Attachment_4_MXAPE-S-001GB_Specs_Rev_1.1.pdf

Summary of Specification Changes Rev 1.1.

Revision Date: 18 Aug 2017

1. Removed Paragraph 2.2.3.1 Vacuum System. Renumbered paragraphs accordingly.

2. Added total table requirement to Paragraph 2.2.3.2 Work Platform Worktables

3. Inserted the following verbiage into Paragraph 2.2.1.7

“Please note: Stand legs will be oriented and constructed in a way that will not interfere with aircraft jacks when installed. The existing set of stands are required to be installed around the aircraft in a specific order and in some cases have to be maneuvered awkwardly around aircraft jacks. This increases risk of equipment damage and employee injury due to the location of aircraft jacks and location of stand legs. Stands can still be interchangeable with existing stands if the working surface shape is compatible and will mate to the new stands. Aircraft stands do not interlock, rather, are parked next to each other to where working surface is uninterrupted.”

4. Added the following verbiage to Paragraph 2.2.2.4 “The engine stands shall have fully removable railing”

5. Added the following verbiage to Paragraph 2.2.1.3.

“The walk ups to allow access to the wings, cockpit glass, and radomes should be removable and allow for minor adjustments to accommodate minor variation in stand placement.”

6. Section 2.2.2.6; sentence reading “Casters shall mate with the steel base frame”, removed the word “steel”. This will no longer have to be a requirement as the government will allow aluminum construction.

7. Paragraph 2.2.2.1; in the sentence “the method of adjusting height is through structural steel telescoping legs with internal jackscrews as shown on the assembly drawings”, removed the word “structural”. The height adjusting mechanism with the jackscrews will still need to be steel, but will not specify structural steel.

8. Section 2.2.4.1; Under Material Requirements, added a requirement for compliance with Aluminum 6061-T6, similar to the A36 steel requirement. In addition, changed the paragraph to read.

Material Requirements. The stands shall be constructed per OSHA 29 CFR 1910.28 and AFOSH 91-501. Steel shall comply with ASTM A36 and Aluminum shall comply with 6061-T6. If stands are constructed of aluminum, contractor shall provide proof that stands will have same or superior load ratings as steel and the aluminum stands must be compatible with existing stands.

NOTE: EXCEPT FOR THE NOTED CHANGES ABOVE ALL OTHER SPECIFICATION REQUIREMENTS REMAIN

UNCHANGED FROM SPEC MXAPE-S-001GB TO SPEC MXAPE-S-001GB REV 1.1

SPECIFICATION

8-52 MAINTENANCE WORK STAND SET

FOR

TINKER AIR FORCE BASE, OKLAHOMA

76 AMXG/QPE

TINKER AFB, OK

MXAPE-S-001GB

Revision 1.1

18 August 2017

B-52 Maintenance Work Stand Set Specification

MXAPE-S-001 GB

18 February 2010

1. SCOPE.

The contractor shall provide a complete turn-key on-site study, fabrication, inspection, testing, documentation, training, delivery, tools, installation, labor and other incidentals necessary to provide one (1) comprehensive modular B-52 Maintenance Work Stand Set for use in any of the aircraft hangar dock areas of Building 2121, Tinker Air Force Base, Oklahoma. The work stand set is to support one aircraft dock. The key objectives of the modular set of B-52 Maintenance Work Stands is as follows: 1.

Provide 100% access to all work areas from the nose, fuselage, wing and tail areas of the B-52 aircraft in order to accomplish programmed depot maintenance operations at Tinker Air Force, Oklahoma. 2.

Provide fall protection for workers performing depot maintenance on the aircraft. 3. Provide a better method for personnel to access the top "backbone" portions of the aircraft for performance of maintenance operations. 4. Provide an easily maintainable work stand set that is easy to move from storage locations, position around the aircraft, reduce the stand set-up and removal times and change configurations when necessary as aircraft maintenance operations progress through their cycle. 5.

Reduce the number of work stand sections that must be moved outside of the building for aircraft movement into and out of the hangar.

2. REQUIREMENTS.

2.1. Start Up.

2.1.1. Work Positions. The contractor shall thoroughly familiarize themselves with the areas along the entire B-52 aircraft where access by the work stand set is necessary. Special attention must be given to enhance the ability of the workers to reach the work area conveniently and safely. The work stand sections, stairways, and any necessary ladders and step platforms, shall provide both an unencumbered work area and fall protection. An individual must be able to reach their work area normally and safely.

However, the inability of the individual to reach their work area safely without fall protection on a stand provided under the following specifications and references cited herein shall because for work stand rejection. All necessary changes shall be implemented prior to delivery and acceptance of the work stand set. There shall not be a backbone ladder.

2.1.2. Configuration Placement. The contractor shall ensure platforms running alongside the aircraft fuselage minimize the risk of falls through openings and provide minimal clearance between the stand edge and the aircraft structure. The work stand set shall be designed so that each stand section provides the maximum access to the work areas, and minimizes interference with other stands and aircraft jacks.

2.2. Requirement Characteristics.

2.2.1. Access.

2.2.1.1. Stand shall be of a modular type and group work stand sections by production zones to provide optimal access, adjustability and fall protection for the personnel and equipment throughout the progression of aircraft maintenance operations during the programmed depot maintenance cycle. A list of example production zones defined by the user is provided in Appendix A. These production zones are examples of aircraft areas that the work stand set must provide access to as part of the 100% access coverage for aircraft maintenance operations and are referenced using Air Force Technical Order (T.O.)

1-B52H-3. Work stand sections for any production zone must be capable of being used as a component of the whole set or as an independent group in order to perform maintenance tasks that occur at random intervals outside of the operational cycle time.

2.2.1.2. Work stand set shall facilitate access and coverage of aircraft areas, both when aircraft components are removed or closed, and after aircraft components have been installed or opened.

Current production zone movement sequences are defined by the user in Appendix B and exhibit the typical order of zones that require adjustments or removal to allow the progression of aircraft maintenance operations.

2.2.1.3. Work stand set shall include all stairways, any ladders and step platforms necessary to allow personnel access to aircraft task areas. The walk ups to allow access to the wings, cockpit glass, and radomes should be removable and allow for minor adjustments to accommodate minor variation in stand placement.

2.2.1.4. All work stand sections, stairways, ladders, and step platforms shall comply with the safety standards of AFOSH 91-501, OSHA 29 CFR 1910 and OSHA 29 CFR 1926 for required components, fall protection, minimum load strength and safety.

2.2.1.5. The maintenance work stand set will serve as the fall protection system for the aircraft workers. The stand set design shall minimize the risk of falls through openings or from the stand, minimize the fall from the aircraft surfaces, provide minimal clearance between the stand edge and the aircraft structure, and provide coverage or adjust for stand and aircraft configuration changes throughout the aircraft maintenance process. Stand shall comply with AFOSH 91-501 for all sections;

stairways; step platforms; stand configurations; stand to aircraft relationships; and personnel access.

2.2.1.6. Modular work stand set shall provide open areas beneath the work platform, deck level, for ground level workspaces with average build personnel in upright standing positions. All levers and handles will be positioned vertically and horizontally to allow 5 foot personnel to operate it comfortably.

Stairways, ladders and step platforms may be designed with box-type base structures as necessary to comply with safety standards AFOSH 91-501 and OSHA 29 CFR 1910.

2.2.1.7. Stand shall be for placement of stand sections around the aircraft in the "jigged" position.

"Jigged" position is measured between the forward edge and aft edge of the bomb bay area and must be a minimum height of 80 inches. Wing height in "jigged" position is measured at the wing tip and must be a height of 158 inches +/- 6 inches. All aircraft tripod jacks and cradles are in position prior to the work stand set being moved into the dock area and installed around the aircraft. An aircraft jacking matrix, including dimensions and locations, is provided in Appendix C. Design should not require that the legs of any aircraft jack be in any specific orientation when installed on the aircraft in order to get the work stand sections fitted to the aircraft and to allow for jacks and cradles to be added or removed when necessary.

Please note: Stand legs will be oriented and constructed in a way that will not interfere with aircraft jacks when installed. The existing set of stands are required to be installed around the aircraft in a specific order and in some cases have to be maneuvered awkwardly around aircraft jacks. This increases risk of equipment damage and employee injury due to the location of aircraft jacks and location of stand legs. Stands can still be interchangeable with existing stands if the working surface shape is compatible and will mate to the new stands. Aircraft stands do not interlock, rather, are parked next to each other to where working surface is uninterrupted.

2.2.1.7.1. Work stand set must be compatible with all aircraft jack leg positions; cradles and aircraft tip gear. The set design must provide a means to cover gaps on work stand deck surfaces around jack, cradle and tip gear locations. Gap covers shall be provided or the stand sections should be designed to prevent personnel or objects from falling through the opening when the jack, cradle and/or tip gear are installed and when the jack/cradle/tip gear is removed. Removable gap covers must change easily and store on the stand. Work Stand shall provide guarding of wall and floor openings in accordance with AFOSH 91-501, Chapter 7. All work stands that are designed to encompass aircraft jacks will have a semi-flexible guide (go/no-go gage) in order to expedite stand orientation.

2.2.1.7.2. Gap covers must provide the same working load strength as the work platform, and must comply with Section 2.2.1.11.

2.2.1.8. Work stand set shall fit around the aircraft without any permanent components protruding beyond the dock lines into vehicle and personnel aisles. Aisles must be clear, or made clear, to allow flow of vehicles when necessary while work stand set is in place. Building 2121 four dock and six dock configuration layouts are provided in Appendices D and E, respectively. These documents illustrate the orientation of the aircraft within the building at each of the dock spaces.

2.2.1.9. Work stand sections shall be capable of entering the building through the hangar doors or overhead vehicle doors. The overhead door being the smaller size will set the criteria of size. Each work stand section shall be sized to fit through the overhead door that is 20 feet wide and 14 feet high with clearance on each side. Clearance is required to protect the stand components and building structures from being struck as the stand components are rolled by manual means or towed by mechanical means into or out of the building.

2.2.1.10. Stand sections must minimize extension into open floor space between trailing edge of wing and the leading edge of the horizontal stabilizer to allow a 25-ton truck mounted crane access to aircraft for installation of aircraft components. Crane access is required always on the right side of the aircraft for vertical stabilizer installations. Crane access is required on the left and right sides of the aircraft, aft of wings, for flap installations. Engine installations require the crane have access from both the left and right sides of the aircraft, forward of the wings.

2.2.1.11. Working Loads. Each work stand section and stairway shall support the working loads (number of personnel) specified by OSHA and AFOSH standards. The contractor shall use a working load of six (6) people (350 pounds each), plus six (6) sets of tools (100 pounds each) for computational purposes, unless modified for specific work areas in this specification.

2.2.1.12. Load Limits. "Working Load" limit signs shall be fastened onto handrails adjacent to platform stair entries. They must state the maximum number of personnel permitted on each work stand section platform and the total supported on the work stand assembly. One sign is required for each stairway entry. Signs shall be in accordance with Section 2.2.2.21 "Signage".

2.2.2. Core Stand Functions. Work stand design and fabrication shall provide all of the following core stand functions.

2.2.2.1. Leveling and Height Adjustment. Each work stand section shall be made with a means of mechanically adjusting the vertical height of the platforms not less than 36 inches travel. The vertical height adjustment of each work stand section is primarily for achieving vertical positioning of the platforms to other section platforms, but the additional adjustment range is required for vertical positioning of stand sections after aircraft components are installed and to compensate for variations in the "jigged" height per aircraft. The method of adjusting height is through steel telescoping legs with internal jackscrews as shown on the assembly drawings. One jacking point for each stand section shall be used to maintain a level platform height. Jackscrew mechanisms shall not create pinch points or shall be guarded. Maximum allowable leveling height variance is one-quarter (1/4) inch between stand sections during assembly and utilization of the work stand set around the aircraft. Stenciling of signs shall be used to note the height adjustment limit on the stand sections. Signs shall be in accordance with Section 2.2.2.21 "Signage". Leveling and height adjustment of each platform shall be achieved by fabrication of the telescoping legs with internal jackscrews as shown in the assembly drawings that will be provided by the government. All work stands will be leveled and secured without any external devices, such as shims or props.

2.2.2.2. Section to Section Connections. Stand shall provide a means of mechanically connecting the work stand sections together, allowing travel from one section to another. Maximum allowable lateral gap is one-half (1/2) inch between sections during assembly and utilization of the work stand set around the aircraft.

Connection mechanisms will be easy to operate, remove and store on the stand. Travel to the other side of the aircraft on the work platform deck level will be designed at the tail of the aircraft only.

2.2.2.3. Guardrails. Guardrails, midrails and toeboards shall be designed and installed on all open sides and ends of the stand set platforms 4 feet or greater above floor level, except the side against the aircraft. Adjustable guardrail sections shall mechanically fasten in the fully extended position. All guardrai ls shall be constructed of metallic material and shall comply with all applicable AFOSH and OSHA standards. All guardrails will have drain holes to prevent the accumulation of fluid.

2.2.2.4. Stand shall provide a means for removable or adjustable guardrail sections for use when only one stand or zone group of stands is used; when loading of equipment onto work stand deck; and when aircraft operations have progressed to the point where a production zone section requires removal or adjustment which creates an opening in fall protection. Contractor will work with user to identify all locations for removable or adjustable guardrail sections are required. All adjustable or removable guardrails shall have midrails and toeboards for compliance with Section 2.2.2.3 of this specification and applicable AFOSH and OSHA standards. Provide a means to store the guardrail sections on the stand when removed. All removable guardrails will be labeled with location of placement. All locations, where removable guardrails will be placed will be labeled with which guardrails it corresponds. Storage of removable guardrails will be on top of silhouette stands as close as possible the installation location without interfering with normal maintenance activities. The engine stands shall have fully removable railing.

2.2.2.5. Stairways. Stairways shall be provided on both sides of the aircraft in the areas of production zones for access and egress of personnel. Each work stand stairway shall be capable of supporting a load of six (6) people plus tools as a minimum. Stair treads shall be solid metallic materials that are self-draining, self-cleaning, sturdy tread with high slip resistance in all directions. The facing edge of the treads and the landing(s) shall be highlighted with yellow paint. Treads and nosings shall be anti-slip surfaces. Stairway guardrails shall be of the same material as the platform guardrails and shall include midrails. The stairs steps will remain horizontal to the floor regardless of the height of the work stand platform or angle of the stairway. Stairways shall be provided with steps at the lowest possible level to meet OSHA step standards. Stairways shall have a means to collect debris falling from stair steps and be removable for disposal purposes.

2.2.2.6. Casters. The stand sections, stairways and step platforms not used on the deck platform shall be moveable on swivel casters with 90-degree locks. Casters shall be minimum of 8-inches in diameter , designed to swivel when in the unlocked position, shall not have foot guards, and have a foot operated locking device, which contacts the entire width of the wheel. Step platforms, used on the work stand deck platform, shall be moveable on casters and have a means to disengage or lock the casters when in position for usage and storage. Casters shall have tapered bearings. Casters shall be designed to support four times the working load and be rated for 5 miles per hour towing speed. Casters shall have tires made of solid polyurethane molded on a cast wheel and shall be resistive to chemicals listed in Section 2.2.4.7. Caster wheels shall have a corrosion resistive coating. Casters shall mate with the base frame. Reference AFOSH 91-501, Section 16.5.4. A set of ten (10) removable pneumatic jacks will be provided that can be attached to the work stand to adjust the caster direction as needed.

2.2.2.7. Electrical Supply. Work stand set will be designed to provide 11OV, 30 amp single phase NEMA receptacle electrical service to each stand section for personnel to utilize for maintenance operations.

Two (2) each heavy duty industrial grade NEMA duplex electric receptacles will be provided at approximately 10 foot spacing along the perimeter of the stand set above the decking and approximately 10 foot spacing below the decking, in the designated work areas. Electrical supply to each stand section will be functional even when individual stand sections are removed. Circuit breaker boxes are to be provided on the stand set to distribute the load and prevent power interruptions.

NEMA twist lock receptacles and plugs are to be used to connect the power between stand sections. All electrical circuits shall be GFCI protected. All electrical devices shall be waterproof. Electrical power to the stand set from the facility is available on the exterior and interior dock walls with twist lock connections for 220 V, single phase, and 30 amps per leg. Electrical requirements shall be met in compliance with OSHA, AFOSH and NFPA 70 standards. All electrical outlets and circuit panels will be marked in accordance with OSHA and AFOSH standards. All electrical panel signs will have labels with OSHA clearance requirements.

2.2.2.8. Lighting. Light fixtures will be provided both under and above the stand work platform levels and for other production zones under structural areas of the aircraft. A maintained illumination level of 50 to 75 foot-candles, measured 3 feet off of the ground, is provided in the hangar dock space and the contractor shall provide supplementary lighting underneath the work stand sections, wings, horizontal stabilizers and aircraft underbelly to maintain the 50 to 75 foot-candle lighting level for medium bench type work. These light fixtures must not impede vision of workers on stand sections or on top of the aircraft. Any light fixture that is part of the work platform deck surface must withstand the same working load as the work platform. Fixtures shall be easily maintainable with sealed, protective covers to prevent breakage. All lighting is to work on each stand independently regardless of stand configuration. Provide a panel for light control at five (5) feet above the floor on the side opposite of the aircraft on each stand section. All wiring shall be in appropriately sized conduit. All electrical circuits shall be GFCI protected. All electrical devices shall be waterproof. Lighting shall comply with OSHA 29 CFR 1910 and 1926, AFOSH 91-501 and NFPA 70-2002.

2.2.2.9. Compressed Air Supply. Work stand set shall provide air supply outlets throughout the stand sections for personnel and equipment to utilize for maintenance operations. Six (6) each outlet American Standard ¼ - inch female quick disconnects are needed in 4 to 6 foot intervals above and below the work platform level and on some step platforms. One each American Standard ½ -inch female quick disconnect , with a shutoff valve is required for HEPA vacuums per production zone above and below the work platform level. Air lines will have capability to work even when individual stand sections are removed. Stand sections must have one each water separator per stand section to provide clean, dry shop air to each user at continuous pressure levels to operate equipment and hand tools simultaneously. Design shall also include the air requirements of four (4) user owned HEPA vacuum systems to be operational simultaneously with other equipment and hand tool operations throughout the work stand set. Air supply from facility is 100 psi rated from shop air and will attach to the work stand at the nose near the Body Station 694 Bulkhead; outboard wing near the tip; and near the tail section on both sides of the aircraft. Connection points are necessary on both sides of the aircraft for these locations to meet the position of the aircraft in the facility. The connection for the tail section may be in the center to service either aircraft position. User has 1-inch air line from the wall to the stand.

Work stand will require an American Standard 1-inch male quick disconnects, with shutoff valves, on the stand where wall supply locations are to connect. Tools use ¼ -inch air line. HEPA vacuum system requires a ½ -inch air line. Contractor will not be required to provide actual HEPA vacuum system. All compressed air piping will be marked in accordance with OSHA and AFOSH standards. Label with compressed air and working pressure.

2.2.2.10. Shop Vacuum Storage. Provide adjustable straps and a locking method for securing user owned shop vacuum equipment to the work stand sections, one per production zone, above and below the work stand deck level. User owned shop vacuum units have 2-1/2 feet diameter typically, +/- 6 inches.

2.2.2.11. Static Discharge. All work stand sections shall have a static ground wire to discharge accumulated static electricity to the ground.

2.2.2.12. Tie Down Straps. Provide removable straps and connection points for attaching at each corner of the work stand sections and to secure the stand to the ground. Both ends of the strap shall terminate with a snap hook. Straps shall be adjustable in length using a ratchet buckle.

2.2.2.13. Field Painting: Touch up any shop applied protective coatings damaged during handling and installation. Apply compatible paint matching color and sheen of shop-coated components. Use galvanizing repair - paint for galvanized surfaces requiring remedial touch up.

2.2.2.14. Stability. The stability of assembled work stand sections shall be achieved by using outrigger assemblies where required. Guy wires, thrust out, or stabilizer extensions shall not be used. All assembled work stand sections (partial or complete) must satisfy the minimum height to base area factor required by AFOSH 91-501.

2.2.2.15. Platform to Aircraft. No portion of the work stand shall transfer a load force upon the aircraft.

The platform may cantilever beyond any structural member of the stand on the aircraft side of the stand as long as the platform and stand complies with OSHA and AFOSH standards. Thickness of the platform shall be limited to 2.5 inches within 6 inches of the aircraft. Protective molding or D-style rubber bumpers shall be attached to all edges and protuberances that may contact the aircraft. Molding or D-style bumpers shall be made from vinyl or rubber, attached by screws or straps to the platform or railing and have a height (material protective thickness) of 0.75 inches to 1.50 inches when installed.

Cylindrical covers for upright tubing posts are permitted. Any component that could come in contact with the aircraft during positioning shall be padded with rubber bumpers. This includes the lifting mechanism for the work stand section at the tail of the aircraft (see Section 2.2.3.2).

2.2.2.16. COBRA Engine Lift. Provide capabilities to allow for work space access for the installation of engines at each of the left and right wing inboard and outboard nacelle location (center line WS 410 and WS 720). Work stand sections shall be capable of allowing access for the Nord aviation TP91-D/SSS hydraulic lifter and complies with AFOSH and OSHA standards. The allowable work space for the COBRA system is defined in Nord Aviation document number O/M 0110 with approximate footprint of 110 inches in the forward to aft direction and 196 inches in the inboard to outboard direction relative to the position of each of the four engine nacelles.

2.2.2.17. Surface Edges. Exposed surfaces shall be free from sharp edges, burrs or other hazards to the aircraft and personnel. Problem areas shall be smooth, rounded off or protected by vinyl or rubber molding/bumpers. All potential head laceration surfaces will be painted red.

2.2.2.18. Fit Test. When stand sections are against the aircraft, no unprotected gaps of greater than 2 inches (horizontally or vertically) shall be allowed between the stand and the aircraft.

2.2.2.19. Working Interference. Structural components shall be positioned in a manner to minimize work interference. Work platforms and stair landings shall have at least 7 feet of vertical clearance of cross-braces, protrusions and low hanging members that could cause tripping or head injury.

2.2.2.20. Nameplate Labeling. Work stand sections shall be labeled on the base frame and all components shall be labeled or stamped with part numbers for identification. Nameplate labels shall be as permanent as the useful life expectancy of the work stand and shall be corrosion resistant. Legibility shall be as required for ready readability. Information contained on the nameplate shall be of a color that is in contrast to the color of the surface of the plate. Letters shall be capitals without serifs (sans-serifs) such as Arial, Futura, Gothic, or other sans-serifs font. Numerals shall be Arabic. Characters generated by automation processes shall be permitted. All words engraved on plates shall be in the English language. Words and numerals shall be engraved, etched, embossed, or stamped in bold-faced letters on a contrasting background. The nameplate label shall contain information as follows:

Work Stand Section Title Manufacturer's Name Manufacturer's Part Number Manufacturer's Serial Number Contract Number or Order Number Date of Manufacture Work Stand Section Assembled Weight

2.2.2.21. Reflective Markings. Comply with AFOSH 91-501 and its referenced Air Force Technical Order (T.0. 35-1-3).

2.2.2.22. Signage. Each sign shall be a minimum size of 5 inches high by 10 inches long and have a white faceplate with % inch high red lettering. Mechanically attach the sign to the work stands.

2.2.3. Optional Stand Functions. Work stand design shall provide plans for all of the following optional stand functions for possible inclusion in fabrication of the prototype, later production units, or for work stand set modification at a later time.

2.2.3.1. Lifting Capability. The design will include an option for providing lifting capability or mechanism on the left side of the aircraft in the tail area as viewed looking towards the nose of the aircraft from the tail. Jib Crane location will be determined by government engineer(s) or the user, contractor can suggest location of jib crane to accommodate their design. Equipment and materials weighing approximately 600 pounds, 150 to 200 pounds per item, are required to be lifted by mechanical means from the floor to the work stand platform level. Lifting mechanism must also be capable of assisting workers to lift equipment and materials for installation onto the aircraft at Body Station (BS) BS 1853 to BS 1853+40 above the work stand platform level. Contractor shall provide a fully functional lifting mechanism, including any necessary lifting straps. Lifting mechanism must not impede aircraft elevator maintenance and installation operations. Lifting device and components shall comply with applicable OSHA Standards 29 CFR 1910.179 and 1910.184; AFOSH Standard 91-46, Chapters 5, 6 and 9; and AFOSH 91-501. In the event that this option is not chosen, contractor will provide a gate, or adjustable guardrails in the tail stand section as covered in Section 2.2.2.4 of this specification and shall comply with applicable OSHA and AFOSH standards.

2.2.3.2. Work Platform Worktables. An option for worktables with replaceable work surfaces shall be designed for use on the work platform level in each of the production zones, including both leading and trailing sides of wings. Working height of worktables shall be 36 inches and adjust up and down 6 inches.

Worktables shall be capable of being raised and lowered and secured to the deck surface for storage and stand movements. Each worktable must prevent tools, parts and materials from falling off the guardrail side of the table. Worktable surfaces shall be non-metallic and be resistant to drilling, sanding or other abrasive operations. Worktable must support equipment and materials weighing 350 pounds and the working surface shall be 60 inches long by 24 inches deep (wide). Work platform worktables will comply with all OSHA and AFOSH safety standards. Contract shall provide 15 total tables for production zones.

2.2.3.3. Consolidated Tool Kit (CTK) Stand Section. Design shall include an option for supportability and securing of one (1) each CTK in the area aft of the trailing edge wing stand section on each side of the aircraft for access from the work platform level. CTK approximate weight is 3000 pounds and the dimensions are to be user defined to the contractor awarded the contract. CTK dimensions for the purpose of the conceptual design are 85 inches long by 29 inches wide by 73 inches high on 6 casters.

Contractor is not to provide the actual CTK units. Design shall provide removable or telescoping guardrails, midrails and toeboards in this area, capable of withstanding the force from the CTK, to permit CTK installation and removal onto the stand section by forklift. CTK zone will also provide a means to immobilize the CTK casters, without hindering forklift capability, while CTK unit is on the work stand section.

2.2.3.4. Hydraulic Fluid Supply. Design shall include an option for providing hydraulic fluid supply high pressure line inlets and return line outlets through the stand sections, nearest the engines, for personnel to utilize for maintenance operations. There are six (6) high pressure line inlets and six (6) return line outlets on each aircraft, three of each on each side of the aircraft. The six hydraulic supply inlets are located at: 1) left wing outboard strut outboard-side mid-engine nacelle; 2) left wing inboard engine nacelle left side mid-nacelle; 3) left wing inboard engine nacelle right side mid-nacelle; 4) right wing outboard strut inboard-side mid-engine nacelle; 5) right wing inboard engine nacelle left side mid-nacelle; and 6) right wing inboard engine nacelle right side mid-nacelle. The six hydraulic return outlets are located at: 1) left wing near Wing Station (WS) 1000 approximately 3 feet forward of the trailing edge; 2) left wing near WS565 approximately 2 feet forward of the trailing edge; 3) left wing near WS374 approximately 6-7 feet forward of the trailing edge; 4) right wing near Wing Station (WS) 1000 approximately 3 feet forward of the trailing edge; 5) right wing near WS565 approximately 2 feet forward of the trailing edge; and 6) right wing near WS374 approximately 6-7 feet forward of the trailing edge. Covers will be provided on the stand surface, for both the high pressure line inlets and return outlets, that meet the working load strength in Section 2.2.1.11 will be designed on the work stand platform level to prevent trip hazard when hydraulics are not in use. Shutoff valves, couplings and attachable dust caps will be required between sections and at inlet and return locations to minimize contamination of hydraulic fluid to each location at continuous pressure levels. Hydraulic lines will have capability to work even when individual stand sections are removed. Hydraulic supply and returns shall be high pressure seamless stainless steel rated to operate at 3000 psi, using MIL-H-5606 hydraulic fluid.

The hydraulic supply will attach to the work stand by a user provided high pressure line hose and return line hose with aircraft filters from one (1) each 2-system hydraulic test stand unit that will be brought to the aircraft dock space at user defined locations. All high pressure line inlets and return line outlets on the stand sections must be compatible with 76 AMXG/MXAPE Drawing X7527266, 8-52 Aircraft Hydraulic Hose Assembly. Shutoff valves shall be provided on the stand to isolate leaks. Pockets of air are allowable in the hydraulic lines due to the use of the 2-system hydraulic test stand unit. All hydraulic fluid piping will be marked in accordance with OSHA and AFOSH standards.

2.2.3.5. Operation Signal Lights. Design shall include an option for providing three operation signal lights at each wing tip, nose and tail locations of the work stand set. Each set of signal lights shall be located so they are visible for personnel on the deck level and below. Lights shall be red for only hydraulic; amber for hydraulic and electrical; and blue for only electrical operations. One switch per light color shall operate the respective operation signal light at all four locations. Control shall be wireless.

Operation signal lights will be operational even when any stand sections are removed or added to the stand set configuration during operations. All light fixtures wiring and control panel shall be waterproof and comply with OSHA and AFOSH standards.

2.2.4. Durability.

2.2.4.1. Material Requirements. The stands shall be constructed per OSHA 29 CFR 1910.28 and AFOSH 91-501. Steel shall comply with ASTM A36 and Aluminum shall comply with 6061-T6. If stands are constructed of aluminum, contractor shall provide proof that stands will have same or superior load ratings as steel and the aluminum stands must be compatible with existing stands.

2.2.4.2. Work Platform Construction. Platform decking shall be Traction TRED decking under and 18" past the perimeter of the aircraft wing and horizontal stabilizer, with "PERF-0-Grip" decking everywhere else outside 18" of the shadow of the Aircraft wing and horizontal stabilizer. The PERF-0-GRIP shall have 7/8" but not greater than 1" diameter surface perforation. This is necessary for the work stand to meet the NFPA requirements. The overall work stand shall meet the load capability specified in the contract statement of work. The surface shall be a solid anti-skid, non-bounce material approved for walkway use. Emphasis shall be placed upon a material, which will provide sturdy, slip resistance, sure footing, environmental and chemical resistance, protection against foreign materials and personnel falling from the work stand platform to the floor of the aircraft hangar and provide ease of modification. Solid decking shall be installed in accordance with AFOSH 91-501 and OSHA 29 CFR 1910 and 1926. Any surrounding edges that have significant risk of head injury or lacerations shall be given protective molding firmly attached to decking edge or rounded off. Wood decking is not allowed.

2.2.4.3. Structural Alignment. Work stand sections shall have horizontal and/or diagonal braces for securing vertical members together laterally. The braces shall be of a length to automatically square or align vertical frame members so the erected work stand section is always plumb, square and rigid.

2.2.4.4. Welding. All welding shall comply with AWS-1. Welding done at Tinker Air Force Base shall comply with safety standards AFOSH 91-5 and TAFBI 32-2001. All work stand welded subframes and assemblies shall be designed for moderate rigidity, expansion and contraction, protection against the sheering of bolts and other fastenings, the close fitting of sections, and satisfactory hazard control.

Fasteners shall be large enough and in sufficient number to maintain the designed strength of the unit.

2.2.4.5. Maintainability and Useful Life. Design, construction methods and materials used in the manufacture of the work stand set and components shall be for maximum access and safety with ease of maintenance to provide a durable and sustainable stand set for a desired useful life of 20 years minimum. Components and hardware must be off the shelf items to the fullest extent possible to ease replacement of parts while minimizing downtime.

2.2.4.6. Working Environment. The work stand will be used indoors on paved aircraft hangar area of Building 2121, and stored outside on the paved aircraft ramp area south of Building 2121 at Tinker Air Force Base, Oklahoma when not in use. These locations are located within the 761 Aircraft Maintenance Group (76 AMXG). The stands will be used and stored in all weather conditions, and all components shall withstand corrosion and temperatures from -20°F to +140°F as a minimum and have ultraviolet protection.

2.2.4.7. Chemical Resistance. The work stand set and components shall maintain full function and durability for operations using the following chemicals:

Hydrochloric Acid Acetic Acid Phenol Ammonia Water Ethyl Alcohol Acetone Toluene Ethyl Acetate Methyl Ethyl Ketone Jet Fuel (JP 4-5-8) Skydrol 500 B-4 Paint Methyl Normal Propyl Ketone PR148 Adhesion Promoter Hydraulic Fluids (PRF5606H, MIL-H-5606, MIL-PRF-87257A)

Alodine Turcoat Alumigold

2.2.4.8. Method of Transport and Set-Up Time. Work stand set will be transported by using both material handling vehicles such as warehouse tugs from storage locations to the building openings and by manual means from the building openings to their position around the aircraft. Contractor shall design the stand sections to minimize damage to the stand sections, personnel, facility and aircraft by either transportation method. Work stand set shall be designed to allow for easy set-up within a four

(4) hour time period using twenty aircraft workers and one towing vehicle. This includes transportation from storage locations to and around the aircraft from 1200 feet away from the Dock hangar door opening.

2.2.4.8.1. Vehicular Transport. Vehicular transport of work stand sections is required for movement of sections outside of the dock space to and from storage. Design shall include a hinged tow bar for each stand section, provides a means for pintle hook connection to allow for towing from the side of the work stand section that will enter the vehicle door opening first. The tow bar and hinge pins shall be rated for full towing load of the stand section. The pintle tow bar shall be provided with a means to store and mechanically secure it on the stand section when not in use. Install a sign on the work stand sections near the tow bar stating "Maximum Tow Speed 5 mph". On a separate sign state "CAUTION - Before Towing, Latch Pintle, Close Trip Lock and Install Pin". Signs shall be in accordance with Section 2.2.2.21 "Signage".

2.2.4.8.2. Manual Transport. Manual transport of work stand sections is required for smaller distance movements (i.e. assembling stand set around the aircraft, adjusting the configuration, or removing stand sections from the set). Each work stand sections shall be designed for ease of manual transport by four (4) average build workers , using normal strength and minimize occurrences of physical strain or potential injury. If the manual transport requirement cannot be met, a towing vehicle can be included to assist in the movement of the work stands. This towing vehicle must be small enough to maneuver within the constraints of the dock/building, yet big enough to be of assistance.

3. QUALITY REQUIREMENTS.

3.1. Quality Assurance. It is the intent of the government that the approach to designing the work stands be the prerogative of the contractor. The contractor shall ensure that the quality of materials, workmanship, design, construction and assembly is adequate to satisfy all requirements of this specification:

3.2. Responsibility for Inspection. Unless otherwise directed by the ACO, or by any requirements stated within these specifications, the contractor is responsible for the performance of all inspection requirements as specified herein. Except as otherwise directed by the ACO or specified, the contractor may use their own facility or any other facilities suitable for the performance of the inspection requirements specified herein. The government reserves the right to perform any of the inspections set forth in the specification when such inspections are deemed necessary to ensure materials, assemblies, workmanship and services conform to prescribed requirements.

3.3. Quality Conformance Inspect ion: Quality conformance inspection shall be applied to each work stand section prior to being offered for acceptance under the contract. Preliminary quality conformance inspection will be conducted at the contractor's manufacturing facility. Final quality conformance inspection shall be conducted at the government installation site, after assembly and fit test, and shall consist of the examination in Section 3.4 herein under the supervision of government representatives.

Failure of any item to pass any examination shall be cause for rejection.

3.4. Examination: The work stand sections shall be examined for design, construct ion, welds , materials, components , workmanship and fit to the aircraft to determine compliance with the requirements of Section 2 "REQUIREMENTS".

3.5. Work stand set will come with a standard commercial warranty that is common to comparable equipment found in an industrial environment.

APPENDIX A

A. PRODUCTION ZONES. As defined by user.

A.1. Nose. Body Station (BS) 0 to BS 345.5, left and right sides, top to bottom of aircraft. Provides access to nose radome area, window posts, in-flight fueling receptacle (IFR), side skins, belly skins, upper forward and aft hatches, and lower hatches and main entry door. Work stand section may be tapered to adjust for facility constraints.

A.2. Forward Fuselage. BS 345.5 to BS 694, left and right sides, top to bottom of aircraft. Provides access to forward wheel well (including forward landing gear), forward electronic counter measures (ECM) bay, alternator deck, forward body fuel tanks (2), wing center section, bonnet, center wing fuel tank , life raft door, side skins and belly skins.

A.3. Center Fuselage. BS 694 to BS 1237, left and right sides, top to bottom of aircraft. Provides access to bomb bay, upper body fuel tanks (3), aft wheel wells (including aft landing gear), aft fuel tanks (2), side skins and belly skins.

A.4. Aft Fuselage. BS 1237 to BS 1727, left and right sides, top to bottom of aircraft. Provides access to miniature receive terminal (MRT) radome, rear access door (section 47), cargo area , aft fuel tank, aft ECM radome, side skins and belly skins.

A.5. Tail. BS 1727 to Aft End of Aircraft, left and right sides, top to bottom of aircraft. Provides access to ammunition doors (both when open and closed), drag chute container, electronic access (left side of aircraft only), 40-inch body extension at BS 1853, tail radomes (8), side skins and belly skins.

A.6. Horizontal Stabilizer and Elevators. Left and right sides of aircraft, over and under sides of horizontal stabilizer. Provides access to the horizontal stabilizer, elevators, flare ejectors, and skins.

A.7. Vertical Stabilizer and Rudder. Left and right sides, top to bottom of vertical stabilizer. Provides access to the vertical stabilizer, rudder, and skins.

A.8. Wing. Fuselage to Wing Tip, left and right sides of aircraft, over and under sides of wing.

Provides access to leading and trailing edges of wings, entire wing surface for upper and lower skins, flaps, spoilers, flap tracks, wing fuel tanks, tip gear, external tanks, and wing tips.

A.9. Inboard Engine. Left and right sides of aircraft. Provides access to engine, engine struts, engine cowling and nose cowls.

A.10. Outboard Engine. Left and right sides of aircraft. Provides access to engine, engine struts, engine cowling and nose cowls.

A.11. Area 5. Provides access to aircraft heat exchanger

A.12. Bomb Bay Door. Provide clearance to open the bomb bay door.

A.13. Landing Gear. Provide access to landing gear(s).

APPENDIX B

B. PRODUCTION ZONE MOVEMENT SEQUENCE

This illustrates a typical movement sequence based on maintenance operations using the existing B-52 work stand set. The design of a new work stand set is to eliminate the need to move stand sections in and out of set configuration. The new design shall minimize the occurrences of when there is no other alternative to moving a stand section out. Fall prevention must be designed for the adjustment and potential removal of stand sections for both the section being adjusted and the remaining stand set.

STAND SECTION MOVEMENT TYPE OTHER CONSIDERATIONS

None Aircraft into dock only Not Applicable None Jack and Cradles only Not Applicable None None Aircraft Jigged One Entire Set Installation around aircraft Fit around aircraft, jacks and cradles ; and around fixed facility and equipment objects

Inboard Forward Body Stands Stand sections are Pulled Out to facilitate hanging Forward Landing Gear

Fall prevention in place on remaining stand set after this stand section is removed.

Bomb Bay Stand Stand section is pulled out prior to installation of Bomb Bay Doors

New stand to allow access inside Bomb Bay area with Bomb Bay Doors Installed.

Inboard Wing Stands 0fVS 303 to Fuselage)

Stand section are Pulled Out to hang Bomb Bay Doors

Fall prevention in place on remaining stand set while this stand section is removed.

Inboard Wing Stands (WS 303 to Fuselage)

Stand section Reinstalled with hinged flange portion lifted (flange approximately 12 - 16 inches wide and the full length of existing stand)

New stand must adjust in some way to accommodate for the Bomb Bay Doors being open and installed on the aircraft and allow work platform level access to the fuselage area.

STAND SECTION MOVEMENT TYPE OTHER CONSIDERATIONS

Inboard Wing Stands (WS 303 to Fuselage)

Stand section removed to facilitate installation of forward gear doors.

Fall prevention in place on remaining stand set after this stand section is removed. Stand needs to allow access to fuselage from work platform level after gear doors are installed and open.

Outboard Wing Stand (WS 1046 to Tip)

Stand section is Pulled Out to load and test Tip Gear

Fall prevention in place on remaining stand set after this stand section is removed. Stand needs to allow access to tip and wing areas from work platform level after Tip Gear and External Tank is installed.

Engine Nacelle/Strut Stands (Leading Edge Forward)

Each Section is Removed to hang Engines onto aircraft. Workers currently remove this stand section and use a B-1 Type stand at its lowest level (approximately 36 inches from the floor) to continue working on the engines.

Fall prevention in place on remaining stand set after this stand section is removed.

New stand needs to be capable of raising and lowering for continuing in place to work on the engines.

All other stand sections None Remain in place until programmed depot maintenance (PDM) is completed on the aircraft.

Any Work Stand Section that blocks in a Jack and Cradle

All Jacks and Cradles are Removed, except the horizontal jack, prior to installing landing gear.

Jack and Cradles are moved away from aircraft to storage locations.

All other stand sections Removal Stand sections are moved away from aircraft to storage locations.

None Horizontal Jacks and Cradles are Removed

Jack and Cradles are moved away from aircraft.

None Aircraft is moved out of hangar None

APPENDIX C

C. AIRCRAFT JACKING MATRIX

This matrix contains aircraft jack locations. Refer to T.O. 1B-52H-3 for additional information regarding jack and cradle information. Contractor shall perform additional measurements as necessary to meet their design needs.

Body Body - Nose Body - Nose AIRCRAFT AREA

BS 345 BS 175.6 BS 110.2 LOCATION

Body Station (BS)

Body Buttock Line (BBL) Body Water Line (BWL)

30-Ton 0…