DRAFT Blast Booth Requirements Rev B SOW.pdf

AMARG Large Component Blast Booth

Goal: Turnkey Blast Booth to support the blasting of ferrous Aerospace Ground Equipment. Blast Booth needs to be housed or integrated into a structure that could be utilized for potential future additional Blast Booth. Structure requirements are to supply all utilities and space required for current and future operation needs. For the purposes of this project, the area of future operations will be referred to as the Maintenance Operations area (MX Ops).

Scope: AMARG requires an Abrasive Media bead blast booth capable of performing operations on

Aerospace Ground Equipment (AGE). Blast booth must be sized to accommodate various sizes of Aerospace Ground Equipment that is listed in Section 4. This includes a plastic media blast booth(s), all associated support equipment, support facilities, and external shelter.

1. GENERAL DESIGN REQUIREMENTS

APPLICABLE GUIDANCE, REGULATIONS, & STANDARDS: The Contractor shall comply with all applicable federal, state, and local guidance, regulations, standards, and codes in the design, construction, installation, and operation of the blast booth facility. A list of potentially applicable guidance, regulations, and standards is provided in Appendix C. The contractor is responsible for identifying and complying with all applicable requirements, whether they are listed in Appendix C or not.

1.1. COTS Preference and Justification

1.1.1. Requirement: The design should utilize 100% Commercial Off-The-Shelf (COTS) items whenever technically feasible and economically advantageous.

1.1.2. Justification Process: If a component or assembly is proposed as non-COTS, the Contractor shall provide a written justification demonstrating:

1.1.2.1. The unavailability of a suitable COTS alternative that meets the required performance specifications.

1.1.2.2. A cost comparison comparing the proposed non-COTS item to potential COTS alternatives, including acquisition cost.

1.2. Documentation:

1.2.1. The Contractor shall maintain a log of all COTS determinations, including the justification for any non-COTS selections. This log shall be submitted to AMARG Contractor Officer (CO) and Project Manager (PM) for review and approval prior to procurement. The log shall include, at a minimum, the following fields:

1.2.1.1. Component Name

1.2.1.2. Required Performance Specification(s)

1.2.1.3. COTS Alternative(s) Considered (if any)

1.2.1.4. Justification for Non-COTS Selection (including specific reasons why COTS alternatives were unsuitable)

1.2.1.5. Cost Comparison

1.2.1.6. Approval:

1.2.2. All non-COTS selections require prior written approval from AMARG CO.

1.3. Software Requirements:

1.3.1. Requirement: All software required for maintenance, troubleshooting, diagnostics, and system operation shall be licensable to AMARG, providing AMARG with the ability to perform updates and troubleshooting. The software must be unlocked and fully functional for these purposes.

1.3.2. Licensing: If a commercial license is required, the license shall be perpetual and transferable to AMARG.

1.3.3. Documentation: The Contractor shall provide complete and accurate software documentation, including user manuals and maintenance manuals.

1.4. Human Machine Interface (HMI):

1.4.1. Requirement: All Human Machine Interfaces (HMIs) shall provide operators with the ability to monitor and adjust all critical system parameters for safe and efficient operation of the blast booth.

1.4.2. Key Features: The HMI shall include real-time data display, alarm management, and user access control.

1.5. Cyber Security

1.5.1. All software should be developed and maintained in accordance with industry’s best practices for cybersecurity.

1.5.2. The Contractor shall provide a comprehensive Hardware/Software list identifying all equipment with software or firmware components. This list shall be provided as an Excel spreadsheet and include the following information for each item:

• Quantity

• Manufacturer

• Model

• Part Number

• Serial Number (if available at the time of submission, otherwise to be provided upon installation)

• Software/Firmware Version

1.5.3. Hardware/Software list (Excel spreadsheet) shall be submitted to AMARG for review and approval prior to procurement and again upon installation and commissioning

1.5.4. The Contractor shall provide a

1.5.5. The PLC/HMI shall be protected against unauthorized access. Contractor(s) shall propose and implement measures to protect against unauthorized access.

2. SITE REQUIREMENTS

This site will be prepped with utilities and a concrete pad to accommodate blast booth, supporting facilities, and equipment. The Contractor is responsible for verifying all site conditions and utility connections and ensuring compliance with all applicable codes and standards.

2.1. Site Location:

2.1.1. Requirement: The site shall be located on AMARG behind building 7213 as shown in Appendix B.

2.1.2. Verification: The Contractor shall verify the site location and dimensions with AMARG prior to commencing any work.

2.2. Concrete Pad:

2.2.1. Requirement: The Contractor shall design and construct a concrete pad that is of sufficient size and strength to support the blast booth, supporting facilities, and equipment, while also complying with all applicable codes and standards.

2.2.2. Verification: The Contractor shall submit design drawings and calculations, stamped by a licensed structural engineer, demonstrating that the concrete pad meets the specified requirements.

2.3. Water Supply:

2.3.1. Requirement: A water supply shall be provided to accommodate fire suppression systems and shall comply with all applicable plumbing codes and fire protection standards.

2.3.2. Verification: The Contractor shall verify the water pressure, flow rate, and connection size prior to commencing any work.

2.4. Sewer

2.4.1. A sewer stub-up shall be provided at the site to accommodate drainage of fire suppression and future water requirements. Sewer stub-up will be designed and installed in accordance with UFC 3-240-01 along with any other applicable building, state, county, and plumbing codes.

2.5. Electrical Supply:

2.5.1. Requirement: An electrical supply shall be provided to power the blast booth and associated equipment and shall comply with all applicable electrical codes.

2.5.2. Verification: The Contractor shall verify the voltage, phase, frequency, and amperage of the electrical supply prior to commencing any work. The contractor shall provide load calculations, stamped by a licensed electrical engineer, to verify the electrical supply is adequate for 2 equal sized blast booths and supporting systems.

3. EXTERNAL STRUCTURE(S)

This section defines the requirements for the external structure or structures that will house the plastic media blast booth and associated facilities. The external structure shall be a Pre-Engineered Metal Building (PEMB) designed for modularity and ease of expansion.

3.1. General Requirements:

3.1.1. The external structure(s) shall be PEMBs that meets all applicable building codes and Air

Force design requirements.

3.1.2. Expandable: The PEMBs shall be designed for modularity, allowing for future expansion with minimal disruption.

3.1.3. Durability: The PEMB shall be durable and resistant to weather, pests, and fire. The expected engineered lifespan of the PEMB shall be 40 years.

3.1.4. Aesthetics: The PEMB shall have an aesthetically pleasing appearance that is consistent with Davis Monthan standards as found in the Base Design Guide.

3.2. Dimensions and Orientation:

3.2.1. The PEMB shall be sized to accommodate the blast booth, supporting equipment, and MX

OPS Area as defined in Section 4 (Supporting Facilities) & Section 5. The PEMB's orientation on the site shall ensure that the blast booth door faces South.

3.2.2. All blasting equipment, including the blast booth and supporting equipment listed in Section 4 shall be consolidated and located on the east side of PEMB structure.

3.2.3. The MX Ops area shall be on the west side of PEMB.

3.2.4. The MX Ops and blast booth areas shall be physically separated by a ceiling to floor 2 hour rated fire wall. All gaps and penetrations will be sealed to prevent bead blast waste media and/or dust from entering the “Clean/Cold” MX Ops area (west end of PEMB).

3.3. Materials:

3.3.1. Requirement: The PEMB shall be constructed of high-quality materials that are appropriate for the intended use and environment and meet all applicable code requirements.

3.3.2. Frame: The frame shall be constructed of structural steel.

3.3.3. Insulation: The PEMB shall be insulated to meet climate control requirements in Section 4.

3.3.3.1. NOTE: Climate controls shall be localized and not connected to network.

3.4. Doors and Windows:

3.4.1. Requirement: The PEMB shall include all necessary doors and windows for access and ventilation and shall meet all applicable code requirements.

3.4.2. Blast Booth Doors: The Blast Booth shall include doors that seal properly to prevent the egress of blast media. The Blast Booth door shall have a minimum height of 20 feet to accommodate the product being blasted.

3.4.3. Equipment Doors: The PEMB shall include doors that are sized to ensure that the equipment may be moved out of the structure for maintenance, replacement, or repair of the largest equipment. The contractor shall provide dimensions of the largest piece of equipment that will be housed in this room and ensure that the door is sized accordingly.

3.4.4. Doors: The PEMB shall include doors for personnel and equipment access in accordance with NFPA 101 life safety code sections 40.1 & 40.2 with applicable occupancy group. [ref

2.1.19 AMARG TAMS SOW]

3.5. Exterior Finish:

3.5.1. Requirement: The exterior of the PEMB shall be finished to provide a durable and aesthetically pleasing appearance that blends in with the surrounding facilities at AMARG.

3.5.2. Color: The main exterior color shall be consistent with the color of adjacent structures.

Exterior color samples shall be submitted to the chief engineer for approval. There shall be exterior accents that match as closely as possible per DMAFB Building Design Guide. This includes gutters and downspouts. Personnel egress and framing shall match one of the colors listed. Color samples shall also be verified and approved by Government Project Engineer (GPE) prior to manufacture and delivery.

3.5.3. Coatings: Exposed structural steel shall be coated for corrosion resistance. Roof and wall panels shall be galvanized and coated or equivalent.

3.6. Structural:

3.6.1. Requirement: Structural design shall comply with all applicable codes and standards, including but not limited to; UFC 3-301-01 Section 1609.1.2 – Aircraft Hangar Wind Loads, using the following specifications:

3.6.1.1. Risk Category: III

3.6.1.1.1. Exposure Category: C

3.6.1.1.2. Site Soil Class: D

3.6.1.1.3. Ground Snow Load: 30 PSF

3.6.1.1.4. Wind Speed: 120 mph

3.6.1.2. All structural design loads shall be submitted with proposal for evaluation. This includes but is not limited to dead loads, live loads, roof snow load, wind loads, and seismic loads.

3.6.1.3. Structural design must accommodate ceiling mounted systems such as fire suppression, Fall arrest systems, HVAC, Lighting, HVLS fans, and other necessary equipment in support of facility/equipment design requirements.

3.6.1.4. Structural design shall be approved and stamped by a licensed professional engineer, registered in any of the 50 united states.

3.7. . Thermal Performance:

3.7.1. Requirement: The PEMB shall be designed and constructed to minimize heat transfer and assist in maintaining the temperature range specified in Section 4.

3.7.2. Insulation: The PEMB shall be insulated to meet energy efficiency requirements and to assist in maintaining the temperature range specified in Section 4.

3.8. Design for Expansion:

3.8.1. Requirement: The PEMB shall be designed to accommodate future expansion with the addition of future PEMB structures of the initial building. The design shall minimize disruption to existing operations during future expansion activities.

3.8.2. Utilities: Utility systems (electrical & water) shall be designed and strategically located connection points to facilitate future expansion. The design shall include provisions for isolating sections of the utility systems during future connection work.

3.8.3. Foundation: The foundation design shall accommodate the anticipated loads of future expansion modules. The foundation shall be designed to ensure blast booth can accommodate a full floor recovery system.

3.8.4. Roof Design: The roof design shall be compatible with future expansion, allowing for the connection of adjacent roof structures without major modifications.

3.9. Personnel Egress:

3.9.1. Provide exits or exit access doors around the entire perimeter of the PEMB to meet UFC 3-600-01, the NFPA 101 Life Safety Code Sections 40.1 and 40.2, and all other applicable personnel egress references.

3.9.2. Personnel egress shall be compliant with Americans with Disabilities Act (ADA) Standards for Accessible Design that apply to Government construction.

3.9.3. Exterior personnel doors shall be covered by awnings in accordance with OSHA 29 Code of Federal Regulations (CFR) 1910 and shall be designed for protection from falling objects and to prevent snow or ice accumulation. Exterior personnel doors shall be weatherproof and comprise of a minimum of 16-gauge metal with a U value of 0.50 or better.

3.9.4. Doors shall follow the keying and hardware requirements in Attachment F of the DMAFB Facility Design Guide, as applicable. Door cutouts shall be finished, framed, weatherproof, and corrosion resistant.

3.10. Storm Water Containment:

3.10.1. Requirement: The design shall be based on a 10-year storm IAW UFC 3-201-01 Section

3.1.2 Building system shall be inclusive of gutters, downspouts, disbursement and associated hardware sized to handle environmental conditions at the site. The PEMB shall be sealed to prevent water intrusion.

3.11. Fire Protection:

3.11.1. Requirement: The PEMB shall include fire protection systems as required by applicable codes and standards (UFC and NFPA). The contractor shall determine the appropriate level of fire protection (e.g., sprinkler system, fire extinguishers, or both) based on a hazard analysis and in accordance with applicable codes and standards.

3.11.2. Design and Installation: If a fire suppression system is required, it shall be designed and installed in accordance with all applicable UFC and NFPA requirements.

3.11.3. Fire suppression system shall be approved by a licensed professional engineer, registered in any of the 50 United States as well as an NFPA Certified Fire Protection Specialist (CFPS).

3.11.4. The fire suppression system shall be tested IAW NFPA 409 Chapter 12 Section 12.5.9.

Testing required by NFPA 409 Chapter 12 Section 11 shall also be performed as applicable to initial install. Passing results shall be supplied to the GPE prior to acceptance.

3.12. Lightning Protection System (LPS):

3.12.1. Requirements:

• The LPS shall be designed and installed in accordance with AFMAN 32-1065, UFC 3-575-01, NEC, and NFPA 780.

• Building ground systems shall be interconnected at a common accessible point in accordance with applicable regulations, including NFPA 780 Section 4.14.5 and Gap Analysis.

• The system shall be installed by a contractor with an Underwriters Laboratories (UL) Lightning Protection Master Certification (LPMC).

• The LPS design shall be approved by a licensed professional engineer, registered in any of the 50 United States.

3.12.2. Inspection and Acceptance:

• The LPS shall require an inspection prior to acceptance.

• The LPS shall be inspected by a commercial, third-party inspector whose sole work is lightning protection.

• The system shall be certified by this third-party inspector in accordance with

AFMAN 32-1065 and NFPA 780 (in that priority order).

• A UL Master Label Certificate shall be provided (CDRL). A UL certification on its own shall not be adequate for acceptance.

3.13. Electrical:

3.13.1. Contractor shall use appropriate NEMA rated enclosures for exterior and/or interior environments as applicable.

3.13.2. Provide an NEC compliant power interruption panel suitable for lock out/tag out

IAW OSHA regulations for blast equipment.

3.14. Lighting:

3.14.1. Internal overhead lighting shall be Solid-state lighting (SSL) Light Emitting Diode (LED), and installed IAW UFC 3-530-01, DMAFB Facility Design Guide and lighting levels per Illuminating Engineering Society (IES) recommendations with the following exceptions:

3.14.2. LED lighting shall be no more than 4100K at Color Rendering Index (CRI).

3.14.3. A photometric lighting plan shall be submitted to the GPE for approval through the design process IAW SOW para 6.3.

3.14.4. Illumination of egress, emergency lighting, and egress markings shall be installed IAW

NFPA 101 Section 40.2.8, 40.2.9, and 40.2.10.

3.14.5. Exit signs shall be the photo-luminescent type.

3.14.6. Exit signs shall be connected to the emergency lighting inverter or provided with emergency battery units.

3.14.7. Interior lights shall be controlled via a combination of occupancy sensors, vacancy sensors, photocells, time clocks, and/or switches.

3.14.8. Exterior lighting to be installed IAW UFC 3-530-01, UFC 4-010-01, and DM BDG

3.14.9. Exterior lighting shall be LED building-mounted fixtures installed over personnel egress.

This includes any external utility or compressor rooms. No standalone light posts should be installed.

3.14.10. Exterior lighting shall be installed to illuminate the surrounding area and any disturbances to existing light coverage or shadowing caused by the PEMB.

3.15. Telecommunications:

3.15.1. fdsaf

3.16. Additional Requirements:

3.16.1. Warranty: The contractor shall provide a 5-year warranty for the overall PEMB structure, components, and coatings of the PEMB from the date of final acceptance.

4. BLAST BOOTH AND SUPPORTING EQUIPMENT (EAST PEMB)

This section defines the requirements for the blast booth and support equipment/spaces of blast operations within the east side of the external structure, including locker rooms, transition area, observation room, and the equipment/storage room. All support facilities and spaces shall comply with applicable building codes, Air Force design requirements, and all applicable codes and regulations listed in Appendix C.

4.1. General Requirements:

4.1.1. Requirement: The support facilities and spaces shall be designed to provide a safe, comfortable, and efficient working environment for employees.

4.1.2. Requirement: Blast Booth and Supporting equipment shall be capable and optimized for effectively removing paint, primer, and corrosion from Aerospace Ground Equipment (AGE) without damaging the underlying material. Blast booth shall utilize Type V media (Acrylic Plastic) with a 3.5MOH hardness defined in the Technical Order 1-1-8.

4.1.3. Layout: The layout of the support facilities and spaces shall be designed to eliminate the potential for blast booth media and dust migration and ensure proper workflow.

4.1.4. Finishes: The support facilities and spaces shall have durable, easy-to-clean, wipeable, industrial level finishes. No carpet is permitted.

4.1.5. Fire Safety: The support facilities and spaces shall include fire protection measures (e.g., fire sprinklers, fire-rated walls) as required by applicable codes and standards.

4.1.6. HVAC:

4.1.6.1. All ancillary spaces shall be climate controlled.

4.1.6.2. Target setpoint temperature to be 60 to 80 deg F unless otherwise noted.

4.1.6.3. Positively pressured to minimize dust migration from dirty/transition areas to clean areas.

4.2. Clean Spaces:

4.2.1. Clean Locker Room (COLD)

Configuration Approval: The proposed configuration of clean and dirty spaces shall be presented to and approved by appropriate Bioenvironmental and Safety representatives. Observation Area can be a standalone area or be within the clean locker room if all requirements are met.

4.2.1.1. Requirement: A clean locker room shall be provided for employees to store personal items.

4.2.1.2. Location: The clean locker room shall serve as the sole entrance into the dirty locker room, which will be adjacent to a transition area into the remaining dirty areas in the blast facility. The clean entrances shall avoid all dirty/transition areas to access clean areas of the facility

4.2.1.3. The clean locker room shall be sized to accommodate a maximum of 4 personnel and shall have a minimum area of 200 square feet.

4.2.1.4. Provide 4 lockers for storage of employees’ personal items that are stacked two high and lockable. Minimum of 18” of depth.

4.2.1.5. PPE Storage: Contractor shall install clean PPE supply storage cabinets for storage of clean blast coveralls, gloves, and Tyvek suits

4.2.1.6. Provide benches, each with a minimum length of 42 inches mounted to concrete.

4.2.1.7. Clean

4.2.2. Observation Area (COLD)

4.2.2.1. An observation room/area shall be provided with a view of the blast enclosure. This room shall be separated from areas in which media may be present.

4.2.2.2. Shall be sized to accommodate 2 personnel.

4.2.2.3. Provide a window large enough to provide a view of the entire blast booth.

4.2.2.4. Window made from safety glass protected by a screen per OSHA 1910.94.

4.2.2.5. Sound Isolation: Shall be isolated from the blast booth/equipment room to a sustained noise level lower than 85 dBA during blast operations.

4.2.2.6. Provide access to all blast system and ventilation system controls and monitoring via the PLC/HMI.

4.2.2.7. Shall have full system emergency stop.

4.2.2.8. Shall have blast booth lighting controls.

4.3. Dirty Spaces:

4.3.1. Dirty Locker Room (WARM):

4.3.1.1. A dirty locker room shall be provided for employees to store dirty PPE.

4.3.1.2. The dirty locker room shall be in the transition area.

4.3.1.3. Size: The dirty locker room shall be sized to accommodate a maximum of 4 personnel and shall have a minimum area of 200 square feet.

4.3.1.4. Provide 4 lockers for storage of employees’ personal items that are stacked two high and lockable. Minimum of 18” of depth.

4.3.1.5. Provide benches, each with a minimum length of 42 inches mounted to concrete.

4.3.1.6. Contaminated PPE Collection: Shall include space for government provided containers to collect contaminated PPE.

4.3.2. Transition Area and Shower (WARM):

4.3.2.1. A transition area shall be provided for employees to transition between the blast booth, air shower, dirty locker room, and the clean room. See UFC 4-211-02 CLEAN- DIRTY Schematic.

4.3.2.2. Shall provide electrical outlets in all WARM areas for HEPA Vacuum.

4.3.2.3. Indicator Lights: Shall have indicator lights at booth entrance which show the status of blast enclosure (Blast system enabled, hoses active/in use).

4.3.2.4. Shall use an air shower to transition from the blast room to dirty locker room.

4.3.2.5. Air showers shall be designed and implemented per NIOSH requirements and offer the best efficiency and efficacy of dust removal and filtration.

4.3.2.6. Air showers shall be designed for ease of maintenance of HEPA filter(s) changes.

4.3.3. Blast Booth Equipment Area:

4.3.3.1. An equipment area shall be provided for media reclaim, recovery, and blast equipment.

4.3.3.2. Blast equipment shall be designed to not leak or permit the migration of media or dust into the equipment area or clean spaces.

4.3.3.3. Access: Provide external access via a roll-up door and a man door.

Equipment/Storage doors shall be sized to ensure that the maintenance, replacement, or repair of the equipment can be easily accomplished in and out of the room. The contractor shall provide dimensions of the largest piece of equipment that will be housed in this room and ensure that the door is sized accordingly.

4.3.3.4. Temperature Control: Shall have basic temperature control, ventilation, and/or insulation to prevent overheating (at or below 90°F) that is independent from ancillary personnel areas HVAC. Contractor to recommend most cost-effective solution.

4.3.3.5. Storage: Shall have space to store 2 pallets of clean blast media barrels.

4.4. Compressor and Electrical Room:

4.4.1. Compressor and electrical room shall be provided.

4.4.2. Size: The rooms shall be sized appropriately to accommodate all necessary electrical and compressor equipment.

4.4.3. Access: The rooms shall have secure access with lockable doors and provide external access for maintenance actions. Doors shall be sized to ensure that the maintenance, replacement, or repair of the equipment can be easily accomplished in and out of the room. The contractor shall provide dimensions of the largest piece of equipment that will be housed in this room and ensure that the door is sized accordingly.

4.4.4. Compressed Air Source:

4.4.4.1. The contractor shall be responsible for providing a compressed air source that is sufficient for the blast booth and all associated equipment for 8 hours of continuous blast booth operations.

4.4.4.2. Air needs to be dried to prevent issues with the blast media

4.4.4.3. All compressed air tanks shall have auto drains installed to prevent buildup of condensate, oil, and/or corrosion.

4.4.5. Breathing Air:

4.4.5.1. The contractor shall provide a system which generates Grade D breathing air for use in the blast booth. The contractor shall provide documentation and demonstrate that the installed system meets Grade D requirements as described in ANSI/Compressed Gas Association Commodity Specification for Air, G-7.1-1989.

4.4.5.2. Compressors used to supply breathing air must be constructed and situated to prevent entry of contaminated air into the air supply system. Compressors used to produce air for supplied air respirators must be capable of meeting Grade D standards described in ANSI/Compressed Gas Association Commodity Specification for Air, G- 7.1-1989.

4.4.5.3. Breathing air couplings must not be compatible with outlets for no respirable worksite air or other gas systems. There should be multiple connection ports for airline respirator hoses to allow worker mobility.

4.4.6. Electrical:

4.4.6.1. Sufficient to run all blast, recovery, reclaim, ventilation, and other equipment

4.5. BLAST ENCLOSURE

This is the room where blasting will occur. The Blast Enclosure shall comply with but not limited to T.O. 1-1-8, UFCs, and all applicable building codes, Air Force design requirements, and the DMAFB Design Guide provided in Attachment 1. Applicable codes and regulations are listed in Appendix C.

4.5.1. Expected Workload for Blast Enclosure Table:

AMARG AGE

Category Equipment Dimension Tallest B-2 Maintenance Stand 17 ft lowered Widest B-52 Tow Bar 12.5 ft Heaviest 4100 R& I Trailer 3,190 lbs.

4.5.2. Combustible Dust Hazards:

4.5.2.1. Requirement: The blast enclosure, including the exhaust system and all electrical wiring, shall be designed to minimize the risk of combustible dust explosions and shall conform to the requirements of applicable codes and standards for dust, stock, and vapor removal or conveying.

4.5.3. Floor Load Capacity:

4.5.3.1. The blast booth floor shall be designed to support the weight of the heaviest configuration of Aerospace Ground Equipment (AGE) that will be used in the booth.

The heaviest AGE per square foot is defined as the 4100 Engine Trailer.

4.5.3.2. Verification: The Contractor shall provide calculations demonstrating that the blast booth floor meets the specified load capacity. The calculations shall include the weight and footprint of the 4100 Engine Trailer.

4.5.4. Construction:

4.5.4.1. Structure will be delivered with most of the fabrication and assembly being accomplished at the factory and much of the installation shall be accomplished from the ground level.

4.5.4.2. May be integrated or an insert of the PEMB

4.5.5. Size:

4.5.5.1. The blast booth interior volume shall be sized to fit various sizes of Aerospace Ground Equipment that is listed in appendix.

4.5.5.2. Internal Dimensions:

4.5.5.2.1. Height: 20 ft

4.5.5.2.2. Width: 20 ft

4.5.5.2.3. Depth: 40 ft

4.5.5.2.4. Must be able to accommodate the following:

4.5.5.2.4.1. Tallest AGE: B-2 at 17’

4.5.5.2.4.2. Heaviest AGE: 3,190 lbs.

4.5.6. Metal walls for enclosure:

4.5.6.1. Sealed to prevent media/dust migration to surrounding areas

4.5.6.2. Walls need to be abrasion resistant

4.5.6.3. Sound damping material installed on the exterior of blat booth walls to ensure noise levels meet the lower than 85 dBA during blast operations.

4.5.6.4. If integrated, then insulated appropriately

4.5.7. Lighting:

4.5.7.1. LED lighting on the walls and the ceiling appropriate for a blast environment, at a minimum Class 2 Div 1 or higher as required based on Fire Department classification of the space.

4.5.7.2. Minimum lighting is ~ 70-foot candles at 2’6” above the floor

4.5.8. Utility hookups:

4.5.8.1. Air connections should have a shut off valve at the wall connection point

4.5.8.2. Air connections shall be managed by regulators to adjust pressure

4.5.8.3. Compressed air/Shop Air

4.5.8.3.1. 100 PSI

4.5.8.3.2. 4 minimum connections

4.5.8.3.3. Connection Type: DeVILBISS Quick Disconnect -High Flow Ball and Ring

Lock Type

4.5.8.3.4. https://www.autorefinishdevilbiss.com/products/hose-fittings.aspx#2696179-technical-specifications

4.5.9. Breathing air

4.5.9.1. 4 minimum connections

4.5.9.2. Breathing Air Couplets must not be compatible with outlets of non-breathing worksite air or other gases.

4.5.9.3. Connection Type: 3M Twist Lock (Shrader), Automatic Connect system (listing in attachment)

4.5.9.4. Carbon Monoxide Monitor is required to ensure safe and compliant respirator program.

4.5.9.4.1. The Carbon Monoxide Monitor shall be the Invertech CAM-900.

4.5.10. Notification system:

4.5.10.1. Breathing air system alarm

4.5.10.2. Fire alarm

4.5.10.3. Door alarm while in operation

4.5.11. Doorways/Openings:

4.5.11.1. Sealed to prevent dust escape or migration

4.5.12. Blast Door:

4.5.12.1. Sized to ensure fit Tallest AGE with a suggested minimum door height and width of

20ft

4.5.12.2. Sealed to prevent dust escape or moisture/outside dirt ingress

4.5.12.3. May be integrated in PEMB (preferred) or as an insert.

4.5.12.4. Door will be facing south towards wrap around road as shown in Appendix B

“General Layout.”

4.5.13. Grounding:

4.5.13.1. 2 Grounding points on/near centerline

4.5.13.2. All blasting equipment and components being blasted shall be properly electrically grounded in accordance with TO 00-25-172

4.5.13.3. Floor gates access panels should be located outside of the booth, where possible.

4.5.13.4. The blast booth must meet fire egress requirements per UFC 3-600-01

4.5.13.5. Noise level within appropriate OSHA levels in and around the booth and support facilities & spaces.

4.6. Blast Equipment

This section details the requirements for all equipment used in the plastic media blast process.

The equipment shall be designed for maintainability and reliability, ensuring consistent and efficient performance. The blast equipment shall be capable of effectively removing paint, primer, and corrosion from Aerospace Ground Equipment (AGE) without damaging the underlying material. Blast booth shall utilize Type V media (Acrylic Plastic) with a 3.5MOH hardness defined in the Technical Order 1-1-8.

4.6.1. General Requirements:

4.6.2. Requirement: All blast equipment shall be designed and constructed to meet all applicable safety standards.

4.6.3. Air Quality: Air shall be dried and filtered appropriately to prevent issues with the blast media or equipment.

4.6.4. Abrasion Resistance: All system transfer ducting shall be able to withstand abrasion from media

4.6.5. Ergonomics and Noise Reduction: Blast equipment shall be designed with noise reduction technology and ergonomics to promote the reduction of user fatigue and safety.

4.6.6. Blast Equipment:

4.6.7. Requirement: The blast equipment shall have 2 independent blast pots capable of blasting continuously for 15 minutes with no interruptions, with the following features.

4.6.7.1. The blast pots shall have capability to operate with media flow enabled or disabled (supplying compressed air only to the nozzle), selected for each pot independently from the Observation Room Programmable Logic Controller (PLC) screen or at the nozzle deadman trigger.

4.6.7.2. The blast pot pressure and the media feed rates shall be changeable for the individual blast pots, controlled from the Observation Room PLC using a supervisor-only pass code.

4.6.7.3. The blast pots shall be able to provide a calibrated and adjustable media flow rate between 0-15lbs/min with 0.1lb/min accuracy minimum, using an AccuFlow media metering valve, or equivalent.

4.6.7.4. The blast pots shall operate at a calibrated and adjustable pot pressure which provides 10-60 PSI at the blast nozzle with 2 PSI accuracy minimum.

4.6.8. Blast Hardware:

4.6.8.1. Nozzle- Marco #8 or equivalent

4.6.8.2. Triggers – standard deadman trigger

4.6.8.3. Media flow/air flow switch at nozzle

4.6.8.4. Hoses (Main and whip hose), sized to reach the full interior space, with room to move vertically as needed

4.7. Media Reclaim Equipment:

4.7.1. Requirement: Blast Booth shall utilize a pneumatic full floor media recovery system.

4.7.2. The media reclaim equipment shall be capable of efficiently and effectively reclaiming and cleaning used blast media for reuse.

4.7.3. Performance: The system shall be capable of processing and storing sufficient media to supply clean media to 2 blast pots operating simultaneously for 2 consecutive 8-hour shifts.

4.7.4. Media Quality: The reclaim system shall clean media to meet the standards in TO 1-1- 8 Section 2.12.

4.7.5. PLC Control: Equipment start/stop, appropriate adjustments, and monitoring shall be performed by the PLC/HMI in Observation area.

4.7.6. Waste Management: The waste generated during the reclamation of the media shall be consolidated into a single waste stream into a waste collection system that is independent of the booth ventilation system. Waste shall be consolidated into a palletized 55-gallon open head steel drum with bolt ring.

4.7.7. System Transfer: All system transfer ducting should be able to withstand abrasion from the media

4.8. Hoppers:

4.8.1. The system shall include a minimum of 2 media storage hoppers including a dirty and clean hopper. All media hoppers shall include the following:

4.8.2. Level sensors to detect media levels within the hopper. These shall be used to automatically start and stop reclaiming/recovery equipment as needed to keep the hoppers full. Hopper media levels shall be displayed on the Observation Room PLC.

4.8.3. Viewing windows to visually observe media levels.

4.8.4. Design to prevent media bridging.

4.8.5. Design to feed all blast pots evenly.

4.8.6. Self-feeding, with ability to physically close off media flow for maintenance.

4.9. Media Cleaning:

4.9.1. Timing adjusted from main PLC

4.9.2. Ionizer to reduce static in media

4.9.3. Vibratory classifier to sort media based on size

4.9.4. Dense particle separator to sort media based on density

4.9.5. Cleaned media should meet testing requirements in TO 1-1-8

4.9.6. Anti-static fluid sprayer to treat reclaimed media (optional)

4.9.6.1. Accessible refill point

4.9.6.2. Only when the media is flowing

4.9.6.3. Capability to adjust the amount of fluid sprayed

4.9.7. New media added to booth floor, special reload mode to speed recovery of new media (Floor gate control option)

4.10. Blast Booth Ventilation Equipment:

4.10.1. Provide 100 CFM minimum cross flow in blast enclosure

4.10.2. Produce negative pressure to minimize dust migration

4.10.3. Maintain temperature below 80 in summer and above 60 in winter with ventilation system on

4.10.4. Clean air into front of booth, evacuate dirty/dusty air at the rear of the booth

4.10.4.1. Balanced across booth cross section

4.10.5. Industrial grade ducting suitable for airflow requirements

4.11. Dust collectors:

4.11.1. Appropriate filters to remove dust from the air (generally main canister filters, pre- HEPA, and HEPA filters)

4.11.2. Differential pressure readings across each filter bank independently and across the filter stack up Route DP readings to PLC screen.

4.11.3. Automatic canister filter cleaning via blow-offs (Adjustable and monitored by Differential pressure readings)

4.11.4. Easy access to change filters

4.11.5. Sealed against weather/water intrusion

4.11.6. Screw auger to collect and transfer dust waste to 55-Gallon Open Head Steel Drum, bolt ring.

4.11.7. Explosion venting and protection per fire requirements

4.11.8. Blower fans, sized appropriately, with VFD to adjust if needed

4.11.9. Adjustable recirculation of dirty/clean air (automatically adjusted to meet temperature requirements)

5. MAINTENANCE OPERATIONS AREA (WEST PEMB)

This section details the requirements for the MX Ops area located on the west end of the PEMB. This area shall be sealed to ensure no blast media enters. The MX Ops Area will be designed to support current MX Ops with the potential for a second blast booth of equal size and equipment.

5.1. General Requirements:

5.1.1. MX Ops Area will have a minimum square footage of 3600 square feet. This allows a duplication of the east blast booth system with a potential blast booth door facing on the west side of the PEMB.

5.1.2. With exception to life safety requirements and the installation of one fire rated man door, Shall be completely sealed off from east side operations to ensure designation as a clean COLD space by appropriate Bioenvironmental and Safety Representatives.

5.2. Electrical:

5.2.1. As workload is yet to be determined for this area, 15 Amp 120v convenience outlets are to be placed at equal distances along the north and south internal walls in 10’ intervals.

5.3. Doors:

5.3.1. Main door shall be facing east with minimum dimensions of door opening 25’ tall and 20’ wide shall have power operations for opening and closing.

5.4. HVAC:

5.4.1. West PEMB shall have its own thermostat-controlled HVAC.

5.4.2. Target setpoint temperature to be 60 to 80 deg F unless otherwise noted.

5.4.3. Positively pressured to minimize dust migration from dirty/transition areas to clean areas.

6. DESIGN

6.1. All design services furnished by the Design-Build Contractor shall be performed under the direct supervision of a licensed Professional Engineer. The Contractor, through its designer, is responsible for the accuracy, adequacy, timeliness and professionalism of the design solutions and design documents. The Contractor shall ensure design solutions to meet the requirements of the contract documents. The Government welcomes opportunities that will allow the schedule to be brought to the left or mitigate risk. If opportunities are identified, the Government is willing to consider for approval. i.e.

procurement of long lead items during design development, deliver of design details early, manufacture of structural components, concurrent development and manufacturing or site preparations, etc.

6.2. Requirements include efficient project management including accurate, on-time submittals of contract deliverables and timely identification and solution of impediments to successful project execution. Technical requirements include early involvement in the process to allow for the development of the most cost- effective and technically sound solution. GPM will rely on the Contractor’s expertise in recognizing and addressing problematic issues and successful execution of this contract. The Contractor shall perform all work IAW federal, state, and local statutes and regulations.

6.3. The schedule shall be maintained and updated at least monthly to accurately reflect program progress and provide realistic forecasts. Unless approved by the Contracting

Officer (CO), the Contractor shall not begin construction on site until the 100% design package has been approved.

DESIGN STAGES DESIGN SCHEDULE TIMELINES

Concept Design (30%) 21 Calendar Days Government Review 7 Calendar Days Preliminary design submittal (60%) 40 Calendar Days Government Review 10 Calendar Days Pre-final design submittal (90%) 40 Calendar Days Government Review 10 Calendar Days Final Design Submittal 21 Calendar Days

6.4. Concept design (30%): The purpose of the concept design meeting shall be to verify design requirements and explain the designer’s approach to a solution. The concept design submittal shall include descriptions of the architectural, mechanical, electrical, and structural systems proposed. A building code survey, discussion of applicable codes, single line floor plan sketches as necessary and any potential conflicts shall be included.

The concept review may be presented by a design charrette /design meeting and shall consist of the following as a minimum:

6.4.1. Description of the Contractor’s understanding of the project requirements, description of the proposed architectural, mechanical, electrical structural systems, civil features and site utilities. Building code survey, description of the existing facility, and any other information needed to clearly express the designer’s intentions and methods.

6.4.2. Floor plans, bubble diagrams and sketches as required expressing spatial relationships.

6.5. Preliminary design submittal (60%): the general direction and details of the design shall be firmly established and clearly indicated at this design level. Drawings shall include basic floor plans, rough architectural details, preliminary mechanical electrical equipment and distribution layouts, schedules, tables and other information required to clearly illustrate the design. The preliminary design submittal shall include, at a minimum, the following information:

6.5.1. Test and survey results, complete design calculations, product and equipment data, and any other information required to clearly illustrate and describe the design.

6.5.2. Drawings to include basic floor plans, rough architectural and structural sections and details, preliminary mechanical and electrical equipment and distribution systems, preliminary elevations, schedules, and tables. Clearly show at this stage that the DMAFB CADD standards are being followed IAW DMAFB Facility Design Standard.

6.6. Final specifications, unedited but indicating which sections will be used.

6.7. Pre-final design submittal (90%): at this submittal stage all work shall be complete. This submittal is intended for approval only. The pre-final submittal shall include the following as a minimum:

6.7.1. Final design analysis including calculations as required.

6.7.2. Final drawings with all sections, details, elevations, schedules and tables completed.

6.7.3. Basis for design clearly described on first sheet of each discipline.

6.7.4. Final edited specifications.

6.7.5. Preliminary review comments, annotated with actions or responses.

6.7.6. Draft DD Form 1354.

6.8. Corrected final design submittal (100%) requirements. Unless otherwise approved the contractor shall not mobilize or start construction until the 100% (For Construction) submittal has been approved and construction Notice to Proceed has been authorized by the GPE. A final DD Form 1354 shall be completed and submitted with 100% design.

6.9. Submittals: Civil Design, Structure and Trailer Construction drawings/details shall be submitted to the Contracting Officer Representative (COR) according to design schedule. Drawings shall be in .dxf, .pdf, and 3D .pdf formats (as applicable). Product literature shall be submitted in pdf. format or standard contractor format upon approval.

No work shall proceed without approved submittals. Reviews will follow, at maximum, the schedule in SOW Para 6.3. If initial submittals are rejected, Contractor shall have 14 calendar days to resubmit from date of notification. The Government shall have 7 calendar days to review from date of receipt, unless otherwise negotiated. (CDRL A007) A design analysis shall be provided with design submittals incorporating all engineering computations, seismic analysis, test and survey results, building code review, fire protection analysis and calculations, structural load analysis and calculations, heating load analysis and calculations, energy code compliance documentation and all other similar pertinent information to clearly define the scope of the project and to express the designer’s intent and methods. The author of each section shall include professional seals and signatures when appropriate.

6.10. As Built Drawings: Record Drawings shall be provided to the COR and OO-ALC/OBP within 30 days after completion of work. Drawings must be complete, accurate and comply with current CAD standards. (CDRL A008)

6.11. The Government shall have the unrestricted right to use, modify, reproduce, release, perform, display, or disclose technical data associated with all designs, drawings, specifications, notes and other works developed and executed in the performance of this contract IAW DFARS 227.7102 – Commercial Items, Components or Processes and 252.227-7015 – Technical Data-Commercial Items. The Contractor for a period of three

(3) years after acceptance of the final phase of the project agrees to furnish all retained works at the written request of the CO.

6.12. Commercial Off-The-Shelf (COTS) Equipment Operations and Maintenance (O&M) Manuals: All hard copy sets included with the equipment and original electronic copies shall be provided to the COR. Any modifications to COTS equipment shall be documented and included as part of the submission. (CDRL A009)

6.13. If readily available include the following

6.13.1. Illustrated parts breakdowns

6.13.2. Exploded views

6.13.3. Compatibility literature

6.13.4. Troubleshooting guides

6.13.5. Wiring schematics

6.13.6. Maintenance checklists

6.13.7. Performance data

6.14. All equivalent or deviations from explicitly stated products shall be sent to the GPE for approval prior to installation.

6.15. The proposed configuration of clean and dirty spaces shall be presented to and approved by appropriate Bioenvironmental and Safety representatives.

7. TESTING/COMMISSIONING

7.1. After install, run for minimum of 80 hours with media flowing to flush out any installation issues

7.2. Demonstrate verification of accurate system calibration

7.3. Nozzle pressure, all pots (set and show reading at nozzle)

7.4. Feed rate, all pots (set and show accurate feed rate)

7.5. Nozzle pressure adjustments functioning

7.6. Ventilation airflow (show CFM)

7.7. Breathing Air verification

7.8. Pass Carbon Monoxide Monitor response check and calibration

7.9. Deadman Functioning all hoses

7.10. Cross flow verification

7.11. Verification of all associated equipment

7.12. Verifications of all safety functions

7.13. Alarms, E-stops, CO bump test

7.14. Blast condemned parts to demonstrate safe blasting per TO 1-1-8 and AGE specific

7.15. Blast 3 articles and address any issues that arise before final sign-off

8. DOCUMENTATION & TRAINING REQUIREMENTS

8.1. Operations and Maintenance Manual encompassing blast booth and associated equipment to include air compressors, HVAC, and facility.

8.1.1. Maintenance manual clearly states intervals of preventative maintenance and associated chemicals, lubrications, and equipment required to perform specified tasks.

8.2. Parts listing including manufacturer and model of all COTS items

8.3. Training for operations, maintenance, and troubleshooting to be provided

8.3.1. Method of delivery can be written or conducted with a schedule

8.3.2. Operations

8.3.2.1. Full walkthrough and during the commissioning process

8.3.2.2. Human Machine Interface training for operators

8.3.3. Maintenance

8.3.3.1. Walk through of maintenance required and task identification in the operations and maintenance manual

8.3.3.2. Human Machine Interface training for maintenance (If applicable)

8.3.3.3. Provide training on daily, monthly, bi-annual, annual inspects/maintenance.

8.3.4. Troubleshooting

8.3.4.1. Documentation on performing basic troubleshooting from an operator level. (E.G.

Nozzle adjustments, Media Recovery)

Appendix A (Definitions & Acronyms) Term/Acronym Definition ACM Air Changes per Minute ADA Americans with Disabilities Act AFCEC Air Force Civil Engineer Center AFI Air Force Instruction AFMAN Air Force Manual

AGE

Aerospace Ground Equipment: Equipment used to service, maintain, and support aircraft and other aerospace systems on the ground. This includes, but is not limited to, maintenance stands, tow bars, and specialized trailers.

AMARG Aerospace Maintenance and Regeneration Group

ASHRAE

American Society of Heating, Refrigerating and Air- Conditioning Engineers

ASTM American Society for Testing and Materials BACnet Building Automation and Control Networks

Blast Booth

An enclosed structure designed to contain the abrasive blasting process, protecting personnel and the surrounding environment from dust and debris.

CFPS Certified Fire Protection Specialist CO Carbon Monoxide

Cold Refers to a clean space, free from blast media contamination.

COR Contracting Officer Representative CRI Color Rendering Index

COTS

Commercial Off-The-Shelf: Commercially available products that require no special modification or customization.

dBA Decibels (A-weighted) DD Form 1354 Transfer and Acceptance of Military Real Property DFARS Defense Federal Acquisition Regulation Supplement DMAFB Davis-Monthan Air Force Base DOD Department of Defense DOT Department of Transportation

Duty Cycle The percentage of time a machine can operate within a given period without overheating.

FAR Federal Acquisition Regulation GPE Government Project Engineer HEPA High-Efficiency Particulate Air

HMI

Human Machine Interface: A user interface or dashboard that allows operators to interact with and control a system.

HVLS High-Volume, Low-Speed IBC International Building Code IES Illuminating Engineering Society IMC International Mechanical Code IPC International Plumbing Code LED Light Emitting Diode LPMC Lightning Protection Master Certification LPS Lightning Protection System MOH Mohs Hardness Scale

MX Ops

Maintenance Operations Area: The designated area within the PEMB structure intended for future maintenance and repair operations.

NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association

NIOSH

National Institute for Occupational Safety and Health

OSHA Occupational Safety…