ASHE 20-1069 Technical Specification.pdf

Project ASHE 20-1069 Technical Specifications

DATE: MAR 2022

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U.S. AIR FORCE

31ST FIGHTER WING

31ST CES/CENM

AVIANO AIR BASE, ITALY

TECHNICAL SPECIFICATIONS FOR

ASHE 20-1069 REPLACE AIRFIELD LIGHTS, AREA F

AVIANO AB, ITALY

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1. SCOPE OF WORK:

Scope of this work is to replace the existing elevated approach lighting (PAR) system a with same type, no LED type (125 lights, power supply, along with new cable connection from Bldg.1243- Vault

B, wirings and commissioning of the system), along with the Overrun and Mike Loop End lights (116 lights, power supply, along with new cable connection).

In addition scope of this work is to remove the light unit and replace the new lighting unit with an upgraded LED light fixture certified for heavy traffic type, by removing also the existing canisters and replacing them with new housing unit heavy traffic type (L-868) at South Ramp (8), Hot Cargo Pad

(4), South Hot Pit (18) and North Hot Pit (18).

Scope of this work is also to replace the existing FCU-1 motherboards and cabling of the existing flashing REIL elevated lights type ADB FCUFFL UEL (local cabling plus new cable connection from

Bldg.1305- Vault A and Bldg.1243 respectively, wirings and commissioning of the system)

Work includes the disposal of old fixtures, lamps and accessories according to environmental law and regulations. The installed fixtures are to be compliant with the below specifications as well as in accordance with references outlined in paragraph six.

2. WORKS LOCATION

AREA F, Aviano Air Base: Runway End 5 and 23, Off Base Approach; Taxyway South Ramp, Hot

Cargo Pad, South Hot Pit and North Hot Pit.

Pic. 1: Overall map of the construction area of the project

3. WORK SITE CONDITIONS:

a. The Contractor is permitted to use reasonable quantities of available electricity and water at the work site. The Contractor shall alter characteristics and shall observe conservation practices at all times. All connections shall be the responsibility of the Contractor including restorations to initial conditions.

b. Before works start, contractor will submit a detail works schedule to C.O. for coordination and approval.

Authorized work hours and days. Performance of work hereunder shall be from Monday through

Friday excluding holidays from 08.00 to 17.00 hours. Work during week-ends or holidays may be

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requested by the Contractor with a minimum of 10 days advance notice, however the Contracting

Officer has the right to deny such request if reasons requiring week-end and holiday work are not valid or for security or other necessities. Additionally, requirements to phase in work for this project within the designated period of performance may be required pending mission requirements and airfield scheduling. The schedule shall be approved by the Contracting Officer with the coordination of the 31 CES and 31 OSS prior to starting work.

c. Toilet facilities in the vicinity of the work site shall not be available for Contractor use. The

Contractor shall provide toilet facilities for use on the site

d. The Contractor shall not use base refuse containers to discard debris. All construction debris shall be discarded by the Contractor off base at authorized sites according to category of debris/refuse in strict observance of all host country laws, decrees and local regulations in force.

e. The Contractor shall be responsible for ensuring all personnel engaged in the performance of this contract observe all host country laws concerning safety and in particular Italian laws D.M. 81/08.

f. The Contractor shall perform no digging until receipt of a completely coordinated AF form 103 from the Contracting Officer. Contractor shall inform the contracting officer anytime any digging he is going to perform at least four (4) weeks in advance. The coordination process for the AF form 103 takes not less than three weeks and last one month only starting from the date of the approval.

g. IAW USAFI 32-1007, Airfield & Heliport Planning and Design, the clearance from the Apron

Boundary Marking (the double yellow lines on the edge of the pavement) to any obstacle must be

115 feet (for that specific area based on the type of aircraft that use those parking spots).

Since some of the working tasks of this project are within 115 feet far from the Apron Boundary

Marking, TACW (Temporary Construction Airfield Waiver) shall be required.

Contractor shall inform the contracting officer at least six (6) weeks in advance anytime he is going to perform a working task requiring TACW coordination.

h. The Contractor shall also prepare written report of any meeting, discussions and evaluations held during the construction period.

i. At least 5 days prior to the pre-final inspection, the Contractor shall furnish to the Contracting

Officer all installed equipment operation and maintenance documentation, certificates concerning installed systems as required by host country laws, test reports and results and as built drawings where required by host nation laws.

l. Before works start, contractor will submit a detail works schedule to C.O. for coordination and approval.

m. The entire performance of this project will be in restricted areas requiring controlled entry/exit and escort at all times and this shall be considered during development of the work schedule.

The government will not be held liable for unproductive time and other related costs due to delays in access/exit to/from the restricted areas or unannounced and immediate suspension of work due to military operations and/or exercises or safety reasons.

The government will only negotiate an equitable extension of the performance period based on documented delays and unannounced suspensions of work.

o. ALS’ to be installed shall be certified in accordance with (IAW) FAA regulations and guidance (Ref: FAA Advisory Circular and FAA Type Certificate Data Sheets (TCDS) database).

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4. WORK DESCRIPTION

EACH ITEM OF THE SCHEDULE IS INCLUSIVE OF FURNISHING AND INSTALLATION OF

MATERIALS AND EQUIPMENT, SCAFFOLDING, TRANSPORTATION TO DUMP OR STORAGE OF

DEMOLISHED AND/OR REMOVED MATERIALS, IN ACCORDANCE WITH CONTRACTING

OFFICER'S INSTRUCTIONS AND ALL FINISHING WORK REQUIRED TO MAKE EACH ITEM

COMPLETE IN A WORKMANLIKE MANNER.

ALL THE QUANTITIES THAT ARE INDICATED OR SUCCESSIVELY ADDED ARE ESTIMATES.

THEREFORE, THE GOVERNMENT SHALL BE NOT HELD RESPONSIBLE FOR THE ACCURACY OF

THE ESTIMATED QUANTITIES. THE CONTRACT REQUIRES A COMPLETED PROJECT ON A LUMP

SUM BASIS. IT IS THEREFORE THE RESPONSIBILITY OF THE CONTRACTOR TO CALCULATE,

FORESEE AND PERFORM ALL QUANTITIES AND WORK NECESSARY EVEN IF NOT MENTIONED

IN THE SPECIFICATIONS BUT INCLUDED IN THE DRAWINGS OR MANIFESTLY NECESSARY TO

DELIVER A COMPLETE PROJECT BASED ON ITS OVERALL SCOPE.

4.1 REPLACE EXISTING APPROACH ELEVATED LIGHTS (PAR)

Furnishing and installation of 125 new elevated Approach, no LED type, high intensity, unidirectional, elevated, pole or mast mounted, type UEL-1-150, mod. ADB 1UE5C2Y01001 or equivalent approved, including:

• Housing with yellow removable front cartridge for easy relamping;

• Clear front glass;

• Lockable adjustment screws;

• Cable mechanically protected inside;

• 150W/6.6A prefocus halogen lamp type Pk30d - long life 1000h;

• Secured optical cartridge;

• Insulation transformer ADB type KR600 series, or equivalent approved, properly sized (125 pcs);

• 1 Primary connector Kit PRKU1 (125 pcs);

• 6kV cables 1x6 mm2, single conductor, XLPE insulated, non-shielded, according to the FAA AC

150/5345-7E (L-824 Type C) Specification, ETL and CE certified. The 6kV cables will run in the existing cable duct (Approx. 1 km)

Connection distance shall consider a solid cable from the previous fixture to the following one.

Any unnecessary connection/junction in the electrical circuit shall be avoided;

• Secondary connectors ADB type SCK2PT200000, or equivalent approved (250 pcs);

• Anti-rodent power cables 3x2.5 mm2 (approx. 2km), along with piping;

Lights shall be elevated mounted fixture, to be installed in the same position of the pole of the existing

(see Pic. 2).

Breakable coupling, type 'MR/F2', diameter 2 inch, thread 11 TPI for pole mounting, may be resumed from the existing installation whenever possible.

Item shall also include:

• Removal all existing 125 fixture parts from the system;

• Removal all current housings/ electrical boxes/piping;

• Disconnection and removal of the insulation transformers;

• Removal of the existing electrical MV lines from the Vault B (Bldg.1243) to PAR’s;

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• Transportation and storage of materials to be reused to storage area or disposed IAW Italian

Law, as directed by the Contracting Officer’s Technical Representative;

• Stripping e repainting of the existing installation poles.

Manpower, tools accessories and every other necessary item to provide a job in a workmanlike manner.

Pic. 2: PAR system

Pic. 3: PAR system (elevated PARs lights and current electrical boxes)

Lump Sum

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4.2 REPLACE EXISTING RUNWAY END AND OVERRUN LIGHTS

4.2.a Furnish and install primary MV series circuit n.1 receptacle connector and n. 1 plug connector kit for unshielded cable type ADB PRKU1A/ PRKU1B, or equal approved, depending on the section of the primary conductor (to be determined before installation by the contractor).

Item shall also include:

• Compliance to ICAO Aerodrome Design Manual Part 5 and FAA L-823 AC 150/5345-

26 (L-823) current edition;

• Heat Shrink Kit type ADB 71A00088-U or equal approved;

• Insulating transformer ADB series KR600, or equivalent approved, properly sized for the artic kit option (see Par. 4.2.b);

• Manpower, cleaning of contacts, tools accessories and every other necessary item to provide a job in a workmanlike manner.

4.2.b Furnishing and installation of 116 new elevated Approach, no LED type, high intensity, unidirectional, elevated, pole or mast mounted, type UEL-1-150, mod. ADB 1UE5C2Y01001 or equivalent approved, including:

• 16 - Elevated one side green/ one side red THRESHOLD LIGHT, type ADB SGEEL-

EAH.1211 or equivalent approved;

• 20 – Semi-flush one side green/ one side red THRESHOLD, type ADB SGEEL-

EAH.12v or equivalent approved;

• 4 – Elevated (Omnidirectional) Red Termination, type ADB SGEEL-EAH.12118 or equivalent approved;

• 40 – Semi-flush Double White Approach Lights (Uni-directional), ), type ADB FAP or equivalent approved;

• 12 – Semi-flush Double Red termination Light (Uni-directional), ), type ADB FEN or equivalent approved;

• 24 - Semi-Flush Double Green THRESHOLD (Uni-directional), type ADB FTH-1-

200,or equivalent approved;

• 116 105W/6.6A halogen lamp type - long life 1000h;

• Insulation transformer ADB type KR600 series, or equivalent approved, properly sized

(116 pcs);

• 1 Primary connector Kit PRKU1 (125 pcs);

• 6kV cables 1x6 mm2, single conductor, XLPE insulated, non-shielded, according to the

FAA AC 150/5345-7E (L-824 Type C) Specification, ETL and CE certified. The 6kV cables will run in the existing cable duct (Approx. 1 km);

Connection distance shall consider a solid cable from the previous fixture to the following one. Any unnecessary connection/junction in the electrical circuit shall be avoided;

• Secondary connectors ADB type SCK2PT200000, or equivalent approved (250 pcs);

Lights shall be elevated mounted fixture, to be installed in the same position of the existing.

Some of the light bases have to be replaced (see par. 4.3).

• Removal all existing 116 fixture parts from the system;

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• Removal all current housings/ electrical boxes/piping;

• Disconnection and removal of the insulation transformers;

• Removal of the existing electrical MV cables of the local series circuits between each two consecutives fixtures;

• Transportation and storage of materials to be reused to storage area or disposed IAW Italian

Law, as directed by the Contracting Officer’s Technical Representative;

• Manpower, tools accessories and every other necessary item to provide a job in a workmanlike manner.

4.3 INSTALL NEW GALVANIZED 12” LIGHT BASES L-868 [South Ramp x8 , Hot Cargo

Pad x4, South Hot Pit x18, North Hot Pit x18, Runway Lights x20]

4.3.a Remove existing elevated airfield taxiway fixtures in accordance with current law in matter.

• Removal existing MV (6kV) connectors;

• Removal of the existing MV (6kV) electrical lines and temporary reconnection from the closer hand holes of the existing primary circuit cable;

• Disconnection and removal of to the existing transformer;

• Transportation and storage of materials to be reused to storage area or disposed IAW

Italian Law, as directed by the Contracting Officer’s Technical Representative;

• Manpower, tools accessories and every other necessary item to provide a job in a workmanlike manner.

Pic. 4: Flush-mounted LED lights @ South Ramp, Hot Cargo Pad, South Hot Pit, North Hot Pit

EA 68

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4.3.b Furnishing and installation galvanized 12” light bases, 24” depth, recessed type, complete with gasket FAA approved, certified for application subjected to aircraft and other heavy vehicular loads certified IAW FAA L868, type ADB 868B24 xH1PA, or equal approved, included mounting accessories. Light bases shall be installed in order to have the fixture at road level, Pic.1 shows a picture of a properly in-set flush mounted fixture.

Item shall also include:

• Compliance to L-867 & L-868 AC 150/5345-42 (Current Edition);

• Any mounting accessories as per manufacture’s installation manual;

• The removal and disposal IAW the Italian codes of the existing light base to be relocated, the filling in layers of the holes and the compaction to the maximum density and the leveling and repair of the surfaces. Only when unused bases are necessary to be re-used to allow change path of the conduit, they shall be simply closed with solid removable cover and that neither removal/disposal nor returning the site to the condition that existed prior to the installation of the old fixture/base will be necessary;

• New 2 Way cable duct for the HV cables from the closer hand holes of the existing primary circuit cable, approx. 2m. The cable duct shall be realized with a heavy rigid 63 mm diameter PVC pipes, thickness of the pipe walls 4.5 mm, covered with C20/25 Class concrete;

• Coring;

• Cut and removal of pavements and sidewalks.

• The excavation of soil of any kind and consistence, including rock, with mechanical means, 70 cm width trench and various depths for the installation of the cable duct in compatible manner with the existing utilities. The average depth of the trench shall be 90 cm;

• The leveling and the compaction of the bottom of the trench and the addition of necessary excavation for the construction of the manholes;

• The installation of warning red PVC tape with the writing “HV CABLES”;

• The filling in layers of the trenches and the compaction to the maximum density;

• The leveling and repair of the surfaces;

• The transportation to the authorized public dump of the surplus excavated material, including the dump fees;

• Supply and install approx. 52 m of 6kV cable, single conductor, XLPE insulated, non-shielded, according to the FAA AC 150/5345-7E (L-824 Type C) Specification, ETL and

CE certified. The 6kV cables will run in the new 2 Way cable duct.

Connection distance shall consider a solid cable from the previous fixture to the following one. Any unnecessary connection/junction in the electrical circuit shall be avoided;

• Heat Shrink Kit type ADB 71A00088-U, or equal approved;

• Primary connectors kit type ADB PRKU1, or equal approved;

• The equipotential connections of the metallic masses, including the cover and the reinforcement bars, with N07V-K cable, complete of terminals, anchoring for the drawing of the cables and necessary accessories for the proper installation and service.

• Manpower, tools accessories and every other necessary item to provide a job in a workmanlike manner.

EA 48

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4.4 INSTALL LED TAXIWAY LIGHT FIXTURES [South Ramp x50 , Hot Cargo Pad x28, South Hot Pit x18, North Hot Pit x18]

4.4.a Furnish and install primary MV series circuit n.1 receptacle connector and n. 1 plug connector kit for unshielded cable type ADB PRKU1A/ PRKU1B, or equal approved, depending on the section of the primary conductor (to be determined before installation by the contractor).

Item shall also include:

• Compliance to ICAO Aerodrome Design Manual Part 5 and FAA L-823 AC 150/5345-

26 (L-823) current edition;

• Heat Shrink Kit type ADB 71A00088-U or equal approved;

• Insulating transformer ADB series KR600, or equivalent approved, properly sized for the artic kit option (see Par. 4.3.b);

• Manpower, cleaning of contacts, tools accessories and every other necessary item to provide a job in a workmanlike manner.

4.4.b Furnish and install flush mounted LED Taxiway Light Fixtures, Aviation Blue, 12” diameter for standard L-868B light base1, 50Hz, provided with built in defrost system, Type ADB ITEL C121 or equal approved, included mounting accessories and neoprene grommet.

Item shall also include:

Compliance to FAA L-852T(L) AC 150/5345-46 (Current Edition) , FAA Engineering

Brief No. 67, ETL, ICAO Annex 14, Vol. I, Ed. 6, para. 5.3.18, CE marking IAW EMC

Directive 2004/108/EC;

Artic kit;

100% checking of the pressurization of each single fixture in accordance with manufacturer specs;

Connection of electrical lines, cleaning of contacts, manpower, tools accessories and every other necessary item to provide a job in a workmanlike manner.

• Transportation and storage of materials to be reused to storage area or disposed IAW

Italian Law, as directed by the Contracting Officer’s Technical Representative;

EA 130

4.5 TOTAL REPLAMENT OF THE FCU MOTHERBOARDS OF THE REIL LIGHTS

[05 End and 23 End]

Contractor shall provide total replacement of control motherboards of the 4 REIL Lights type ADB

FCUFFL UEL, placed at 05 End and 23 End (2 each).

Item shall include:

Removal of existing equipment. All removed equipment should be taken to a designated area on base to be indicated on issuance of the notice to proceed and where contracting officer representatives shall select equipment to be:

- salvaged and to remain Government property

- disposed of in accordance with host nation legislation.

Supply and install mounting accessories;

Supply and install 8 dedicated Junction Box (EP);

Supply and install 2 FCU1 units, one for each Lamp (EP);

Supply 1 spare FCU1 units;

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Supply and set 3 Local Master Controller (for the master box); install 2 of them, one for each couple of REIL Lights, third one has to be turned over to the user as spare part;

Supply and install approx. 2km of a non-corrosive rated cable for the multiwire connections of the FCU Controller to the existing Airfield Lighting Control System (ALCS) panel of the Vault, along with dedicated local piping;

Supply and install 2km of a non-corrosive power cable, rated to a minimum of 10 percent higher than the recommended power of the system, 4x6 mm2 minimum, type NYCY 0.671kV, from the

FCU Controller to the dedicated breaker in the existing EP panel of the each Vault (1 in Vault A, 1 in Vault B);

Supply and install 2 IP 65 2x push buttons stations, one for each master FCU unit, to allow local activation of the REIL functions (for maintenance purpose, to be allocated inside one of the electrical junction boxes);

Wirings and commissioning of the system to the new ADB ALCMS, adding new J-Bus interface full control (both remote controls and diagnostic feedbacks) for the existing REIL lights;

Manpower, cleaning of contacts, tools accessories and every other necessary item to provide a job in a workmanlike manner.

Each controller panel shall include:

Piping;

Junction Box

Mounting accessories;

Dedicated Electrical Panel (EP);

Over-voltage protection modules (MOV);

Multiwire interfaces;

J-Bus Interfaces;

Mains socket outlet to be installed inside the EP.

Pic. 5: Existing REIL Lights FCU-1 Motherboard overview

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5. MATERIAL SUBMITTALS

Materials and other items shall be submitted for the approval by the Contracting Officer (see attached

Schedule of Material Approval Submittals). The Government will review, approve and/or disapprove material submittals within 10 working days.

6. FINAL ACCEPTANCE TEST , CERTIFICATIONS & OTHER REQUIREMENTS:

All machines, equipment and electric and mechanical components shall bear "CE" Mark IAW latest applicable EU Directives.

Furthermore the electric equipment shall be in compliance with the Legislative Decree No.81/08 and subsequent modifications.

All installed items must be installed IAW Federal Aviation Association (FAA), guidance for the Air

Force Central European Command (AFCEC), UFC 3-535-01, and UFC 3-535-02.

In particular they will have to comply with current edition of:

ETL 9-11: Civil Engineering Industrial Control System Information Assurance Compliance;

ICAO Annex 14 Vol. l (current edition) para 5.3.6, 5.3.16, 5.3.22;

NATO STANAG 3316;

FAA EB 67D;

IEC TS 61827.

At the end of the work, the Contractor to provide three copies set of AS BUILT drawings signed and stamped by qualified engineer and CD with AutoCAD and pdf electronic version of same drawings

(AUTOCAD latest release) at least for the following documents IAW UFGS 26 56 20.00 10:

As built of the lighting fixtures layout complete of identification items & geospatially referenced using real world coordinates WGS-1984 UTM 33N;

As built of the electrical lines path layout complete of identification items section views & geospatially referenced using real world coordinates WGS-1984 UTM 33N;

As built of single line diagram, functional diagram, complete material list (multiline diagram, terminal strips if needed) if any;

As built layout of grounding system;

As built of Table of cable with the following minimum information;

Cable item number (the same item number to be used at each cable ends permanent labels/tag to be applied);

From switchboard/feeder, To switchboard/feeder, Type of cable;

Cable formation/section;

Cable length and Cableways/piping path;

Site acceptance test in accordance to the standards required (in particular insulation test on cables/devices and earthing measures/continuity tests shall be performed);

Certificates of Compliance IAW L. 186/68 (outdoor system) and D.M. 37/2008 (indoor system);

Datasheets of all installed equipment;

O&M manuals of all installed equipment;

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Warranty certifications and Warranty plan if available.

7. ATTACHMENTS:

1. ASHE 20-1069 ATCH #1 Schedule of Material Submittals