Draft Earle Boxcar PWS.docx
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- Manufacture and Delivery of Quantity of 25 Railway Boxcars: U. S. Naval Weapons Station Earle, NJ
- Solicitation number
- 6913G625Q300022
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This Performance Work Statement (PWS) details a U.S. Department of Transportation procurement for 25 newly manufactured 50-foot railway boxcars and one automated single car test device for the U.S. Naval Weapons Station at Earle, New Jersey. The boxcars must meet specific technical requirements including a 50-year service life, 80-ton load capacity, wood floors, belt rail system, and compliance with Association of American Railroads (AAR) standards. The boxcars will be white-painted, feature sliding doors, specific dimensional requirements, and include 28 reflective markers.
The procurement is structured as a Small Business Set-Aside with two Contract Line Item Numbers (CLINs): CLIN 00100 for the 25 boxcars with delivery by August 31, 2026, and CLIN 00200 for the automated railcar air brake test machine with delivery by August 31, 2025. The solicitation will be competed among qualified small businesses with fewer than 1,500 employees, using the North American Industry Classification System (NAICS) code 336510. The government intends to award to one vendor using a best value evaluation approach, with the solicitation expected to be released within 60 days of the pre-solicitation notice.
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US DOT / Volpe V3352301
Performance Work Statement
50 Foot Damage Free (DF-Type) Railway Boxcars for NMCLANT Det Earle, Colts Neck, NJ
January 2025
Office of the Secretary, U.S. Department of Transportation Volpe National Transportation Systems Center Infrastructure Engineering and Deployment
Contents
| DESCRIPTION | 3 | |
| 1. | GENERAL | 4 |
| 1.2. | REFERENCE DOCUMENTS | 4 |
| 1.3. ORDER OF PRECEDENCE | 4 | |
| 2. | 50-FOOT DAMAGE FREE (DF-TYPE) BOXCARS | 4 |
| 2.1. | DIMENSIONS and LIMITS | 4 |
| 2.2. | DESIGN/ENGINEERING/FABRICATION | 5 |
| 2.3. | PERIOD OF PERFORMANCE | 5 |
| 2.4. | DELIVERY REQUIREMENTS | 5 |
| 2.5. | DOORS | 5 |
| 2.6. | TRUCKS | 6 |
| 2.7. | BRAKES | 6 |
| 2.8. | MECHANICAL DUNNAGE SYSTEM | 6 |
| 2.10. | DRAFT GEARS AND COUPLERS | 7 |
| 2.11. | PAINTING AND STENCILING | 7 |
| 2.11.1. | PAINT SPECIFICATIONS | 7 |
| 2.12. | QUALITY CONTROL | 8 |
| 2.13. | DRAWINGS AND DOCUMENTATION | 9 |
| 2.13.1. | Parts/Service Manual | 9 |
| 2.13.2. | Operator's Procedure Manual | 9 |
| 2.13.3. | Documentation Package | 9 |
| 2.14. | INSPECTION PROCEDURE | 10 |
| 2.14.1. | Inspection | 10 |
| 2.14.2. | Tests | 10 |
| 3. | Automated Single Car Test Device | 11 |
| 3.1 Description | 11 | |
| 3.2 Period of Performance | 11 | |
| 3.3 Delivery Requirements | 11 | |
| 3.4 Documentation Package | 11 | |
| Attachment 1: | 12 |
DESCRIPTION
The U.S. Department of Transportation, Volpe National Transportation Systems Center (Volpe Center), Cambridge, MA, 02142, is seeking to acquire general purpose railway boxcars as described herein. All boxcars shall be delivered to U.S. Naval Weapons Station Earle, Colts Neck, New Jersey and shipping costs shall be included in the CLIN price. All boxcar deliveries shall be within timeframe specified. It is noted upon delivery/acceptance for each railway boxcar the standard commercial warranty will begin.
| CLINs |
| Description |
| Quantity |
| Delivery |
| Unit Price |
| Total Price |
| 00100 |
| 50-Foot Boxcars, Delivered |
| 25 |
| 08/31/2026 |
| $___________ |
| $___________ |
| 00200 |
| Automated Railcar Air Brake Test Machine and Calibration Kit |
| 1 |
| 08/31/2025 |
| $___________ |
| $___________ |
1. GENERAL
The contractor shall provide the following items:
1. The contractor shall provide a quantity of twenty-five (25) 50-foot, damage free (DF –Type) railway boxcars with wood floors and belt rail equipped, with a load capacity of no less than 80-tons and a service life of 50-years according to AAR when manufactured new. All boxcars shall be delivered to U.S. Naval Weapons Station Earle, Colts Neck, New Jersey.
2. The contractor shall provide a quantity of one (1) automated single car test device used for testing and evaluation of Railway freight car air brake systems. The device shall meet AAR specification S-4027.
1.2. REFERENCE DOCUMENTS
The railroad boxcars must satisfy all the following documents in effect at the time of this procurement:
1. Association of American Railroads (AAR) Manual of Standards and Recommended Practices
2. AAR Interchange Rules
3. The Official Railway Equipment Register
4. Code of Federal Regulations (CFR) 49, Transportation
5. American Society for Testing and Materials (ASTM) A53
6. American Welding Society (AWS) D15.1
7. American Iron and Steel Institute (AISI) Standards
8. AAR M-976, Truck Performance for Rail Cars
9. NAVSEA SW023-AK-SAF-010
10. Existing Crossmember Exhibits (1) through (4) Attachment-1
1.3. ORDER OF PRECEDENCE
The Order of Precedence is established in FAR 52.212-4. In addition to the Order of Precedence set in FAR 52.212-4, if there is a conflict between the text of this document and the references cited above, the text of this document takes precedence.
2. 50-FOOT DAMAGE FREE (DF-TYPE) BOXCARS
All boxcars offered shall be newly manufactured for this effort. This includes all dated components. All cars proposed must meet the requirements of this PWS and must have a 50-year lifespan. The following specifications are applicable to the 50-foot boxcars. The Government is seeking boxcars similarly sized and configured to the boxcars identified in this specification. The dimensions presented in this document, unless otherwise stated, are dimensions taken from the existing boxcars for reference. Any proposed lengths and distances that are different from the dimensions specified in this document must be presented for review and approval prior to award. External dimensions have a greater need of being the same as the dimensions provided herein.
2.1. DIMENSIONS and LIMITS
1. Extreme width: Highly desirable to be no wider than 10’-3” (123 inches)
2. Extreme height: No taller than 14’ – 3” (171 inches) from top of rail
3. Length: 50’ nominal boxcar classification length
4. Deck (platform) Height (empty car, from top of rail): 43 – 44 inches
5. Coupler Height: 2’ - 11” (35 inches) from top of rail to the coupler
6. Minimum Gross Rail Load: 263,000 pounds, 286,000 pounds is acceptable
7. Minimum Capacity requirement: 80 Ton (160,000 pounds)
8. Light Weight (LT WT): determined by design
9. AAR Mechanical Designation: XL
10. AAR Car Equipment Type Code: A330
11. Minimum coupled curve negotiation: 255 feet radius (23 degrees)
2.2. DESIGN/ENGINEERING/FABRICATION
| 1. | The boxcars shall be manufactured from materials conforming to AAR and ASTM specifications. |
| 2. | All boxcars must satisfy all AAR Interchange requirements at time of delivery. |
| 3. | The boxcars shall be commercial standard 56-½ inch rail wheel gauge and shall meet or exceed AAR design specifications and Code of Federal Regulations, 49CFR Part 231 – Railroad Safety Appliance Standards). |
| 4. | The boxcar inside walls shall have thirty-two (32) anchor belt rails permanently attached. See Belt Rail Section below. Wood wall lining fabricated from ¾-inch external commercial grade plywood on inside walls and between belt rails is required. |
| 5. | All boxcars offered shall be similar by size, type, deck height, doors, age, and volume. |
| 6. | Prior to any work/re-work, the Government reserves the right to inspect and accept or reject previously manufactured boxcars planned for this procurement. |
| 7. | All work to be accomplished for the deliverables associated with this work statement shall be performed by an AAR certified rail shop with these current active certificates: AAR M-1003 Quality Assurance certificate and AAR S-2034 Car Builder Certification. |
| 8. | The Vendor shall provide a Quality Assurance Plan which identifies the process used to assure product quality as it relates to this effort. |
9. Standard boxcar roof galvanized steel per AAR shall be used.
2.3. PERIOD OF PERFORMANCE
All boxcars shall be delivered by 08/31/2026.
2.4. DELIVERY REQUIREMENTS
Delivery of boxcars to destination shall be by railroad. Each boxcar shall be prepared for delivery in accordance with AAR requirements for Interchange Service. The USN car ID Road Numbers will be provided at a later date.
Final acceptance of boxcars will be at U.S. Naval Weapons Station Earle, Colts Neck, New Jersey. Acceptance will require inspection for carrier damage and proper operating condition of doors and other functions at the destination prior to any payment to the contractor. The delivery destination is:
Conrail Interchange, at Receiving Yard on board U.S. Naval Weapons Station Earle, Colts Neck, New Jersey. Receiving Customer Address:
NMCLANT DET EARLE
201 Highway South BLDG C-9 NWS Earle Colts Neck, NJ 07722-5017
2.5. DOORS
1. All boxcars shall have sliding doors centered on both sides of the superstructure.
2. The minimum door opening shall be 10’ – 2” (122 inches).
2.6. TRUCKS
1. Each boxcar superstructure shall be mounted on two 2-axle trucks.
2. Reconditioned trucks side frames and bolsters may be used.
| 3. | The trucks and truck components shall be suitable for a gross rail load (GRL) of at least 263,000 pounds on four axles per boxcar. Trucks shall have manganese steel vertical liners. |
| 4. | Wheels shall be new, one-wear, 36-inch diameter, heat-treated, curved plate, cast or wrought steel and appropriate for the truck capacity. Under any circumstances, wheels must satisfy acceptance inspection criteria at destination. |
| 5. | Axles and roller bearings for each boxcar shall be of appropriate size and capacity for each boxcar type and meet all AAR requirements. |
| 6. | The spring travel shall be in accordance with truck design capacity and deck height desired. Truck spring grouping in accordance with truck design. |
| 7. | Each car shall be equipped with AAR approved constant contact or constant contact/roller combination side-bearings adjusted to AAR specifications. |
| 8. | Center bowl diameter to be appropriately sized for gross rail load of boxcar per AAR. |
2.7. BRAKES
| 1. | Air brakes, single capacity, providing constant braking force. The control valve shall be ABDX or newer design approved for use by the AAR and shall incorporate a four-port receiver for an automated single-car test. High friction composition brake shoes shall be used in accordance with latest AAR requirements. |
| 2. | The car brake piping system shall conform to ASTM A-53 schedule 80 or latest revision and shall meet the requirements of AAR and shall be installed in a location protected from accidental damage during side loading operations. |
| 3. | Boxcars shall pass testing as specified in AAR Standard S-486 Single Car Testing Device - Code of Tests for Freight Car equipment. |
| 4. | Net air brake and hand brake force, as determined by a static brake test, shall conform to AAR standard S-401. |
| 5. | The hand brake shall be end-mounted and comply with 49CFR 231.27. |
| 6. | Brake beams shall be of the unit type and brake head to reject cast iron shoes. |
| 7. | Brake air reservoirs shall conform to AAR requirements. |
| 8. | Boxcar brake cylinders having 12” total travel shall have travel of 7 1/2” +/-1/4” travel at acceptance. Automatic double acting slack adjusters shall be used. |
| 9. | Chains used in the braking system shall be confined only to the handbrake linkage. |
| 10. | Cars shall be equipped with AAR approved air brake hoses long enough to safely negotiate curves and coupler travel. The air hose and end arrangement shall be in accordance with AAR standards. |
2.8. MECHANICAL DUNNAGE SYSTEM
1. DF System shall be comparable with MIL-STD-1320D and compatible with existing dunnage bars currently in use at U.S. Naval Weapons Station Earle.
2. The inside dimensions of the DF Type boxcar are: length, 50 feet 6 inches between end walls; width, 8 feet 11 inches between wall members; and height, 10 feet at the eaves. Each car contains, as standard equipment, thirty-two (32) horizontal permanently mounted steel rails along the length of the boxcar from the door opening to the end wall.
3. Each rail shall be one continuous length.
4. Height of each rail shall be 10, 24, 30, 36, 48, 60, 72, and 84 inches above finished floor height.
5. Rails shall accommodate crossmember bar adjustment in one (1) inch increments along the horizontal plain of each rail.
6. Existing crossmember is adjustable from 105 inches to 109 inches.
7. Note: Attachment-1: Reference 11 - photos of existing crossmember bars.
2.9. BOXCAR FLOORING
1. Flooring shall consist of nominal 5.5” wide tongue and groove yellow pine or similar (not hardwood) that can be used for nailing and fastening blocking material and in conformance with AAR Manual of Standards and Recommended Practices, Section A, Part II, Specification M-907, Group IV. Wood decking to be applied per AAR requirements.
2. Floor Minimum Load Rating 25,000 pounds per square foot, (25K).
2.10. DRAFT GEARS AND COUPLERS
| 1. | Couplers shall be AAR approved Type-E bottom shelf design. |
| 2. | Cars shall have manganese steel coupler carrier wear plates (no nonmetallic wear plates allowed). The uncoupling arrangement shall be such that an AAR-approved replacement coupling rod can be applied without modification to the car body or uncoupling device support brackets. |
| 3. | Cars shall be equipped with mechanical draft gears offering 3.5 inches of travel. No end-of-car hydraulic valve cushioning devices are to be installed on the boxcars. |
| 4. | Knuckles shall be of reduced slack design. |
2.11. PAINTING AND STENCILING
1. Contractor shall follow AAR Requirements for surfaces that are not to be painted.
2. Placards, four per railcar, permanently fixed as specified in NAVSEA SW023-AK-SAF-010 and 49 CFR part 172.510 (one on each A & B End, and one each side). No less than 13.5 inches square in size. Each placard shall have seven metal flip indicator signs on white background identifying the following: Explosive 1.1, Explosive 1.2, Explosive 1.3, Explosive 1.4, Dangerous, Empty, Inert (an example of the type is: Labelmaster Style 81SF-7).
3. Newly galvanized steel shall not be painted.
2.11.1. PAINT SPECIFICATIONS
| 1. | Paint Specifications shall conform to AAR Standard M-1001 Section C, Part II, Section 5.2, and current industry practices. |
| 2. | Paint classification shall be Urethane or equal and follow the Federal Color Standard: 595B |
White # 27886 Black # 17038 Gray # 26270 Yellow # 13591
3. Primer shall be urethane compatible Substrate: Primed Steel Pre-treatment: Sandblasted
4. Application to Boxcars Car body: White (exterior) Trucks: Fog coat only Ladders, handholds, steps, brake wheels and levers: Black Alkyd Enamel (TT-E-1 593 B or equivalent) Stenciling: Black “United States Navy” located on both sides of boxcar on one side of the sliding door and “USN (followed by Road Number that will be provided at a later date)” on both sides of car on the other side of the sliding door.
| 5. Interior wood wall lining seal coated clear. | |
| 5. | Reflective surfaces applied to A and B ends, and on both sides extending from the ends at least 8-feet towards the center. |
| 6. | A consolidated stencil with appropriate brake maintenance information shall be attached to the cars. |
| 7. | Grab irons and steps shall be painted yellow. Only component supplier will paint telescoping portions of uncoupling lever. |
| 8. | Anti-skid deck-covering compound shall be applied to the metal steel deck plate before painting. Decks made of wood or anti-skid material do not require anti-skid coating. |
| 9. | Stenciling and markings shall be done with AAR approved contrasting-color materials. White paint stenciling must be of a consistency to cover black background thoroughly and provide a sharp contrast that will remain legible for a minimum period of 96 months. Stenciling on each end of car shall be done with black paint and will include but not be limited to identification of couplers, wheels, end-of-car cushioning, springs, and snubbers. "JACK HERE" and "LIFT HERE" stencils shall be applied at the appropriate places. Additional markings including loading and weight dimensions (LT WT and LD LMT) shall be in accordance with AAR Section L– Lettering and Marking of Cars, as applicable. Adhesive backed film markings must be applied at surface temperatures between 40- and 100-degrees Fahrenheit. |
10. In addition to AAR Reflectorization markings, there shall be twenty-eight (28) reflective markers (quantity of 14 red color and 14 amber color) attached to each boxcar with the following characteristics:
a) Have a minimum reflective diameter of 4-inches
b) Be of armored/protected type by enclosed in a steel or aluminum housing
c) Four markers to be installed on each end of the boxcars and ten markers installed on each side of each boxcar superstructure (see reference pictures)
d) Stencil arrangement drawing to be submitted for approval prior to stenciling
Pictures provided for reflective marker reference locations
2.12. QUALITY CONTROL
| 1. | Structural members shall be free of notch sensitive areas and discontinuities that could result in highly localized stress concentrations. |
| 2. | Welding shall be in accordance with AWS D15.1 and AAR section C, part II, volume 1 - Specifications for Design, Fabrication, and Construction of Freight Cars, M-1001. The surface of parts to be welded shall be free from rust, scale, paint, grease, and mill scale or other foreign matter that can be removed by chipping and wire brushing. Spot, tack, or intermittent welds for strength will not be permitted. Weld penetration shall be such as to provide transference of maximum design stress through the base metal juncture. Fillet welds shall be provided to reduce stress concentration. |
| 3. | Unless otherwise specified in the contract or purchase order, the contractor is responsible for the performance of all inspection requirements (examinations and tests) as specified herein. Except as otherwise specified, the contractor may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any of the inspections set forth in the specification where such inspections are deemed necessary to ensure supplies and service conform to prescribed requirements. |
| 4. | The contractor is responsible for ensuring that components and materials used are manufactured, examined, and tested in accordance with referenced specifications and standards or for providing evidence that AAR has previously approved the components. |
2.13. DRAWINGS AND DOCUMENTATION
The boxcar design shall be provided with a Parts/Service Manual, Operator’s Procedure Manual, and Documentation Package. The following shall be submitted to the contracting officer upon delivery:
2.13.1. Parts/Service Manual
The boxcar parts/service manual shall be designed to provide quick access to information for the experienced and novice user. The parts/service manual will provide parts pages and component illustration pages and shall provide a description for all mechanical assemblies and all special tools required to perform repairs if failure occurs. Safety will be announced when describing procedures that have the capability to cause damage to equipment or harm personnel. This description shall describe and illustrate the assembly and/or subassemblies contained in all main assemblies. The subassemblies will be illustrated in exploded view style and the breakout of parts will be cross-referenced by item number to provide identification by name and part number and quantity required. The part number is the manufacturer's number for the component. The manual will also contain a description and part number for special tools required for the removal/replacement of assemblies and sub-assemblies. Manual quantities are described in the following Sections.
2.13.2. Operator's Procedure Manual
The Contractor shall supply a stand-alone Operator's Procedure Manual. The boxcar Operator's Procedure Manual will contain a step-by-step process to operate all systems and assemblies. This shall include all safety warnings and safety related operations. Manual quantities are described in the following sections.
2.13.3. Documentation Package
The documentation package to be submitted shall consist of two hard copies and two electronic copies of the following:
1. Component (part) identification
2. Maintenance Manual (including troubleshooting guide)
3. Operator's Procedure Manual (described above)
4. Parts/Service Manual (described above)
5. Identification and results of all certifications, tests, repairs and inspections NOTE: All electronically formatted documentation shall be compatible with Adobe Acrobat Reader and can be electronically reproduced for Government use.
2.14. INSPECTION PROCEDURE
2.14.1. Inspection
Each boxcar shall be examined for, but not limited to, the following characteristics:
1. AAR M-1003 Certification for Activity Code A20 (Manufacturer of Freight Cars) and AAR S-2034 Car Builder Certification from Vendor performing the boxcar construction.
2. Boxcars shall safely negotiate track curvature as specified.
3. All boxcar’s dimensions and paint as specified.
4. Materials resistant to corrosion and deterioration or treated to be resistant to corrosion and deterioration in the applicable storage and operating environments.
5. Contractor provides required manuals and documentation identifying materials, material finishes or treatment.
6. Safety appliances as required per AAR.
7. Painting and markings.
8. Design and construction in accordance with AAR/FRA requirements.
9. Brake equipment as specified.
10. Wheels with unacceptable defects. In this situation, the car will not be acceptable until repaired.
2.14.2. Tests
1. Any tests required by AAR shall be in accordance with AAR specifications, and as specified herein. No specific order of testing is required. All tests listed below will be conducted at the contractor’s designated location.
2. The entire air brake system shall be tested to ensure correct functioning of all components. The boxcar shall be tested with a single car-testing device in accordance with AAR Standard S 486 Single Car Testing Device Code of Tests for Freight Car Equipment or AAR Standard S-4027 Automated Single-Car Test Equipment. The brake cylinder piston travel shall be as specified in S 400, Specification No.2518 Freight Car Brake Equipment, and Installation Specifications and shall be tested for interference and correct travel. Nonconformance to AAR requirements shall constitute failure of this test. A braking force test in accordance with AAR requirements shall be conducted to determine brake shoe pressure at each wheel.
3. The hand brake shall be tested in accordance with AAR requirements to determine the brake shoe pressure at each wheel. Nonconformance shall constitute failure of this test.
4. The side bearings shall be tested with the car on level tangent track and the car body level. Side bearing clearances shall be measured at each bearing. Nonconformance to manufacturer's, AAR or CFR Title 49 clearance limits shall constitute failure of this test.
3. Automated Single Car Test Device
3.1 Description
The contractor shall provide one (1) portable cart mounted automated single car test device that is used for the testing and evaluation of railway freight car air brake systems as used in North American interchange service and governed by AAR. The device will be used to facilitate the testing of pneumatic brake equipment to AAR specification S-4027. The contractor shall also provide a calibration kit for the automated single car test device.
3.2 Period of Performance
The automated single car test device shall be delivered by 08/31/2025.
3.3 Delivery Requirements
The delivery destination is:
Conrail Interchange, at Receiving Yard on board U.S. Naval Weapons Station Earle, Colts Neck, New Jersey. Receiving Customer Address:
Russ Wicks Bldg C-50, 201 NWS Earle, Hwy 34, Colts Neck NJ, 07722-5018
3.4 Documentation Package
The automated single car test device shall be provided along with a standard documentation package including a parts/service manual and an operations procedure manual.
Attachment 1: Reference 11, Photos of existing crossmember bars.
Belt Rail
Belt Rail hole dimensions
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