Attachment 1 Statement of Work - FR DTB Seals Supply.pdf

Statement of Work (SOW) Draft Tube Bulkhead Seal Replacement at Fort Randall Dam

1.0 General Information

1.1 Background

The Fort Randall powerhouse is located on the Missouri River at Pickstown, South Dakota. Fort Randall currently has eight (8) draft tube bulkheads fabricated in 1949, in need of seal replacement. The seals show signs of cracking, deformation, and erosion which are leading to an increase in leakage through the bulkheads. The bulkheads are maneuvered with a lifting beam by a 25-ton draft tube gantry crane.

1.2 Objective

This project will supply nine (9) rubber draft tube bulkhead seal assemblies. The scope includes one (1) spare seal assembly.

1.3 Scope

The Contractor shall supply items listed in the table.

Quantity Description 9 Complete Rubber Seal Assemblies

1.4 Delivery Information

1.4.1 Delivery Period

The work must be completed 150 days after the date of contract award.

1.4.2 Place of Delivery

The supplies requested under this contract will be delivered to:

United States Army Corps of Engineers Fort Randall Dam 399 Powerhouse Road Pickstown, SD 57367

1.5 Quality Control

The Contractor shall designate, in writing, an employee who shall serve as the contact for matters involving quality and performance or nonperformance of the required work stated in this SOW. The employee(s) shall be qualified and fully competent with full authority to act for, and on behalf of, the Contractor as necessary to ensure that the required work is performed in accordance with the standards contained herein. The Contractor shall furnish the above written designation to the Contracting Officer Representative (COR) no later than the first day of work. The Contractor shall include the name(s), address(s), and telephone number(s) of the responsible individual(s).

The Contracting Officer reserves the right to disapprove any individual whom he considers incompetent to perform the work required. The Contracting Officer will provide a written notice of any disapproval to the Contractor.

1.6 Quality Assurance

The Government will ensure that the Contractor is performing the work required by this SOW in an acceptable manner.

The Government has the right to inspect all items called for by the contract, to the extent practicable at all times and places during the term of the contract.

If any of the work does not conform to contract requirements, the Government may require the Contractor to re-perform the work in conformity with contract requirements and at no increase cost to the Government.

1.7 Communication

Prior to commencing any activities, the COR will schedule a kick-off meeting with the Contractor to establish methods of communication, set clear expectations, discuss the work requirements, scheduling, and submittal process. The Contractor will be responsible to schedule periodic meetings to ensure all milestones are being met according to the agreed upon schedule. At least one (1) week prior to commencing work, the Contractor shall coordinate their proposed work schedule with the COR.

1.8 Submittals

Prior to commencement of the work, the Contractor will submit the following documents to the COR for review and approval. Government approval is required for submittals with a "G" classification. Submittals not having a "G" classification are for Contractor Quality Control approval. When used, a code following the "G" classification identifies the office that will review the submittal for the Government. Submit the following electronically to the COR:

a. Seal Manufactures Recommended Storage, G

b. Seal Manufactures Recommended Delivery, G

c. Seal Shop Drawings, G

d. Material Test Report, G

e. Fluorocarbon Adhesion Bond Test Report, G

All submittals requiring Government approval will be reviewed and approved within 30 business days unless otherwise stated.

1.9 Standards and Regulations

The Contractor shall perform to the standards in the contract and comply with all Local, State, and Federal Regulations during the services performed. The Contractor is responsible for ascertaining the extent to which these regulations affect the operations resulting from this contract. The Contractor shall comply will all applicable regulations. Applicable regulations include, but are not limited to the following:

a. ASTM D395 (2014) Standard Test Methods for Rubber Property - Compression Set

b. ASTM D412 (2006a; R 2013) Standard Test Methods for Vulcanized Rubber and Thermoplastic

Elastomers – Tension

c. ASTM D413 (1998; R 2017) Standard Test Methods for Rubber Property - Adhesion to Flexible Substrate

d. ASTM D471 (2012a) Standard Test Method for Rubber Property - Effect of Liquids

e. ASTM D572 (2004; R 2010) Rubber Deterioration by Heat and Oxygen

f. ASTM D2137 (2011) Standard Test Methods for Rubber Property - Brittleness Point of Flexible

Polymers and Coated Fabrics

g. ASTM D2240 (2005; R 2010) Standard Test Method for Rubber Property - Durometer Hardness

h. EM 385-1-1 (2014) Safety and Health Requirements Manual

1.10 Payment

The Government will make payment once all seal assemblies (CLIN 1) are received, inspected, and accepted by the Government. The Government will review, approve, and process the Contractor’s invoice before payment is authorized. The Contractor shall submit the invoice to the COR. Payments will be made for the performance listed below:

a. Delivery of nine (9) complete rubber seal assemblies.

The Contractor must provide the Contractor’s name, address, contract number, CLIN number and specific quantities of work performed, and total requested, for an invoice to be considered proper.

1.11 Operation and Maintenance Data

The following types of information, if applicable, will be required:

a. Operating instructions

b. Installation procedures and/or best practices/recommendations

c. Maintenance requirements

The Contractor will provide applicable information at time of delivery via secure FTP site (i.e. DoD SAFE: https://safe.apps.mil/) or e-mail in Adobe Acrobat .pdf format.

2.0 Specific Tasks

2.0.1 Time of Delivery

The Government requires delivery of nine (9) rubber seal assemblies to be made in accordance with section 1.4, Delivery Information.

2.0.2 Drawings

Contractor shall immediately check the Reference Drawings and Contract Drawings furnished as a part of the SOW and notify the Government of any discrepancies.

2.1 Bulkhead Seals

2.1.1 Seal Shop Drawings

Prior to any manufacturing submit detailed shop drawings of the seals (para. 1.8, item c) for Government approval. Show complete details of materials (including teflon coverage), tolerances, connections, and bolting hardware on shop drawings. Include catalog cuts, templates, fabrication and assembly details, and type of materials, as appropriate on shop drawings. Utilize AWS A2.4, AWS A3.0M/A3.0, AISC 303, AISC 325, and AISC 326 for shop drawing preparation. Provide shop drawings as electronic CAD files in AutoCAD (.dwg).

2.1.2 Delivery and Storage

Seals must be stored and shipped in accordance with seal manufactures guidelines. Seals must be shipped flat and fully vulcanized. Submit seal manufactures recommended storage methods and seal manufacturer recommended delivery method for review (Reference para. 1.8, items a & b). Storing and shipping seals coiled is not allowed. Coiled seals will be replaced at the Contractor’s expense.

2.1.3 Materials

2.1.3.1 Rubber Seals

Provide rubber seals that are of the fully molded type only and are compounded of natural rubber/Polyisoprene. Provide fully molded seal corners with splices a minimum of 12 inches from the vertical and horizontal seal intersection or as indicated on the drawing. All splices must be factory vulcanized. Provide rubber seals which include reinforcing carbon black, zinc oxide, accelerators, antioxidants, vulcanizing agents, and plasticizers. Do not provide rubber compounds made of reclaimed polymers. Properly cure the rubber seal profile into a homogeneous form and keep free of oils, grease, or other materials which would deteriorate the rubber. Meet the following requirements for the physical characteristics of the seals:

Physical Test Specification Test Value Test Method

Tensile Strength 3,000 psi (min.) ASTM D412 Elongation at Break 450 % (min.) ASTM D412

300% Modulus 900 psi (min.) ASTM D412 Durometer Hardness, Shore

Type A 60 to 70 ASTM D2240

Water Absorption 5% by weight (max.) ASTM D471 Immersed at 70 C for

166 hours Compression Set 30% (max.) ASTM D395

Method B Tensile Strength After Oxygen Bomb Aging

80% of strength (min.) ASTM D572 48 hours of aging

Low Temperature Brittleness

Non-brittle after 3’ @ -40 degrees F

ASTM D2137

Method A

Perform the "Water Absorption" test with distilled water. Blot dry the washed specimen with filter paper or other absorbent material and suspended by means of small glass rods in the oven at a temperature of 70°C plus or minus 2°C for 22 plus or minus 1/4 hour. Remove the specimen, allow to cool to room temperature in air, and weigh. Record the weight to the nearest 1 mg as W1 (W1 is defined in ASTM D471). The immersion must be 70°C + 1°C and the duration of immersion must be 166 hours.

2.1.3.2 Fluorocarbon (PTFE) Clad Rubber Seals

Provide a fluoro-carbon film vulcanized and bonded to the sealing surface of the bulb on the top and side rubber seals. Provide film that is 0.060-inch-thick Huntington Abrasion Resistant Fluorocarbon Film No.

4508, or equal, having the following physical properties:

Tensile strength ............... 2,000 psi (min.)

Elongation ..................... 250 percent (min.)

The outside surface of the rubber seal and must be free of adhering or bonded rubber. Provide strips and corner seals molded in lengths suitable for obtaining the finish lengths shown and with sufficient excess length to provide test specimens for testing the adequacy of the adhesion bond between the film and bulb of the seal as specified in Testing below.

2.1.3.2.1 Testing

Test the fluorocarbon film for adhesion bond in accordance with ASTM D413, using either the machine method or the deadweight method. Submit a Fluorocarbon Adhesion Bond Test Report (para. 1.8, item e) prior to shipping of the structures. At one end of each strip or corner seal to be tested, mask the fluorocarbon film during bonding to prevent a bond for a length sufficient to hold the film securely during testing. Use a 1" piece of seal cut from the end of the seal which has been masked and subjected to tension at an angle relative to the dimensions of the rubber surface. There must be no separation between the fluorocarbon film and the rubber when subjected to the following loads:

Thickness of Fluorocarbon Film

Machine Method at 2 inches Per Minute

Deadweight Method

0.060 30 lbs per inch width 30 lbs per inch width

2.1.4 Material Test Report

Contractor is required to have material tests and analyses performed and certified by an approved laboratory, at the Contractor's expense, to demonstrate that materials are in conformity with the specifications. Reports of the tests, inspections, and verifications of all materials used under this contract are to be approved by the Government before incorporation into the structure (para. 1.8, item d). Conform tests, inspections, and verifications to the requirements of the particular sections of these specifications for the respective items of work unless otherwise specified or authorized. Government may request that tests be conducted in the presence of the Government. Furnish specimens and samples for additional independent tests and analyses upon request by the Government.