manufactured 160-ton Chain-Tiedown Flatcar with or without container handling capability. Flatcar 5.

with AIM bulkhead nut plates. Flatcar 6.

TOTAL PRICE

(CLINs 00100 through 00900)

1. GENERAL

The contractor shall provide the following items:

1. The contractor shall provide design and engineering (CLIN 00100) for a new heavy-duty chain-tiedown flatcar operating in AAR interchange service with a minimum load capacity of 160-tons and a minimum service life of 50 years and meeting the specifications herein. The gross load on rail shall not exceed 65,750 pounds per axle. Railcars shall be capable of carrying two M1 Abrams tanks and other wheeled and tracked vehicles via circus loading. Cars shall be Association of American Railroads (AAR) mechanical designation FM and AAR Equipment Type Code F423 or F424 and shall safely negotiate 150-foot radius horizontal curves.

2. CLIN 00200 (Option): The Contractor shall provide the same as CLIN 00100 with the inclusion that railcars shall also be capable of carrying three ANSI/ISO standard size 20-foot-long containers.

3. CLIN 00300 (Option): The Contractor shall provide the same as CLIN 00100 with the inclusion that railcars shall also be equipped with AIM Railcar Bulkhead nut plates and meet the minimum requirements defines for this flatcar.

4. CLIN 00400: The contractor shall provide one new heavy-duty chain-tiedown flatcar meeting the requirements and specifications of CLIN 00100 (with or without container handling capability is to be determined).

5. CLIN 00500 through 00800 (Option CLINs): Provide up to four additional flatcars identified in CLIN 00400.

6. CLIN 00900 (Option): The contractor shall provide one flatcar as designed with the AIM bulkhead nut plates and meeting the additional requirements identified in this Statement of Work.

Disclaimer: All railcars in this procurement are specified to be manufactured with new components. The government will also take into consideration proposals offering options for cost saving solutions such as reutilized components. Railcar underframes and decks shall be newly manufactured under any circumstance.

1.2. REFERENCE DOCUMENTS

The railroad flatcars must satisfy all the following documents in effect at the time of this procurement:

1. Association of American Railroads (AAR) Manual of Standards and Recommended Practices

2. AAR Interchange Rules

3. The Official Railway Equipment Register

4. Code of Federal Regulations (CFR) 49, Transportation

5. AAR Rules Governing the Loading of Commodities on Open Top Cars:

Section 1, General Rules Section 6, Rules Governing the Loading of Department of Defense Material

6. American Society for Testing and Materials (ASTM) A53

7. American Welding Society (AWS) D15.1

8. American Society of Mechanical Engineers (ASME), Boiler and Pressure Code Section IX, Welding Qualifications.

9. American Iron and Steel Institute (AISI) Standards

1.3. ORDER OF PRECEDENCE

The Order of Precedence is established in FAR 52.212-4. In addition to the Order of Precedence set in FAR 52.212-4, if there is a conflict between the text of this document and the references cited above, the text of this document takes precedence.

2. 160-TON, HEAVY-DUTY CHAIN-TIEDOWN FLATCARS

The following specifications are applicable to the 160-ton, Heavy-Duty, Chain-Tiedown Flatcars.

2.1. DIMENSIONS

1. Condition: New

2. Length (Deck): Minimum of 68 feet and a maximum of 80 feet (maximized between fitting within the clearance plate and engineering design parameters)

3. Width (Deck): Minimum of 10 feet 5 inches

4. Width (Maximum): Not to exceed AAR Clearance Plate J

5. Deck Height (from top of rail): Not to exceed a nominal 4 feet 3 inches (51 inches) with 4 feet (48 inches) deck height being minimum and optimum

6. Deck Material: Steel with anti-skid coating

7. Length over couplers (overall length): Minimum 72 feet 10 inches; Not to exceed 84 feet 10 inches

8. Minimum service life according to AAR: 50 years

9. Coupler Height: 2 feet 10.5 inches (34.5 inches)

10. Gross Rail Load: Not to exceed 65,750 pounds per axle when carrying two 80-ton heavy tracked vehicles (i.e., M1 Abrams tanks).

11. Load Limit (minimum): 160-tons

12. Light Weight (LT WT): Determined by design

13. Truck Centers: Designed to safety negotiate 150-foot radius horizontal curve when coupled. Truck center spacing (or spacing between equivalent primary pivot locations) shall not exceed 50 feet.

14. Axles: Roller bearing type

15. AAR Designation: FM

16. AAR Equipment Type Code: F423 or F424 (determined by design)

2.2. DESIGN/ENGINEERING/FABRICATION

a. Tracked vehicles weighing 80 tons with weight evenly distributed over 14 track wheels (7 on each side) having a total wheelbase of 180 inches.

b. Wheeled vehicles weighing 50 tons unevenly distributed on 5 axles over a total wheelbase of 315 inches with axle loads and spacing as follows:

Axle 1: 11.5 tons Axle 2: 11.3 tons at 58.7 inches from axle 1 Axle 3: 8.2 tons at 137.5 inches from axle 2 Axle 4: 9.8 tons at 58.8 inches from axle 3 Axle 5: 9.2 tons at 60 inches from axle 4

(Option Items)

2.3. PERIOD OF PERFORMANCE

All work shall be completed NLT September 30, 2025.

2.4. DELIVERY REQUIREMENTS

Delivery of cars to destination will be by railroad. Each car shall be prepared for delivery in accordance with AAR requirements for Interchange Service. The Contracting Officer’s Representative (COR) will supply car numbers. Acceptance will require inspection for carrier damage at the destination prior to any payment to the contractor.

3. GENERAL SPECIFICATIONS

3.1. TRUCKS

3.2. BRAKES

3.3. PAYLOAD SECUREMENT SYSTEM

(Option Items)

3.4. DRAFT SYSTEM AND COUPLERS

3.5. GRAB IRONS AND SAFETY APPLIANCES

3.6. PAINTING AND STENCILING

1. Contractor shall follow AAR Requirements for surfaces that are not to be painted.

2. Blast surface profile shall be in accordance with paint manufacturer’s specifications.

3.6.1. Paint Specifications

Substrate: Primed Steel Pre-treatment: Sandblasted Compliance Status: 3.5 lb. /gal volatile organic compound (VOC) mixed (maximum)

4. Application to Flatcars Car body: Burlington Northern green Underframe: Burlington Northern green Trucks: Black (fog coat only, unless received pre-painted from manufacturer) Stenciling: White Reflective Surfaces: Yellow

3.7. QUALITY CONTROL

3.8. DRAWINGS AND DOCUMENTATION

Each flatcar design shall be provided with a Parts/Service Manual, Operator’s Procedure Manual, and Documentation Package. The following shall be submitted to the contracting officer upon delivery:

3.8.1. Parts/Service Manual

The railway flatcar parts/service manual shall be designed to provide quick access to information for the experienced and novice user. The parts/service manual will provide parts pages and component illustration pages and shall provide a description for all mechanical assemblies and all special tools required to perform repairs if failure occurs. Safety will be announced when describing procedures that have the capability to cause damage to equipment or harm personnel. This description shall describe and illustrate the assembly and/or subassemblies contained in all main assemblies. The subassemblies will be illustrated in exploded view style and the breakout of parts will be cross-referenced by item number to provide identification by name and part number and quantity required. The part number is the manufacturer's number for the component. The manual will also contain a description and part number for special tools required for the removal/replacement of assemblies and sub-assemblies. Manual quantities are described in the following Sections.

3.8.2. Operator's Procedure Manual

The Contractor shall supply a stand-alone Operator's Procedure Manual. The Railway Flatcar Operator's Procedure Manual will contain a step-by-step process to operate all systems and assemblies. This shall include all safety warnings and safety related operations. Manual quantities are described in the following sections.

3.8.3. Documentation Package

The documentation package to be submitted shall consist of two hard copies and two electronic copies of the following:

1. Component (part) identification

2. Maintenance Manual (including troubleshooting guide)

3. Operator's Procedure Manual (described above)

4. Parts/Service Manual (described above)

5. Identification and results of all certifications, tests, repairs, and inspections NOTE: All electronically formatted documentation shall be compatible with Adobe Acrobat Reader and have the ability to be electronically reproduced for Government use.

3.8.4. Design Package

The design package to be submitted shall consist of two hard copies, two un-editable electronic copies, and two copies of the original, editable files, including all 3D model assemblies and parts.

1. Full engineering production design drawings reflecting as-built condition suitable for manufacture by AAR-qualified railcar manufacturers.

2. Full specifications reflecting as-built condition suitable for manufacture of the railcar by AAR-qualified railcar manufacturers.

3. Provide Equivalent Cooper Loading (E-value) data for a loaded unit train of flatcars of this design compared to Equivalent Cooper Loading (E-value) for the existing, 6-axle arrangement, heavy-duty flatcar. Analyze loadings of two (2) M1 Abrams tanks per railcar with notional weights of 72, 75, and 80 tons each. Data shall be presented in graph format showing Equivalent Cooper Loading vs. bridge span length.

4. Provide finite element analysis (FEA) of nut plate attachment on optional AIM railcar (CLIN 0003). FEA shall show adequacy of the designed and installed nut plate to carry the fully loaded Navy AIM carrier and sustain reasonable railroad impact including hump yard operations.

NOTE: Noneditable electronic files shall be compatible with Adobe Acrobat Reader. Native, editable files shall be provided in the file type native to the software used to create the document. 3D model assemblies shall be in “.step” or “.iges” file type in addition to native file types. All design package materials shall have no restrictions from distribution to any other railcar manufacturer or another private firm as the Government deems appropriate.

3.9. INSPECTION PROCEDURE

i. Inspection Each car shall be examined for, but not limited to, the following characteristics:

1. AAR M-1003 Certification for Activity Code A20 (Manufacturer of Freight Cars) from shop performing the new flatcar construction.

2. Flatcars shall safely negotiate track curvature as specified.

3. Flatcar dimensions as specified.

4. Materials resistant to corrosion and deterioration or treated to be resistant to corrosion and deterioration in the applicable storage and operating environments.

5. Contractor has documentation available for identification of materials, material finishes, or treatment.

6. Load limit for car design not to exceed 65,750 pounds per axle Safety appliances as required per AAR, except where existing DoD waivers are in place.

7. Painting and markings.

8. Design and construction in accordance with AAR/FRA requirements.

9. Brake equipment as specified.

ii. Tests

1. Contractor shall supply the government with a testing report signed/certified by a competent railcar manufacturing engineer describing each test performed, date and location of test, objective threshold values with citation of standard, and result.

2. Any tests required by AAR shall be in accordance with AAR specifications, and as specified herein. No specific order of testing is required. All tests listed below will be conducted at the contractor’s designated location.

3. The entire air brake system shall be tested to ensure correct functioning of all components. The car shall be tested with a single car-testing device in accordance with AAR Standard S 486 Single Car Testing Device Code of Tests for Freight Car Equipment. The brake cylinder piston travel shall be as specified in S 400, Specification No.2518 Freight Car Brake Equipment, and Installation Specifications and shall be tested for interference and correct travel. Nonconformance to AAR requirements shall constitute failure of this test. A braking force test in accordance with AAR requirements shall be conducted to determine brake shoe pressure at each wheel.

4. The hand brake shall be tested in accordance with AAR requirements to determine the brake shoe pressure at each wheel. Nonconformance shall constitute failure of this test.

5. The side bearings shall be tested with the car on level tangent track and the car body level. Side bearing clearances shall be measured at each bearing. Nonconformance to manufacturer's, AAR or CFR Title 49 clearance limits shall constitute failure of this test.

Appendix-A, Flatcar Chain Tie-down Assembly

1.0 Description

Rail chain tiedown assemblies, as a whole and individual components, shall be composed of all new material and conform to the requirements of Association of American Railroads (AAR) Open Top Loading Rules (OTLR), Section 1, Part 2, paragraph 21 current as of the date of shipment. The railcar chain tiedown assembly shall have a working load limit of 13,750 lbs. or greater; a proof test of 27,500 lbs. or greater; and a minimum breaking strength of 55,000 lbs. or greater. The assembly shall be a minimum of ten feet in length when under load with the load binder at full extension. The design of the assembly shall permit any necessary replacement of parts without torching or welding. Ferrous components other than the chain must be painted or hot dip galvanized, unless prohibited by the OTLR. Components shall be connected to each other so that there shall be no twisting of the assembly or any component when anchored to a flatcar at the anchor end, and a vehicle at the hook end, with the hook engaging a shackle having its pin in a horizontal plane.

1.1 Components

Each rail chain tiedown assembly shall include the following components:

1.1.1 Floor Anchor

An anchor which interfaces with the common or ‘toothed track’ flatcar tiedown anchor channel using four (4) pairs of projections corresponding to the notches in the anchor channel is required. The projections shall be sized to accommodate distortion of the notches resulting from normal wear and tear. The anchor shall have a minimum breaking strength of 55,000 lbs. both independently and when engaged in the anchor channel. The anchor and its attachment to the remainder of the assembly shall be designed to permit insertion or removal of the anchor at any point along an anchor channel having a nominal five-inch depth. The anchor device shall be placed at one extreme end of the assembly.

1.1.2 Load Binder

A load binder is required. It shall be a ratchet-type or turnbuckle-type binder and shall conform to the same standards as those listed in the OTLR Manual, Section 1, paragraph 21.7.2. The load binder shall be for 0.5-inch chain with minimum breaking strength of 55,000 pounds. The load binder shall be permanently attached to the assembly. Adjustment of the load binder shall be by an adjustable wrench, a monkey wrench, or an attached handle. The load binder shall have a locking device (a jam nut or similar device is not acceptable) able to prevent loosening while in transit and not subject to degradation by wear and tear resulting from normal use. The load binder shall be delivered fully lubricated and equipped with permanent fittings which allow for the application of additional lubrication to each adjustment screw thread without disassembly.

1.1.3 Compression Unit

A compression unit or shock absorber capable of protecting the components of the assembly from damage or distortion under loads up to the limits as stated in paragraph 1.1 is required.

1.1.4 Chain

Chain shall be nominal 0.5-inch special alloy chain or other AAR-approved chain as stated in the OTLR, Section 1, paragraph 21.10.11 and Table 21.4 with strength per unit weight relationship not less than nominal 0.5-inch special alloy chain.

1.1.5 Chain Length Adjustor

A claw hook or other device capable of adjusting the chain length is required. The adjustment device, in concert with the load binder, shall permit tightening of the assembly to the required tension per load.

1.1.6 Metal Tag

A metal tag stamped with “Department of Defense”, the name of the manufacturer, the year of contract award, and the manufacturer’s part number is required.

1.1.7 Clevis-type Hook

A clevis-type hook, with the ability to accept at least a nominal 1.75-inch shackle body and to interface with all equipment tiedown provisions that meet MIL-STD-209K, shall be placed at the extreme end of the assembly opposite the chain anchor device. The hook shall not have a locking latch or provision for attaching a locking latch. The dimensions of the hook and the assembly shall be such that three of the hooks may be placed on a shackle with a nominal 1.75-inch diameter body and a nominal 4-inch diameter bail, so that, with the pin of a suspended shackle held horizontally and the assemblies hanging naturally (i.e. affected only by gravity and contact with the other hooks and the bail), all contact with the inner surface of the shackle takes place within an arc length of 5-inches opposite the pin.

2.0 Current DOD Vendors

Pacific Cargo Control, Inc.

18200 SW Teton Ave.

Tualatin, OR 97062-8881 Telephone: 503-692-9297 Rick Sander, rsander@pac85.com

Peck & Hale, LLC 180 Division Ave West Sayville NY 11796-1303 Telephone: 631-589-2510 ext. 236 Dan Becker, dbecker@peckhale.com Shae Koenke, shae@peckhale.com