SOW_Fac1434-1437-1464_RollUpDoorsMotors_15Nov2017.pdf

DATE: NOV 2017

31stCES/CEOER 1

U.S. AIR FORCE

31ST FIGHTER WING

31ST CES/CEOER

AVIANO AIR BASE, ITALY

SCOPE OF WORK FOR

REPLACE ROLL UP DOORS MOTORS KITS

AT FAC. 1434-1437-1464

AREA F, AVIANO AB, ITALY

31stCES/CEOER 2

1 SCOPE OF WORK

The Contractor shall provide all necessary works not limited to the following as labor, equipment, materials, supervision and transportation to accomplish all works outlined in the Statement of Work (SOW). All removals and installations will be accomplished within the designated work site that are Buildings 1434-1437-1464, Area F, Aviano Air Base, Italy.

The purpose of this project is to remove and dispose the existing q.ty19 roll up doors motors kit, installed in Fac.1434-1437-1464 door gates, and install new roll up doors motors kit including all required ancillary activities and finishing works.

Contractor work, inside the facility, shall be coordinated with contracting officer in order to not affect normal activities at Buildings 1434-1437-1464.

The Contractor shall provide CONS a detailed work schedule after contract award (the works are not required to be performed at the same time at all the facilities and there are not particular phasing requested).

2 WORK SITE CONDITIONS

a. The Contractor is permitted to use reasonable quantities of available electricity and water at the work site. The Contractor shall alter characteristics and shall observe conservation practices at all times. All the utility connections shall be the responsibility of the Contractor including restorations to initial conditions;

b. Authorized work hours and days: Performance of work hereunder shall be from Monday through Friday excluding US and IT holidays from 08.00 to 17.00 hours (to be confirmed by Contracting Officer). Work during weekends or holidays may be requested by the Contractor, with a minimum 15 days advance notice, however the Contracting Officer Representative (COR) has the right to deny such request if reasons requiring weekend and holiday work are not valid or for security or other necessities. A proposal work schedule will be submitted by the Contractor for C.O. approval;

c. Toilet facilities in the vicinity of the work site shall be available for Contractor use. The Contractor shall use facilities in a manner to maintain their state of cleanliness and hygiene;

d. If welding is to be performed the Contractor shall ensure a welding permit is obtained from the Aviano Air Base Fire Department prior to performing welding operations;

e. The Contractor shall not use base refuse containers to discard debris. All construction debris shall be discarded by the Contractor off base at authorized sites according to category of debris/refuse in strict observance of all host country laws, decrees and local regulations in force;

f. The Contractor shall be responsible for ensuring all personnel engaged in the performance of this contract observe all host country laws concerning safety and in particular D. lgs. 81/2008 and latest reviews. The Contractor shall prepare a site-specific Plan for Operational Safety (POS) IAW D. lgs 81/08. Electronic copies of safety-related plans and documents shall be transmitted to 31FW.SEG@us.af.mil <mailto:31FW.SEG@us.af.mil>. Contractor shall attend a pre-performance briefing on applicable regulations prior to starting works.

31stCES/CEOER 3

g. It will be contractor responsibility to guarantee the area clean separating working areas from other people used building areas. Protection with adequate barriers and polyethylene sheets will be used by contractor in order to avoid to damage or get dirty to any other facility equipment & furniture. Furthermore contractor shall maintain the area clean as much as possible and remove resulting material daily.

h. At least 5 days prior to the pre-final inspection, the Contractor shall furnish to the Contracting Officer all installed equipment operation and maintenance documentation, manuals, as built drawings, warranty, certificates of conformity concerning installed systems as required by host country laws, test reports and results, close out documentation, certifications according DM 37/08.

3. WORK DESCRIPTION

All the quantities that are indicated or successively added are estimates. Therefore the government shall be not held responsible for the accuracy of the estimated quantities.

The contract requires a completed project on a lump sum basis. It is therefore the responsibility of the contractor to calculate, foresee and perform all quantities and work necessary even if not mentioned in the specifications but included in the drawings and/or are manifested, in order to deliver a complete project based on its overall scope.

Each item of the schedule is inclusive of furnishing and installation of materials and equipment, profit and over-head, scaffolding and/or lifting system, transportation to dump including dump fees, or storage of demolished and/or removed materials, in accordance with contracting officer's instructions in order to perform all finishing works required and to make each item completed in a workmanlike manner.

The contractor is required to perform a fully finished workmanlike job including all accessories, materials, devices, activities also not here specifically mentioned in order to replace the existing roll up doors motors kit installed into the following buildings at Area F of the USAFE Aviano AB with a new roll up doors motors kit in accordance to CEI- EN, UNI standards and Italian national laws and safety Italy/EC law in force:

-q.ty 10 roll up door motors kit at Fac.1434;

-q.ty 6 roll up door motors kit at Fac.1437;

-q.ty 3 roll up door motors kit at Fac.1464.

The supplied equipment and the installation performed shall be according the Italian and European laws and standards, in particular to the following here below listed:

a) CEI 64-8;

b) DM 37/08;

c) 1999/5/EC R&TTE Directive;

d) 2004/108/EC Electromagnetic compatibility directive;

e) 2006/95/EC Low-voltage directive;

f) EN 12453 Safety requirements for motorized doors;

g) EN 12445 Test procedures for motorized doors.

31stCES/CEOER 4

3.1 REMOVAL AND DISPOSAL

3.1.1 Removal and disposal existing doors motorized systems for Facility 1434

a. Uninstall/remove the existing q.ty 10 roll up doors motors kits each composed by:

-existing doors control panels;

-existing control/command/signal devices as limit switches, sensors, pushbuttons, semaphore etc;

-existing single-phase motors and relevant mechanical supports, transmission chain, gear wheels (crowns fixed on doors rotation axis), drive chain, manual un-lock with chain;

-existing 1-phase circuit breakers and boxes;

-cables connection and conduits where no more used;

-other minor accessories/equipment not more reused.

NOTE: the hardwire connections from/to the console remote console panel will remain in place and will be re-connected to the new door motors control systems in order to permit the centralized movements of all the new motor doors remotely.

Roll up doors kits are installed on column beside each door as per below elevation layout:

Fac. 1434 Elevation view layout

31stCES/CEOER 5

The existing protective cables conduit system, as per below pictures, could be not removed where it will be re-used for new cables connection installation from new SEP03 circuit breakers to new doors control panels and downstream new sensor & devices.

Typical existing control panel Fac.1434 Typical existing door motor Fac.1434 SEP03 electric panel

Contractor in any case will provide and install eventual all needed additional PVC IP55 protective conduits with the adequate diameter for the connection of all new equipment/sensor/devices required for the correct operations of the new systems supplied.

b. Uninstall/remove/ Dispose off the base, including dump fees, the existing q.ty 2 feeding line circuit breakers 4p 10A 6kA installed in panel SEP03 (installed at the base of Fac.1434 east wall) and relevant cables connection up-to the above mentioned door motors single-phase circuit breakers.

Existing cable route run at about 6m height upper the doors (those have dimensions LxH=about 4.5x5.5m each) along all the Fac.1434 north wall for q.ty5 doors and along Fac.1434 south wall for other q.ty5 doors) considering the below layouts:

31stCES/CEOER 6

Fac. 1434 Plan view layout

c. Dispose off the base the removed q.ty 10 roll up doors motors kits, the related control panels, the relevant downstream existing devices (as limit switches, sensors, commands etc) and circuit breaker, relevant connections, accessories etc no more re-used.

The disposal shall be done at authorized dump sites, including dump fees, according to waste category of debris/refuse in strict observance of all host country laws. The disposal activities will include but not limited also to transportation, charging/discharging and classification of the waste typology.

31stCES/CEOER 7

3.1.2 Removal and disposal existing doors motorized systems for Facility 1437 a Uninstall/remove the existing q.ty 6 roll up doors motors kits each composed by:

-existing control panels;

-existing control/command/signal devices (as limit switches, sensors, pushbuttons, semaphore etc);

-existing 3-phase motors and relevant mechanical supports installed on transmission axes, manual un-lock with chain;

-cables connection and conduits where no more used;

-other minor accessories/equipment not more re-used;

Fac. 1437 Elevation view layout

Fac. 1437 Plan view layout

31stCES/CEOER 8

The existing protective conduit system, as per below pictures, could be not removed where it will be re-used for new cables connection installation to new doors control panels and downstream new sensor & devices.

Typical existing control panel Fac.1434 Typical existing door motor

Contractor in any case will provide and install eventual all needed additional PVC IP55 protective conduits with the adequate diameter for the connection of all new equipment/sensor/devices required for the correct operations of the new systems b Dispose off the base the removed q.ty6 roll up doors motors kits, the related control panels, the relevant downstream existing devices (as limit switches, sensors, commands etc) and accessories etc no more re-used.

The disposal shall be done at authorized dump sites, including dump fees, according to waste category of debris/refuse in strict observance of all host country laws. The disposal activities will include but not limited also to transportation, charging/discharging and classification of the waste typology.

31stCES/CEOER 9

3.1.3 Removal and disposal existing doors motorized systems for Facility 1464

a. Uninstall/remove the existing q.ty 3 roll up doors motors kits each composed by:

-existing control panels;

-existing control/command/signal devices (as limit switches, sensors, pushbuttons, rotating blinking light etc);

-existing 3-phase motors and relevant mechanical supports, transmission chain, gear wheels (crowns fixed on doors rotation axis), drive chain, manual un-lock with chain;

-cables connection and conduits where no more used;

-other minor accessories/equipment not more reused.

Fac. 1464 Elevation view layout

Fac. 1464 Plan view layout

31stCES/CEOER 10

The existing protective conduit system, as per below pictures, could be not removed where it will be re-used for new cables connection to new doors control panels and downstream new sensor & devices.

Typical existing control panel Fac.1464 Typical existing door motor

Contractor in any case will provide and install eventual all needed additional PVC/metallic IP55 protective conduits with the adequate diameter for the connection of all new equipment/sensor/devices required for the correct operations of the new systems

b. Dispose off the base the removed q.ty 3 roll up doors motors kits, including dump fees, the related control panels, the relevant downstream existing devices (as limit switches, sensors, commands etc) and relevant connections, accessories etc no more re-used.

The disposal shall be done at authorized dump sites according to waste category of debris/refuse in strict observance of all host country laws. The disposal activities will include but not limited also to transportation, charging/discharging and classification of the waste typology.

31stCES/CEOER 11

3.2 NEW ISTALLATION

3.2.1 Supply and install new doors motorized systems for Facility 1434

a. Supply and install q.ty 2 feeding line circuit breakers 400V 50Hz 4p 32A 6kA curve type C with differential protection 30mA (type B or other suitable for the load characteristic without inopportune service interruption), to be installed in panel SEP03 (installed at the base of Fac.1434 east wall) each one used to feed q.ty5 roll-up door motors kit (one circuit breaker for each q.ty5 motors kits feeding lines at each building side);

b. Supply and install q.ty 2 feeding line cables FG16OR16 0.6/1kV 5G10sqmm (or 4x10sqmm+1G10sqmm) in accordance to Costruction Product Regulation in existing cable route at about 6m height upper the doors along all the Fac.1434 north wall for q.ty5 doors (for about 70m) and along Fac.1434 south wall for other q.ty5 doors (for about 100m).

The connection lines will be completed with q.ty10 downline cables connections (q.ty 5 for each door wall side) FG16OR16 0.6/1kV 5G4sqmm (or 4x4sqmm+1G4sqmm) from door upper line up to each control panel and motors (for about 6m each) providing conduits, junction boxes and accessories where existing ones are not more suitable;

c. Supply and install of new q.ty10 circuit breakers 400V 50Hz 4p 10A 6kA curve type C each completed of PVC protection box IP55 to be installed on each columns (at about 1.6m height) in order to feed and protect individually each roll-up door motor kits;

d. Supply and install of new q.ty10 roll up doors motors kits each one composed by IP54 components as per following items:

-q.ty1 new 3-phase motors 400V 50Hz in accordance to Machinery Directive No 89/392/EEC and its amendments, weather protection, high-starting torque, reversible type with adequate rated power and adequate rated torque to retract and extend the sectional door (each one with dimensions LxH=about 4.5x5.5m and weight of about 300kg) in either direction from any position. Provide a motor to produce a door travel speed of not less than 200 mm or more than 300 mm per second (in any case to be in accordance to the safety standards in force) without exceeding the rated capacity. Motors shall be operate on current of the characteristics indicated at not more than 3000, connected to the rotating axes by means of gear wheel and not directly fixed on it.

-q.ty1 set complete for mechanical hardware of motor and equipment, supports as needed, transmission motor chain, gear wheels (fixed on doors rotation axis and on motor), accessories and installation materials in order to reach the adequate door movement speed and safety operations;

-q.ty1 manual un-lock system with chain able to permit to manually raise and lower the door in case of motor kit fault. The chain system will be completed by adequate stretch pulley installed at about 1m height and safety system in order to avoid door dropping during manual operations;

- q.ty1 new control panels, hard shock resistant case, feed at 3-phase 400V 50Hz or 1-phase 230V 50Hz with adequate internal transformer to safely convert the voltage for control use if needed, able to perform dead-man commands or automatic opening/closing commands in accordance to the last safety standards by means limit switches and photocells signals and by means of adequate programming.

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Moreover the connected safety device on the bottom edge shall immediately stop and reverse the door movement during the closing travel upon contact with an obstruction in the door opening or upon failure of any component of the control system. Panel will be electrically sectioned by proper disconnector device mounted on panel or externally.

NOTE: the new control panels shall have the feature to be managed remotely by existing hardwired connection from existing remote console;

- q.ty1 new set push buttons (open/close/stop as required by Machinery Directive No 89/392/EEC) full-guarded against accidental touch, also integrated in the control panel but installed at accessible height of about 1.6m, able to perform opening/closing/stop by momentary pressure (in automatic mode) or by means constant pressure (in dead-man mode);

-q.ty2 new photocell limit switches for each door to be positioned at different height in order to detect the front shape of AAB fire department trucks on two different height position (detailed positioning will be defined on place);

-q.ty1 set new connection to all existing doors limit switches, functional devices and safety device on the bottom edge of the electrically-operated doors. These new connections to be provided to control panel complete of IP55 PVC protection conduit system;

-q.ty1 semaphore with green and red LED lamps, anti-shock resistant (with adequate diameter to be clearly recognized by truck operator, connected to control panel in order to safely indicate the permission to proceed or stop the fire truck in accordance to the door position, to be installed at height adequate to be visible at truck operator height (detailed positioning will be defined on place);

-q.ty1 set connections to all above mentioned devices, but not limited to them in order to accomplish a full workmanlike manner work, completed with adequate cable connections and IP55 PVC protection conduits and accessories like flexible conduits, junction boxes, cable glands etc as needed;

e. Provide the repositioning of remote console into room 113 about 8m from the actual position providing an adequate IP55 PVC junction box with terminal strips, and extension multipoles in accordance to Costruction Product Regulation LSOH cables in dedicated IP55 PVC conduits in order to extend the existing cables from the actual remote console position up to the new position. The exact final installing position will be defined on site. Provide re-connections from/to all above mentioned motor door control systems to the existing remote console (through existing cables and their extensions) and ancillary activities (including eventual replacement of broken minor components) in order to restore in service the remote console. Provide the refurbishing of the existing control panel components where needed in order to permit the correct functioning. The existing remote console will open/close separately door by door by pushbuttons or will open/close all north or all south doors by selectors as per following picture:

31stCES/CEOER 13

Existing Remote Console commands Existing Remote Console internal wiring and relays

f. Provide the cleaning and new greasing of existing doors rotating mechanism and door guides, checking and correct as needed the tight and position of supports, chains, guides, mechanism, bolts and fixing system in order to deliver a complete workmanlike job of entire door motorized system.

3.2.2 Supply and install new doors motorized systems for Facility 1437

a. Supply and install of new q.ty 6 roll up doors motors kits each one composed by IP54

-q.ty1 new 3-phase motors 400V 50Hz in accordance to Machinery Directive No

89/392/EEC and its amendments, weather protection, high-starting torque, reversible type with adequate rated power and adequate rated torque to retract and extend the sectional door (each one with dimensions LxH=about 4.5x5.5m and weight of about 300kg) in either direction from any position. Provide a motor to produce a door travel speed of not less than 200 mm or more than 300 mm per second (in any case to be in accordance to the safety standards in force) without exceeding the rated capacity. Motors shall be operate on current of the characteristics indicated at not more than 3000, connected to the rotating axes by means of gear wheel and not directly fixed on it.

-q.ty1 set complete for mechanical hardware of motor and equipment, supports as needed, transmission motor chain, gear wheels (fixed on doors rotation axis and on motor), accessories and installation materials in order to reach the adequate door movement speed and safety operations;

-q.ty1 manual un-lock system with chain able to permit to manually raise and lower the door in case of motor kit fault. The chain system will be completed by adequate stretch pulley installed at about 1m height and safety system in order to avoid door dropping during manual operations;

- q.ty1 new control panels, hard shock resistant case, feed at 3-phase 400V 50Hz or 1-phase 230V 50Hz with adequate internal transformer to safely convert the voltage for control use if needed, able to perform dead-man commands or automatic opening/closing commands in accordance to the last safety standards by means limit switches and photocells signals and by means of adequate programming.

Moreover the connected safety device on the bottom edge shall immediately stop and reverse the door movement during the closing travel upon contact with an

31stCES/CEOER 14 obstruction in the door opening or upon failure of any component of the control system. Panel will be electrically sectioned by proper disconnector device mounted on panel or externally.

- q.ty1 new set push buttons (open/close/stop as required by Machinery Directive No 89/392/EEC) full-guarded against accidental touch, also integrated in the control panel but installed at accessible height of about 1.6m, able to perform opening/closing/stop by momentary pressure (in automatic mode) or by means constant pressure (in dead-man mode);

-q.ty2 new photocell limit switches for each door to be positioned at different height in order to detect the front shape of AAB fire department trucks on two different height position (detailed positioning will be defined on place);

-q.ty1 set new connection to all existing doors limit switches, functional devices and safety device on the bottom edge of the electrically-operated doors. These new connections to be provided to control panel complete of IP55 PVC protection conduit system;

-q.ty1 semaphore with green and red LED lamps, anti-shock resistant (with adequate diameter to be clearly recognized by truck operator, connected to control panel in order to safely indicate the permission to proceed or stop the fire truck in accordance to the door position, to be installed at height adequate to be visible at truck operator height (detailed positioning will be defined on place);

-q.ty1 set connections to all above mentioned devices, but not limited to them in order to accomplish a full workmanlike manner work, completed with adequate cable

b. Provide the cleaning and new greasing of existing doors rotating mechanism and door

3.2.3 Supply and install new doors motorized systems for Facility 1464

a. Supply and install of new q.ty 3 roll up doors motors kits each one composed by IP54

-q.ty1 new 3-phase motors 400V 50Hz in accordance to Machinery Directive No

89/392/EEC and its amendments, weather protection, high-starting torque, reversible type with adequate rated power and adequate rated torque to retract and extend the sectional door (each one with dimensions LxH=about 4.5x5.5m and weight of about 300kg) in either direction from any position. Provide a motor to produce a door travel speed of not less than 200 mm or more than 300 mm per second (in any case to be in accordance to the safety standards in force) without exceeding the rated capacity. Motors shall be operate on current of the characteristics indicated at not more than 3000, connected to the rotating axes by means of gear wheel and not directly fixed on it.

-q.ty1 set complete for mechanical hardware of motor and equipment, supports as needed, transmission motor chain, gear wheels (fixed on doors rotation axis and on motor), accessories and installation materials in order to reach the adequate door movement speed and safety operations;

31stCES/CEOER 15

-q.ty1 manual un-lock system with chain able to permit to manually raise and lower the door in case of motor kit fault. The chain system will be completed by adequate stretch pulley installed at about 1m height and safety system in order to avoid door dropping during manual operations;

- q.ty1 new control panels, hard shock resistant case, feed at 3-phase 400V 50Hz or 1-phase 230V 50Hz with adequate internal transformer to safely convert the voltage for control use if needed, able to perform dead-man commands or automatic opening/closing commands in accordance to the last safety standards by means limit switches and photocells signals and by means of adequate programming.

Moreover the connected safety device on the bottom edge shall immediately stop and reverse the door movement during the closing travel upon contact with an obstruction in the door opening or upon failure of any component of the control system. Panel will be electrically sectioned by proper disconnector device mounted on panel or externally.

- q.ty1 new set push buttons (open/close/stop as required by Machinery Directive No 89/392/EEC) full-guarded against accidental touch, also integrated in the control panel but installed at accessible height of about 1.6m, able to perform opening/closing/stop by momentary pressure (in automatic mode) or by means constant pressure (in dead-man mode);

-q.ty2 new photocell limit switches for each door to be positioned at different height in order to detect the front shape of vehicles and trucks on two different height position (detailed positioning will be defined on place);

-q.ty1 set new connection to all existing doors limit switches, functional devices and safety device on the bottom edge of the electrically-operated doors. These new connections to be provided to control panel complete of IP55 PVC protection conduit system;

-q.ty1 semaphore with green and red LED lamps, anti-shock resistant (with adequate diameter to be clearly recognized by truck/car operator, connected to control panel in order to safely indicate the permission to proceed or stop the truck/car in accordance to the door position, to be installed at height adequate to be visible at truck/car operator height (detailed positioning will be defined on place);

-q.ty1 set connections to all above mentioned devices, but not limited to them in order to accomplish a full workmanlike manner work, completed with adequate cable

b. Provide the cleaning and new greasing of existing doors rotating mechanism and door

31stCES/CEOER 16

4. CLOSEOUT DOCUMENTATION

For main item/works included in the project (electrical systems, mechanical systems and equipment, etc) warranty period will be indicated in accordance with CE norms (2 years) unless otherwise indicated.

Before contract close out, for main items/works included in the project (electrical systems, mechanical systems and equipment, etc), for warranty call purpose, Contractor will be required to provide 3 copies of a letter identifying project number, item, company address, phone number, point of contact, item warranty expiration date, etc. One copy of the letter will be installed next the item for immediate consultation;

Before contract close out, Contractor will be responsible to provide q.ty3 paper sets of AS BUILT drawings in Italian and English language and q.ty1 cd with original Autocad (AUTOCAD Release 2007 for drawings) and .pdf electronic version of same documentation paper delivered that will include at least:

- schematic diagrams connections drawings complete of equipment codes, main characteristics;

- installed equipment material list and technical datasheets;

- O&M manuals and all needed documentation necessary to perform the right maintenance activities;

- Warranty management plan complete of contacts for each equipment supplied;

-Declaration of compliance (one for each building involved in the project) stamped and wet signed by authorized company technical manager or registered engineer for all mechanical and electrical systems supplied in accordance with D.M. No.37 22/01/2008 in Italian language.

4. CLOSEOUT DOCUMENTATION