StatementOfWork.pdf

13 May 2015

Statement of Work (SOW) for

B52 Towbar Repair

Prepared by

AFLCMC/WNZ SUPPORT EQUIPMENT AND VEHICLE DIVISION

235 BYRON ST, SUITE 19A

ROBINS AFB GA 31098-1813

DISTRIBUTION STATEMENT A. Approved for public release: Distribution is unlimited.

THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 Government documents

2.1.1 Specifications standards and handbooks

2.1.2 Other Government documents, drawings, and publications

2.2 Non-Government documents

2.3 Order of precedence

3. REQUIREMENTS

3.1 Program management

3.1.1 Program manager

3.1.2 Plant access

3.1.3 Monthly status report and program schedule

3.2 Program reviews

3.2.1 Post-award conference (PAC)

3.2.2 Program management review support

3.2.3 Conference room

3.2.4 Meeting agendas

3.2.5 Meeting minutes

3.3 Repairs

3.3.1 Stripping, cleaning, degreasing components

3.3.2 100% Inspection and repair of welds

3.3.3 Boss holes

3.3.3.1 Boss holes inspection criteria

3.3.4 Aft bar inside corner welds

3.3.5 Tow head straps

3.3.6 Main tube center splice

3.3.7 Steering Arm

3.4 Assembly and verification demonstration

3.4.1 Hardware kits

3.5 Inspection and test procedure

3.6 Inspection and test reports

3.7 Protective coatings, and finish

3.7.1 Surface preparation and pretreatment

3.7.2 Primer

3.7.3 Ferrous surfaces

3.7.4 Aluminum and mixed aluminum and ferrous surfaces

3.7.5 Topcoat

3.7.6 Finish

3.8 Configuration management

3.8.1 Engineering change proposals (ECPs)

3.8.2 Request for variance (RFV)

3.8.3 Technical data package (TDP)

3.9 Welding process quality control

3.10 Government property

3.10.1 Contractor responsibility

3.10.2 Government property to be provided

3.10.3 Loss of Government property

3.10.3.1 Definition of loss of Government property

3.10.3.2 Reporting Loss of Government property

3.10.3.3 Return of Government property

3.10.3.4 Commercial Asset Visibility-Air Force (CAV-AF)

3.11 Safety and health

3.12 Risk management

3.13 Workmanship

3.13.1 Bolted connections

3.13.2 Cleaning

3.14 Packaging

3.14.1 Packaging and marking

3.14.2 Protection and preservation

3.14.3 Shipping containers

3.14.4 Palletization

3.15 Government-Industry Data Exchange Program (GIDEP)

ATTACHMENTS

Attachment A - Boss hole repair guidelines Attachment B - Tow head straps Attachment C - Center splice Attachment D – Hardware

1. SCOPE

This document defines the tasks and deliverables associated with the repair of B52 Towbars.

The towbars shall be repaired in accordance with this SOW and technical data package (TDP).

The TDP consists of the towbar drawing package F52606-501 as well as all supporting documents, drawings, and attachments cited within this SOW.

2. APPLICABLE DOCUMENTS

The following documents are applicable to the SOW to the extent specified herein.

2.1 Government documents.

2.1.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this SOW to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C/26173 Gray

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-23377K Primer Coatings: Epoxy, High-Solids MIL-PRF-26915D(2) Primer Coating, for Steel Surfaces MIL-DTL-53030D Primer Coating, Epoxy, Water Reducible, Lead and

Chromate Free MIL-DTL-81706B(1) Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys MIL-PRF-85285D(3) Coating: Polyurethane, Aircraft and Support Equipment

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129P Military Marking for Shipment and Storage MIL-STD-130N Identification Marking of U.S. Military Property MIL-STD-2073-1D Standard Practice for Military Packaging MIL-STD-147E Palletized Unit Loads

2.1.2 Other Government documents, drawings, and publications.

DEPARTMENT OF DEFENSE GUIDES

(no identifier) Risk Management Guide for DoD Acquisition, Sixth Edition, Version 1.0

DATA ITEM DESCRIPTIONS (DIDs)

DI-MGMT-80227

DI-NDTI-80603A

Contractor's Progress, Status and Management Report Test Procedure

DI-SESS-80639D

DI-SESS-80640D

Engineering Change Proposal (ECP)Request for Variance (RFV)

DI-SESS-80642D

DI-NDTI-80809B

Notice of Revision (NOR) Test/Inspection Report

DI-ADMN-81249A Conference Agenda

DI-ADMN-81250A

DI-MGMT-81634B

DI-QCIC-80125B

DI-QCIC-80126B

DI-QCIC-80127A

Conference Minutes Commercial Asset Visibility Air Force (CAVAF) / Government Furnished Material Report) GIDEP Alert/Safe-Alert Report GIDEP Alert/Safe-Alert Response GIDEP Annual Progress Report

(Copies of these documents are available online at http://quicksearch.dla.mil.)

DRAWINGS

Part Number CAGE Code Nomenclature

F52606-501 82918 Towbar Assembly, Airplane

(Copies of drawings will be provided with the solicitation.)

2.2 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AMERICAN WELDING SOCIETY (AWS)

D1.1/D1.1M:2010 Structural Welding Code–Steel–22nd Edition D1.2/D1.2M:2008 Structural Welding Code–Aluminum–Fifth Edition

(Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami FL 33126.)

ASTM INTERNATIONAL (ASTM)

E165 Standard Practice for Liquid Penetrant Examination for General Industry

E1417/E1417M Standard Practice for Liquid Penetrant Testing

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA, 19428-2959.)

2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Program management.

3.1.1 Program manager. The contractor shall identify to the Government and maintain a single point of contact (Program Manager) for all matters under this contract. The contractor shall also ensure that all program management personnel assigned to the program shall be available, as required, to meet program objectives.

3.1.2 Plant access. The contractor shall arrange for full access to applicable contractor facilities and offices by Government representatives conducting any business, making observations, or performing inspections required by public law or by this contract.

3.1.3 Monthly status report and program schedule. The contractor shall prepare and submit a monthly status report and program schedule in contractor format for the towbar repair effort.

The monthly status report and schedule shall cover all phases of the repair program including, but not limited to; the design fabrication and assembly of necessary tooling, status of inspection and repairs for work in progress, as well as a projection of planned work for the remaining effort.

Delivery of the first completely repaired towbar shall not exceed 180 days from contract award.

Delivery of the remaining towbars shall not exceed the period of performance for the contract.

Reports shall document tasks, issues, actions, and deliverables. Problem areas shall be identified with proposed solutions and outcomes. The monthly status report and schedule shall be submitted for the life of the program or until the program manager notifies the contractor that the report is no longer required. (DI-MGMT-80227, Contractor's Progress, Status and Management Report)

3.2 Program reviews.

3.2.1 Post-award conference (PAC). The Government will convene the PAC at Robins AFB within 45 days after effective date (AED) of first delivery order. The Procuring Contracting Officer (PCO) will coordinate the actual date, time, and location of the conference with the contractor.

3.2.2 Program Management Review support. The contractor shall participate in and support all reviews, audits, and meetings as requested by the PCO or the contractor. Program Management Reviews shall be conducted quarterly or as required at a mutually agreeable location or via teleconferences.

3.2.3 Conference room. The contractor shall provide a conference room suitable for meetings of up to five Government representatives, plus contractor personnel, in support of scheduled meetings at the contractor’s facility.

3.2.4 Meeting agendas. The contractor shall publish an agenda for all meetings and conferences.

The contractor shall request from the Government any items or issues to be discussed or presented at the meetings, and shall include such items in the agenda. Agendas shall be submitted not less than five working days prior to any meeting. (DI-ADMN-81249A, Conference Agenda)

3.2.5 Meeting minutes. The contractor shall provide a written record of the discussions, decisions, and action items identified at each meeting. (DI-ADMN-81250A, Conference Minutes)

3.3 Repairs.

3.3.1 Stripping, cleaning, and degreasing components. Strip paint/primer and thoroughly clean and degrease all components. Caution, to avoid contamination and insure proper welding, do not use cleaning methods that may imbed contamination into the aluminum. Tag or mark each towbar component to maintain traceability of components to each unique towbar ID number.

Towbar ID traceability shall be maintained for each towbar component throughout the repair process.

3.3.2 100% Inspection and repair of welds. Perform 100% visual as well as 100% nondestructive (penetrant) inspection of the entirety of each component of the towbar including 100% of all welds for weld defects including but not limited to cracks, excessive undercut, incomplete fusion, excessive reinforcement, lack of penetration, etc., in accordance with ASTM E1417 and ASTM E165. Thoroughly remove and replace all defective welds in accordance with AWS D1.2. The contractor shall submit supporting data in the inspection and test report to show the location, extent, and progression of each weld repair accomplished. Pictures of the area before repair, following weld preparation, and of the final weld repair (prior to primer/paint finishing) shall be provided in the inspection and test report.

3.3.3 Boss holes. Remove and replace all bosses for main pivot points (5X) in accordance with guidelines of Attachment A and associated drawings F52606-501. Fabricate and install bushings in accordance with drawings F52606-501. All bushings are to be flanged bushings of the latest revision identified within the drawing package F52606-501. See Attachment D and drawing package F52606-501 for identification of pivot bushings.

3.3.3.1 Boss holes inspection criteria. The contractor shall measure and record each of the boss holes bore sizes and bushing sizes prior to assembly of bushings to demonstrate and verify that the press fit requirements associated with all bushings are met in accordance with the drawing package F52606-501. Press fits associated with bosses at the tail end of the -368 AFT Bar Assembly as well as fits associated with all other bosses shall be documented and verified by the contractor’s quality personnel and Government Defense Contract Management Agency (DCMA) Quality Assurance Representative (QAR) prior to assembly. See also, Attachment D, for inspection guidelines related to bosses and boss holes. Critical dimensions associated with each of the 5 main pivots shall be measured, recorded, and included in the inspection and test report.

The contractor shall submit all supporting data in the inspection and test report to verify that the boss hole repair is accomplished in accordance with the requirements in 3.3.3.1.

3.3.4 Aft bar inside corner welds. Weld the four inside corners of the -18 and -20 plates located in the corners of the long horizontal window through the center of the tube of the -368 AFT Bar Assembly (see sheet 8, C7, C8, C9 of drawing package F52606-501) in accordance with AWS D1.2. Welds shall extend all the way across the inside corners of each of the 4 joints inside the window. The contractor shall submit all supporting data in the inspection and test report to verify that the welds are accomplished in accordance with the requirements in 3.3.4.

3.3.5 Tow head straps. Fabricate, locate, and weld two -204 head straps to the tow head, 2 places, in accordance with AWS D1.2. See Attachment B, Figure 3-1, page 3-3 of TO 35B5-15-

21. See also Attachment B paragraph 3.10, pages 3-6A and 3-6B of TO 35B5-15-21. The contractor shall submit all supporting data for the tow head straps in the inspection and test report to verify that the straps are accomplished in accordance with the requirements in 3.3.5.

3.3.6 Main tube center splice. Repair the -376 Forward bar and -368 Aft bar center splice. The original configuration of the tube splice between the -376 Forward bar and -368 Aft bar at the center of the towbar incorporates 4 rows of 3 bolts each, 90 degrees apart. See view 1B9-9 of drawing package F52606-501 sheet 4 for reference. Repairs to the center splice shall be in accordance with section 3-13 of TO 35B5-15-21 page 3-7, Figure 3-13 page 3-21, Figure 3-14 page 3-22. See Attachment C. Note: Disregard use of 7/16 inch hardware. Install ½ inch hardware exclusively in the center splice for this repair effort. The contractor shall provide all supporting data for the center splice repair in the inspection and test report to verify that the main tube center splice repair is accomplished in accordance with the requirements in 3.3.6.

3.3.7 Steering arm. Inspect the steering arm for straightness, dents, or other damage. If the steering arm is bent or dented, fabricate a new steering arm in accordance with the drawing package F52606-501. Install new steering arm bushings in accordance with the drawing package F52606-501. All bushings are to be flanged bushings of the latest revision identified within the drawing package F52606-501. See Attachment D and the drawing package F52606-501 for identification of steering arm bushings. The contractor shall provide all supporting data for the steering arm in the inspection and test report to verify that the steering arm repair is accomplished in accordance with the requirements in 3.3.7.

3.4 Assembly and verification demonstration. Upon completion of all repairs, prior to finishing with primer/paint, the contractor shall assemble and verify the complete towbar assembly. The contractor shall assemble and verify all major components at the 5 main pivots and center splice to verify alignment of the towbar assembly and to insure there are no issues with fits or interferences. The contractor shall assemble the -368 AFT Bar Assembly, -364 Cross Beam, - 413 Steering Arm, -374 Beam Assembly-RH, -375 Beam Assembly-LH and -376 Forward Tube Assembly. All components shall move freely and smoothly through their full range of motion without binding or interference. Critical dimensions, alignment, straightness, squareness and parallelism of assembled components shall be measured and verified to meet applicable requirements of the TDP. The contractor shall include all measurements taken during the assembly and verification demonstration in the inspection and test report. The contractor shall submit all supporting data in the inspection and test report to verify that the assembly and verification demonstration is accomplished in accordance with the requirements in 3.4. The Government DCMA QAR shall be present during assembly and verification of each towbar. The contractor shall notify the procuring activity of the date, time, and location of the assembly and verification demonstration 30 days prior to the start of the demonstration. The Assembly and Verification demonstration may be witnessed by one or more Government (Robins and Barksdale) representatives.

3.4.1 Hardware kits. The contractor shall supply complete hardware kits containing all necessary hardware (nuts, nut plates, bolts, pivot bolts, flat washers, lock washers, etc.) required for final assembly of each of the towbars at the center splice and at each of the 5 main pivot points. The hardware kits shall be made up of new hardware. The hardware kits shall be shipped to the destination identified in the contract when the towbar components are returned to the destination identified in the contract. See 3.3.6 above and Attachment C for hardware associated with the main tube center splice. See Attachment D and the drawing package F52606-501 for identification of hardware used at each pivot point. All hardware shall be of the latest revision within the drawing package F52606-501.

3.5 Inspection and test procedure. The contractor shall identify the critical dimensions, inspections, tests, and data to be executed and recorded for quality control purposes in the course of all repairs and assembly verification for each major component of the towbar: -368 AFT Bar Assembly, -364 Cross Beam, -413 Steering Arm, -374 Beam Assembly-RH, -375 Beam Assembly-LH, -376 Forward Tube Assembly. Detailed inspection and test procedures shall be developed and executed to demonstrate and insure that each of the repairs and assembly verification meet the requirements set forth within the TDP and this SOW. The inspection and test procedures shall include data record sheets to be used in recording inspection and test results.

Inspection and test instruments shall be identified by manufacturer, model number, serial number and calibration date. The inspection and test procedure shall address the requirements of each of the paragraphs 3.3.1, 3.3.2, 3.3.3, 3.3.3.1, 3.3.4, 3.3.5, 3.3.6, 3.3.7, 3.4, and 3.4.1.

(DI-NDTI-80603A, Test Procedure)

3.6 Inspection and test reports. The contractor shall submit inspection and test reports to the procuring activity for each complete set of repaired towbar components. Each report shall be reviewed and approved (signed) by the contractor and Government DCMA QAR prior to submission to the procuring activity for approval. The report shall include all data collected during inspection, testing and assembly verification in accordance with the approved inspection and test procedures including the requirements of each of the paragraphs 3.3.1, 3.3.2, 3.3.3, 3.3.3.1, 3.3.4, 3.3.5, 3.3.6, 3.3.7, 3.4, 3.4.1 and 3.7, see 3.5. (DI-NDTI-80809B, Test/Inspection Report)

3.7 Protective coatings, and finish. All repaired towbar components shall be primed and finished as described below prior to shipment. The contractor shall provide all supporting data for the primer and topcoat materials in the inspection and test report.

3.7.1 Surface preparation and pretreatment. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications. Structures shall be cleaned, degreased, and scuffed or blasted prior to priming; primer shall be applied before any oxidation or rusting occurs. Aluminum surfaces shall have MIL-DTL-81706, Type II, Class 1A, chemical conversion coating applied in accordance with the manufacturer’s directions prior to priming.

3.7.2 Primer. Raw metal edges, to include fastener and drain holes, shall be coated with primer before applying topcoat.

3.7.3 Ferrous surfaces. Ferrous structures and surfaces shall be primed with a water reducible zinc rich primer in accordance with MIL-PRF-26915, Type II, Class B; this shall be followed, within four hours, by a coat of MIL-DTL-53030 intermediate primer in a wet-to-wet primer application. This two part primer system shall yield a dry-film thickness of 2.0-2.5 mils for the zinc primer and 0.9 to 1.1 mils for the intermediate primer. The two-primer system shall be allowed to dry and fully cure in accordance with the primer manufacturer's directions prior to top coating.

3.7.4 Aluminum and mixed aluminum and ferrous surfaces. Aluminum and mixed aluminum and ferrous structures and surfaces shall be primed with an epoxy primer, Type II, Class N of MIL-PRF-23377. This single part primer system shall yield a dry-film thickness of 0.6 to 0.8 mils.

3.7.5 Topcoat. Topcoat shall be polyurethane in accordance with Type I, Class H of MIL-PRF-85285. Neither Chemical Agent Resistant Coating (CARC) nor powder coating shall be used. Topcoat shall be applied to a dry film thickness of 1.6 to 2.4 mils in all instances, regardless of the primer system utilized. The coating shall be free from runs, sags, orange peel, or other defects.

3.7.6 Finish. The exterior finish color of the towbar components shall be GRAY, Color Number 26173 of FED-STD-595.

3.8 Configuration management.

3.8.1 Engineering change proposals (ECPs). Notwithstanding any other provision in the contract, no contractor or subcontractor's change in design, fabrication, assembly, part, material, process, or source of supply shall be made to the towbars unless such change is included within documents associated with this SOW or submitted in writing by ECP and approved by the procuring activity. Any request for change shall be accompanied by complete documentation supporting the need for the change. A Notice of Revision (NOR) shall be submitted with each ECP. (DI-SESS-80639D Engineering Change Proposal (ECP), DI-SESS-80642D, Notice of Revision (NOR))

3.8.2 Request for variance (RFV). The contractor shall prepare an RFV whenever a departure from the contractually-specified base line is proposed for a specific number of units or for a specific time. (DI-SESS-80640D, Request for Variance (RFV))

3.8.3 Technical data package (TDP). The TDP forms a part of this SOW and constitutes the end item product drawings F52606-501 as well as all other supplementary documents, drawings, and attachment provided as part of this SOW. The TDP is mandatory for use in repairing the towbars. No deviation from the TDP is permissible except as specified herein without prior approval of the procuring activity. Where tolerances could cumulatively result in incorrect fits, the contractor shall provide tolerances within those prescribed on the drawings to ensure correct fit, assembly, and operation of the towbar. If discrepancies with the TDP are noted during the repair of the towbar the contractor shall notify the procuring activity of such discrepancies via ECP’s. Any data prepared by the contractor or obtained from a vendor to support repair of the towbar shall be made available, upon request, for inspection by the procuring activity. Any changes or deviations from the TDP required to effect repairs shall be processed via approved ECP(s) if not otherwise authorized within documents provided herein.

3.9 Welding process quality control. The contractor shall establish and maintain a comprehensive welding process quality control program for the repair and fabrication of all welded components of the towbars in accordance with the applicable welding specifications AWS D1.1, AWS D1.2. Detailed welding procedures and necessary jigs and fixtures shall be developed, qualified and maintained. All personnel performing welding tasks using the qualified welding procedures shall be certified to perform the procedures. Responsibility for establishing and maintaining welding quality control procedures and processes lies with the prime contractor.

The prime contractor must coordinate and maintain the welding quality control program with all subcontractors performing welding tasks. The prime contractor shall maintain appropriate auditable records documenting the welding process quality control program, qualified welding procedures, and welding personnel certifications for the life of the contract.

3.10 Government property.

3.10.1 Contractor responsibility. The contractor shall be responsible for Government property in their possession in accordance with the Federal Acquisition Regulation (FAR) and applicable supplements including, but not limited to, FAR Part 45, Government Property; FAR 52.245-1, Government Property; and Defense Federal Acquisition Regulation Supplement (DFARS) Part 245, Government Property. The FAR and applicable supplements can be accessed at the site below.

http://farsite.hill.af.mil

3.10.2 Government property to be provided. The Government will provide only the major components of the towbar to be repaired or necessary for use in assembly verification demonstration: -368 AFT Bar Assembly, -364 Cross Beam, -413 Steering Arm, -374 Beam Assembly-RH, -375 Beam Assembly-LH, -376 Forward Tube Assembly. Hardware such as bushings, nuts, bolts, etc., will not be provided. The Government property will be available for contractor pickup at Barksdale AFB within approximately 30 days after contract award. The contractor shall have use of the property for the duration of the repair effort and return it to the Government at the conclusion of the repair effort. The contractor shall be responsible for all costs associated with shipping of the property from Barksdale AFB to the contractor facility and from the contractor facility back to Barksdale AFB.

3.10.3 Loss of Government property.

3.10.3.1 Definition of Loss of Government Property. In accordance with DFARS 252.245-7002, Reporting Loss of Government Property, “loss of Government property” means unintended loss of or damage to Government property including property that cannot be found after a reasonable search, loss due to inadequate storage, theft, loss due to lack of security, damage requiring repair to restore the item to usable condition, or damage that renders the property useless for its intended purpose or Beyond Economical Repair (BER). Loss of Government property does not include manufacturing defects, obsolescence, normal wear and tear, or purposeful destructive testing. Unless otherwise stated in the contract/order, loss of Government property does not include normal and reasonable inventory adjustments, i.e., losses of low priority consumable material, such as common hardware, as agreed to by the contractor and the Government Property Administrator.

3.10.3.2 Reporting loss of Government property. The contractor shall use DCMA eTools software application to report loss of Government property at the site below. The reporting requirement does not change any liability provisions or other reporting requirements that may exist under the contract/order.

http://www.dcma.mil/aboutetools.cfm

3.10.3.3 Return of Government property. All property provided by the Government remains the property of the Government and shall be returned to the Government upon completion of the contract/order. All Government property shall be returned to the Government in the condition provided or in the fully repaired condition in accordance with this SOW unless approved in advance by the PCO. All material generated under the contract/order becomes the property of the Government and shall be returned to the Government upon completion of the contract/order.

All Department of Defense (DD) Form 1423, Contract Data Requirements List (CDRL), deliverables become the property of the Government upon receipt.

3.10.3.4 Commercial Asset Visibility-Air Force (CAV-AF) . The Contractor shall report production using CAV-AF. The Contractor shall provide data on the actions conducted for each unit. The Contractor shall report daily or as actions occur. If CAV-AF training is required, Contractor personnel may send an email to: 406scms.cav.af.ar@robins.af.mil.

(DI-MGMT-81634B, Commercial Asset Visibility Air Force (CAVAF) / Government Furnished Material Report)

3.11 Safety and health. While performing work under this contract the contractor shall comply with all applicable federal, state, and local regulations regarding occupational safety and health.

The contractor shall notify the PCO within eight (8) hours of any damage to the Government property where the dollar value exceeds $500,000.00 and within two workdays, for any damage to the Government property less than $500,000.00 during the execution of the contract.

Mishap notifications shall contain, as a minimum, the following information:

a. Contract, Contract Number, Name and Title of Person(s) Reporting

b. Date, Time and exact location of accident/incident

c. Brief Narrative of accident/incident (Events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to repair/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

g. Corrective actions (taken or proposed)

h. Other pertinent information

If requested by the designated PCO, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

3.12 Risk management. The contractor shall develop, implement, and conduct a risk management program; criteria can be found in the Risk Management Guide for DoD Acquisition.

Risk is defined as:

A measure of future uncertainties in achieving program performance goals within defined cost and schedule constraints. It has three components: a future root cause, a likelihood assessed at the present time of that future root cause occurring, and the consequence of that future occurrence.

A future root cause is defined as, “The reason, which, if eliminated or corrected, would prevent a potential consequence from occurring. It is the most basic reason for the presence of a risk.” A consequence is defined as, “The outcome of a future occurrence expressed qualitatively or quantitatively, being a loss, injury, disadvantage, or gain.” A related term is an issue, defined as, “A problem or consequence which has occurred due to the realization of a root cause. A current issue was likely a risk in the past that was ignored or not successfully mitigated.” The risk management process deals with identifying and mitigating risks so that they do not become issues.

The risk management process model includes the following activities, performed on a continuous basis:

a. Risk Identification,

b. Risk Analysis,

c. Risk Mitigation Planning,

d. Risk Mitigation Plan Implementation,

e. Risk Tracking

The risk management analysis, mitigation plan, and tracking shall be included as an attachment to the monthly status report (see 3.1.3).

3.13 Workmanship. The towbars, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.13.1 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.13.2 Cleaning. The towbars shall be thoroughly cleaned. Loose, spattered, or excess welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly and prior to finishing in accordance with 3.7.

3.14 Packaging.

3.14.1 Packaging and marking. The contractor shall package and mark end items and components in accordance with the contract (basic or order, as applicable) Air Force Materiel Command (AFMC) Form 158, Packaging Requirements; MIL-STD-129P, MIL-STD-130N, and MIL-STD-2073-1D. The contractor shall package and mark material in accordance with other applicable Government regulations including, but not limited to, those regarding security, safety and environmental concerns.

3.14.2. Protection and preservation. The contractor shall package and mark material for movement, shipment, receipt and storage in a manner that ensures the protection and preservation of the material for shipment to and storage at the destination.

3.14.3 Shipping containers. In accordance with MIL-STD-2073-1D, shipping containers received, which meet the requirements of the AFMC Form 158 and are suitable for return shipment of serviceable assets, shall be reclaimed and stored for reutilization. Unsuitable shipping containers shall be disposed of and replaced with new containers that meet the requirements of the AFMC Form 158.

3.14.4 Palletization. If applicable, the contractor shall palletize loads for shipment in accordance with MIL-STD-147E.

3.15 Government-Industry Data Exchange Program (GIDEP). The Contractor shall participate in GIDEP in accordance with Air Force Joint Instruction (AFJI) 63-108, Government-Industry Data Exchange Program (GIDEP), and GIDEP Operations Manual S0300-BT-PRO-010, Government-Industry Data Exchange Program. The Contractor shall submit all appropriate data to GIDEP, as it is generated, in accordance with the CDRLs of the contract/order.

The Contractor shall review each Alert/Safe-Alert report received from GIDEP to determine if the item or process for which the Alert/Safe Alert report is issued is applicable to the contract/order and take appropriate action. Upon the determination that an Alert/Safe-Alert report is applicable, the Contractor shall inform the impacted organizations and subcontractors in accordance with the CDRLs. The Contractor shall maintain a record of the status and disposition of all Alert/Safe-Alert reports in accordance with the CDRLs. (DI-QCIC-80125B, GIDEP Alert/Safe-Alert Report; DI-QCIC-80126B, GIDEP Alert/Safe-Alert Response; DI-QCID- 80127A, GIDEP Annual Progress Report)

ATTACHMENTA

BOSS HOLE REPAIR GUIDELINES FOR B52 TOWBAR

Boss holes shall be repaired in accordance with specifications within drawing package F52606-

501. There are 5 areas on the -501 Tow Bar that contain sets of boss holes. The -368 AFT Bar Assembly contains boss holes at the -364 Cross Beam center pivot (1A) and at the -413 Steering Arm pivot (1B). The -374 Beam Assembly-RH contains boss holes at the -364 Cross Beam right side pivot (2A) and at the -413 Steering Arm pivot (2B). The -375 Beam Assembly-LH contains boss holes at the -364 Cross Beam left side pivot (3A). Altogether, there are 5 locations on the - 501 Tow Bar that contain boss holes. Since the assemblies to be repaired are of hard welded construction, particular minor deviations from the drawing specifications may be necessary to effect the repairs.

1) Repair guidelines for Aft Bar Assembly -368

1A) Boss holes at -364 Cross Beam center pivot.

Remove -366 bosses from -22 aft towbar flanges (2x) and -365 plates (2x), see Note 1 below.

Fabricate -366 bosses (2x).

3A

Press fit -366 bosses into -22 aft towbar flanges (2x) and -365 plates (2x).

Weld -366 bosses to -22 towbar flanges and -365 plates.

Bore 1.7500/1.7506 diameter boss holes inline and square to centerline of Aft Bar Assembly.

Finish machine the 10.98/11.00 dimension square to centerline of boss holes.

Note 1: Replace -365 plates only as required. Straighten aft towbar flanges as required.

Inspection: Check hole size and alignment of 1.7500/1.7506 diameters (2x), (alignment may be checked with functional gauge), 10.98/11.00 dimension including squareness of these surfaces to boss hole centerline (may be checked with functional gauge).

1B) Boss holes at -413 Steering Arm pivot (section 1C8)

Bore 1.3750 diameter holes (4x) to 2.500 diameter (4x) inline and through - 17 boss, - 236 tube and -18 stiffener.

Clean up -236 tube (2x) as required to remove any remaining portions of -17 bosses.

Chamfer the 2.500 diameter hole in the -18 stiffener .13x45 degrees for weld prep (2x).

Fabricate aluminum repair plugs (2x) for slip fit with 2.500 diameter holes, plugs approximately 4.00 long. Chamfer plugs .13 x 45 degrees for weld prep.

Check the 4.50 plus/minus .03 dimension.

Locate plugs for welding flush to the surface of the -18 stiffener and protruding approximately .20 above -236 tube. Note: The plug protruding from the tube will eliminate the need for -17 boss. Assemble the plug such that the chamfer on the plug mates with the chamfer on the hole to allow a flush weld. Weld plugs all around (4x).

Weld plugs flush to -18 stiffener.

Clean up weld as required, maintain 4.50 plus/minus .03 dimension.

Bore 1.3750/1.3756 diameter holes through the plugs, inline and square to centerline of the Aft Bar assembly. The 1.3750/1.3756 diameters shall be held for a minimum depth of 1 inch on both ends of each plug, bore may be larger elsewhere.

Inspection: Check hole size and alignment of 1.3750/1.3756 diameters (4x), (alignment of all holes at once may be checked with functional gauge), 4.50 plus/minus .03 dimension.

2) Repair guidelines for Beam Assembly-RH -374 (see -234 & -135 Beam Assembly-RH)

2A) Boss holes at -364 Cross Beam right side pivot.

Remove -40 bosses from Beam Assembly-RH (2x).

Fabricate -40 bosses (2x).

Fit -40 bosses into Beam Assembly-RH (2x).

Weld -40 bosses.

Bore 1.3750/1.3756 diameter boss holes inline and square to centerline of Beam Assembly-RH (2x).

Finish machine the 10.98/11.00 dimension square to centerline of boss holes.

Inspection: Check hole size and alignment of 1.3750/1.3756 diameters (2x), (alignment may be checked with functional gauge), 10.98/11.00 dimension including squareness of these surfaces to boss hole centerline (may be checked with functional gauge).

2B) Boss holes at -413 Steering Arm pivot.

Remove -38 bosses from Beam Assembly-RH (2x).

Fabricate -38 bosses (2x).

Fit -38 bosses into Beam Assembly-RH (2x).

Weld -38 bosses.

Bore 1.3750/1.3756 diameter boss holes inline and square to centerline of Beam Assembly-RH (2x).

Finish machine 4.50 plus/minus .03 dimension square to centerline of boss holes.

Inspection: Check hole size and alignment of 1.3750/1.3756 diameters (2x), (alignment may be checked with functional gauge), 4.50 plus/minus .03 dimension including squareness of these surfaces to boss hole centerline (may be checked with functional gauge).

3) Repair guidelines for Beam Assembly-LH -375 (see -235 & -236 Beam Assembly-LH)

3A) Boss holes at -364 Cross Beam left side pivot.

Remove -40 bosses from Beam Assembly-LH (2x).

Fabricate -40 bosses (2x).

Fit -40 bosses into Beam Assembly-LH (2x).

Weld -40 bosses.

Bore 1.3750/1.3756 diameter boss holes inline and square to centerline of Beam Assembly-LH (2x).

Finish machine the 10.98/11.00 dimension square to centerline of boss holes.

Inspection: Check hole size and alignment of 1.3750/1.3756 diameters (2x), (alignment may be checked with functional gauge), 10.98/11.00 dimension including squareness of these surfaces to boss hole centerline (may be checked with functional gauge).

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d. Prior to removing guide sleeve (15), remove sleeve seal details (12 through 14) and key (16). Then ascertain that set-screw (6) which secures guide sleeve threads is removed or fully loosened; and unscrew guide sleeve from housing (23).

e. Do not remove plug (18) from end of traveling sleeve

(17) unless damaged.

3-8. REPLACEMENT OF POWER-PAK ACTUATOR, FIG-

URE 3-15.

The assembled towbar weighs approximately 2500 pounds. No attempt shall be made in performing re-placement of power-pak without first supporting aft towbar tube assembly at left and channels and by supporting forward tube assembly just aft of lunette.

Serious injury to personnel may result when handling unsupported or unstable towbar.

NOTE

Repair of bracket assembly Figure 3-1, index 7 when welds break may be accomplished by locally manu-facturing a plate, 4” X 15” X 1/2” T. Drill three 1/2-inch holes in addition to drilling upper and lower matching holes and then insert hi-coils. Attach plate using six each 1/2-inch bolts approximately 3” long securing it to the tube assembly.

(1) Remove power-pak actuator (24), Figure 3-1, and attached clevis assemblies (8) from towbar.

(2) Remove clevis assemblies (8) and traveling sleeve

(17) Figure 3-2.

(3) Attach one clevis assembly to the threaded end of the traveling sleeve.

NOTE

If traveling sleeve is not available, a suitable steel bar may be used in its place with both ends machined to

1.25 inches in diameter, see Figure 3-15.1.

(4) Attach clevis assemblies to threaded bar and secure with roll pins. Ensure both clevis assemblies are positioned identically on the traveling sleeve to allow proper installation on the towbar.

(5) Attach clevis bar to the towbar using quick release pins 5315-00-702-3139, wire rope 4010-00-575-6234 and swedges 4030-00-431-5538 to each clevis.

(6) Obtain aluminum stock NSN 9530-00- 236-0333.

Cut one piece 12” by 6” and two pieces 4” by 6”.

(7) Drill four holes and assemble aluminum pieces using bolts NSN 5306-00-151-0694, washers NSN 5310-00-167- 0823 and nuts NSN 5310-00-067-9507, see Figure 3-15.2.

(8) Set aluminum assembly on cross-member arm, 4.5 inches from the end, see Figure 3-15.2. Drill three holes and attach aluminum assembly to arm. Drill 0.75 inch hole cen-tered 2.5 inches from the top of the aluminum arm assembly, see Figure 3-15.2.

NOTE

Due to the weight of the trunnion and wheel assem-blies, it is advisable one person be available on each side of towbar to raise and lower to the desired posi-tion while the third person installs the quick release pin.

3-9. CLEANING.

• Perform all solvent cleaning operations in an ap-proved cleaning cabinet or in a well ventilated ar-

ea. Avoid prolonged breathing of vapors. Avoid eye and repeated skin contact. Keep solvents away from sparks and flames.

• Use approved personal protective equipment (gog-gles/face shield) when using compressed air. Maxi-mum allowable air pressure for cleaning operations is restricted to less than 30 psi. Provide protection from flying particles when using com-pressed air. Do not direct airstream towards self or other personnel.

3-10. INSPECTION AND REPAIR OF TUBES FOUND

WITH MISSING ALUMINUM ALLOY BARS (FIGURE 3-

1, INDEX 204).

a. Secure wheels with chocks.

b. Inspect forward bar assembly (index 115) for two alumi-num alloy bars.

Change 25 3-6A

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3-13. The following repair procedures may be performed on the towbar when necessitated by component damage or equip-ment malfunction:

• All weld repairs shall be performed in a well-ven-tilated area, removed from vicinity of oil, paint, or other flammable material.

• Welding/cutting/brazing operations produce heat, metal fumes and slag, injurious radiation and air-borne particles. Adequate ventilation is required in accordance with AFOSH Standard 161-2. Welding helmet/hand shield, welding goggles with proper tinted lenses, apron/jacket, welding gloves and welder’s boots are required.

• Penetrant inspection includes exposure to flamma-bles, chemicals that may affect skin, eyes, and res-piratory tract, and also the use of black light. Wear neoprene gloves and keep insides of gloves clean when handling penetrant materials. Chemical gog-gles, apron, and gloves will be worn when spray-ing penetrant or when processing parts. Care will be exercised when using hot black lights so as to not burn hands, arms, face, or other exposed body areas. When recommended by the Base Bioenvi-ronmental Engineer, an approved respirator will be worn when working in areas where adequate venti-lation cannot be practically provided.

a. All structural end welded areas may be repaired by welding. After performing weld repairs, test each repaired fer-rous alloy part for cracks with magnetic particle inspection process specification MIL-I-6868 and test repaired alum-alloy parts for cracks with fluorescent penetrant inspection method, specification MIL-I-6866. All weld repairs shall be performed in a well ventilated area, removed from vicinity of oil paint, or other flammable material. The channel assembly Part No.

F52606-42 and -56 attachment holes for six bolts Part No.

AN10-43A sometimes become elongated allowing the attach-ing plate Part No. F52606-41 to slip. They may be reworked by drilling the holes in the channel and attaching plates to 3/4 inch to allow using bolts AN12-43A, FSN 5306-590-2700 to replace the original bolts Part No. AN10-43A.

(1) If bolt holes in tube assembly (203) become elon-gated, follow repair procedures outlined below. Bolts holes in this position come from the manufacture size 0.469 - 0.473 inch. Torque in accordance with TO 1-1A-8. The maximum size the elongated holes can be drilled is 0.531 inch. If elonga-tion exceeds the limits set forth in paragraph (2) (d) repair procedures in paragraph (3) shall be authorized. After repair procedure (3) (d) has been accomplished twice, a 107 shall be submitted to WRALC for evaluation and repair.

(2) Manufacture repair plates in accordance with Figure 3-13. Eight plates will be used, four on the inside and four on the outside. The outside plates will act as a wearing surface for bolts and the inside plates will have nut plates installed on them. The inside plates will be attached to the tube with 3/16 inch countersunk screws. Disassemble and follow repair pro-cedures:

(a) When 7/16 inch bolts are used and holes are elon-gated between a tolerance of 0.474 and 0.493 inch use 7/16 inch hardware listed in Figure 3-14 and 0.437 inch holes in repair plates.

(b) When 7/16 inch bolts are used and holes are elon-gated beyond 0.493 inch in tube, redrill tube to 0.500 inch.

Use 1/2 inch hardware listed in Figure 3-14 and 0.500 inch holes in repair plates.

(c) When 1/2 inch bolts are used and holes are elon-gated between a tolerance of 0.510 and 0.520 inch use 1/2 inch hardware listed in Figure 3-14 and 0.500 inch holes in repair plates.

(d) When 1/2 inch bolts are used and holes are elon-gated beyond 0.520 inch in tube, redrill to 0.531 inch, use 1/2 inch hardware listed in Figure 3-14 and 0.500 inch holes in repair plates.

Inner Tube: Locate the bolt holes from the towbar to the plate and 3/16 inch screws to mount plates on towbar. Install the nut plates on repair plate and secure the plate to the towbar with 3/16 inch countersunk screws in 4 places in accordance with Figures 3-13 and 3-14.

Outer Tube: Locate the holes from the towbar to the plate in accordance with Figures 3-13 and 3-14.

(3) The maximum size the elongated holes can be drilled is 0.531 inch. If elongation exceeds the limits of 0.551 inch, repair by the following procedures shall be authorized:

(a) Repair by plug welding the elongation with weld-ing rod MIL-4043 in accordance with MIL-E-15597 and redrilling the hole to 0.437 - 0.446 inch diameter. During welding process, the holes should be welded alternately 180 degrees from each other to reduce heat concentration. Manu-facture inner tube repair plates as described in Figure 3-13 using 0.437 inch holes and 7/16 inch hardware listed in Figure 3-14.

(b) When 7/16 inch bolt holes are elongated between a tolerance of 0.447 and 0.467 inch use repair procedures in paragraph (2) with 7/16 inch hardware listed in Figure 3-14 and 0.437 inch holes in repair plates.

(c) When holes are elongated beyond 0.467 inch in tube, redrill tube to 0.500 inch. Use 1/2 inch hardware listed in Figure 3-14 and 0.500 inch holes in repair plates.

(d) When elongation is beyond 0.520 inch revert back to repair procedures (2) (d) and repeat repair process.

(4) Ferrous-alloy handle assembly (23), stabilizer assemblies (40, 41), steering arm assemblies (46), latch lever assemblies (52, 53) and weldment of crank assembly (66).

(5) Aluminum-alloy bumper plate assembly (96), weld-ment of support assembly (100), and handle assemblies (106).

Change 21 3-7

Figure 3-13. Tube Assembly Repair Plates

Change 23 3-21

Figure 3-14. Tube Assembly Repair #1

3-22 Change 23

Figure 1. Aircraft Towbar, PN F52606-501 (Sheet 2)

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