Attachment 1 - Statement of Work.pdf

Statement of Work

Secure Hybrid Composite Container (SHCC)

Manufacturing Optimization:

Materials Identification, Evaluation, Analysis & Test

1.0 BACKGROUND

The Department of Homeland Security’s (DHS) goal of the secure container development initiative was to provide a level of security to law enforcement officials that ensured contraband products and malicious agents have not been inserted into the container for smuggling into the United States (US). This could include contraband classes including drugs, weapons, explosives, illegals, chemical and biological agents, and weapons of mass destruction. The container would support condition monitoring, automated alerting and advanced communications and be constructed using composite materials making it lighter, more durable and be cost competitive with current steel containers used in the intermodal supply chain. In addition to commercial usage, the container could serve the Intelligence Community (IC) needs by providing the capability of securing sensitive cargo for shipment between the US and embassies, forward operating bases and conflict areas.

The Department of Homeland Security Science & Technology Directorate (DHS S&T) investment produced a prototype container design that received ISO certification but is not optimized for commercialization, it is difficult to produce and too expensive. The current Secure Hybrid Composite Container (SHCC) integrates thermosetting composites with an imbedded security system in the container walls, door, floor and ceiling.

Under this Statement of Work (SOW), the Contractor shall investigate alternative production materials and manufacturing methodologies and develop testing and validation procedures to evaluate the most promising candidates supporting efficient production of the next generation of SHCC at a level of between 1,000 and 3,000 containers annually. Note: the resultant contract is strictly for research and development, not production.

Tasking in this SOW is intended to further the critical goal of reducing production time and cost of the secure containers. Initial analysis has determined that thermoplastic composite materials could be used to achieve project goals. They offer several advantages over conventional composite materials including increased recyclability, environmentally friendly manufacturing process with zero Volatile Organic Compounds (VOCs), good impact resistance, and may support faster and less expensive production methods. The Contractor may elect to utilize thermoplastic materials or select other composite materials they deem superior to support the goals of this SOW. This project will result in a next generation design of the SHCC which is easier to manufacture, lighter, recyclable, and more durable than the previous version resulting in an overall lower cost. This would allow for the technology to be more readily adopted by government and commercial customers resulting in improved security from shipment origin through US Ports of Entry (POE) to final deconsolidation.

This effort will evaluate the proposed SHCC design based on cost, weight, durability, ease of sensor integration and performance, and structural performance. The container design must be capable of meeting all the operational, structural, and customs requirements of standard steel 20ft and 40ft shipping containers (ISO-certification).

This SOW supports:

• Research and Development (R&D) needed to identify thermoplastic or other composite material systems to produce a next generation SHCC which will achieve the strength, durability, weight, and cost targets and confirm this through sample testing and cost-estimating.

• Employ the selected materials to construct and test completed ISO container wall segments to validate the compatibility of the alternative with the requirements and performance using an embedded security system.

• R&D needed to identify a next generation security system for door monitoring and container intrusion detection that is capable of wirelessly transmitting status to a designated cognizant authority.

2.0 SCOPE

The goal of this effort is to identify, demonstrate, and test alternative composite materials with integrated intrusion monitoring for use in the manufacture of the SHCC with the goal of optimizing the producibility of the container system.

The long-term objectives of this SHCC project are to support the production of ISO certified dry-freight containers with six-sided intrusion detection/tracking/reporting which will operate efficiently and effectively in the global supply chain. The container design and production will be cost and weight competitive with a steel container over its lifecycle. The container design must be such that externally it looks the same as a current steel container. The effort will include the evaluation of available manufacturing technologies, including thermoplastic production methods, through analysis, design, small-scale production, and structural/security testing to confirm performance.

3.0 APPLICABLE DOCUMENTS

3.1 ISO Container Standards for 1CC Type Container (Series 1)

• ISO 668 External Dimensions and Ratings [Amd. 1995 (E)]

• ISO 830 Terminology in Relation to Freight Container [Amd. 1999]

• ISO 1161 Corner Fittings Specification [Amd. 1990]

• ISO 1496-1 Specification and Testing Part:1 General cargo containers for general purposes. [Amd. 1990 (E)]

• ISO 6346 Identification, Coding and Marking -1995 (E)

• International Maritime Organization (IMO) Safety of Life at Sea (SOLAS)

Regulation 54.2.2 “Sources of Ignition”

3.2 T.I.R Certification

• "The Customs Convention on the International Transport of Goods under the cover of T.I.R. Carnets." or "The Customs Convention on Containers."

3.3 C.S.C. Certification

• “International Convention for the Safe Containers” requirements.

3.4 T.C.T Certification

• Requirements set forth by the Commonwealth Department of Health in Australia.

4.0 TECHNICAL OBJECTIVES

4.1 CLIN 0001 – Material Identification/Analysis/Manufacturability, and Test

4.1.1 System Requirements

Requirements for Manufacturability – The contractor shall identify criteria for SHCC material selection that supports optimized manufacturability and incorporate into a manufacturability requirements document. Evaluation criteria for material selection shall include but are not limited to:

• Recyclability, environmentally friendly with no Volatile Organic Compounds (VOCs) generated during the manufacturing process.

• Good impact resistance, sufficient strength, durability, and stiffness to meet ISO requirements.

• Adhesion to steel to easily integrate into a steel container frame.

• Easily Integrates with the contractor proposed security system contained within the container walls, roof, doors and floors.

• Supports a manufacturing process with low production wastage.

• Supports an optimized production method that is faster and less expensive than currently identified processes (FASTVARTUM, SAWL, Pultrusion).

In conformance with these requirements, the contractor shall identify and demonstrate alternative composite materials for use in SHCC’s that support advanced manufacturing methods.

System Requirements Document – The contractor shall generate a System Requirements Document (SRD) in accordance with Data Item Deliverable (DID) A005 incorporating the manufacturability requirements and the SHCC requirements derived from the proposed design.

4.1.2 Material Identification/Analysis/Manufacturability

Identification of Material Options – The contractor shall evaluate alternatively available SHCC composite materials, to include thermoplastics, that will optimize production methods and processes and are expected to meet SRD requirements.

Material Analysis – The contractor shall conduct material evaluations through analysis, design, cost estimating, and small-scale production to confirm physical performance. The contractor shall fabricate small components of the container design such as walls, joints and any other sections critical to container construction to ensure physical performance will meet the SRD.

Material Compatibility with Security system (analysis and sample production) –The contractor shall conduct analysis, design and generation of small-scale production samples in preparation for testing to ensure integration of the new materials and the proposed security system will not adversely affect security system performance. The proposed security grid design must integrate easily with any composite materials used for the container design.

The contractor shall produce an engineering Trade Study that compares the identified composite materials, their compatibility with advanced manufacturability methods, and overall production costs at the quantity between 1,000 and 3,000 containers annually. The trade study shall include cost, weight and durability comparisons with existing steel ISO containers. Additionally, it shall address how SHCC maintenance could be incorporated into the existing shipping industry support infrastructure, outlining how the SHCC could operate efficiently and effectively in the global supply chain.

After review and acceptance of the Engineering Trade Study, the Government will provide the Contractor with a written Go/No-Go decision.

4.1.3 Material Testing

Conduct testing on materials – The contractor shall conduct physical testing of the selected material small-scale production samples to confirm they are capable of meeting ISO requirements referenced in Section 3.0 when used in a composite container.

Test Compatibility with security system – The contractor shall conduct testing of the selected material small-scale production samples that have been integrated with the proposed security system to confirm they support security system performance under conditions expected in the global supply chain.

Based on the requirements in this SOW and the associated documents, the Contractor shall develop Test Plans for, as a minimum, those tests which may be witnessed by the Government or its designated representative. The Test Plans shall be used to verify physical and security system performance requirements are met. Testing may combine these two focus areas to reduce redundant testing when possible.

Currently, all formal small-scale production sample testing could be witnessed by the Government and consequentially require the Contractor to develop a Test Plan (A008), and a Test Report (A009). The Government reserves the right to add or delete testing that will be witnessed or to witness other tests which shall be performed. Note that some of this testing may be destructive.

4.1.4 CLIN 0001 Reviews

The contractor shall host a System Requirements Review and Test Results Meeting which will be held no less than 30 calendar days prior to the end of CLIN 0001 at the Contractor’s facility or as otherwise directed by the Government.

The Contractor shall prepare presentation materials for the meeting and prepare Meeting Minutes summarizing the results of the meeting (A003).

After review of the test results and System Requirements Review, the Government will provide the Contractor with a written Go/No-Go decision.

4.2 CLIN 1001 –Manufacturing 20ft Secure Composite Container Wall Components for Installation in a Standard Container Frame

4.2.1 Manufacture

Using the previously developed set of manufacturing system requirements, the Contractor shall manufacture full-size SHCC wall components capable of meeting the ISO, environmental and security/intrusion requirements previously defined. The number of wall components produced will be based on the production process selected and the cost of tooling for the unique wall components (side wall, front wall, floor, ceiling, and door).

4.2.2 Testing

The Contractor shall conduct formal testing on the produced container with composite wall components to verify that it can meet the requirements in the SRD. The Contractor shall conduct testing and analysis to ensure that the container would pass formal ISO certification tests for these wall components.

Currently, all formal SHCC testing could be witnessed by the Government and consequentially require the Contractor to develop a Test Plan (A008), and a Test Report (A009). The Government reserves the right to add or delete testing that will be witnessed or to witness other tests which shall be performed.

3.2.1 Analysis

The Contractor shall conduct analysis to determine the cost of procurement and operation of the manufacturing equipment for the quantities of containers specified to include, but not limited to, total equipment cost, operations costs (space, labor, power, etc.) and container costs (including production and security verification testing).

The Contractor shall hold a meeting to present the results of testing to include identification of any issues or problems.

4.3 CLIN 1003 –Design & Development of a Security System for a composite container

4.3.1 Security System Requirements

The Contractor shall conduct engineering studies supporting the design and development of a Security System that shall:

• Detect and report door openings of more than 2” when the door is opened for more than 1 second.

• Detect and report intrusions equal to or larger than a 3” diameter hole in any of the six faces of the container.

• Wirelessly report a door open or intrusion event to a designated cognizant authority when a communication pathway exists or becomes available.

• When activated shall be capable of continuous operation for at least 70 days.

• Probability of detection of alarm events shall be no less than 95% with a probability of false alarm of no more than 0.2%.

The contractor shall use commercially available technology in the design to minimize development, procurement and support costs.

The Contractor shall prepare an engineering studies report documenting the design of the Security System to include a list of assumptions and constraints and any supporting analysis or testing done to show how well the system meets the performance requirements.

The Contractor shall hold a meeting with the Government to present the results of the engineering study to include identification of any issues or problems.

5.0 PROJECT MANAGEMENT

5.1 Monthly Reports

The Contractor shall provide monthly reports for the entire term of the project. The Contractor shall manage resources and costs to achieve program objectives on-time and within budget, which shall be reflected in a Monthly Progress Report (A001). The Contractor shall report detailed costs, expenditures, commitments and obligations against the program baseline. The Contractor shall include technical and programmatic risks with mitigation plans; status of project activities including progress to date; planned activities;

deliverable updates; and a review of action items. The Contractor shall provide a Master Schedule update which shows task progress, milestone tracking and critical path events.

This report shall highlight the changes and provide additional details on any changes that occur from the previous month and provide an explanation of the changes and the impact to the program cost, technical and schedule.

5.2 Deliverables

DIDs are provided for all documentation deliverables. All materials prepared for this SOW, including all reports and documents associated with DIDs, shall be in accordance with Government-approved Contractor format. Any changes or updates to previously provided data, if required, shall be delivered as "change pages" to existing documents.

The Government reserves the right to review all the submitted deliverables, provide comments and allow the Contractor the time to include/address the Government comments.

5.3 Meeting Minutes

The Contractor shall provide Meeting Minutes (A003) specified within this Statement of Work and for all meetings which include the Government and any meetings which are relevant to the execution of this project.

5.4 Bi-Weekly Teleconferences

The Contractor shall coordinate and participate in bi-weekly status meetings with the Government by teleconference (or other electronic media) to exchange information on current technical and management issues. These conferences shall be approximately one hour in duration. The Contractor shall prepare a top-level agenda for the teleconferences and provide the agenda to the Government No Later Than (NLT) one (1) working day prior to the meeting. The Contractor shall record action items resulting from these teleconferences and distribute minutes to both the Contractor and Government teams (A003).

5.5 Kickoff Meeting

The contractor shall host a kick-off meeting (A002). Meeting will be held within 30 calendar days of contract award at the Contractor’s facility or as otherwise directed by the Government. In addition to the topics provided in the presentation materials, the Contractor shall present to the Government their understanding of the requirements contained in this SOW. The contractor shall present a list of any questions and issues associated with the requirements contained in these and other applicable documents to the Government no later than 7-days before the meeting.

6.0 GOVERNMENT FURNISHED PROPERTY/MATERIAL

6.1 Government Furnished Information

The Government will evaluate any written request for information or documentation on a case-by-case basis and, at its discretion, will either accept or reject the request.

6.2 Government Furnished Material

The Government will evaluate any written request for material on a case-by-case basis and, at its discretion, will either accept or reject the request.

6.3 4.3 Government Furnished Property

The Government will evaluate any written request for equipment or property on a case-by-case basis and, at its discretion, will either accept or reject the request.

6.4 Government Furnished Access

The Government will evaluate any written request for access on a case-by-case basis and, at its discretion, will either accept or reject the request.

7.0 TRAVEL

All travel shall be in accordance with the Federal Travel Regulation (FTR) and Federal Acquisition Regulation (FAR) Part 31. The contractor shall use the most logical and economical method of travel available. All travel shall be invoiced on an actual travel cost basis and supporting documentation (invoices and receipts) shall be provided with submission of the invoice. All foreign travel, and any additional travel not contemplated by the Statement of Work, requires prior approval by the Contracting Officer Representative. All travel will be reported as part of the Contractor’s Monthly Progress Report.

8.0 Place of Performance

Work performed under this contract will occur at the contractor’s designated location.

9.0 OTHER

9.1 Security

The work shall be unclassified.

Attachments:

Attachment 1a: Data Item Deliverables (DID)