B08_Attach_1_FOS_deck_SOW_071921.pdf

SCOPE OF WORK

2021 Main Deck, transom, bulwarks and associated repair and replacement at Salem Maritime National Historic Site on FRIENDSHIP of SALEM

SALEM, MASSACHUSETTS

PMIS 163908A

1. General Intention and vessel overview

It is the intention under the terms and conditions of this contract to obtain repair services for the sailing vessel Friendship of Salem in order to maintain the vessel’s seaworthiness and possible future re-certification as a small passenger vessel, as described in Code of Federal Regulations chapters 33 and 46. The Contractor shall furnish all supervision, labor, materials and equipment needed to complete the replacements and repairs identified in this scope of work.

Friendship of Salem is a full-scale replica of a 1797 merchant ship. Construction of the modern three-masted, square-rigged sailing ship began in 1996 in upstate New York. In 1998, the unfinished vessel was launched and delivered to Salem Maritime National Historic Site, where masts, rigging, sails, and other features were added. Friendship of Salem has a lapsed certificate of inspection as a subchapter-T small passenger vessel. NPS plans to operate Friendship of

Salem as a dockside attraction throughout the year, and to sail her up on occasion, either as an uninspected or inspected vessel. Repairs will be performed to permit either option.

Friendship of Salem is a replica sailing vessel measuring 171 feet of sparred length with a 340 ton displacement. She has a beam of 34 feet and draws 11 feet. The vessel is fully rigged, with the tallest of the ship’s three masts reaching a height of 115 feet. Friendship of Salem’s hull is of laminate cold-molded construction.

Established in 1938 as a unit of the National Park Service, Salem Maritime National Historic Site preserves and provides public inspiration on the maritime history of New England and the United

States. The ship was built to help meet this mandate. The National Park Service offers a range of tours, programs and demonstrations about Friendship of Salem and related history topics. These uses occur when Friendship of Salem is berthed at Salem Maritime NHS, sailing to other ports, or participating in special events, festivals and tall ship parades.

2. Location

Friendship of Salem will be berthed in Salem, MA at Salem Maritime National Historic Site for the duration of this project. She is berthed on the West face of Derby Wharf next to a handicapped accessible floating steel dock. Derby Wharf is located across from 174 Derby St., Salem, MA 01970.

3. Scope of Work

The purpose of this repair is to maintain vessel in good and seaworthy condition. This will be accomplished by correcting deterioration in a number of locations, creating a well-sealed vessel that will not have fresh water leaks, and incorporating changes that will make future maintenance more effective and successful. Specifically this contract will:

• replace all deteriorated materials in the specified locations

• stop water leaks into the vessel from the transom, deck, deck edges, deck penetrations and waterway area. Leaks from the deck or other areas addressed by the contract will be included under the specified warranty.

Repair Details

Directions for these repairs are from this scope of work and the following documents: Repair

Survey and plans from Paul Haley (a marine surveyor who has been hired to perform the repair survey associated with previous repairs) dated 2011-12 and 2018 that detail the same type of frame, beam and hull repairs as contained in this document; the specifications document titled

“02010 materials”; and the design plans for Friendship of Salem.

USCG will occasionally monitor, approx. monthly, the progress and details of the work, but as the vessel has a lapsed COI, they will not be making required or weekly inspections. Repairs will be made to the standards for Subchapter T small passenger vessels. USCG inspection and observation visits will be coordinated by NPS COR.

Selections from design plans and all of the other documents listed above are included with this

RFP. A complete copy of Friendship of Salem’s design plans is available upon request. If not clearly stated in the scope of work, repair survey, plans or “02010 materials”, all materials should be replaced and installed in kind to original construction, and all materials and scantlings should match existing ones. If the standards and direction from the above sources cannot be met the designated NPS representative must be consulted prior to proceeding.

Summary of repair Details

Unless stated differently in a specific line the following apply to work under this contract:

For hull repairs under this contract all hull layer repairs will be laminated using Douglas fir, unless otherwise specified. Where the wood grain has slope, the slope will be alternated each layer. Unless otherwise specified, West System 105, or equivalent, 2-part epoxy resin with compatible hardeners and fillers, will be used as an adhesive on hull laminate layers, except for the outer planking layer above the wale where 3M 5200 or equivalent adhesive caulk may be substituted. The climate in the areas of repairs will be monitored and managed to ensure proper curing of epoxies, sealants and paints.

Surfaces that are sealed or covered with cured epoxy will have the “blush” from the epoxy curing process removed prior to proceeding with lamination or sealing to this surface. For all repairs the exterior surfaces will be prepared and painted with marine oil paint to match existing paint scheme. Interior surfaces will be finished in the same manner as existing. Those that are sealed with clear-coat epoxy will be treated with a 3:1 borate solution, allowed to dry 48 hrs. minimum, and then coated with clear-coat epoxy. Once dry, the treated surface will be sanded, brushed or wiped as recommended by the manufacturer prior to adhesives, paints or sealants being applied to the surface. The epoxy manufacturer’s recommended procedures will be followed in all instances.

New and exposed existing wood surfaces, not including those that will be laminated to another surface, will be coated with a borate preservative, such as Bora Care or equivalent. The selected product will be applied and allowed to dry as recommended by the manufacturer. Once dry, the treated surface will be sanded, brushed or wiped as recommended by the manufacturer prior to adhesives, paints or sealants being applied to the surface. All end grain and faying surfaces will be treated with 3:1 borate solution, let dry a minimum of 48 hrs., and then coated with two coats of clear epoxy prior to bedding and caulking.

One sample of two cut-off wood pieces laminated together with epoxy and marked with the date will be provided for every day that hull layers or framing members are being laminated. This sample should consist of two 1 foot long pieces of wood glued together with epoxy and having a minimum six inch overlap where they are glued together with epoxy. These pieces will be 2 inches wide and ½ inch thick with the unglued portions extending on opposite ends of the sample. This sample will be made using the same epoxy, wood and fasteners from that day’s work and will be allowed to cure in the same environment as the work. Each sample will be labeled with the date of its assembly, and what it represents. Once cured, the sample will be given to the NPS staff designated to collect the control samples.

In replacing layers of hull planking scarf joints are required except as follows:

A. Scarphs will be 12:1 except where interference prevents this, in which case they can be between 6:1 and 12:1

B. On the same planking layer, adjacent scarphs must be staggered by at least ½ a scarph length, with the scarph location repeating not more than once every 3 planks. On batten layers, planks may be staggered in groups of 3. SEE

DRAWING/PHOTO.

C. On the diagonal 3/8 inch layers staggered butt joints may be used in place of scarf joints provided the area of the next outer layer overlaps the repairs on the next inner layer by 1 foot or more. In areas where 1 foot overlaps or staggers are not possible, these may be reduced, with surveyor approval, and typically require the additional a 2 inch backing block laminated inboard of the inner hull layer at the effected location.

D. Where scarph joints are used on the batten or diagonal layers, scarphs must not be located on top of those on any inner layer.

E. On all horizontal layers butts joints may be used if butts are staggered by 5 or more feet horizontally and separated by 4 planks vertically.

F. On all outer layers above the wale butt joints shall be used in existing locations, and scarphs can be used in other locations.

If temporary fasteners are used, in addition to those specified below, to ensure adhesion while epoxy is curing, these will be removed once cure is achieved. Use Stainless Steel 316 or 18-8 fasteners for all fasteners that will be left in place in laminations or other locations. Where fasteners are removed after lamination, these holes will be filled with epoxy or a wood plug and epoxy. On the outer diagonal layer above the wale, and the outer batten layer below the top of the wale, fasteners of sufficient length to secure into the frames will be used and not removed with 2 fasteners at each frame section. Also, fasteners of sufficient length to secure approx. 5/8” into the inner batten layer will be used and not removed at approx. 1’ intervals between frames.

All outer layers planks will be secured with counter-bored stainless steel wood screws covered with wooden bungs using existing schedule. Existing hull layers typically, and other laminates occasionally, contain embedded steel fasteners.

On all caprails, planksheers, taffrails, transom cap, deck bullnose (if approved) and any other suitable location, add a 1/8”wide x ¼” deep notch type drip edge on the bottom face approx. 3/8” in from the edge, that is fully clear of where it meets the structure below it.

Except where it is specifically stated otherwise, awardee is responsible for shifting utilities, structural or other built-in vessel components as required to remove interference, create access or otherwise perform other work listed in this SOW. This includes temporary removal and/or relocation as required, and re-installation of all electrical, fire suppression, alarm system or other wiring, piping and related fixtures and equipment, either above or below the weather deck. Any damage to above mentioned items shall be repaired or replaced at the awardee’s expense.

All measurements are the responsibility of the contractor; the size and square footage of actual repairs included in the Scope of work and bid sheet are approximate.

Site Details at Salem Maritime NHS

A. NPS will provide use of two wooden floats, capable of supporting two layers of standard staging, of approximate dimension 8 feet by 20 feet and with1 foot of freeboard. Access to and use of Friendship of Salem’s floating dock, which has approximate freeboard of 3 feet and extends from the transom at the waterline to a point 20 feet aft of the stem, will be available.

B. 120v AC, 208v AC and 208v 3-phase electrical service is available at panels on the vessel and on shore close to the vessel. 120v AC and 208v 3-phase outlets are available aboard the vessel and 120v AC outlets are available ashore close to the vessel. If other electrical service is required these may be added temporarily at or from existing panels, at the vendor’s cost, by a professional licensed electrician. For all electrical service, NPS will pay the electrical utility costs.

C. NPS will provide an on-site location where up to two construction or storage trailers, a dumpster and a staging area, may be located. Contractor will confine storage of materials to locations designated by the Contracting Officer and Park managers as acceptable storage/laydown areas.

D. Work shall be generally performed during normal business working hours, 7:00 a.m.

to 5:00 p.m., Monday through Friday, except when otherwise indicated. Weekend, holiday, early or late Hours are not allowed without prior approval of the

Government. Request these a minimum of two (2) weeks prior to performing the work, and approval will be at the discretion of the CO.

E. Vehicles may drive on Derby Wharf, or other areas of Salem Maritime NHS, for work related to this contract. Not more than two vehicles, other than those actively engaged with the work, may be parked at the site and only during work hours.

F. At all times, due to the nature of public access to this location, placement of tools and supplies must be done in manner to protect public safety.

G. NPS will conduct public guided tours of the vessel on days when the awardee is not working, typically weekends and holidays. Work under this contract will be planned and coordinated to ensure that this can be carried out in a successful and safe manner, for as much of the vessel as possible, on at least 66% of days when awardee is not working on the vessel.

H. NPS will conduct public guided tours of the vessel on days when the awardee is working. These will be guided tours of a limited area of the vessel to the extent possible, and may include at a minimum viewing from the appox. 15’x15’ area just inboard of one of the gangways. Work under this contract will be planned and coordinated to ensure that this can be carried out in a successful and safe manner to the extent possible, and at least 66% of days when awardee is working on the vessel.

I. Only the 3 lower masts will be stepped and in place on the vessel, being supported with a mix of permanent and minimal temporary rigging, when work under this contract starts. NPS will not alter the state or extent of the rigging after award, except at the request of the contractor if rigging needs to be shifted to accommodate cover or other work.

J. As of 5/27/21 the vessel is secured port side to the dock. NPS might turn the vessel prior to the start of work under the contract, but not later than the notice to proceed is issued, except at the request of the contractor if turning the vessel is requested, and only once during the performance of work.

K. NPS staff will be working intermittent on minor carpentry, rigging, systems or other projects during performance of the contract. COR and Awardee project manager will coordinate work to ensure no interruption in contract work and continued access for both parties.

L. Contractor is responsible for ensuring work under this contract will not compromise short-term structural integrity, and using temporary support to address this if required.

M. NPS and awardee will coordinate sequencing of the work to ensure that sufficient mooring points are available on the vessel, and to move the vessel from starboard side to port side tie-up one time during the project if requested by the awardee.

N. All areas impacted by work under this contract will be kept in a safe and workmanlike condition.

Contract Base Items: Firm Fixed Price

00010 General:

a. Work barge or floats, in addition to NPS-supplied, if required

b. Crane or other lifting equipment as needed

c. Lay-down area supplies, office, storage or construction containers

d. Heating supply or equipment

e. Insurance

f. Awardee will prepare and submit a Quality Assurance Plan and a safety plan for approval, after contract award, and will follow that plan for the duration of work.

g. When existing routes are disturbed by the work, provide safe means of access to the main deck and interior portions of the ship, and permit NPS staff, volunteers and representatives to perform checks and inspections.

h. Permit and assist with access for NPS personnel, surveyors and US Coast Guard to perform inspections or other work during the performance period. Also provide access to ship for all work covered under this contract, using staging, ladders, mechanical lifts or other means.

i. Contractor is responsible for ensuring work under this contract will not compromise the vessel’s short-term structural integrity, using shoring, bracing, or other temporary structural support as needed.

j. Develop, submit and follow a plan to document, prevent, monitor and correct if necessary the structural and hydrostatic measurements and characteristics of the vessel. Also, manage the stability of the vessel throughout the duration of the work.

k. Even if not specifically stated below, disconnect, shift, reconnect or use other temporary measures to permit work where vessel systems pass through, are supported by, or interfere with items under this contract.

l. Provide any and all other labor, services, supplies or equipment to accomplish and support the work under this contract.

m. Disposal

n. Final clean-up of all vessel and site areas affected by this contract: broom cleaned and returned to original condition; repair of items damaged during the performance of work; removal of contractors equipment and supplies not being transferred to NPS;

dust and debris removal from adjacent spaces if these were not properly isolated.

o. Travel mileage, lodging and per-diem

00020, Design, supply and install full multi-season cover.

A. To facilitate an effective and high quality repair, and improve future maintenance, the contractor will design, supply, install, maintain or alter during this project, and then remove when work is completed, a weather resistant cover over the deck, railings and other work areas. This line includes providing the cover, and staging or other means of access for all work areas, as integrated or separate components. The design of the staging, frame and cover is the responsibility of the awardee, conceptual drawings are included with this solicitation. The cover will:

1. Be effective enough to exclude rain, snow and wind, and withstand associated loads, at

FOS Derby Wharf berthing location.

2. Permit at least 80% of its framing to be taken apart and laid flat, stored and then reused for multiple seasons. Cover material may be reusable (such as tarps) or single-season use

(shrink wrap).

3. Be built to cover and provide access, as separate or integrated components, for work on all lines of this SOW.

4. For reuse in subsequent years:

a. permit set-up and take-down by a crew of 4 people in not more than two weeks, and take down in one week (a week is 5 8-hour days), using commonly available tools.

b. the outboard ends of the cover frame will rest on and be secured to the caprail, and if needed, a centerline wall/ridge.

c. Intermediate knee wall may not be required

d. must work or be readily able to be modified to work with rigging components installed.

00030. Remove and replace all deteriorated transom framing and planking.

The upper sections of the transom, including planking, plywood and framing (extending from the taffrail to approx. 4’ below the main deck) have significant visible deterioration. Deteriorated material will be removed to the extent of deterioration and the repair plan described below will be re-evaluated then.

A. Remove and replace all transom framing, planking and associated components vertically from the taffrail to the intercostal that supports the aft edge of the ‘tweendeck, and horizontally for the full width of the transom. Removals of framing and planking between the main deck and the

‘tweendeck will be done carefully so the scope of removals can be limited if the extent described here is not required:

1. Remove and store until re-assembly unless noted: transom carvings, exterior window sash and framing.

2. Remove deteriorated portions of the transom rail, taffrail, frames, fir planking, plywood planking, and fashion piece planking until all deterioration is removed, or full width down to the level of and including the ‘tweendeck intercostal, whichever is smaller.

3. Laminate and replace 4 transom frames, 12” x 12” x approx. 18’ long, straight laminate, with reduced “stanchion” section at upper end, of PT laminated fir or PT SYPINE.

4. Replace multiple layers of transom marine plywood on the transom including the fashion pieces, approx. 125 SF/layer, with varying details per location, 3-6 layers and ¾” and ¼’ plywood, per plans.

5. Replace Transom planking, approx. 120 SF, with Port Orford cedar

6. Replace all other transom components above the ‘tween deck, such as Transom Rail, taffrail, lam-cap (outer edge trim of transom rail and fashion pieces), gunport frames, window frames and sash and trim, other exterior trim, and ceiling, etc. Use Spanish cedar or other rot resistant wood where suitable. Remove and replace associated hardware as required.

7. In frame “stanchion” section above the main deck and 4’ section below the main deck if not already PT, install borate rods, across laminations, w/bunged ends and proscribed gap. Size, quantity, location and details of installation per manufacturer’s instructions which differ by brand. On all interior wood surfaces and end grain where possible, that are not already PT, treat with 3:1 borate solution, let dry minimum 48 hours, then coat with two coats epoxy clear coat. On all exterior surfaces, prime and paint with oil-based paint.

8. Inspect, service, shift or remove, and reinstall all mechanical, electrical, and hydraulic steering and rudder components in the tiller box area, and move any other steering or rudder components as required, to permit work under this line and the deck line. Paint any previously painted steering components in the tiller box area, and replace corroded fittings, hoses and flanges where found.

9. Reinstall all items from line A of this section, replacing any that are deteriorated or damaged. Transom window framing and paneling will be installed with new ¼” vertical battens between them and transom posts to permit ventilation and drainage in this area.

00040. Remove and replace stanchions, hull, bulwark planks, caprails, planksheer and change frame/stanchion connection

Replace the caprail, bulwark planks, stanchions and planksheer (lower caprail), generally from the forward end of the port aft gangway opening, and from 3 frames aft of the starboard aft gangway opening, to the knightheads on either side of the stem, except where noted.

This replacement will change some design and material details, with the intent of increasing access, ventilation and drainage to improve maintainability thus reducing water infiltration and deterioration. The area between the aft timber-head and the stem will be carefully inspected and evaluated, and subsequent replacement in this area may be limited if the full scope of the planned repairs is not required in this area. There will be no leaks through this area if the work under this item is successfully completed. Notes: Deck and covering board replacement and sealing related to work under this item are included in the line 00050. All end grain and faying surfaces will be treated with 3:1 borate solution, let dry for a minimum of 48 hrs., and then coated with two coats of clear epoxy prior to bedding and caulking:

A. Removals and Frames:

1. From the aft gangway opening to the knightheads, remove the caprail, bulwark planks, chesstrees, planksheer, stanchions and timberheads. Make patterns as needed.

2. Cut frames flush to the top of the deck beams, approx. 44 locations.

3. Repair frames with deterioration below the cut point from previous line with full-width scarphs/graving pieces to replace approx. 1’ of deterioration below deck level (approx. scarph length 4’). Include 10 locations.

4. Repair less significant frame deterioration of up to ½ the width of a frame, and approx. 1’ high, using scarphs/graving pieces. Include 20 locations.

B. Hull

1. From the aft gangway opening to the knightheads, cut the hull down to the top of the deck beam ends, fairing the top edge to match the camber of the top of the deck beams.

2. Remove and replace deteriorated hull planking, measured as replacement of inner layer planking, including required overlaps on the three other layers, in 3 locations or approx. 42 SF each with their top edge being the new sheer plank, and totaling approx. 126 SF. Include 126 SF, billed per SF, of hull planking replacement above the top of the wale plank on the inner layer. See “Summary of repair details” section for details.

3. In all main deck waterway bays from the aft gangway opening to the transom, on both sides, cut an approx. 2” high x 6” long scupper through the hull planking layers, with its lower edge flush to the top of the deck plywood, at the forward end of the bay. Seal the exposed hull laminate layers on all four sides of these scuppers with 2 coats minimum of g-flex epoxy. The bottom surface of these scuppers will be covered by the covering board. NOTE: drainage wedges and any associated existing FG in these bays will be removed, and is included with the deck replacement lines.

C. Stanchions

1. Make and install approx. 57 new stanchions and timberheads (see attached drawing for new stanchion arrangement). Approx. 47 stanchions are “structural,” and extend through the deck to connect to frame heads. The other approx. 8 do not connect to frames and extend from the covering board to the caprail. There are

6 timber heads. The “structural” stanchions will be made long enough to secure at the frames/beam junction below deck level, using the same diameter and type fasteners and attachment method as previously used to connect frame head to beam ends, but longer to accommodate stanchion bottom. Bed this connection with roofing tar or bedding compound. Stanchions will be PT fir or PT SYpine.

D. Bulwarks, waterway and caprail:

1. Fit and install a “scupper plank” between the deck and the bottom of the planksheer, on the interior and exterior sides of the stanchions, of African mahogany, with similar dimensions and installation details to the bulwark planks

(see included drawing). Scuppers will be cut into bottom edge of these planks full length between stanchions. The exterior plank will create approx. 2” high scuppers, and the interior one will create approx. 5-1/2” high scuppers. The exterior board will be the same thickness dimension as the hull, approx. 2-1/2”.

The interior board will be thick enough to allow the planksheer to overhang it by

½”. They will be secured with marine adhesive sealant. The exterior boards will be fastened to the stanchions with 5/8” lag-bolts. The interior boards will be fastened with #18 wood screws. The fasteners will be counter-bored and bunged.

2. Make and install new African mahogany (or similar rot-resistant) wood planksheer, in-kind to existing design, supported by, fastened and bedded to the scupper planks. Cleats on the fore and aft faces of the stanchions as additional attachment points may be used if required for proper planksheer attachment. If cleats are used they will be made of African mahogany, secured with SS fasteners and thoroughly bedded to the stanchion.

3. Make and install new Spanish or port orford or Alaskan cedar bulwark planks, installed with the bottom of the lower plank ¾” above the planksheer. All end grain and faying surfaces will be treated with 3:1 borate solution, …let dry 48 hrs., and then coated with clear epoxy prior to bedding and caulking with a flexible marine adhesive sealant.

4. Make and install new fir caprails. Secure the caprails to the stanchions with 3/16” thick x approx. 1-1/2” wide x 2-1/2” long SS angle brackets, fabricated to match the rail sheer. Each bracket will secure the bottom of the caprail to the fore/aft face of the stanchion with two 3/8” dia. lag-bolts. The lag-bolts to the stanchions will be approx. 1-1/2” long, the ones to the caprail will be ½” less than the vertical thickness of the caprail.

E. Coatings and utilities:

1. Remove, clean and re-condition all approx. 7 sections of all tank vents, fills, discharges and associated systems piping, supports and thru-deck fittings, from their upper end to approx. 5’ below the main deck. Where these have corroded iron or steel components or replaceable seals, flanges or gaskets, between their upper end and the tanks, replace these with SS or other corrosion resistant materials if possible matching adjacent pipe, with COR approval, including but not limited to the 4 corroded elbows just below the ‘tweendeck in both heads.

Carefully fit these through the deck and planksheer, caulk any gaps with marine adhesive sealant, and install new gaskets and flanges. Perform similar shifting, and disconnect and reconnect, and sealing on any other non-electrical utilities that pass through the deck and covering board and are not specifically referenced in this item.

2. Disconnect, shift if needed, re-connect and seal around 1 approx. 2” electrical shore-power pipe conduit, approx. 6 1” electrical pipe conduits, and 2 approx. 1” emergency shut-off pipes that all penetrate the main deck and planksheer and up to 5’ below the main deck. Carefully fit these through the deck, planksheer, bulwark and stanchions, caulk any gaps with marine adhesive sealant, and install new gaskets and flanges in existing locations. Where these have corroded iron or steel components, or replaceable seals flanges or gaskets, replace these with SS other corrosion resistant alternative, to be approved by COR. Also, included in this item are removal and re-installation of the outlets, boxes, plugs, etc. that are associated with these electrical items. Perform similar shifting, and disconnect and reconnect, and sealing on any other electrical items that pass through the deck and covering board and are not specifically referenced in this item.

3. In top 4’ section of frames below the main deck, install borate rods, across laminations, w/bunged ends and proscribed gap, of size, quantity, location and details of installation per manufacturer’s instructions, which differ by brand. On all interior wood surfaces and end grain where possible, that are not already PT, treat with 3:1 borate solution, let dry minimum 48 hours, then coat with two coats epoxy clear coat. On all exterior surfaces, prepare, caulk, prime and paint with oil-based paint.

00050. Replace the main deck top layer, portions of the three sub-deck layers and associated beam repairs, that are deteriorated, need to be removed because they interfere with other repairs or to create desired overlaps. There will be no leaks through the deck, around the deck edge, or at through-deck penetrations if the work under this item is successfully completed.

The end result of this project will be a completely new top deck, installed with stated modifications from the original design, and sub-deck layers that are free of deterioration and meet the structural requirements of the vessel. Bidders will determine how much sub-deck to remove per layer to replace deterioration, meet structural requirements, and gain required access for inspections and other repairs. The most significant modification of the top deck, i.e. having it extend over the top of the hull, will apply from the aft end of the aft gangway opening to the knightheads. Because the stanchion and hull arrangement aft of the aft gangway opening is not being altered, in this area all other deck repair details will apply, except that the covering board will only extend past the deck edge where a scupper is cut in the hull at the forward end of each bay, and the rest of the covering outboard edge will seal to the hull where it meets the inboard face of the hull.

A. General and Removals:

1. Remove, re-install and paint, making small repairs or replacements as necessary of all deck-mounted items, including the following, and any others not addressed here or elsewhere in this proposal: Main and Aft escape hatches (wood façade, trim and any aluminum portions non-integral to the deck houses), helm, binnacle, 10 deck staples, 4 tiller eye-bolts, and cathead bolts. The escape hatch façade and trim requires significant replacement. Store these as templates or for re-installation. NOTE: Main and Fore Hatches, and steering and system components are addressed in separate lines.

2. Remove entire approx. 2100 Sq. Ft. top layer of decking, including any drainage wedges and FG installed in bulwark stanchion bays, for all of main deck, including area aft of the aft gangway opening.

3. Remove portions of all of 3 sub-deck layers, per bidder’s proposal, to remove deteriorated existing wood, gain access for inspections or other work, or to create approved overlaps between layers. Perform a careful inspection of sub-deck layers, beams, beam-ends, mast partners and carlings to determine where these will need to be exposed for inspection. Minimum overlap 8” between plywood layers. Awardee will plan deck repairs to meet requirements. Bidders should assume approx. 1600 SF (75%) removal of the top plywood layer, 1050 SF (50%) removal of the lower plywood layer, and 650 SF (30%) of the tongue and groove fir overhead layer. NPS determined these numbers assuming that the overhead layer will be removed 2’ back from the deck edge and 1’ back from all other penetrations and the deck beam being replaced, plywood layers will be removed

1’ additional each layer, and approx. 10% additional removals for unforeseen conditions and access requirements.

B. Capstan

1. Remove, clean of corrosion and deposits, repair and reinstall the capstan and its bearings. In its current condition the capstan does turn, with the upper bearing functioning as designed, but the lower bronze bearing bushing (with attached lower plate) is seized to the shaft. The capstan arrangement has been previously modified from what the plans indicate. Remove the capstan by disconnecting the shaft (approx. 10” dia. Steel) from its lower coupling, freeing or cutting away the tween deck bronze bearing bushing, and lifting the shaft out of the vessel.

Remove corrosion from the shaft, inspect and repair by metal spray and machining to existing OD, or adding SS sleeves at the bearing locations. Machine the inside of both bushings for additional clearance of .002” clearance per inch of shaft diameter (approx. .020” plus .003/minus 0). Also add a grease groove to each bushing if they are found to be missing. On bearing assemblies at both decks clean and check all seal and retaining rings, and adjust by machining if necessary for proper fit and clearances (clearance of rings to shaft should exceed those of the bushings at a minimum, approx. .003” per inch of shaft diameter, approx.

.030” plus .010/minus 0). Replace the lip seals at both decks, and add additional grease fitting for each bearing, not on the weather deck, and which communicates with the existing fittings and the groove. Reinstall the bearings and the capstan shaft, adding or adjusting blocking and fasteners at the main and ‘tween deck level where the old fasteners or blocking have sheared and deteriorated. Test and adjust during and after reassembly for proper alignment, support and rotation.

This capstan differs from what the plans indicate. The details can be found in the photos and sketch provided upon request.

C. Beam and related repair. Repair or replace deteriorated beam ends, carlings, mast partners, pawl post or other structures below the level of the deck. For proposal purposes assume:

1. The beam directly aft of the foremast will require full replacement or substantial repair to replace known deterioration from approx. 3’ to stbd. of CL to 10’ to pt.

of CL. Pawl post shall be replaced, and the laminated oak for the new Pawl Post will be provided by NPS.

2. Remove and replace deterioration of beam ends in 10 locations requiring removal of the outer 2’ of the beam, Remove and replace deterioration of deck beam end requiring removal of the outer approx. 2’ of the beam, and adding two 1/3 thickness Dutchmen on fore and aft faces of approx. 3’ and 4’ lengths. Dutchmen secured with flexible marine adhesive and 6 ½” bolts. See drawing. Include 10 locations, billed per location.

3. Remove and replace deterioration in beam tops, not at an end, of approx.1’ length and not more than ½ of cross section, using scarphed Dutchmen. Include 10 locations.

4. Replace mast partners and carlings at one mast.

5. Apply borate spray or rods to adjacent 18” of original wood and new wood, in areas of beam repairs.

D. Sub-deck and camber.

1. Increase deck camber approx. 1.5” as measured at the centerline of the vessel in the area between the aft watertight door of the main house and the forward end of the main hatch. The awardee will propose a plan to best accomplish this, considering benefits of jacking up the center of the beams, adding a post, adding a shim to the top of the beams, or building up the sub-deck layers. Bidders will consider adding a post between the ‘tweendeck and a main deck beam, supported to the keelson, between the capstan and the main mast.

2. Replace what was removed in line item 00050 (A)(3) on all 3 sub-deck layers to sound condition to create a suitable surface for installation of the top-deck, including but not limited to; replace, with approved overlaps, any removed portions of 3 sub-deck layers; Sub-deck layers will extend to, lay on top of, and secure to the top edge of the hull using a cleat, per current installation, using epoxy and stainless steel fasteners. All other edges where the sub-deck meets a structure that penetrates the deck (excluding metal piping or conduit) will be edge-banded with 1” wide teak and caulked. Plywood butt seams will be separated by 8” minimum on all seams, and where this requirement cannot be met a 6:1 or better scarph joint is required.

3. Lay two layers of 10 Oz. e-glass fiberglass cloth impregnated with epoxy over the top of the finished subdeck and extending 3” below the deck/hull joint on the outboard face of the hull planking, with approx. 6” overlaps. Lay one additional layer of cloth over the deck/hull joint, extending down the hull 3” and with its inboard edge falling between existing overlaps and extending at least 9” inboard of the deck edge. The upper, outboard edge of the sub-deck may have a radius added if this is required for proper cloth adhesion around this corner. This item includes filling all voids, fairing and removing blush prior to installation of the top deck layer.

E. Deck planking, covering boards and related:

1. Fit and install a complete new top layer of main deck planking of ¾” thick fir, and covering boards of ¾” thick mahogany, with matching lengths and butt locations to existing installation, and using a similar tapering scheme. Deck planks will have a maximum width of 6”. A two-piece notched covering board, with inner and outer pieces of approx. equal 8” width, will be notched around the stanchions and be installed from 3” inboard of the inner stanchion edge to 1-1/2” outboard of the hull outer edge. A mahogany molding, 1-1/2” W and 3-1/2” H, will be installed outboard at the sheer plank to support the outer edge of the outer covering board, and will have a drip edge on its bottom edge. The deck planks and covering boards will be laminated to the plywood sub-deck or other faying surfaces with a flexible marine epoxy suitable for this installation, ensuring that the sub-deck is properly prepared prior to installation of the top deck. Seams will be 3/16” wide, full depth, prepared as recommended by the caulk mfg. including bottom priming or bottom tape if specified, and filled with suitable black, flexible, marine deck caulk. The planks will be installed with 100% adhesions between the bottom of the deck planks and the plywood sub-deck. Except on the covering board and approx. 10% of other planking where this is impractical, deck planks will be secured to the sub-deck using vacuum bag installation to ensure full adhesion with no voids between the substrate and the sub-deck. The vacuum-bagged portion of the installation will require no or very few fasteners. Bidders will consider having the vacuum-bagged portion of the deck factory laid with flexible epoxy onto a biaxial cloth, phenolic or other suitable substrate panel, and then secured to the sub-deck with flexible epoxy using vacuum bag installation.

On the covering board and other deck sections that cannot be vacuum bagged, use

SS fasteners per existing deck planking, and as needed. Where these fasteners will be left in place they will be counter bored and bunged. Where fasteners are removed after laminating, the remaining holes filled with epoxy and the smallest diameter bung possible. In all deck sections fasteners with bungs, and simulated bungs, will be installed at existing intervals to simulate a traditional deck. Caulk all main deck seams not addressed under this item with the same caulk specified elsewhere.

2. Install “bosses” in place of deck planking under the following: main and fore hatch coamings, helm, and capstan base and pawl. These bosses will be made of

African mahogany or a similar rot-resistant hardwood that accepts paint well, or pressure treated Southern Yellow Pine. They will be twice the thickness of, and secured to the sub-deck in the same manner as, the deck planks. They will extend

¾” beyond any exposed edge of the structure that sits on top of them, with the exposed section being beveled on its top edge.

3. Add a boss, with similar details to the one described in the previous item, under the aluminum coaming of both deck houses to make these watertight, durable and able to be maintained more effectively than the existing construction.

NOTES: Main deck pipe scuppers and the tops’l tie boxes (galvanized Steel boxes built into the fore and main bulwarks) will be removed and NOT replaced. Electrical and piping that impacts the deck lines are addressed in 00040 “coatings and utilities.”

00060. Hatch coamings. Remove and replace the main and fore hatch coamings. Their dimensions, fastening details, and height from the deck will be the same as existing. Build the new ones from wood that holds paint well, is harder than cedar, and is rot resistant, IE, either suitably treated pressure treated fir or yellow pine, or African mahogany. Hatch timbers are 8”w x 8” H x length/width of the hatch. The bottom timber will be reduced from the existing to account for the increased height of the “boss” that supports it. Corners joints are ½-lapped box joints. Prepare, prime and paint.

Contract Option Items: Each option corresponds with a line on the Offer Schedule

A. Options related to 00030, transom:

a. Remove and replace; great cabin settee and rudder post box, transom interior trim and paneling, with small repairs as needed. Period of Performance (POP) will be extended 10 days if this option is elected.

b. Remove and replace tiller box and its top. Use Spanish cedar or mahogany for the framing and vertical portions of the box. For the top, laminate this from three layers of ¼” marine plywood with 3” of camber, edge caps and cleats to match type of wood used on the box components, and detail the top with routed planking lines. Prep., prime and paint. POP will be extended 10 days if this option is elected.

c. Sand, spot prime and paint all carvings with high quality oil based paint. POP will be extended 5 days if this option is elected.

B. Options related to 00040, bulwarks, stanchions, etc.:

a. Remove and store until re-assembly bulwarks attachments, such as pinrails, cleats, hardware, gunports w/hinges, wood kevel cleats w/blocking and hawse.

Mark accordingly for location. POP will be extended 3 days if this option is elected.

b. Fit as needed and reinstall all items from line a of this section (pinrails, cleats, hardware, gunports w/hinges, wood kevel cleats w/blocking and hawse), repairing or replacing items that are deteriorated or damaged. Secure Gunport hinges to the bottom of the caprail with lag bolts (not through-bolts). POP will be extended 10 days if this option is elected.

c. Additional frame repair if more than the 10 from the base contract are required, to remove and replace, with 6:1 or better scarph, up to 1’ of full width/thickness deterioration below the main deck. Same as 0040.a.3. Price each not to exceed

(NTE) 10. POP will be extended 3 days if this option is elected, each.

d. Additional frame repair if more than the 20 from the base contract are required to repair less significant frame deterioration of up to ½ the width/thickness of a frame, and approx. 1’ high, using scarphs/graving pieces. Same as 00040.a.4. .

Price each not to exceed (NTE) 10. POP will be extended 2 days if this option is elected, each.

e. Major additional frame repair to remove and replace, with 6:1 or better scarph, 1-

3’ of full width/thickness deterioration below the main deck. Price each not to exceed (NTE) 5. POP will be extended 3 days if this option is elected, each.

f. Major additional frame repair to remove and replace, with 6:1 or better scarph, 3-

5’ of full width/thickness deterioration below the main deck. Price each not to exceed (NTE) 5. POP will be extended 4 days if this option is elected, each.

g. Additional hull planking replacement if more than 125 SF from base contract are required. State cost to replace up to 5 additional SF measured on the inner layer, including required overlaps on other layers. Above the wale plank. Price each 5

SF unit, not to exceed (NTE) 100 SF (20 units). POP will be extended 3 days if this option is elected, each unit.

h. Remove and reinstall two backstay rigging staples and the one associated backing iron, either to create access or to repair and rebed these items. Replace any corroded bolts, nuts or washers. Refresh galvanized coatings, prime and paint all removed staples and backing plates before reinstallation. Price each location, not to exceed (NTE) 4. POP will be extended 3 days if this option is elected, each.

i. Remove and replace a main or fore chain-wale and associated chainplate, including backing irons and all associated hardware, to create access to hull and frames for repair if needed. The chainplate epoxy compression wedge between nut and iron shall be installed to permit simplified adjustment, removal and reinstallation for future repairs by pre-pouring the epoxy and drilling the chainplate bore prior to installation, or by using a solid wedge with equivalent or greater strength to existing system. Note: the existing arrangement of the chainplate lower end is different than shown in the design plans; please see the photograph from current arrangement. Replace any corroded bolts, nuts or washers. Recoat before reinstallation w/caulking or filling. Price each location, not to exceed (NTE) 4. POP will be extended 5 days if this option is elected, each.

j. Make new and install one main or fore pinrail. Price each location, not to exceed

(NTE) 4. POP will be extended 3 days if this option is elected, each.

C. Options related to 00050, beam and deck:

a. Additional beam end or other similar size repair if more than the 10 from the base contract are required. Remove and replace deterioration of deck beam end requiring removal of the outer approx. 2’ of the beam, and adding two 1/3 thickness Dutchmen on fore and aft faces of approx. 3’ and 4’ lengths. Dutchmen secured with flexible marine adhesive and 6 ½” bolts. Same details as 00050.C.3

See drawing. Price each location, not to exceed (NTE) 5. POP will be extended 3 days if this option is elected, each.

b. Beam repair requiring more substantial repair than the previous item. Replace deterioration of up to full thickness and up to 3’ athwartships with scarphed

Dutchman. Price each location, not to exceed (NTE) 5. POP will be extended 4 days if this option is elected, each.

c. Repair major beam deterioration more than ½ thickness and width and more than

3’ athwart-ship, requiring a scarphed Dutchman longer than the previous item, and up to full replacement. Price each location, not to exceed (NTE) 3. POP will be extended 5 days if this option is elected, each.

d. Replace mast partners and carlings at one location. Price each, same details and in addition to 00050.c.4. Price each location, not to exceed (NTE) 2. POP will be extended 3 days if this option is elected, each.

e. Remove and replace sub-deck layers in addition to base bid proposal amounts, if greater than expected deterioration is found, or to access repairs in other option lines. State the cost per SF of sub-deck, per layer, NTE 3050 SF. Same details as

00050.A.3 and 00050.D.2. POP will be extended 1 day for each election of this option between 1SF and 32SF, and 1 day for each 32 SF increment if more than

32 SF are elected.

f. Remove and replace deterioration in beam tops, not at an end, of approx.1’ length and not more than ½ of cross section, using scarphed Dutchmen. Price each, in addition to 10 from base contract, same details as 00050.c.3. Price each, not to exceed (NTE) 5. POP will be extended 2 days if this option is elected, each.

g. Install PT SY pine blocks halfway between all stanchions, equal to the width and length of the stanchions. The top and bottom of blocks will fay against bottom of planksheer and top of covering board respectively. All faying surfaces will be bedded. The planksheer will be counter bored and bolted through the block with two ¾" SS bolts, through the deck and secured to the underside of the deck with nuts and oversized washers or steel backing plate. This block is intended to secure the planksheer to the deck, provide attachment points for the scupper boards and to strengthen the bulwark assembly. POP will be extended 15 days if this option is elected.

h. Replace windlass posts, fore fife rails and belfry. The laminated oak for these posts will be provided by NPS. POP will be extended 15 days if this option is elected.

D. Misc. Options

a. Remove, replace and paint all aft deck house sheathing, strapping and trim, from all sides and roof, including the sliding hatch, escape scuttle, vents and doors. All wood components that are currently fir will be replaced with Port Orford or

Alaskan Yellow Cedar. Replace damaged or corroded hardware, reinstall and ensure proper operation of removed and replaced items. POP will be extended 15 days if this option is elected.

b. Perform two laser scans, to help monitor and confirming vessel shape and…