Appendix H GRC-Jacksonville ANGB FL 125 LRS B641-NJC109- rev 1.pdf

APPENDIX H

FOR

GRAVITY ROLLER CONVEYORS

AT

JACKSONVILLE AIR NATIONAL GUARD BASE, FLORIDA

125 LOGISTICS READINESS SQUADRON (LRS)

LRS WAREHOUSES

BUILDINGS 1006 (SUPPLY)

CSN: NJC109

DATE: 1 March 2022

PREPARED BY:

Emmanuel A. Parel

EMMANUEL A. PAREL

PROJECT ENGINEER

AFLCMC/EZPAE

Megan Blackwell__

MEGAN BLACKWELL

REVIEWER

AFLCMC/EZPAE

Appendix H (rev 1) July 6, 2022

Jacksonville – LRS WHS, App H, GRC - Page i

Table of Contents

1. SCOPE

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. INTERFACES AND TRANSFERS

3.2.2. DEFORMATION UNDER IMPACT

3.2.3. LOAD CAPACITY

3.2.4. DIMENSIONS/FLOOR SLOPES

3.2.5. ROLLERS

3.2.5.1. REPLACEMENT ROLLERS

3.2.6. AXLES

3.2.7. BEARINGS

3.2.8. FRAMES

3.2.8.1. FRAME FABRICATION

3.2.9. PALLET STOPS

3.2.9.1. REMOVABLE PALLET STOPS

3.2.9.2. FIXED PALLET STOPS

3.2.10. GUIDERAILS

3.2.11. FRAME PROTECTORS

3.2.12. DEFLECTORS

3.2.13. COLOR

3.2.14. FLOORING

3.2.15. INSTALLATION

3.2.15.1. ANCHOR BOLTS

3.2.15.2. SHIMS

3.2.15.3. FRAME ANCHORING POINTS

3.2.15.4. GUIDERAILS ANCHORING

3.2.15.5. END-TO-END CONNECTION

3.2.15.6. CONVEYOR LEVELNESS

3.2.15.7. PALLET MOVING FORCE

3.2.15.8. PALLET TRACKING

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

4.2. TESTS

4.3. CERTIFICATIONS

Jacksonville – LRS WHS, App H, GRC - Page 1

1. SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, and test requirements for gravity roller conveyors for the 125 Logistics Readiness Squadron (LRS), LRS Warehouses, in Buildings 1006 (Supply), at Jacksonville Air National Guard Base (ANGB) Florida. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force Drawing NJC109-04. This appendix covers all equipment, materials, and labor necessary to complete the installation of the system.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

The gravity roller conveyors (GRCs) located at the outside covered storage adjacent to Building 1006, as shown on AF Drawing NJC109-04, shall interface with Government-furnished 10k forklifts, AF 463L pallets and AF ISU-90 contianers. The 463L pallets are 88 inches deep by 108 inches wide. The ISU-90 containers are 88 inches deep by 108 inches wide by 90 inches high. Both the 463L pallets and ISU-90 containers shall hereafter be referred to as pallets. The GRCs shall consist of two roller conveyor lanes, each with three roller sections spaced under each pallet as shown on the AF Drawing specified herein. The GRCs shall aid in the off-loading, build-up, and staging of pallets. The pallets will be stored on the roller lanes and will be placed or picked up with a 10,000 pound capacity forklift.

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. INTERFACES AND TRANSFERS

The GRCs shall transfer and store pallets with either the wide edge or narrow edge leading perpendicular to the direction of travel for all possible pallet loads, from empty to fully loaded. Pallets shall not snag or bind along the GRC lanes, at the interfaces between adjacent roller frames, and between adjacent guide rails for all pallet travels/transfers in any direction.

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3.2.2. DEFORMATION UNDER IMPACT

All roller frames, rollers, bearings, roller shafts, and guiderails shall be capable of withstanding repeated impacts from on-loading, off-loading and moving of pallets (fully loaded) without suffering any permanent deformations.

3.2.3. LOAD CAPACITY

The GRCs shall be designed to easily convey pallets weighing from ranges of fully loaded to empty. Each roller shall have a minimum load capacity of 550 pounds. The installed GRCs shall be capable of sustaining distributed impact loadings from the lowering of pallets weighing up to 10,500 pounds by a forklift or pallet truck.

3.2.4. DIMENSIONS/FLOOR SLOPES

All building/column dimensions shown on the AF Drawing specified in 3.1. are nominal. The contractor shall field verify all building/column dimensions and floor conditions and slopes. The inside width (guiderail to guiderail) shall be 112-inches wide.

The conveyor lanes shall be as shown on the AF Drawing specified in 3.1.

3.2.5. ROLLERS

Each roller shall have a minimum load capacity of 550 pounds.

The rollers shall be a minimum 2 1/2-inch diameter steel tubing with 11-gauge wall thickness. The conveying surface of the rollers shall extend a minimum of 1/4 inch above the frame.

Each roller shall have a pin/ring shaft retainer or equivalent to permit easy removal. The rollers shall be located on a maximum of 6-inch centers and shall provide a level carrying surface. The rollers shall be easily removable for inspection and maintenance. All roller tubes shall have electrodeposited zinc coatings. Roller tube plating shall comply with ASTM B633, Service Condition 2, Type I, Flo-Coat specifications, or equivalent as approved by the Contracting Officer's Technical Representative (COTR). Rollers shall be designed to have a minimum service life of ten years at a usage rate of 5,000 hours per year based on ANSI/CEMA 401, using an equivalent radial load which is greater than or equal to 10,500 pounds divided by half of the minimum number of rollers under a pallet and a roller surface speed of 40 feet per minute.

3.2.5.1. REPLACEMENT ROLLERS

Jacksonville – LRS WHS, App H, GRC - Page 3

Twenty-four (24) additional rollers shall be provided to be used as replacements. The rollers shall include all parts (i.e, shaft, clips, etc.) needed to install a fully operational roller.

3.2.6. AXLES

Axles shall be a minimum 11/16-inch hex cold rolled steel. All axles shall be of the through type and shall be pin/ring retained to facilitate easy removal of rollers for cleaning and maintenance.

3.2.7. BEARINGS

Roller bearings shall be the nonprecision, dusttight, light-oil lubricated, zinc-plated, antifriction ball type. Greased bearings shall not be acceptable. Each bearing shall have a minimum static load rating of 275 pounds. The bearings shall be securely mounted by swaging the roller ends or an equally suitable method approved by the COTR. The bearings shall be shielded or steel labyrinth sealed on both sides. If shielding is used, the shield shall be a solid rigid material that will not flake or otherwise introduce foreign material into the bearing. Felt shields shall not be acceptable. The conveyor roller bearings shall have separate steel inner and outer rings.

3.2.8. FRAMES

All frames shall be standard 10-foot sections, where possible, of minimum 4-inch at 5.4 pounds-per-foot structural steel channel as shown on the AF Drawing specified in 3.1. or equivalent formed channel as approved by the COTR. Axle holes shall be punched in the high position on the channel so that rollers will have a minimum 1/4 inch of roller surface above the frame rail. There shall not be an interference fit between the axle holes and the axle.

3.2.8.1. FRAME FABRICATION

All frames shall be connected by steel angle sections as shown on the AF Drawing specified in 3.1. or equivalent as approved by the COTR. All steel angle pieces shall be a minimum of 3-1/2 inches high by 3-inches long by 3/8-inches thick. Both legs of the steel angles shall be welded to the frames. The welds shall be continuous along both sides of each leg. Steel angles shall be installed back-to-back on 30-inch centers to provide removable pallet stop locations. Each bottom leg of the steel angles shall have a hole that will provide an anchoring point

Jacksonville – LRS WHS, App H, GRC - Page 4 for the conveyor. The holes shall be sized for a minimum 1/2-inch anchor bolt. The holes not used for the initial anchoring may be used by the Government for future anchoring if the anchors become excessively loose. The steel angles shall not interfere with operation of conveyor rollers.

3.2.9. PALLET STOPS

All pallet stops shall be a minimum 1/2-inch thick steel painted safety yellow. Pallet stops shall be designed to withstand the impact of a load up to 10,500 pounds, moving a 40 feet/minute without suffering any permanent damage.

3.2.9.1. REMOVABLE PALLET STOPS

A total of 24 individual removable pallet stops shall be provided (three on each forklift access area of each lane – six total – and 18 for other locations along the GRC lane) and constructed as shown on the AF Drawing specified in 3.1.

Receptacles for the removable stops shall be placed in the roller conveyor sections a minimum of every 30-inches, in conjuction with the steel angles specified in 3.2.8.1. The bottom of the removable pallet stops shall not extend beyond the bottom of the conveyor frame. The removable stops shall weigh less than 15 pounds each.

3.2.9.2. FIXED PALLET STOPS

A total of six (6) individual fixed pallet stops shall be provided (three on each back-end of the GRC lanes) and constructed as shown on the AF Drawing specified in 3.1. Fixed pallet stops shall be bolted to the steel angle to provide a secure stop so as to prevent removal without tools.

3.2.10. GUIDERAILS

All gravity roller lanes shall have pallet guiderails.

Guiderails shall be positioned and flare out in accordance with the AF Drawing specified in 3.1. Rails shall be a minimum of 6-inch by 4-inch by 1/2-inch structural angle steel. Each rail section shall be standard 10-foot sections where possible. The anchor holes shall be sized for a minimum 1/2-inch anchor bolt.

3.2.11. FRAME PROTECTORS

The frames at the forklift interfaces shall have hardwood, steel or other material, as approved by the COTR, to protect the frame from forklift tines. The frame protectors shall be placed in

Jacksonville – LRS WHS, App H, GRC - Page 5 the inside edge of the outer two roller frames and both edges of the middle roller frames. The frame protectors shall be easily removable for repair/replacement. If hardwood is used, a minimum 7-foot section at the forklift interface area shall have treated hardwood bolted to the frame in at least four places.

The bolt heads shall be recessed into the wood. The hardwood shall be painted the same color as the frame. If steel is used, the frame protectors shall be 8 feet long, minimum 0.18 inch thick galvanized steel or other material, as approved by the COTR, and bolted to the frame in at least three places. The bolt heads shall be recessed to prevent snag points. The frame protectors shall not interfere with GRC operation.

3.2.12. DEFLECTORS

Deflectors shall be installed at the beginning of each roller section of all conveyor lanes as shown conceptually on the AF Drawing specified in 3.1. The design of the deflector shall be approved by the COTR prior to installation. The deflector shall allow forklift tines to be deflected upwards so the impact is not felt by the frames. The deflectors shall be painted red.

Deflectors shall not extend above the frames.

3.2.13. COLOR

All conveyor frames and associated supports shall be painted brown. All guiderails and associated supports as well as all stops shall be painted safety yellow. The paint shall completely cover all parts, excluding rollers and fasteners, and shall provide a hard scratch enamel type surface. A minimum of one quart of each color shall be provided for future touch up.

This additional paint shall be provided as new and shall not be used by the Contractor to touch up the paint during installation.

3.2.14. FLOORING

The supporting flooring shall be reinforced, as needed, to support the fully loaded GRCs, support the anchor bolts as specified in 3.2.15.1. and provide a smooth installation surface minimizing the number of shims as specified in 3.2.15.2.

Reinforced flooring shall provide a safe walking surface for personnel.

3.2.15. INSTALLATION

3.2.15.1. ANCHOR BOLTS

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Anchor bolt length shall be increased appropriately to compensate for shim thickness to ensure that proper embeddment of the anchor bolt is maintained. All anchor bolts shall maintain a minimum embeddment of 3-inches into the supporting surface. All items shall be anchored with minimum 1/2-inch diameter anchor bolts. The supporting surface bolted to shall be reinforced, if necessary, to prevent pull out, permanent deformation, or other damages during useage of the GRC.

3.2.15.2. SHIMS

If shims are installed, the conveyor frames shall be shimmed at each anchor point and each point where two conveyor sections butt together. The shims shall be held in place by the anchor bolt. Shim holes shall be punched or drilled. Slotted shims shall not be acceptable. Beveled or half-shims shall be provided where required to ensure that each conveyor frame is level with the floor and provides a level conveying surface.

The guiderails need only be shimmed to the point where they extend a minimum of 1-1/2 inches above the conveyor frames along the entire length of the conveyor. Shim width shall be a minimum width of 75% the width of the item shimmed and installed so that they do not extend beyond the frame or guiderail. All shims at any point shall be the same length and width. Shims shall be of sufficient varying thickness so that no more than five shims are installed at any anchor point. In addition, the maximum total shim height shall be 2-1/2 inches above the anchoring surface. Beyond this elevation, supports shall be provided as specified in 3.2.14.

3.2.15.3. FRAME ANCHORING POINTS

All conveyor sections shall be anchored in a minimum of three locations that are evenly spaced over the length of the conveyor section.

3.2.15.4. GUIDERAILS ANCHORING

All rail sections shall be anchored in a minimum of three locations that are evenly spaced over the length of the guiderail section as specified in 3.2.10. Two of the total anchor points for each section shall be within six inches of the end of each section. Rail sections shall be mounted flush end to end to prevent snag points. Guiderail sections shall be welded or spliced to provide a continuous, smooth surface.

3.2.15.5. END-TO-END CONNECTION

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Frame sections shall be bolted together flush end-to-end with lock washers or self-locking nuts to provide a continuous level conveying surface.

3.2.15.6. CONVEYOR LEVELNESS

The gravity roller conveyor shall provide a smooth surface for transporting palletized loads. All roller conveyor sections, within a conveyor lane shall be at the same elevation along both length and width, plus or minus 1/8 of an inch.

3.2.15.7. PALLET MOVING FORCE

The force to move a pallet shall not exceed 25-pounds per 1,000 pounds of load.

3.2.15.8. PALLET TRACKING

All conveyor lanes shall be level and true. Palletized loads shall be able to be pushed a minimum of 50-feet down the lane (when previously centered) without the edge of the pallet touching the guide rail.

4. QUALITY ASSURANCE PROVISIONS

4.1. INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2. TESTS

The following tests as a minimum shall be performed on the system as part of the system checkout test and again as apart of the quality conformance test.

No. Paragraph Description

1. 3.2.3. Test to ensure each roller has a minimum load capacity of 550 pounds. Position fully-loaded pallets on each conveyor lane and leave on the conveyor for two hours. Inspect the roller conveyor system for any deformation. If any deformation is present the system shall fail.

Jacksonville – LRS WHS, App H, GRC - Page 8

2. 3.2.2. Test to ensure all roller conveyor frames, pallet stops, rollers, bearings, roller shafts, and guide rails are capable of withstanding repeated impacts from on-loading of pallets (full-loaded) without suffering any permanent deformations. Position a fully-loaded pallet on the roller conveyor lanes. Move the pallet up and down the conveyor lane five times. Repeat this procedure for all conveyor lanes using a fully-loaded pallet. Inspect the roller conveyor system for any deformation. If any deformation is present, the system shall fail.

3. 3.2.9. Test to ensure the pallet stops are designed to withstand impact of a load up to 10,500 pounds moving at 40 feet/minute without suffering any deformations to the pallet stops or to the load.

With a fully-loaded pallet, impact all sets of pallet stops (three stops in a set) at a speed of 40 feet/minute. Inspect all pallet stops for deformation. If any deformation is present, the system shall fail.

4. 3.2.15.6. Test to ensure that the gravity roller conveyor is level along its entire length and width providing a smooth surface for transporting loads. Using a level, verify levelness at 10 different locations along the gravity roller conveyor. If the gravity roller conveyor is not level to within 1/8-inch over 10 feet, the system fails.

5. 3.2.15.7. Test to ensure that the force to move the loaded pallets does not exceed 25-pounds force per 1,000 pounds of weight moved.

6. 3.2.15.8. Test to ensure that pallets roll straight on all conveyor lanes. A palletized load shall be centered in a conveyor lane. The pallet shall be pushed down the entire length of the conveyor. If the pallet touches the guide rail before reaching the end of the conveyor, they system shall fail. This test shall be repeated until all lanes of conveyor have been tested in both directions.

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4.3. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with the Contract Data Requirements List.

No. Paragraph Certifications

1. 3.2.3. Certify that each roller has a minimum load capacity of 550 pounds.

2. 3.2.7. Certify that the conveyor roller bearings are nonprecision, dust-tight, oil lubricated, zinc-plated, antifriction ball type.

Solicitation Number: FA8604- -R-

Jacksonville – LRS WHS, App H, GRC TPQ - Page 1 of 2

TECHNICAL PROPOSAL

FOR

GRAVITY ROLLER CONVEYORS

Offeror:

Solicitation Number: FA8604- -R- Project Title: Materials Handling System Base: Jacksonville ANGB FL CSN: NJC109 Appendix H, Gravity Roller Conveyors, 1 March 2022

This questionnaire shall be completed by the Offeror. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment.

Please attach product literature/cut sheets for all equipment detailed in this questionnaire and attach any exceptions to the requirements of this appendix.

Paragraph Characteristics

3.2.5. Rollers load capacity is _____ pounds.

Rollers extends _____ inches above frame.

Rollers are located on _____-inch centers.

Rollers are _____-inch diameter steel tubing with a _____-gauge wall thickness.

Rollers will be as specified. YES NO

3.2.7. Will the bearings have a minimum static loading of

275 pounds. YES NO

Will the bearings be nonprecision, dust-tight, light-oil lubricated, zinc-plated, anti-friction ball type? YES NO

How are bearings mounted on roller ends?

Are bearings shielded or steel labyrinth sealed?

YES NO

3.2.8. What material and size/weight are the roller

frames? _________________________________________

Solicitation Number: FA8604- -R-

Jacksonville – LRS WHS, App H, GRC TPQ - Page 2 of 2

3.2.9. How thick are the stops? _________________ inches

Will pallet stops have sharp edges or corners that create a safety hazard? YES NO

3.2.9.

3.2.9.1.

3.2.9.2.

A total of _____ fixed pallet stops will be provided.

A total of _____ removable pallet stops will be provided.

Stops extends _____ inches above the conveying surface.

EXCEPTIONS

Attach any exceptions taken to the Purchase Description Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken? YES NO

Number of pages attached: ____________________________________