Attachment 1a - Travis AFB - VTR001 - Appendix A - Vertical Carousel REV 1a (MIPR).pdf

APPENDIX A

FOR

VERTICAL CAROUSELS

AT

TRAVIS AIR FORCE BASE, CALIFORNIA

Building 883

CSN: VTR001

DATE: 17 June 2021 REV 1: 25 October 2022

PREPARED BY:

Bradley Thompson Bradley Thompson

PROJECT ENGINEER

AFLCMC/EZPAE

Megan Blackwell Megan Blackwell

REVIEWER

AFLCMC/EZPAE

Travis AFB – App A - Page i

Table of Contents

1. SCOPE

1.1. GENERAL SCOPE

1.2. DEFINITIONS

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

(REV 1)

3.2. PERFORMANCE AND PHYSICAL CHARACTERISTICS

3.2.1. UNIT DIMENSIONS

(REV 1)

3.2.2. CARRIERS

3.2.2.1. CARRIER INSTALLATION

3.2.2.2. CARRIER CONFIGURATION

3.2.2.3. CARRIER CAPACITY

3.2.2.4. CARRIER DIMENSIONS

3.2.2.5. CARRIER FABRICATION

3.2.2.6. CARRIER DEFORMATION

3.2.2.7. CARRIER TIER MARKINGS

3.2.3. SAFETY FACTOR

3.2.4. TRAVEL SPEED

3.2.5. RETRIEVAL METHOD

3.2.6. STOPPING ACCURACY

3.2.7. SERVICE LIFE

3.2.8. STRUCTURE

3.2.9. ENCLOSURE PANELS

3.2.10. MAINTENANCE SERVICE DOOR

3.2.11. MECHANICAL CONTROL

3.2.12. WORK COUNTER

3.2.13. UNIT MARKINGS

(REV 1)

3.2.14. DRIVE COMPONENTS

3.2.14.1. MOTORS

3.2.14.2. GEAR REDUCERS

3.2.15. LOCKERS

(REV 1)

3.2.15.1. LOCKER CONFIGURATION

(REV 1)

3.2.15.2. LOCKER BAR CODE HOLDERS

3.2.16. BOLLARDS

3.3. ELECTRICAL CHARACTERISTICS

3.3.1. OPERATION

3.3.2. CONTROLS

3.3.3. INDEPENDENT DISCONNECT

3.3.4. IMBALANCED LOAD INDICATOR

Travis AFB – App A - Page ii

3.3.5. OBSTRUCTION SENSORS

3.3.6. LIGHTING

3.3.7. HOUR METER

3.3.8. RS232C PORT

3.3.9. BACKUP POWER CABLE

(REV 1)

3.3.10. ELECTRICAL OUTLETS

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

4.2. TEST

4.3. CERTIFICATIONS

Travis AFB - App A - Page 1

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for six vertical carousels with storage lockers built-in for the 349th Security Forces Squadron (SFS) in Building 883 at Travis Air Force Base, California. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) Drawing VTR001-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.2. DEFINITIONS

Carrier - A fabricated metal structure attached to the carrier lift chains used to contain and transport stored items.

Carrier live load capacity - Actual amount of load supported by a carrier, but not including the weight of the carrier.

Multiple tier carrier - A carrier that provides more than one storage level.

Single tier carrier - A carrier that provides one storage level.

Storage levels - The number of levels available within a carousel to contain and transport stored items provided by single and/or multiple tier carriers.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION (REV 1)

The Contractor shall provide four (4) vertical carousels located as shown on AF Drawing VTR001-01 which shall store and retrieve individually locked personnel lockers. The contractor shall provide four Manufacturer: Kardex Remstar, Model #: MEG RS

350.1.3250.6.533.8 units, or equivalent. Lockers shall be retrieved by keying in the carrier tier number where the locker is located. Each carousel shall rotate vertically and shall consist of the following:

Travis AFB - App A - Page 2

A. Carriers

B. Controls

C. Conduit, wiring, mechanical fasteners and all other items required to install an operational vertical storage carousel.

D. Lockers

3.2. PERFORMANCE AND PHYSICAL CHARACTERISTICS

3.2.1. UNIT DIMENSIONS (REV 1)

The external dimensions of the four carousels shall be a nominal 5 feet-5 inches ± 1 inches deep and 122.5 inches ± 1 inches wide. Depth shall exclude the 12.6 inch collapsible countertop (stainless steel). The collapsible countertop will have a minimum load limit of 80lbs when extended and in use. The Contractor shall provide a vertical carousel that is a height of 10 feet 2.5 inches ± 1 inch.

3.2.2. CARRIERS

3.2.2.1. CARRIER INSTALLATION

The Contractor shall maximize the number of storage levels within the carousels if more than the quantities specified in

3.2.2.2. can be installed. Spacing between the top of a carrier side and the bottom of the next carrier side shall not exceed 2 inches.

3.2.2.2. CARRIER CONFIGURATION

Each carousel shall have carriers with a minimum pitch of 16 inches. The contractor shall maximize the number of carriers within each carousel. At least 8 multipurpose carriers shall be in each carousel.

3.2.2.3. CARRIER CAPACITY

Each carrier shall have a minimum net live load capacity of 772 pounds. Each carrier shall have a minimum net live load capacity, not including the weight of the carrier and tiers, as follows:

STORAGE LEVELS PER CARRIER X ___ POUNDS (MAX) PER STORAGE LEVEL

Travis AFB - App A - Page 3

= MINIMUM NET LIVE LOAD CAPACITY PER CARRIER

3.2.2.4. CARRIER DIMENSIONS

The minimum usable depth of each carrier shall be a nominal 24.7 inches. Carriers in each carousel shall have a minimum usable width of 128 inches. Each carrier shall have a clear height of

19.02 inches.

3.2.2.5. CARRIER FABRICATION

All carrier tiers shall have a lip to prevent items from accidentally sliding over the edge of the carrier. The lip shall be a minimum of 1/4 inch high and a maximum of 1/2 inch high. Each tier shall have a solid back that extends from the bottom to the top of the usable height of each tier. All carrier tiers shall have slots to permit insertion of metal dividers.

3.2.2.6. CARRIER DEFORMATION

All carrier structural members shall not exhibit elastic deformation greater than 0.50 percent of the distance between the ends of each carrier when loaded to capacity. No carrier structural members shall exhibit permanent deformation.

3.2.2.7. CARRIER TIER MARKINGS

Each carrier tier shall be marked with its associated number beginning with number one and progressing through all the tiers of the carousel. The number shall be contrasting to the tier color and shall be located in three positions (left, center, right), which are visible to the operator, on a fully loaded tier. The numbers shall be stuck on labels permanently affixed to the tiers.

3.2.3. SAFETY FACTOR

Each carrier lift chain shall have a minimum 6-to-1 safety factor based on yield strength.

3.2.4. TRAVEL SPEED

The carousel carrier travel speed shall be a minimum of 15 ft/min.

3.2.5. RETRIEVAL METHOD

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Each carousel shall automatically utilize the shortest route method of retrieval.

3.2.6. STOPPING ACCURACY

Each carrier tier shall stop within 0.60-inch of the position of the previous carrier tier chosen at the carrier access opening while at balanced load conditions when measured from the work counter.

3.2.7. SERVICE LIFE

All equipment furnished shall be new and shall be of high quality to ensure that the completed system is designed to function a minimum of 1,500 hours based on the time registered by the hour meter specified in 3.3.7. or that all equipment has a design service life of 15 years or longer.

3.2.8. STRUCTURE

Each carousel shall have a steel framework that shall support the fully loaded system without the use of the enclosure panels as specified in 3.2.9. and shall not be attached to another carousel or to the building, except for the floor. Each carousel shall be anchored to the floor in a minimum of four places.

3.2.9. ENCLOSURE PANELS

Outer surfaces of each carousel shall have bolted solid metal enclosures for security. The enclosures shall be bolted from the outside to permit removal for maintenance or emergency access. A solid metal enclosure to close off the top of the carousel shall be installed. The front of the carousel shall have a carrier access opening to permit operator access to storage areas of entire carrier. The access opening shall be a maximum of 40 inches from the floor to the bottom of the access opening. The height of the opening shall be a minimum of 36 inches high. The carrier access opening shall have a spring-loaded counter balanced door capable of being closed and locked to provide maximum security when unattended. Two sets of keys shall be provided.

3.2.10. MAINTENANCE SERVICE DOOR

A service door shall be provided below the counter for maintenance access to operating parts such as motors, brakes, and reducers. The door shall be equipped with safety interlock

Travis AFB - App A - Page 5 switches to prevent carousel operation when the service door is open.

3.2.11. MECHANICAL CONTROL

Each carousel shall have some means of operation, such as a hand crank, which shall rotate the carriers in the case of a power outage or maintenance requirements. The mechanism shall easily and manually rotate the carriers and shall be easily accessible.

3.2.12. WORK COUNTER

Each carousel shall have a fixed work counter in front of the carrier access opening. The counter shall have a stainless steel covering. The counter shall be a minimum length no less than the width of the carriers and have a minimum depth of 12 inches. The counter shall be installed a nominal height of 40 inches above the floor.

3.2.13. UNIT MARKINGS (REV 1)

The units shall be marked with the letters “A” through “D”. The letters shall not be placed on the carousel until approval for correct lettering is provided by the Contracting Officer or techincal representative (COTR). The letters, which shall be placed on the vertical carousel face at a position visible and legible to the operator, shall be a contrasting color to the carousel color. The letters shall be a minimum 8 inches high and 6 inches wide and shall be stick on labels permanently affixed to the units.

3.2.14. DRIVE COMPONENTS

3.2.14.1. MOTORS

Motors shall be of sufficient size for the duty to be performed and shall not exceed their full-rated load when the driven equipment is operating at the specified maximum capacity under the most severe conditions likely to be encountered. All motors shall be designed for continuous duty at ambient temperature, 32 to 104 degrees Fahrenheit. Motors shall be drip proof and shall be designed to operate on electrical power characteristics as they exist at the site. Motor shall have an electronically controlled soft start and shall be equipped with an overload device. Motors shall be located at the bottom of the carousel for easy access for service and maintenance.

3.2.14.2. GEAR REDUCERS

Travis AFB - App A - Page 6

Gear reducers shall not permit oil to leak. The maximum input horsepower rating of the gear reducer shall not be less than the horsepower of the attached drive motor. Motor and reducer frames shall be compatible.

3.2.15. LOCKERS (REV 1)

Each vertical carousel shall be equipped with four (4) storage lockers built-in to each carriage. Each carousel shall be equipped with 32 storage lockers (128 total). These lockers shall be assembled in a non tamper way, so that unwanted entry is not permitted. Locker shall be approved by the COTR at the time of proposal. All lockers shall be individually lockable, with three keys per locker provided. Two master keys that open all lockers shall be provided. One storage locker shall be provided to the Government (AFLCMC/EZPAE, 5215 Thurlow Street, Suite 5, Wright-Patterson AFB, OH 45433-5547) within 60 days after contract award for acceptance tests.

3.2.15.1. LOCKER CONFIGURATION (REV 1)

There shall be one locker size provided, Type A. The Contractor shall install the lockers on the vertical carousel carriers as dimensionally specified in Table 1, or approved by the COTR. See Image 1 below for reference.

Type Door Color Height Width Depth Qty

A Matching Carousel 19” 28”~30” 24” 4

TABLE 1 – Configuration Per Carrier Per Carousel A – D

Image 1 – Locker Configuration Example with 5 Doors

Travis AFB - App A - Page 7

3.2.15.2. LOCKER BAR CODE HOLDERS

All lockers shall be capable of holding the bar codes holders for standard bar code labels, 3-1/2 inches wide by 1-1/2 inches high. Bar code label holders shall be provided for each locker.

Each bar code label holder shall facilitate the easy removal and replacement of bar code labels.

3.2.16. BOLLARDS

Bollards shall be located near the carousels as detailed on drawing VTR001-01.

3.3. ELECTRICAL CHARACTERISTICS

3.3.1. OPERATION

The carousel shall operate on 3/PE 220V (50/60hz) electricity obtained from an existing power panel, labeled “sub panel” on AF Drawing VTR001-01 (TBD).

3.3.2. CONTROLS

The vertical carousel shall have a permanent control cluster that is push button or membrane type. The control cluster shall be located to the right of the carrier access opening and shall be no higher than 76 inches from the floor. The control cluster shall contain as a minimum, a numeric keypad for inputting a carrier tier address, manual up and down keys, a button to clear an incorrect carrier tier address, a button to activate movement of the carousel to the desired carrier tier, and a red emergency stop button. The control cluster shall have a LED display which shall indicate the current carrier tier. A carrier tier shall be called by keying in on the numeric keyboard the carrier tier number which shall be as specified in 3.2.2.7.

3.3.3. INDEPENDENT DISCONNECT

The vertical carousel shall have a master on/off switch on the face of the carousel to control each carousel's electrical power. This switch shall have some means (i.e. key switch, padlock, etc.) of locking it into the off position.

3.3.4. IMBALANCED LOAD INDICATOR

An indicator shall be mounted on the face of the carousel to indicate if the carousel exceeds the designed imbalanced load limit of the vertical carousel. If the imbalance load limit is

Travis AFB - App A - Page 8 exceeded, the carousel shall produce an indication that the limit has been exceeded.

3.3.5. OBSTRUCTION SENSORS

Sensors shall be mounted on the carousel at the work station to stop the movement of the carousel if an object should extend through the plane of the carrier access opening. The sensors shall include light curtains with max 1 inch spacing projecting horizontally across the top and bottom of the carrier access opening and touch bars on the top and bottom of the carrier access opening.

3.3.6. LIGHTING

The vertical carousel shall have integrated overhead lighting, which shall measure a minimum of 50 foot-candles at the work counter. The lighting shall be continuous along the length of the work counter.

3.3.7. HOUR METER

An electrically operated hour meter shall be provided and installed on each carousel to register cumulatively the duration of operation. The hour meter shall not be of the type that can be reset. The hour meter shall only operate when the carousel carriers are moving. The hour meter shall have a minimum of four positions to register run time of up to 9,999 hours and shall have a minimum of one position to register fractional increments of an hour. The hour meter shall be located in an area that the face of the meter is easily accessible and seen.

3.3.8. RS232C PORT

The controller shall be a command driven interface with asynchronous responses communicating through an ASCII RS232C 9 pin connection.

The controller shall respond when commands are completed and not require continuous polling to determine completion status.

3.3.9. BACKUP POWER CABLE (REV 1)

A minimum 100 foot power cord shall be provided for each carousel to provide backup power to the vertical carousels from a portable generator. The power cord shall connect to the front of each vertical carousel on one end and a government furnished portable generator on the other.

3.3.10. ELECTRICAL OUTLETS

Travis AFB - App A - Page 9

The contractor shall provide one 110 volt electrical outlet on the vertical carousel.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the Cover PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2. TEST

The following test shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No. Paragraph Description

1. 3.3.1.1.

Cover PD

Acceptance test of 1 hour as registered by the hour meter shall be made on each vertical carousel. This test shall demonstrate the reliability as specified in 3.3.1.1. of the cover PD. Each carrier tier shall be loaded as determined in 3.2.2.3. with Contractor supplied test loads. All carrier tiers shall be called randomly during the test. If this test shows that the installation is defective in any respect or does not comply with this appendix and the Cover PD, the Contractor shall immediately make all changes necessary to correct all defects to the satisfaction of the CODR prior to acceptance. The system shall be operational at least 95 percent of the test period based on the time registered on the hour meter.

Travis AFB - App A - Page 10

2. 3.2.4. Two random carriers shall be chosen to determine if the carousels operate at a minimum speed of 25 ft/min. The distance from the bottom of one carrier to the bottom of the next carrier shall be measured. A carrier shall be chosen that is ten carriers away. The carousel will then be activated and the time to move from the original to the final carrier will be recorded. The following formula will be used to determine if the carousel operates at a minimum speed of 25 ft/min:

[Distance Measured Between Chosen Carriers in inches x 10 / 12] / [Travel Time in seconds / 60] = Speed

3. 3.2.5. Two random carriers shall be chosen and observed to determine if the carousels utilize the shortest route method of retrieval.

4. 3.2.2.6. The deformation shall be tested in conjunction with test number 1 to determine if the carriers exhibit elastic deformation less than 0.50 percent of the distance between the ends of the carriers when loaded to capacity. The distance from the mid-point of the bottom of the selected carrier shall be measured and recorded as M1. The carrier will then be loaded to capacity and left for a minimum of four hours.

After four hours, the distance between the two points where M1 was measured shall be measured and recorded as M2. The following formula shall be used to determine the deflection:

[(M1 - M2) / 100] x 100 = Percent Deflection

If the calculated deflection exceeds 0.50, then the carousels shall fail the test. After all loads are removed, the carriers shall be examined for permanent deformation. If permanent deformation has occurred, the carousels shall fail the test.

5. 3.2.11. Means to rotate carriers in case of power outage shall be demonstrated. If no means exist, this shall constitute a failure.

Travis AFB - App A - Page 11

6. 3.3.5. All safety interlock switches, sensors, touchbars, and stop buttons shall be tested to ensure that they are completely operational.

4.3. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with the Contract Data Requirements List.

No. Paragraph Certifications

1. 3.2.3. The Contractor shall certify each carrier support chains have a minimum 6-to-1 safety factor based on yield strength.

2. 3.2.7. The Contractor shall certify that the carousels are designed to function a minimum of 1,500 hours based on the time registered by the hour meter specified in 3.3.7. or that all equipment has a design service life of 15 years or longer.

3. 3.2.8. The Contractor shall certify that the weight of a fully loaded carousel is adequately distributed to not exceed the capacity of the floor as specified.

TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

Travis AFB – Vertical Carousel TPQ - Page 1 of 2

VERTICAL CAROUSELS

Contract Number: FA8604- -R- Project Title: Storage Aid System Base: Travis AFB, California CSN: VTR001 Appendix A, Vertical Carousels, 24 August 2022

This questionnaire shall be completed by the Offeror. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment.

Please attach product literature/cut sheets for all equipment detailed in this questionnaire and attach any exceptions to the Purchase Description Appendix as detailed below.

Vertical Carousel Manufacturer: ______________________________ Model Number: ________________________________________________

No. Paragraph Characteristics

1. 3.1. Carousel Manufacturer:_______________________

Carousel Model Number for A - D units:_____________________

2. 3.2.1.

(REV 1)

Carousel A - D dimensions:

Width: _____________________________ inches Height: ____________________________ inches Depth excluding counter top: _______ inches

Is the counter top collapsible: ___________

3. 3.2.2.2. Number of carriers per carousel: ______________

Carrier pitch: _________________________ inches

4. 3.2.2.3. Number of levels per carrier in Carousel A - D:______________

Minimum Net Live Load Capacity per Carrier:____________

Solicitation Number: FA8604- -R-

Travis AFB – Vertical Carousel TPQ - Page 2 of 2

5. 3.2.15.

(REV 1)

Locker Manufacturer: ______________________

Locker Specs for A - D:

Height: ___________________________ inches Depth: ____________________________ inches Width: ____________________________ inches Color/Finish: ____________________________ Quantity Per Carrier: ____________________

Number of Lockers per Carrier: _____________

Lockers are Individually Lockable: ____________

Lockers are anti-tamper: ________________

6. 3.2.16. Backup Power Cables shall be provided, as specified: __________________

7. 3.3.2. Where will the control cluster be located?

EXCEPTIONS

Attach any exceptions taken to the Purchase Description Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken? YES NO Number of pages attached: ____________________________________