Vertical Carousel Product Description.docx

Offeror:

-R-

PRODUCT DESCRIPTION

FOR

VERTICAL CAROUSELS

AT

ARKANSAS AIR NATIONAL GUARD

LITTLE ROCK AFB AR

BUILDING 140

CSN: NLR0A6

DATE: 2 August 2010

PREPARED BY:

Robert O. Burns

PROJECT ENGINEER

403 SCMC/GUEC

Timothy L Madden

REVIEWER

403 SCMC/GUEC

Vertical Carousels TPQ Page 1 of 4 Table of Contents

ARANG Little Rock AFB AR PD - Page iii

SCOPE

General Scope This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for two vertical carousels for the Engine Shop, in Building 140, Arkansas Air National Guard, at Little Rock AFB AR. The work shall be completed in accordance with this appendix, the cover purchase description (PD), and Air Force (AF) Drawing NLR 0A6-01. This appendix covers all equipment, materials, and labor necessary to complete the installation of the system.

Definitions Carrier - A fabricated metal structure attached to the carrier lift chains used to contain and transport stored items.

Carrier live load capacity - Actual amount of load supported by a carrier, but not including the weight of the carrier.

Multiple tier carrier - A carrier that provides more than one storage level.

Single tier carrier - A carrier that provides one storage level.

Storage levels - The total number of levels available within a carousel to contain and transport stored items provided by single and/or multiple tier carriers.

APPLICABLE DOCUMENTS

The following documents form a part of this PD to the extent specified herein. The issue in effect on the date the solicitation is issued shall apply.

Government documents

AIR FORCE OCCUPATIONAL SAFETY AND HEALTH (AFOSH)

AFOSH 48-19

AFOSH 91-5

Hazardous Noise Program

Welding, Cutting, and Brazing

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) STANDARDS

AIR FORCE DRAWING

Bldg. 140 Arkansas Air National Guard Little Rock AFB AR 2 August 2010

Non-Government documents

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

(Applications for copies shall be addressed to the American Institute of Steel Construction, Inc, 1 East Wacker Drive, Chicago IL 60601)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

(Applications for copies shall be addressed to the American National Standards Institute, 1430 Broadway, New York, NY 10018)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A153/A153M

Standard Specification for Zinc Coating(Hot-Dip) on Iron and Steel Hardware

(Applications for copies shall be addressed to the American Society for Testing and Materials, 1916 Race Street, Philadelphia PA 19103)

AMERICAN WELDING SOCIETY (AWS)

(Applications for copies shall be addressed to the American Welding Society, Inc, 550 NW Lejeune Road, P.O.Box 35140, Miami FL 33135)

NATIONAL ELECTRICAL MANUFACTURER'S ASSOCIATION (NEMA)

(Applications for copies shall be addressed to the National Electrical Manufacturers Association, 2101 L Street, NW, Washington DC 20037)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

(Applications for copies shall be addressed to the National Fire Protection Association, One Batterymarch Park, P.O. Box 9101, Quincy MA 02269-9101)

SOCIETY OF AUTOMOTIVE ENGINEERS, INC (SAE)

(Applications for copies shall be addressed to the Society of Automotive Engineers, Inc, 400 Commonwealth Drive, Warrendale PA 15906)

REQUIREMENTS

System description The Contractor shall provide two vertical carousels located as shown on AF Drawing NLR 0A6-01 which shall store and retrieve a wide range of small parts tools. Items shall be retrieved by keying in the carrier tier number where the part is located. The carousels shall rotate vertically, independent of the other vertical carousels and shall consist of the following:

A. Carriers B. Controls C. Conduit, wiring, mechanical fasteners and all other items required to install operational vertical storage carousels.

D. Storage containers and dividers E. Metal dividers

Performance and physical characteristics Unit dimensions The external dimensions of the carousels shall be a maximum of 6 feet 6 inches deep and 11 feet 6 inches wide. Depth shall exclude the countertop. The Contractor shall provide vertical carousels that are a minimum of 10 feet high, but no higher than 12 feet high. All carousels shall be the same height.

Carriers Carrier installation The Contractor shall maximize the number of storage levels available within both carousels within the limitations imposed by the maximum height cited in 3.2.1., the facility and the design of the contractor’s proposed equipment. Spacing between the top of a carrier side and the bottom of the next carrier side shall not exceed 2 inches.

Carrier configuration Both carousels shall have one-half of its carriers as double-tier carriers and one-half of its carriers as single-tier carriers. The contractor, in accordance with the manufacturer, shall maximize the storage configuration based on the shelf levels.

Carousel Unit Letter

Storage Levels

Or Dividers

Single Tier Containers Dividers

Single Tier Containers Dividers

Carrier capacity Each storage level shall have a minimum net live load capacity of 200 pounds. Each carrier shall have a minimum net live load capacity, not including the weight of the carrier and tiers, as follows:

STORAGE LEVELS PER CARRIER X 200 POUNDS PER STORAGE LEVEL

= MINIMUM NET LIVE LOAD CAPACITY PER CARRIER

Carrier dimensions The minimum usable depth of each carrier shall be:

Each carrier shall have a minimum usable width based on the containers specified in 3.2.15. and the following formula:

(PUBLISHED MAX EXTERNAL WIDTH OF A CONTAINER IN INCHES + 1/4)

X 14

= MINIMUM USABLE CARRIER WIDTH IN INCHES

The minimum usable depth of each carrier shall be 24 inches. Each carrier tier shall have a minimum usable width of 96 inches.

CARRIER FABRICATION

All carrier tiers shall have a lip to prevent items from accidentally sliding over the edge of the carrier. The lip shall be a minimum of 1/4 inch high and a maximum of 1/2 inch high. Each tier shall have a solid back that extends from the bottom to the top of the usable height of each tier. All carrier tiers shall have slots to permit insertion of metal dividers.

Carrier deformation All carrier structural members shall not exhibit elastic deformation greater than 0.50 percent of the distance between the ends of each carrier when loaded to capacity. No carrier structural members shall exhibit permanent deformation.

CARRIER Tier markings Each carrier tier shall be marked with its associated number beginning with number one and progressing through all the tiers of the carousel. The number shall be contrasting to the tier color and shall be located in three positions (left, center, right), which are visible to the operator, on a fully loaded tier. The numbers shall be stick on labels permanently affixed to the tiers.

Safety factor Each carrier lift chain shall have a minimum 6-to-1 safety factor based on yield strength.

Travel speeD The carousel carrier travel speed shall be a minimum of 24 ft/min.

Retrieval method Each carousel shall automatically utilize the shortest route method of retrieval.

Stopping accuracy Each carrier tier shall stop within 0.60-inch of the position of the previous carrier tier chosen at the carrier access opening while at balanced load conditions when measured from the work counter.

Service life All equipment furnished shall be new and shall be of high quality to ensure that the completed system is designed to function a minimum of 1,500 hours based on the time registered by the hour meter specified in 3.2.25. or that all equipment has a design service life of 15 years or longer.

Structure The carousels shall have a steel framework that shall support the fully loaded system without the use of the enclosure panels as specified in 3.2.9. and shall not be attached to another carousel or to the building, except for the floor. The carousels shall be anchored to the floor in a minimum of four places. The carousels shall be designed such that the weight of a fully loaded carousel shall be uniformly distributed over the warehouse floor with a live load capacity of 250 pounds per square foot.

Enclosure panels Outer surfaces of the carousels shall have bolted solid metal enclosures for security. The enclosures shall be bolted from the outside to permit removal for maintenance or emergency access. A solid metal enclosure to close off the top of the carousels shall be installed. The front of the carousels shall have a carrier access opening to permit operator access to stored material. The carrier access opening shall have a spring-loaded counter balanced door capable of being closed and locked to provide maximum security when unattended. Two sets of keys shall be provided for the unit.

Maintenance service door A service door shall be provided below the counter for maintenance access to operating parts such as motors, brakes, and reducers. The door shall be equipped with safety interlock switches to prevent carousel operation when the service door is open.

Mechanical control The carousels shall have some means of operation, such as a hand crank, which shall rotate the carriers in the case of a power outage or maintenance requirements. The mechanism shall easily and manually rotate the carriers and shall be easily accessible.

Work counter The carousels shall have a fixed work counter in front of the carrier access opening. The counter shall be laminate. The counter shall be a minimum length no less than the width of the carriers and have a minimum depth of 10 inches. The counter shall be installed a nominal height of 40 inches above the floor.

Unit markings The unit shall be marked with a letter beginning with the letter A. The letters shall not be placed on the carousels until approval for correct lettering is provided by the Contracting Officer or technical representative (COTR). The letters, which shall be placed on the vertical carousels face at a position visible and legible to the operator, shall be a contrasting color to the carousels color. The letters shall be a minimum 8 inches high and 6 inches wide and shall be stick on labels permanently affixed to the units.

Drive components Motors Motors shall be of sufficient size for the duty to be performed and shall not exceed their full-rated load when the driven equipment is operating at the specified maximum capacity under the most severe conditions likely to be encountered. All motors shall be designed for continuous duty at ambient temperature, 32 to 104 degrees Fahrenheit. Motors shall be drip proof and shall be designed to operate on electrical power characteristics as they exist at the site. Motor shall have an electronically controlled soft start and shall be equipped with an overload device. Motors shall be located at the bottom of the carousels for easy access for service and maintenance.

Gear reducers Gear reducers shall not permit oil to leak. The maximum input horsepower rating of the gear reducer shall not be less than the horsepower of the attached drive motor. Motor and reducer frames shall be compatible.

Vertical CAROUSEL Containers Vertical CAROUSEL ‘A’ double-tier carrier Containers A minimum of 14 plastic containers shall fit on each double-tier. The containers shall be Akro-Mils Shelf Bin Model Number 30138 or equivalent as approved by the COTR. The containers shall have nominal exterior dimensions of 6-1/2 inches wide by 4 inches high by 18 inches deep. The containers shall have a minimum inside width of 5-1/2 inches to permit use of Government identification labels. The containers shall have a minimum of 6 positions to install dividers. Three dividers shall be provided for each container. The dividers shall be easily inserted into or removed from the positions to hold the dividers within the container and shall remain secured while in position.

single-tier carrier Containers A minimum of 10 plastic containers shall fit on each single tier. The containers shall be Akro-Mils Shelf Bin Model Number 30265 or equivalent as approved by the COTR. The containers shall have nominal exterior dimensions of 8-1/2 inches wide by 9 inches high by 18 inches deep. The containers shall have a minimum label slot width of 5-1/2 inches to permit use of Government identification labels. The containers shall have a minimum of 6 positions to install dividers. Three dividers shall be provided for each container. The dividers shall be easily inserted into or removed from the positions to hold the dividers within the container and shall remain secured while in position.

Vertical CAROUSEL ‘B’ double-tier carrier Containers A minimum of 10 plastic containers shall fit on each double-tier. The containers shall be Akro-Mils Shelf Bin Model Number 30164 or equivalent as approved by the COTR. The containers shall have nominal exterior dimensions of 6-5/8 inches wide by 4 inches high by 23-5/8 inches deep. The containers shall have a minimum label slot width of 5-1/2 inches to permit use of Government identification labels. The containers shall have a minimum of 6 positions to install dividers. Three dividers shall be provided for each container. The dividers shall be easily inserted into or removed from the positions to hold the dividers within the container and shall remain secured while in position.

Container markings The containers on each carrier tier shall be marked with the corresponding carrier tier number and container letter from left to right (i.e. "1A","1B","1C" ...). The letters I and O shall be omitted. The container markings shall be stick on labels. The labels shall not peel, rub, slip, or chip off. Numbers and letters shall be a minimum 1 inch high and 1/2 inch wide and contrasting to the container color.

metal Dividers A minimum of five plain metal dividers, of the appropriate size, shall be provided for each tier of both vertical carousels. The dividers shall be utilized with slotted carrier tiers to separate property. The dividers shall be a minimum of 5 inches high and the depth shall extend within 1 inch of the usable depth of the carrier tier.

Noise levels The Contractor shall consider noise levels in the design of the equipment. Hazardous noise shall not exceed 85 decibels A-weighted sound pressure level (dB(A)) for 8 hours in any 24-hour period or equivalent in accordance with AFOSH 48-19. Noise level measurements will be taken at a three-foot distance from the equipment producing the noise and at a level of five feet above the ground/floor in all locations in which personnel may be present during normal operations. If noise levels of installed equipment exceed this requirement, then noise shall be reduced through engineering controls; i.e., insulation, dampening, and isolation.

Electrical characteristics Operation The carousels shall operate on 208/120 volt, 60 hertz, 3 phase, 4-wire electricity obtained from the power panel on the electrical mezzanine, Room 119 as shown on AF Drawing NLR0A6-01.

Controls The carousels shall have a permanent control cluster that is push button or membrane type. The control cluster shall be located above the carrier access opening and shall be no higher than 76 inches from the floor. The control cluster shall contain as a minimum, a numeric keypad for inputting a carrier tier address, manual up and down keys, a button to clear an incorrect carrier tier address, a button to activate movement of the carousel to the desired carrier tier, and a red emergency stop button. The control cluster shall have a LED display which shall indicate the current carrier tier. A carrier tier shall be called by keying in on the numeric keyboard the carrier tier number which shall be as specified in 3.2.2.7.

Independent disconnect The carousels shall have a master on/off switch on the face of the carousel to control the carousel's electrical power. This switch shall have some means (i.e. key switch, padlock, etc.) of locking it into the off position.

Imbalanced load indicator An indicator shall be mounted on the face of the carousels to indicate if the carousel exceeds the designed imbalanced load limit of the vertical carousel. If the imbalance load limit is exceeded, the carousel shall produce an indication that the limit has been exceeded.

Obstruction sensors Sensors shall be mounted on the carousels at the work station to stop the movement of the carousel if an object should extend through the plane of the carrier access opening. The sensors shall include photoeyes projecting horizontally across the top and bottom of the carrier access opening and touch bars on the top and bottom of the carrier access opening.

Lighting The carousels shall have integrated overhead lighting, which shall measure a minimum of 50 foot-candles at the work counter. The lighting shall be continuous along the length of the work counter.

Hour meter An electrically operated hour meter shall be provided and installed on the carousels to register cumulatively the duration of operation. The hour meter shall not be of the type that can be reset. The hour meter shall only operate when the carousel carriers are moving. The hour meter shall have a minimum of four positions to register run time of up to 9,999 hours and shall have a minimum of one position to register fractional increments of an hour. The hour meter shall be located in an area that the face of the meter is easily accessible and seen.

RS232C port An RS232C port shall be provided and installed in the carousels for future use. The RS232C port shall be connected to the controls to permit an optional computer input interface.

Power source The Contractor shall run electrical power from the electrical supplies located on AF Drawing NLR0A6-01. The Contractor shall furnish and install all necessary wiring and equipment for power distribution to the system and for control of the system.

POWER DISTRIBUTION PANELS

Power distribution panels (panelboards) with circuit breakers shall be furnished and installed by the Contractor. Panelboards shall not exceed 78 inches in height and shall be mounted so that the height of the top operating handle shall not exceed 60 inches from the floor. Each panelboard door shall be provided with a lock and keyed alike. The Contractor shall supply two keys per lock set. Directories shall be typed to indicate load served by each circuit and shall be mounted in a holder behind a translucent protective covering on the inside of the panel door. The function of the panel shall be clearly labeled on the outside of the panel. All panelboards shall be in compliance with Article 384, NFPA 70.

CONTROL PANELS

The Contractor shall install a lockable control cabinet(s) which houses motor controllers, communications and control wiring, LAN and programmable logic controller (PLC) processor interfaces. The cabinet(s) shall be freestanding, floor mounted and installed near the equipment and such that it shall not interfere with equipment operation, operator workstation and warehouse activities, and shall not block aisles when closed. Cabinet(s) shall not exceed 78 inches in height, with the height of the top operating handle shall not exceed 60 inches from the floor. The locks of all the cabinet(s) shall be keyed alike and the contractor shall provide two keys per lock set. Control wiring diagrams shall be provided as part of all drawing submittals, with the as-built copy mounted in a plastic case inside the panel door. The control panel shall have a key activated system start/stop button. The function of the control panel shall be clearly labeled on the outside of the panel.

Installation code The installation shall, at a minimum, conform to applicable rules of NFPA 70 (National Electrical Code).

Conduit All wiring shall be encased in rigid metal conduit conforming to Article 346 of NFPA 70; electrical metallic tubing conforming to Article 348 of NFPA 70; or flexible metallic tubing conforming to Article 349 of NFPA 70. If conduit/cables are dropped from overhead, they shall be enclosed in a power pole. No conduit/cable shall run on top of the floor/ground. Exposed conduit shall be installed parallel or perpendicular to walls, structural members, or intersections of vertical planes and ceilings. Exposed conduit and fasteners shall match the color of the walls and/or existing conduit color. Changes in direction of conduit shall be made with symmetrical bends or cast metal fittings. Field made bends shall be made with the proper hickey or conduit-bending machine. Crushed or deformed conduit shall not be accepted. Conduit shall be rigidly fastened in place at intervals of not more than 10 feet.

Grounding Each component of the system shall be properly grounded to ensure safe working conditions. This shall include adequate ground against static charges that may be generated. Grounding shall conform to Article 250 of NFPA 70.

Wiring Conductors shall be copper. Wire connectors of insulating material or solderless pressure connectors properly taped shall be utilized for all splices where possible. Soldered mechanical joints shall not be accepted. All wiring shall be color-coded, uniquely tagged, or uniquely numbered for identification. Marking shall be applied in such a manner so as to facilitate tracing of wires (circuits) during repairs and/or maintenance. Wiring and wiring installation shall conform to Article 300 of NFPA 70.

Overcurrent protection The power distribution panel shall be equipped with circuit breakers and fuses in compliance with Article 240 of NFPA 70. Motors shall be equipped with disconnect switches and thermal overload devices.

Environmental protection All indoor enclosures and controls shall be in accordance with NEMA ICS 6, Type 12. All outdoor enclosures and controls shall be in accordance with NEMA ICS 6, Type 3S.

Protection fROM mechanical damage No pushbuttons, control panel, conduit, shielded cable, wire, or electrical device shall be installed so as to expose it to mechanical damage during normal use. If an electrical device, which includes photoeyes, is exposed to damage by material or personnel, then it shall be guarded.

Design and fabrication Design criteria Reliability/availability Each component of the system shall demonstrate a mean time between failure (MTBF) and availability greater than or equal to that listed in the following table. A failure is defined as any interruption that causes corrective maintenance to be made to the system. The operating time will be based on the hours listed on the following table or the actual hours read from the hour meter. The following formulas will be used to calculate MTBF and availability.

Reliability/Availability Table

(Hours)

MTBF

(Hours) Availability

Maintainability The system shall be designed, fabricated, and installed to facilitate maintainability and ensure a minimum service life of 15 years. The design shall provide for modular assembly of components and subassemblies where feasible to permit repair or replacement of parts in a minimum of time. This shall include plug-in electrical connections for major electrical subassemblies.

Environmental conditions The system shall operate in a temperature range of 32 to 100 degrees Fahrenheit with up to 99 percent relative humidity. The system shall be constructed to operate in an open warehouse environment. For components located outdoors, the component shall be constructed for year-round outdoor use, operating in sun, rain, snow, and wind.

Standard, commercial components Standard, commercial components which have been for sale and available for purchase to the general public or government agencies for at least one year shall be used to the maximum extent possible. If requested by the COTR (Contracting Officer's Technical Representative), the Contractor shall furnish evidence that equipment of approximately the same design as that proposed to be installed has been tested and successfully operated. Where two or more units of the same type of equipment are required, these units shall be products of the same manufacturer. All equipment and materials shall be new.

Standardization Mechanical and electrical interchangeability shall exist between like assemblies, subassemblies, and replaceable parts regardless of the manufacturer's supplier. Interchangeability does not necessarily mean complete identity, but requires that a substitution of such like-assemblies and replacement parts be easily effected without physical or electrical modifications, including cabling, wiring, and mounting.

Special tools Use of special tools shall be minimized and, where required for operational adjustments, shall be securely mounted within the equipment in a readily accessible location. Standard tools, fittings, lubricants, and fluids shall be used to the maximum practicable extent.

Accessibility Structural members shall not prevent access to or removal of components for repair or replacement. Equipment shall be designed for rapid and easy removal as well as replacement or repair of malfunctioning units, by one individual where feasible. Mechanical components shall be designed to permit lubrication of components without disassembly.

Structural requirements The system shall be designed and constructed in accordance with state and local codes. The system shall also be designed to withstand seismic zone 2 conditions.

Verification of dimensions The contractor shall become familiar with all details of the work, verify all dimensions in the field, and shall advise the Contracting Officer of any discrepancy before performing the work.

OZONE DEPLETING SUBSTANCES (ods) The Contractor shall not use or prescribe to the greatest extent possible any ODS in the installation and maintenance of the system. ODS includes, but is not limited to aerosol cans, certain cleaning solvents, and certain lubricants. If there is a question pertaining to the applicability of a substance, submit the name of the substance to the Contracting Officer for verification.

Safety The Contractor shall consider the safety of personnel and equipment when designing and installing the system. Safety provisions shall be incorporated to the maximum extent possible. When possible, hazards shall be eliminated through design. When this is not possible, safety devices such as guards, interlocks, and barriers shall be installed. If this does not eliminate the hazard, warning devices such as warning signs, indicator lights, and audio devices shall be installed. Safety requirements shall include, but are not limited to, the following.

Occupational Safety and Health Administration The system installation practices and completed system shall meet all applicable requirements of OSHA 29 CFR 1910 and OSHA 29 CFR 1926.

Protection against moving parts Moving parts shall be provided with guards to protect personnel from possible injury. Guards shall be in accordance with ANSI B15.1.

Placards Conspicuous placards shall be mounted adjacent to areas where hazards may exist (i.e., high voltage, pinch points, and tripping hazards). Placards shall also be used to identify operating limits (i.e., capacity, speed, and incline) in a conspicuous location for operators' use.

Fail-safe controls No controls shall cause false operation or endanger personnel if a part should fail. No damage or destruction of any component shall result from reduced voltage or complete loss of power.

CLEAN-UP

The Contractor shall, at all times, keep the work area, including storage areas, free from the accumulation of waste materials and dust which would cause a hazard or nuisance to others. The approved methods of stabilization for dust control are sprinkling, chemical treatment (non-ODS) or a similar method approved by the COTR. If there is a cutting process, the solution shall be vacuumed up during the process to prevent dust pollution and water damage. Before leaving the site, the Contractor shall remove all rubbish, tools, equipment, and materials that are not the property of the Government. At the completion of the installation/test, the Contractor shall leave the site in a clean, neat and orderly condition satisfactory to the COTR. Waste will be removed daily from the site and shall not be allowed to accumulate to the extent that it becomes a safety or fire hazard. It shall be the Contractor's responsibility to dispose of waste in accordance with all applicable Federal, State, County and Municipal codes.

Human engineering The system design and layout shall incorporate ergonomic design criteria so the optimal interface between operator and equipment is attained.

MaterialS Steel The structural steel components shall meet all design property requirements of AISC M016.

Mechanical fastening devices Unless otherwise specified, all threaded connectors of diameter greater than 7/16 inch shall be either A325 bolts conforming to ASTM A325 or SAE Grade 5 bolts conforming to SAE J429. All structural joints shall be in accordance with AISC M016. Bolt hole diameters shall not exceed nominal bolt diameters by more than 1/16 inch. All bolt holes shall be free of burrs, pins, or slivers. Bolts shall extend a minimum of two threads beyond the nuts. All nuts, bolts, and other threaded fasteners shall be plated or galvanized to prevent corrosion. All threaded fasteners shall utilize plated flat and lock washers as required.

Anchors Anchors shall, at a minimum, meet the requirements of ASTM A307. Anchors shall be either the drop-in expansion type or wedge type. All anchors shall be sufficient in size to withstand the calculated pullout and shear forces experienced by the equipment. Minimum anchor sizes shall be 3/8 inch in diameter or, if applicable, as specified in the appendices. Anchor lengths shall be long enough to assure that the manufacturer's minimum embedment in concrete is maintained and shall be installed properly to maintain the required minimum concrete embedment. Anchors shall be spaced so that the manufacturer's recommended minimum allowable spacing between anchors is maintained and the recommended minimum allowable edge distance is maintained. All anchors shall be torqued to the manufacturer's recommended installation torque. When required, adhesive anchors may be used; subject to approval by the COTR.

Protective coatings All system component surfaces shall be protected from corrosion by painting, plating, or galvanizing.

Painting Metal surfaces, which are not galvanized or plated, shall be cleaned, treated, and painted to protect against rust, corrosion, and deterioration. The first coat of paint or primer shall be applied to a dry clean surface as soon as practicable after cleaning and treating the metal. The primer shall not interfere with the application and adhesion of subsequent coats. Paint shall last the service life of the equipment. Paint shall be lead and chromate free and meet air pollution requirements for solvent emissions. When several standard colors are available, a color selection chart shall be submitted to the COTR with the shop drawings for selection. The finish coat shall be a smooth, even surface, free from runs, sags, and defects when dry. Welded surfaces shall be cleaned and painted after the welding process is complete. Prepainted accessories, as well as surfaces not requiring paint, shall be protected from overspray.

Plating All surfaces to be plated shall be thoroughly cleaned to provide a surface free of mill scale, oil, grease, dirt, rust, and any other foreign material prior to being plated. Plating at a minimum shall comply with ASTM B633, Service Condition 1, Type I unless otherwise specified.

Galvanizing All metal surfaces to be galvanized shall be thoroughly cleaned to provide smooth surfaces and shall comply with ASTM A153 and ASTM A123.

Dissimilar metals Materials used and their locations shall not promote galvanic corrosion. No combination of materials shall be used that form an electrolytic couple of such nature that corrosion is accelerated.

Welding Dimensional tolerances for welded construction, details of welds, and quality of welds shall be in accordance with the applicable requirements of AWS B2.1, AWS D1.1, and AWS D14.1. The Government reserves the right to perform supplemental nondestructive and destructive tests to determine compliance. Safety precautions during welding shall conform to ANSI Z49.1.

Welding procedure qualification Qualification of welding procedures shall conform to the applicable requirements of AWS B2.1, AWS D1.1, and AWS D14.1. The Government reserves the right to request copies of Welding Procedure Specifications for any welding procedure followed in the fabrication of this system.

Welder performance qualification Each welder, welding operator, and tack welder assigned to work on this system shall be qualified in accordance with the applicable requirements of AWS B2.1, AWS D1.1, and AWS D14.1. The Government reserves the right to request certification (Performance Qualification Test Record) that each welder, welding operator, or tack welder is qualified as specified.

fire protection All welding, cutting, brazing, and burning operations shall be accomplished in strict compliance with the requirements outlined in AFOSH 91-5 and NFPA Standard 51B. Prior to starting any welding, cutting, brazing, or burning operations, the Contractor shall obtain a permit (USAF Welding, Cutting, and Brazing AF Form 592). This permit can be obtained by contacting the Little Rock AFB Fire Department at least 24 hours in advance. A copy of each permit will be retained at the work site until the work has been completed. Operations that produce flying, dropping slag, metal or embers shall have sufficient non-combustible materials and fire blankets on site to protect against fire damage or personal injury. In addition, the contractor shall provide a minimum of 2 portable fire extinguishers at the work site until the work has been completed. Extinguishers shall meet a rating of 4A-40BC and the requirements outlined in AFOSH 91-56. At the close of their operation, the contractor shall make a thorough inspection of each building in which he/she has performed work. This inspection shall ensure that all necessary safeguards relative to potential fire hazards are in effect and operational. The contractor shall familiarize themselves and their personnel on the location of all telephones needed for fire reporting. The contractor shall maintain good housekeeping practices to reduce the risk of fire, damage, and/or personal injury. All scrap materials, rubbish, and refuse shall be removed daily from in and around the building and shall not be permitted to be strewn on adjacent property. Flammable and combustible materials used inside the building shall be kept to a minimum and removed from the building during unused periods. Storage of flammable/combustible materials shall not be permitted inside the building.

Cutting All edges produced by oxygen-flame cutting or any cutting operation shall be finished by grinding (or other method approved by the COTR) to a surface finish equivalent to that of adjacent surfaces. Sharp edges shall not be acceptable.

Coordination The Contractor shall obtain approval from the local base civil engineering, fire, safety, and bioenvironmental offices before making any modifications to the existing structure to accommodate the new system. The modifications shall match existing work and shall be of comparable quality. The COTR shall also approve all modifications before they are made.

Nameplates The Contractor shall provide and install one corrosion resistant metal nameplate for each component. A nameplate for each row of shelving/rack shall be provided such that if one row is dismantled, the nameplates will exist elsewhere. For conveyors, a nameplate shall be provided for each kind of conveyor in the system (i.e. takeaway, gravity, curves, incline/decline, etc). Nameplates shall be located in a visible and safe location. Nameplates shall last the life of the equipment and shall be capable of withstanding local environmental conditions. Nameplates shall be stamped, engraved, or etched in a print type not less than 1/8-inch tall. No nameplate or product marking shall be installed until all touch-up painting has been completed. The nameplate or product marking shall clearly display the following headings and corresponding information.

Type of equipment Name of manufacturer Model Number Contract Number Serial Number Capacity Weight Manufacture Date, Month/Year "Property of US Government"

Precedence Where local codes and standards conflict with the contents of this PD, the more stringent requirement shall prevail.

Documentation The Contractor shall provide documentation (data) in accordance with the Contract Data Requirements Lists (CDRL). Where possible, the Contractor shall print on recycled paper. Also, where possible, the Contractor shall not require the use of any ozone depleting substance in any submittal. The Contractor shall incorporate maintenance, testing, inspection, and operator qualification requirements of AFOSH 91-46 into the maintenance and operator manuals

Orientation The Contractor shall provide technical services and materials to orient Government personnel. Fully qualified Contractor personnel who are knowledgeable of the system shall accomplish all orientation. Courses shall be combined in accordance with the Contractor's standard commercial training courses, where applicable, provided all aspects of training are included. Orientation shall be provided at Little Rock AFB. The Contractor shall provide each attendee with a certificate indicating successful completion of the orientation. All orientation shall be completed prior to the start of the quality conformance test.

System operator orientation This orientation shall provide instructions in the overall operational functions that are performed by the system operators. Instructions shall include the operation of all the system components. Upon completion of this course, the operators shall be able to operate all components of the system. Operators shall be able to perform these functions using only the reference manuals provided with the system relative to operations. An estimated 10 students with possibly no experience will attend.

System operator classroom instructions The classroom phase shall include instructions in the operational requirements of the installed system. Classroom instructions shall include a briefing and orientation on the use of the operation manuals supplied by the Contractor. Classroom instructions shall be developed so that it can be placed on videotape. Classroom instructions shall be a minimum of 1 hour.

System operator hands-on instructions The hands on phase shall include actual operation of the system under the supervision and instruction of the Contractor. Hands-on instruction shall be a minimum of 1 hour.

Maintenance orientation This orientation shall provide instructions in corrective and preventive maintenance of the system delivered. Instruction shall include installation and adjustment of all system components. Upon completion of this orientation, students shall be able to install, adjust, and maintain equipment stated using only the maintenance reference manual delivered. An estimated 5 students with possibly no experience will attend.

Maintenance classroom instruction The classroom phase shall include instruction in the maintenance requirements of the installed system. Classroom instruction shall include a briefing and orientation on the use of the maintenance manuals supplied by the Contractor. Classroom instruction shall be developed so that it can be placed on videotape. Classroom instruction shall be a minimum of 1 hour.

Maintenance hands-on instruction The hands-on phase shall include actual field instruction in the maintenance requirements of the installed system. Hands-on instructions shall be a minimum of 1 hour.

QUALITY ASSURANCE PROVISIONS

General The COTR shall monitor the installation of the system. The system delivery dates shall not be extended because of work stoppages caused by unacceptable practices and/or test failures. For all inspections and tests, the Contractor shall provide all test apparatus (i.e., tape measures, levels, calipers, micrometers, stop watches). All test apparatus will be returned to Contractor upon completion of all tests. The Government will provide all test loads. The Contractor shall be responsible for loading and unloading all test loads and performing all inspections and tests. The Contractor shall provide a knowledgeable and authoritative representative on site during the entire acceptance tests.

Acceptance Tests Three tests must be successfully completed prior to the Government accepting the system. These tests are the system checkout test, the quality conformance test, and the reliability demonstration test.

System checkout test Upon completion of installation, the Contractor using loads of the type specified herein and in the appendices shall check out the system. The Contractor shall inspect the system to assure that the system meets all the requirements of 4.3.1. The Contractor shall also test the system in accordance with the test defined in 4.3.2. All inspections and tests shall be repeated until all modifications and/or adjustments are complete and the system passes all inspections and tests. The Contractor shall submit to the Contracting Officer written certification that the system has passed the requirements of this paragraph. The COTR will schedule the quality conformance test to start within 10 days following the receipt of the written certification from the Contractor.

Quality conformance test As part of the quality conformance test, the Contractor shall provide written certification that the requirements listed in 4.3.3. have been met. This certification is required on or before the start of the quality conformance test. The Contractor, in the presence of the COTR, shall inspect the system to confirm that the system meets all the requirements of 4.3.1. The Contractor, in the presence of the COTR, shall also test the system in accordance with the test defined in 4.3.2. Upon successful completion of all tests and inspections and the receipt of all certifications, the reliability demonstration shall start.

Reliability demonstration test After successful completion of the quality conformance test, each component of the system shall demonstrate a reliability and availability greater than that listed in the reliability/availability table in 3.3.1.1. In addition, all static components shall demonstrate compliance with the requirements of the purchase description (PD). The test period shall be the 30 calendar days immediately following the successful completion of the quality conformance test. If the system does not demonstrate the required reliability and availability or compliance with the PD, the test will be restarted from the beginning after the Contractor has taken corrective action. The Contractor shall be allowed to restart the reliability demonstration test a maximum of 2 times. If the system fails to pass the reliability demonstration within 3 attempts, then the system shall be rejected.

Inspections, tests, and certifications This section defines all inspections and tests that must be completed as part of the system checkout test and repeated at the quality conformance test. This section also includes a list of all certifications that must be received from the Contractor on or before the start of the quality conformance test. The Contractor may add to this list, or question any requirement, by sending a letter to the Contracting Officer prior to the acceptance tests. The COTR will classify all deficiencies encountered into one of the defect classification listed below. Any critical or major defect found shall be cause for rejection of the system. Any combination of two or more minor defects shall leave the rejection of the system at the discretion of the COTR.

Critical Defect - A defect that judgment and experience indicate is likely to result in hazardous or unsafe conditions for individuals using, maintaining, working near, or depending upon the equipment.

Major Defect - A defect other than critical that is likely to result in failure, or reduce materially the system for its intended purpose.

Minor Defect - A defect that is not likely to reduce materially the usability of the system for its intended purpose, or is a departure from established standards having little bearing on the effective use or operation of the system.

Inspections The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of the cover purchase description (and associate appendices, if applicable). These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

Tests The tests in associated appendices shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.