19R81080003.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

1. CONTRACT ID CODE

See Block #2

PAGE OF PAGES

2. AMENDMENT/MODIFICATION NO.

3. EFFECTIVE DATE

4. REQUISITION/PURCHASE REQ.NO.

5. PROJECT NO. (If applicable)

6. ISSUED BY AFLCMC/PZIEB CODE FA8604 7. ADMINISTERED BY (If other than Item 6) CODE

USAF/AFMC/AFLCMC

AF LIFE CYCLE MANAGEMENT CENTER

2275 D STREET, BLDG 16, RM 128

WRIGHT-PATTERSON AFB OH 45433-7228

ZACHARY P. REYNOLDS 937-656-7381

ZACHARY.REYNOLDS@US.AF.MIL

8. NAME AND ADDRESS OF CONTRACTOR (No., street, county, State and ZIP Code) (X) 9A. AMENDMENT OF SOLICITATION NO.

FA860419R8108000

X

9B. DATED (SEE ITEM 11)

10A. MODIFICATION OF CONTRACT/ORDER NO.

10B. DATED (SEE ITEM 13)

CODE FACILITY CODE

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers X is extended, is not extended.

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods:

(a) By completing Items 8 and 15, and returning 0 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted; or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER.

If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATION OF CONTRACTS/ORDERS,

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

(X )

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: ( ) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT ORDER NO. ITEM

10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation data, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor X is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

Non-ACAT, MMHS,Osan AB Storage Aids Sys, Incorporate Revised Cover Purchase Description, (REV 1), Section J, Attachment 1, dated 23 April 2019, and Response to Questions.

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print).

16A. NAME AND TITLE OF SIGNER (Type or print)

15B. CONTRACTOR/OFFEROR

15C. DATE SIGNED 16B. UNITED STATES OF AMERICA

16C. DATE SIGNED

(Signature of person authorized to sign)

BY________________________________________

(Signature of Contracting Officer)

NSN 7540-01-152-8070 30-105 STANDARD FORM 30 (REV.10-83)

PREVIOUS EDITION UNUSABLE Prescribed by GSA ConWrite Version 7.1.2.2 FAR (48 CFR) 53.243 Created 23 Apr 2019 2:40 PM

CONTRACT DOCUMENTS, EXHIBITS AND ATTACHMENTS

FA860419R81080003 PAGE 2 OF 3

1. This amendment hereby incorporates Revised Cover Purchase Description, (REV 1), Section J, Attachment 1, dated 23 April 2019, and Response to Questions.

2. All other terms and conditions remain the same.

SCHEDULE

FA860419R81080003

DOCUMENT PGS DATE TITLE

ATTACHMENT 1 34 23 APR 2019 COVER PURCHASE DESCRIPTION (REV 1)

COVER PURCHASE DESCRIPTION

FOR

A MECHANIZED MATERIALS HANDLING SYSTEM

AT

OSAN AIR BASE, REPUBLIC OF KOREA

BUILDING NO. TBD

CSN: BOS613

DATE: 18 JANUARY 2019

REV 1: 23 APRIL 2019

PREPARED BY:

Megan Blackwell

MEGAN BLACKWELL

PROJECT ENGINEER

AFLCMC/EZPAE

Ron Parsons

RON PARSONS

REVIEWER

AFLCMC/EZPAE

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Table of Contents

1. SCOPE

1.1. GENERAL SCOPE

1.2. ACRONYMS

1.3. DEFINITIONS

1.3.1. PALLETS

1.3.1.1. 463L PALLETS

1.3.1.2. ISU 70/90 PALLETS

1.3.1.3. PALLET CONDITIONS

1.3.1.3.1. NON-FLATNESS

1.3.1.3.2. RESTRAINING STRAPS

1.3.1.3.3. LOAD DISTRIBUTION

1.3.1.4. PALLET HANDLING

1.3.1.4.1. 10K FORKLIFT

1.3.1.4.2. 4K FORKLIFT

1.3.1.4.3. K-LOADERS

1.3.2. GRAVITY ROLLER CONVEYOR SECTION

1.3.3. GRAVITY ROLLER CONVEYOR LANE

1.3.4. ADJACENT CONVEYOR

2. APPLICABLE DOCUMENTS

2.1. GOVERNMENT DOCUMENTS |R1

2.2. NON-GOVERNMENT DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.1.1. PALLET LIFTS

3.1.2. GRAVITY ROLLER CONVEYOR

3.1.3. BALL TRANSFER CONVEYOR

3.1.4. PALLET RACK

3.2. CHARACTERISTICS

3.2.1. NOISE LEVELS

3.2.2. ELECTRICAL CHARACTERISTICS

3.2.2.1. POWER SOURCE

3.2.2.2. INSTALLATION CODE

3.2.2.3. CONDUIT

3.2.2.4. GROUNDING

3.2.2.5. WIRING

3.2.2.6. OVERCURRENT PROTECTION

3.2.2.7. ENVIRONMENTAL PROTECTION

3.2.2.8. PROTECTION FROM MECHANICAL DAMAGE

3.3. DESIGN AND FABRICATION

3.3.1. DESIGN CRITERIA

3.3.1.1. RELIABILITY AND AVAILABILITY

3.3.1.2. MAINTAINABILITY

3.3.1.3. ENVIRONMENTAL CONDITIONS

3.3.1.4. STRUCTURAL AND SEISMIC REQUIREMENTS |R1

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3.3.1.5. STANDARD, COMMERCIAL COMPONENTS

3.3.1.6. STANDARDIZATION

3.3.1.7. SPECIAL TOOLS

3.3.1.8. ACCESSIBILITY

3.3.1.9. VERIFICATION OF DIMENSIONS

3.3.1.10. OZONE DEPLETING SUBSTANCES (ODS)

3.3.1.11. SAFETY

3.3.1.11.1. OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

3.3.1.11.2. PROTECTION AGAINST MOVING PARTS

3.3.1.11.3. PLACARDS

3.3.1.11.4. FAIL-SAFE CONTROLS

3.3.1.11.5. CONVEYOR SAFETY STANDARD

3.3.1.11.6. SAFETY STANDARD

3.3.1.11.7. PERSONNEL HAZARDS

3.3.1.12. HUMAN ENGINEERING

3.3.2. MATERIALS

3.3.2.1. STEEL

3.3.2.2. MECHANICAL FASTENING DEVICES

3.3.2.3. ANCHORS

3.3.3. PROTECTIVE COATINGS

3.3.3.1. PAINTING

3.3.3.2. PLATING

3.3.3.3. GALVANIZING

3.3.3.4. DISSIMILAR METALS

3.3.4. WELDING

3.3.4.1. WELDING PROCEDURE QUALIFICATION

3.3.4.2. WELDER PERFORMANCE QUALIFICATION

3.3.4.3. FIRE PROTECTION

3.3.5. CUTTING

3.3.6. CLEAN-UP

3.3.7. COORDINATION

3.3.8. NAMEPLATES

3.3.9. PRECEDENCE

3.4. DOCUMENTATION

3.4.1. MANAGEMENT REPORTS

3.4.2. SHOP DRAWINGS

3.4.3. EQUIPMENT MANUALS

3.4.4. EQUIPMENT CERTIFICATIONS

3.4.5. TESTING CERTIFICATIONS

3.4.6. AS-BUILT DRAWINGS

3.5. ORIENTATION

3.5.1. SYSTEM OPERATOR ORIENTATION

3.5.1.1. SYSTEM OPERATOR HANDS-ON INSTRUCTIONS

3.5.2. MAINTENANCE ORIENTATION

3.5.2.1. MAINTENANCE HANDS-ON INSTRUCTION

4. QUALITY ASSURANCE PROVISIONS

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4.1. GENERAL

4.2. ACCEPTANCE TESTS

4.2.1. SYSTEM CHECKOUT TEST

4.2.2. QUALITY CONFORMANCE TEST

4.2.3. RELIABILITY DEMONSTRATION TEST

4.3. INSPECTIONS, TESTS, AND CERTIFICATIONS

4.3.1. INSPECTIONS

4.3.2. TESTS

4.3.3. CERTIFICATIONS

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1. SCOPE

1.1. GENERAL SCOPE

This purchase description (PD) establishes the minimum performance, design, fabrication, installation, orientation, and test requirements for a Mechanized Materials Handling System

(MMHS) for the 731st Air Mobility Squadron (AMS) in the new Air

Freight Terminal (AFT) at Osan Air Base (AB), Republic of Korea

(ROK). The work shall be completed in accordance with this PD and Air Force (AF) Drawing BOS613-01. This PD covers all equipment, materials, and labor necessary to complete installation of the system. It also includes performing tests and making adjustments to the system as well as providing on-the-job instructions to Government personnel.

1.2. ACRONYMS

AB – Air Base

AF – Air Force

AFT – Air Freight Terminal

COTR – Contracting Officer’s Technical Representative

MMHS – Mechanized Materials Handling System

MTBF – Mean Time Between Failure

MTTR – Mean Time To Repair

ODS – Ozone Depleting Substances

PD – Purchase Description

ROK – Republic of Korea

1.3. DEFINITIONS

1.3.1. PALLETS

Loads consist of 463L (both orientations), ISU 90, and ISU 70 pallets. References to pallets shall refer to all types listed above and detailed below:

1.3.1.1. 463L PALLETS

The 463L pallet consists of an end-grain balsa-wood or redwood core sandwiched between two sheets of aluminum with frames on all sides consisting of extruded aluminum edge rails. Steel tie-down rings are distributed around the perimeter of the pallet to secure nets and to facilitate handling. The entire pallet measures 108 inches wide by 88 inches long by 2.25 inches thick. Cargo on 463L pallets is normally no higher than 96 inches, but over height pallets may be stacked up to 156 inches high for transport on C-5 aircraft. The pallet has a rated

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Osan AB - Cover PD – Page 2 capacity of 10,000 pounds and weighs approximately 290 pounds.

Nets and straps add an average of 65 pounds for a total pallet tare weight of 355 pounds. 463L pallets can be utilized in both orientations. The orientation with the 108-inch edge leading is called wide-edge leading. The orientation with the 88-inch edge leading is called narrow-edge leading.

1.3.1.2. ISU 70/90 PALLETS

The ISU pallet base is the same as the 463L pallet base. Steel tie-down rings are distributed around the perimeter of the pallet to secure nets and to facilitate handling. The ISU pallet weight is between 1,400 and 1,700 pounds with a payload capacity of 10,000 pounds. Dimensions of the ISU 70/90 is 108 inches wide by 88 inches deep and either 70 or 90 inches high.

1.3.1.3. PALLET CONDITIONS

The following pallet conditions shall be assumed for all types of pallets.

1.3.1.3.1. NON-FLATNESS

Approximately two-thirds of the maximum possible pallet contact is made with the rollers, a condition that results from the pallet surface being warped. The bottom surface of unloaded pallets can deflect up to 0.31-inch from level. The deflection of loaded pallets varies with specific loading conditions.

1.3.1.3.2. RESTRAINING STRAPS

Cargo restraining straps may hang below the pallet edges. These straps shall not become entangled in structure or transfer elements nor shall they interfere with any sensing or control devices.

1.3.1.3.3. LOAD DISTRIBUTION

Pallet weights range from fully loaded to empty. The center of gravity may deviate by as much as 10 inches from the center of the pallet.

1.3.1.4. PALLET HANDLING

The following type of government-furnished equipment is used to handle pallet loads.

1.3.1.4.1. 10K FORKLIFT

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A 10K forklift is a diesel or electric powered, manually operated forklift weighing approximately 23,000 pounds. The 10K forklift is capable of lifting and transporting pallets with loads up to 10,000 pounds. The 10K forklift is also used to move freight, to load materials onto and unload materials from pallets, and to place empty pallets on and remove empty pallets from the forklift tine cutouts provided on the conveyors. The

10K forklift interfaces with forklift tine cutouts provided on the conveyors.

1.3.1.4.2. 4K FORKLIFT

A 4K forklift is a powered, manually operated forklift weighing approximately 5,000 pounds and capable of lifting up to 4,000 pounds. The 4K forklift is used to move freight, to load materials onto and unload materials from pallets, and to place empty pallets on and remove empty pallets from the forklift tine cutouts provided on the conveyors.

1.3.1.4.3. K-LOADERS

A K-loader is a military transporter with a powered rollerized deck to assist the loading and unloading of pallets between the

K-loader and aircraft, forklifts, and conveyors at the proper elevation. The K-loader has a platform that can be raised to interface with aircraft. There are two types of K-loaders. The

60K-loader (Tunner) can carry up to six 463L pallets with a total net weight up to 60,000 pounds. The 60K-loader weighs about 65,000 pounds and the powered deck can be positioned at all elevations between 39 inches and 222 inches. The 25K-loader

(Halvorsen) can carry up to three 463L pallets with a total net weight up to 25,000 pounds. The 25K-loader weights approximately 32,000 pounds. The deck of the 25K-loader can be positioned at all elevations between 39 and 220 inches.

1.3.2. GRAVITY ROLLER CONVEYOR SECTION

A gravity roller conveyor section is a set of non-powered rollers within frames along the direction of travel of the pallet.

1.3.3. GRAVITY ROLLER CONVEYOR LANE

A gravity roller conveyor lane is a set of three non-powered roller conveyor sections and two guide rails laid out across the width of the pallet to convey it in a particular direction.

1.3.4. ADJACENT CONVEYOR

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All nearby conveyors that a particular conveyor interfaces with for pallet transfer are called adjacent conveyors.

2. 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.

2.1. GOVERNMENT DOCUMENTS

AIR FORCE INSTRUCTION (AFI)

AFI 48-127

Occupational Noise and Hearing

Conservation Program

AFI 91-203 Air Force Consolidated Occupational

Safety Instruction, Chapter 23, Confined Spaces; Chapter 27, Welding, Cutting and Brazing; Chapter 35, Material Handling Equipment

AIR FORCE DRAWING

BOS613-01 Mechanized Materials Handling System

731st Air Mobility Squadron

New Air Freight Terminal

Osan Air Base, ROK

12/21/2018

OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) STANDARDS

29 CFR 1910 Occupational Safety and Health

Standards, (General Industry)

29 CFR 1926 Safety and Health Regulations for

Construction

US ARMY CORPS OF ENGINEERS INSTRUCTION

TI 809-04 Seismic Design for Buildings

UNIFIED FACILITIES CRITERIA (UFC)

UFC 3-310-04 Seismic Design of Buildings

UFC 3-301-01 Structural Engineering

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2.2. NON-GOVERNMENT DOCUMENTS

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC 325 Steel Construction Manual

(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)

ANSI A14.3 American National Standards for Fixed

Ladders – Safety Requirements

ANSI B11.19 Machines – Performance Criteria for

Safeguarding

ANSI B15.1 Safety Standard for Mechanical Power

Transmission Apparatus

ANSI MH29.1 Safety Requirements for Industrial

Scissor Lifts

ANSI/CEMA 401 Roller Conveyors – Non-Powered

National Standards Institute, 25 West 43rd Street, 4th Floor, New York, NY 10036)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B20.1 Safety Standard for Conveyors and

Related Equipment

Society of Mechanical Engineers, Two Park Avenue, New York, NY

10016)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A123/A123M Standard Specification for Zinc (Hot

Dip Galvanized) Coatings on Iron and

Steel Products

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ASTM A153/A153M

Standard Specification for Zinc Coating

(Hot-Dip) on Iron and Steel Hardware

ASTM A307 Standard Specification for Carbon Steel

Bolts and Studs, 60,000 psi Tensile

Strength

ASTM A325 Standard Specification for Structural

Bolts, Steel, Heat Treated, 120/105 ksi

Minimum Tensile Strength

ASTM B633 Standard Specification for

Electrodeposited Coatings of Zinc on

Iron and Steel

Society for Testing and Materials, 1916 Race Street, Philadelphia PA 19103)

AMERICAN WELDING SOCIETY (AWS)

AWS B2.1 Welding Procedure and Performance

Qualification

AWS D1.1 Structural Welding Code – Steel

AWS D14.1 Welding of Industrial and Mill Cranes and Other Material Handling Equipment, Spec for

AWS Z49.1 Safety in Welding and Cutting

Welding Society, Inc., 550 NW Lejeune Road, P.O.Box 35140, Miami

FL 33135)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS 2 Industrial Control Systems:

Controllers, Contactors, Overload

Relays, Rated Not More Than 2000

Volts AC or 750 Volts DC

NEMA ICS 6 Industrial Control and Systems:

Enclosures

NEMA MG 1 Motors and Generators

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(Applications for copies shall be addressed to the National

Electrical Manufacturers Association, 1300 North 17th Street, Suite 900, Arlington VA 22209)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 51B Standard for Fire Prevention During

Welding, Cutting and Other Hotwork

NFPA 70 National Electrical Code

(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)

SAE J429 Mechanical and Material Requirements for Externally Threaded Fasteners, Standard

(Applications for copies shall be addressed to the Society of

Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale

PA 15906)

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

The system will be used for building up, breaking down, moving, staging, and storing pallets. The system shall be as shown on

AF Drawing BOS613-01. The following major components shall be integrated to form the complete Mechanized Materials Handling

System:

3.1.1. PALLET LIFTS

Two pallet lifts shall be installed as specified in Appendix A and this Cover PD. Existing pallet pits shall be used for the installation of the pallet lifts. The pallet lifts shall interface with the gravity roller conveyor specified in Appendix

B.

3.1.2. GRAVITY ROLLER CONVEYOR

The gravity roller conveyor (GRC) shall be installed as specified in Appendix B and this Cover PD. The GRC shall

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Osan AB - Cover PD – Page 8 interface with the pallet lifts specified in Appendix A and the ball transfer conveyor specified in Appendix C.

3.1.3. BALL TRANSFER CONVEYOR

The ball transfer conveyor (BTC) shall be installed as specified in Appendix C and this Cover PD. The BTC shall interface with the GRC specified in Appendix B.

3.1.4. PALLET RACK

Pallet rack shall be installed as specified in Appendix D and this Cover PD.

3.2. CHARACTERISTICS

3.2.1. 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 AFI 48-127. 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.

3.2.2. ELECTRICAL CHARACTERISTICS

The electrical characteristics shall be as follows unless specified otherwise in an appendix:

3.2.2.1. POWER SOURCE

The Contractor shall use electrical power from an existing panel in the air freight terminal. The Contractor shall furnish and install all necessary wiring and equipment for power distribution to the system.

3.2.2.2. INSTALLATION CODE

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

3.2.2.3. CONDUIT

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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 or cables are dropped from overhead, they shall be enclosed in a power pole. Conduit or cable ran on top of the floor or ground shall be minimal and approved by the COTR before installation. 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.

3.2.2.4. 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.

3.2.2.5. 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 maintenance.

Wiring and wiring installation shall conform to Article 300 of

NFPA 70. All circuits shall be checked for grounds or poor connections prior to being energized.

3.2.2.6. OVERCURRENT PROTECTION

Power distribution panels shall be equipped with circuit breakers in compliance with Article 240 of NFPA 70. Fuses shall not be used unless required by NFPA 70. Motors shall be equipped with disconnect switches and thermal overload devices.

3.2.2.7. ENVIRONMENTAL PROTECTION

All enclosures and controls shall be in accordance with NEMA ICS

6, Type 12 if installed indoors and Type 4 if installed

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Osan AB - Cover PD – Page 10 outdoors. Moisture shall not enter electrical enclosures. All electrical enclosures and components installed near fire sprinkler systems shall be protected such that they will not be harmed by activation of the sprinkler system. No electrical components shall be installed directly on the floor or ground.

3.2.2.8. PROTECTION FROM MECHANICAL DAMAGE

No push button, 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 is exposed to damage by material or personnel, then it shall be guarded.

3.3. DESIGN AND FABRICATION

3.3.1. DESIGN CRITERIA

3.3.1.1. RELIABILITY AND AVAILABILITY

Each component of the system shall demonstrate a mean time between failure (MTBF) and availability greater than or equal to that listed in Table 1. A failure is defined as any condition that does not conform to the specification or any interruption that causes corrective maintenance to be made to the system.

Failures also include situations requiring the use of maintenance personnel and situations requiring the resetting or restarting of any component. The operating time shall be based on the hours listed in Table 1 or the actual hours read from the hour meter. Each individual component shall meet the MTBF and availability requirements specified (i.e., each pallet lift must meet the MTBF and availability requirements). The following formulas will be used to calculate MTBF and availability.

Table 1 – Reliability and Availability

MTBF = Operating Time / Total Failures

Mean Time to Repair (MTTR) = Total Repair Time / Total Failures

Availability = MTBF / (MTBF + MTTR)

Equipment Operating Time

(hours)

MTBF

(hours)

Availability

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Pallet Lifts 720 240 99

Gravity Roller

Conveyor 720 360 99

3.3.1.2. 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. Grease fittings shall not be blocked and access shall be possible from platforms, walkways, or the ground.

3.3.1.3. ENVIRONMENTAL CONDITIONS

All system components shall operate in a temperature range of 0 to 104 degrees Fahrenheit with up to 100% relative humidity.

All system components shall be designed to not trap precipitation. Drain holes, cutouts, sloped surfaces, and drain passages shall be provided as necessary to eliminate water accumulation, standing water, and ponding. All system components shall be constructed to operate in an outdoor environment.

3.3.1.4. STRUCTURAL AND SEISMIC REQUIREMENTS

The system shall be designed and constructed in accordance with seismic design codes at Osan AB. The system shall be designed to withstand seismic forces as specified in TI 809-04 UFC 3-310-

04 and UFC 3-301-01. All mechanical components shall be designed and installed to withstand seismic activity. Vibration isolation devices and bracing shall be used as necessary to meet this requirement.

3.3.1.5. 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 Contracting Officer’s

Technical Representative (COTR), the Contractor shall furnish evidence that equipment of approximately the same design as that proposed to be installed has been tested and successfully

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Osan AB - Cover PD – Page 12 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.

3.3.1.6. 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.

3.3.1.7. 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.

3.3.1.8. 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.

3.3.1.9. 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.

3.3.1.10. 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.

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3.3.1.11. 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:

3.3.1.11.1. 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.

3.3.1.11.2. 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.

3.3.1.11.3. 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.

3.3.1.11.4. 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.

All control systems shall fail-safe to a fully stopped position with all components maintained in position. All components shall remain in position when power is returned to ensure no unexpected movement occurs. Movement of components shall only occur following operator input.

3.3.1.11.5. CONVEYOR SAFETY STANDARD

Conveyor design, components, and controls shall conform to ASME

B20.1.

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3.3.1.11.6. SAFETY STANDARD

The system shall comply with the material handling safety and confined space standards in AFI 91-203. All necessary permits shall be obtained before removal of existing equipment or installation of the system begins.

3.3.1.11.7. PERSONNEL HAZARDS

Sharp objects or edges shall not be exposed in areas accessible to personnel. Electrical components that could heat to above

100 degrees Fahrenheit shall be guarded to prevent accidental contact by personnel.

3.3.1.12. HUMAN ENGINEERING

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

3.3.2. MATERIALS

3.3.2.1. STEEL

The structural steel components shall meet all design property requirements of AISC 325.

3.3.2.2. 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 325. 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.

3.3.2.3. 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

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Osan AB - Cover PD – Page 15 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. Chemically bonded anchors may be used if approved by the COTR.

3.3.3. PROTECTIVE COATINGS

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

3.3.3.1. 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. Touch up paint shall be applied where necessary. Prepainted accessories, as well as surfaces not requiring paint, shall be protected from overspray.

3.3.3.2. 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.

3.3.3.3. GALVANIZING

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

ASTM A123.

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3.3.3.4. 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.

3.3.4. 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 AWS Z49.1.

3.3.4.1. 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.

3.3.4.2. 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.

3.3.4.3. FIRE PROTECTION

All welding, cutting, brazing, and burning operations shall be accomplished in strict compliance with the requirements outlined in AFI 91-203 and NFPA 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 Osan AB

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

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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 AFI 91-203. 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.

3.3.5. 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.

3.3.6. 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.

3.3.7. COORDINATION

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The Contractor shall obtain approval from the local base civil engineering, fire, safety, and bioenvironmental offices before making any modifications to the existing structure or adjacent grounds to accommodate the new system. The modifications shall match existing work and shall be of comparable quality. The

COTR shall approve all modifications before they are made. The

Contractor shall request all power outages required for installation to the Osan AB Civil Engineering office a minimum of 15 days prior to the requested outage. Power shall not be shut off until approval has been obtained from the base civil engineering office, and the actual outage date and time shall match the approved period.

3.3.8. NAMEPLATES

The Contractor shall provide and install one corrosion resistant metal nameplate for each GRC lane, each pallet lift, the ball transfer conveyor, and the 463L pallet rack. 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 of scissor lift, ball transfer bearings, conveyor rollers, uprights, shelf beams, decking, etc.

Contract Number

Serial Number

Capacity

Weight

Manufacture Date, Month/Year

Name of Contractor and Point of Contact

Contractor Web Address

"Property of U.S. Government"

3.3.9. PRECEDENCE

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

3.4. DOCUMENTATION

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The Contractor shall provide documentation (data) as described below and distributed in accordance with Table 2.

3.4.1. MANAGEMENT REPORTS

The Contractor shall provide a monthly status report, which includes the following:

A) A heading which includes the title and date of the report, the companies name and address, the base name and contract number, and the name of the person submitting the report.

B) A schedule showing planned start and completion dates for the following milestones: shop drawings, fabrication, shipping, installation, and testing.

C) The report shall summarize the progress to date. It shall identify any problem areas; explain changes in schedule or equipment; describe engineering change proposals; and discuss all significant trips, emails, and telephone calls affecting the performance or scope of the contract.

3.4.2. SHOP DRAWINGS

The Contractor shall provide shop drawings, which include architectural, electrical, civil, and fire suppression drawings.

The specific drawings required shall be defined by the project engineer at the post award orientation meeting.

3.4.3. EQUIPMENT MANUALS

The Contractor shall provide operation and maintenance manuals and illustrated parts breakdown manuals for system components with moving parts, electrical/electronic parts and components requiring maintenance. Warranties shall be described for each system component in its respective manual.

3.4.4. EQUIPMENT CERTIFICATIONS

The Contractor shall certify that the system meets all

Certification requirements listed in Section 4 of this Cover

Purchase Description and all appendices. A general statement that the delivered system meets all system requirements is not acceptable; the Contractor shall certify each requirement individually.

3.4.5. TESTING CERTIFICATIONS

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The Contractor shall certify that the system checkout test, described in Section 4 of the Cover Purchase Description and all appendices, has been successfully completed.

3.4.6. AS-BUILT DRAWINGS

The Contractor shall provide as-built drawings, which shall be a resubmittal of the shop drawings including all changes to the system after approval of the shop drawings.

Table 2 – Data Requirements

SUBMITTAL DUE DATE Distribution List

Engineer megan.blackwell.

1@us.af.mil

Buyer

(identified at time of award)

Base POC jackie.phillips.2

@us.af.mil

Management

Reports

(3.4.1.)

1st business day of each month starting after the month the contract was awarded

Email with attachment of report

Email with attachment of report

Email with attachment of report

Shop Drawings

(3.4.2.)

Due date is same as CLIN

Email with attachment of drawings

(AutoCAD and

PDF)

Email with drawings (PDF) drawings (PDF) and one set of hard copies (D size)

Manuals

(3.4.3.)

With delivery of equipment

Email with attachment of manuals (PDF)

Email indicating delivery of manuals completed manuals (PDF) and 2 sets of hard copies

Certifications

(3.4.4.) Within 2 business days of system installation completion

Email with attachment of certifications

(Word Document or PDF)

Email with attachment of certifications

(Word Document or PDF) certifications

(Word Document or PDF)

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As-built Drawings

(3.4.6.)

30 days after

Government acceptance of system

Email with attachment of drawings

(AutoCAD and

PDF)

Email with drawings (PDF) drawings

(AutoCAD and

PDF) and one set of hard copies (D Size)

3.5. 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 Osan AB. 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.

3.5.1. 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.

3.5.1.1. 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.

3.5.2. 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

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Osan AB - Cover PD – Page 22 only the maintenance reference manual delivered. An estimated 5 students with possibly no experience will attend.

3.5.2.1. 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.

4. QUALITY ASSURANCE PROVISIONS

4.1. 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.

4.2. 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.

4.2.1. 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.

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4.2.2. 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.

4.2.3. RELIABILITY DEMONSTRATION TEST

After successful completion of the quality conformance test, the system will be used for 30 calendar days. The test period shall begin immediately following the quality conformance test. If the system fails during this time, the Contractor shall take corrective action and restart the test from the beginning. 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.

4.3. 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.

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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.

4.3.1. 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).