ZCN102-App B - 463L Gravity Roller Conveyor (REV1).pdf

APPENDIX B

FOR

463L PALLET GRAVITY ROLLER CONVEYOR

AT

CANNON AIR FORCE BASE, NEW MEXICO

BUILDING 160

CSN: ZCN102

DATE: 17 JANUARY 2023

REVISION 1: 6 MARCH 2023

PREPARED BY:

James F. Rowland James F Rowland

PROJECT ENGINEER

AFLCMC/EZPAE

Brad Thompson Brad Thompson

REVIEWER

AFLCMC/EZPAE

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Cannon AFB, NM – App B – Page i

Table of Contents

1. SCOPE

1.1. GENERAL SCOPE

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. DEFORMATION UNDER IMPACT

3.2.2. LOAD CAPACITY

3.2.3. PALLET TRANSFER

3.2.3.1. INTERFACES

3.2.3.2. CONVEYOR LEVELNESS

3.2.3.3. PALLET TRACKING

3.2.3.4. MANUAL OPERATION

3.2.4. DIMENSIONS

3.2.5. ROLLERS

3.2.5.1. AXLES

3.2.5.2. BEARINGS

3.2.6. ROLLER FRAMES

3.2.6.1. ANCHOR PLATES

3.2.7. CROSSTIES

3.2.8. PALLET STOPS (REV1)

3.2.8.1. FIXED PALLET STOPS

3.2.8.2. REMOVABLE PALLET STOPS (REV1)

3.2.9. CONVEYOR GUIDERAILS

3.2.10. SHIMS

3.2.11. FRAME PROTECTORS FORKLIFT TINE DEFLECTORS (REV1)

3.2.12. SPARE PARTS

4. QUALITY CONFORMANCE

4.1. INSPECTIONS

4.2. TEST

4.3. CERTIFICATIONS

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Cannon AFB, NM – App B - Page 1

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, orientation, and test requirements for 463L pallet gravity roller conveyor in Building 160 at Cannon Air Force Base, New Mexico. The work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) Drawing ZCN102-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

1.1.1. DEFINITIONS

Conveyor lane - A set of three roller conveyor sections laid out across the width of the pallet to convey it in a particular direction.

463L pallet - The 463L pallet is used to transport air cargo throughout AF bases worldwide. 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 measure 108 inches wide by 88 inches long by 2.25 inches thick. Cargo on 463L pallets may be stacked up to 108 inches high on a single pallet. The pallet's rated capacity is 10,000 pounds and weighs approximately 355 pounds.

2. APPLICABLE DOCUMENTS

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

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

The pallet gravity roller conveyor system, as shown on AF Drawing ZCN102-01, shall consist of eight roller conveyor lanes, each with four roller sections spaced equally under the pallets.

The roller conveyor system shall permit the transfer of 463L Pallets and ISU containers from an existing 10K forklift to existing conveyor lanes. Pallets will be lifted from the floor and onto the conveyor lane by fork truck or pallet jack. The

Cannon AFB, NM – App B - Page 2 gravity roller conveyor system will interface with the mezzanine as specified in Appendix A.

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. DEFORMATION UNDER IMPACT

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

3.2.2. LOAD CAPACITY

The roller conveyor system shall be designed to easily convey 463L pallets and containers weighing from ranges of fully loaded to empty. Each roller shall have a minimum load capacity of 550 pounds. The installed conveyor system shall be capable of sustaining distributed impact loadings from the lowering of pallets weighing up to 10,500 pounds by a forklift.

3.2.3. PALLET TRANSFER

3.2.3.1. INTERFACES

Pallets shall not snag or bind at interfaces between conveyor frames and guiderails or across gaps in the conveyor frames and guiderails.

3.2.3.2. 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. The contractor shall verify the existing warehouse floor slope prior to installation of the gravity roller conveyor.

3.2.3.3. PALLET TRACKING

All conveyor lanes shall be level and true. Palletized loads shall be able to be pushed the entire length of the lane (when previously centered) without the edge of the pallet touching the guide rail.

3.2.3.4. MANUAL OPERATION

Cannon AFB, NM – App B - Page 3

All rollers shall be free rolling and free spinning without binding during all operations. The force required to start and maintain pallet transfer shall not exceed 25 pounds per 1,000 pounds of load. Manual transfer without using tools for leverage shall meet the force requirement. The force shall be applied 48 inches above the conveying surface at the edge of the pallet. The force requirements apply to rollers for pallet transfer perpendicular to the axles.

3.2.4. DIMENSIONS

All dimensions shown on AF Drawing ZCN102-01 are nominal. The contractor shall field verify all building dimensions. The inside width (guiderail to guiderail) shall be 112 inches wide.

The conveyor lanes shall as shown on AF Drawing ZCN102-01.

3.2.5. ROLLERS

One of the following commercially produced rollers shall be used for this project: Litton model number RG2507, Interlake model number 4107, Bushman model number 256, or Mathews series B1070 roller or equivalent as approved by the Contracting Officer or technical representative (COTR). If an equivalent roller is proposed, the proposed roller and bearing shall be submitted for approval to the COTR with the shop drawing submittal. The rollers shall be minimum 2 1/2-inch diameter steel tubing with 7-gauge wall thickness. The rollers shall extend a minimum of 1/4 inch above the frame. Each roller shall have a pin/ring shaft retainer 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 B633-85, Service Condition 2, Type I. 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 CEMA 401-78, using an equivalent radial load which is greater than or equal to 10,000 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. 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.

3.2.5.2. BEARINGS

Cannon AFB, NM – App B - Page 4

The conveyor roller bearings shall be the nonprecision, dusttight, 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. The conveyor roller bearings shall have separate steel inner and outer rings. The Frantz 4113-GS shall not be an acceptable bearing due to interference caused by the inner hex-shaped shield.

3.2.6. ROLLER FRAMES

All frames shall be standard 10-foot sections, where possible, of minimum 4-inch at 5.4 pounds-per-foot structural steel channel. Frame sections shall be bolted together flush end-to-end with lock washers or self-locking nuts to provide a continuous level conveying surface. Axle holes shall be punched in the high position on the channel so the conveying surface is a minimum 1/4-inch above the top of the frames. Axles shall easily slide into and out of the axle hole without binding or interference from the frame. Frames shall be as shown in Figure 5.

Figure 5. Typical Gravity Roller Conveyor Section

3.2.6.1. ANCHOR PLATES

Cannon AFB, NM – App B - Page 5

Frames shall be anchored or attached to the surface below through anchor plates. Anchor plates shall be welded to both frames. Frames shall be anchored on maximum 5 foot centers.

The bottom of the anchor plate shall be flush with the bottom of both frames.

3.2.7. CROSSTIES

A minimum of 4 steel crossties shall be positioned in every 10-foot section to provide structural support. Crossties shall be welded to side frames. Crossties shall not interfere with operation of conveyor rollers. Crossties shall be equally spaced along the 10-foot length of the frames. Crossties shall not be used to anchor conveyor sections to the mezzanine/floor.

3.2.8. PALLET STOPS (REV1)

Eight sets of 3 4 fixed pallet stops shall be required for the gravity roller conveyor. 24 sets of 4 removable pallet stops shall be required for the gravity roller conveyor (96 removable stops in total). All pallet stops shall withstand repeated impacts of pallets weighing up to 10,000 pounds moving at 40 feet per minute. Pallet stops, pallet stop supports, pallet guides, conveyor frames, and pallets shall not exhibit damage, deformation, or decreased performance from such impacts. Pallet stops shall extend a minimum of 4 inches above the conveying surface. Pallet stops shall be painted safety yellow. Pallet stops shall not have sharp edges or corners that create a safety hazard. Pallet stops shall be installed in sets spanning the width of the roller. All pallet stops in a set shall be installed the same distance + 1/8-inch from the end of the conveyor.

3.2.8.1. FIXED PALLET STOPS

Fixed pallet stops shall be bolted or welded in place. Fixed stops shall be as shown in Figure 6. One set of fixed pallet stops shall be installed at the end of each gravity roller conveyor lane as shown on AF Drawing ZCN102-01. All fixed stops shall be as wide as the conveyor section.

Cannon AFB, NM – App B - Page 6

Figure 6. Fixed Pallet Stop

3.2.8.2. REMOVABLE PALLET STOPS (REV1)

The removable pallet stop plates and support angles shall be constructed as shown on Figure 7. Removable pallet stops shall be provided as shown on AF Drawing ZCN102-01. When the removable stops are removed, there shall be no remaining protrusions that can snag the pallets or interfere with pallet transfer. Removable stops shall be 11.75 inches wide. A hand opening approximately 1 inch high by 4 inches wide shall be punched in removable stops to provide a handle. The top of the hand opening shall be located approximately 1 inch below the top of the stop. The removable stops shall slide between two support angles.

Figure 7 – Removable Pallet Stop

3.2.9. CONVEYOR GUIDERAILS

All gravity roller lanes shall have pallet guiderails.

Guiderails shall be positioned in accordance with AF Drawing ZCN102-01. Rails shall be 6-inch by 4-inch by 1/2-inch structural angle steel. Each rail section shall be standard 10-foot sections where possible. Rail sections shall be anchored to the warehouse floor on maximum five-foot centers.

Cannon AFB, NM – App B - Page 7

Additionally, the rails shall be anchored within six inches of the end of each section. Each rail section shall be mounted to the floor/mezzanine in a minimum of two places. 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. All guiderails shall be painted safety yellow.

3.2.10. SHIMS

As a minimum, the conveyor frames shall be shimmed at each anchor point. 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. The guiderails need only be shimmed to the point where they extend a minimum of two inches above the conveyor frames along the entire length of the conveyor. Each shim shall be a minimum of 4 inches in length by 4 inches in width and shall be installed so that they are not visible.

Shims shall be of sufficient varying thickness so that no more than five shims are installed at any anchor point. The slope of all the floors will be field verified prior to installation of the conveyor.

3.2.11. FRAME PROTECTORS FORKLIFT TINE DEFLECTORS (REV1)

Frame protectors shall be installed at the each end of exposed roller section where it will interface with a forklift. The frame protector shall be similar in design to the fixed pallet stops. Protectors shall not extend above the frames. Carriage bolts shall be used to connect the protectors to the frames.

The design of the frame protector shall be approved by the COTR prior to installation. The deflector shall prevent forklift tines from having direct impact with the rollers. The protectors shall be painted red.

Deflectors shall be installed at the beginning of the conveyor lane. The design of the deflector shall be approved by the COTR prior to manufacturing. The deflector shall allow forklift tines to be deflected upwards so the impact is not felt by the frames. The deflectors shall be galvanized. Deflectors shall not extend above the frames.

3.2.11.1. FORKTINE FRAME PROTECTORS

The forklift interfaces shall have forktine frame protectors placed in the inside edge of the outer two roller frame sections

Cannon AFB, NM – App B - Page 8 and both sides of the middle roller frame sections. The protectors shall be 8 feet long. The forktine frame protectors shall be minimum 0.18 inch thick galvanized steel or other material approved by the COTR. The forktine frame protectors shall be bolted to the frame in at least three places. The forktine frame protectors shall be easily removable for repair/replacement. The bolt heads shall be recessed to prevent snag points. The forktine frame protectors shall not interfere with conveyor operation. The forktine frame protectors shall protect the conveyor frame from damage from forklift tines.

Forktine frame protectors shall be galvanized.

3.2.12. SPARE PARTS

The contractor shall provide 2 percent of the number of rollers in the system, rounded up to the next integer, to a maximum of 20 for each type of roller included in the system.

Spare rollers shall include the roller tube, both bearings, and the shaft.

4. QUALITY CONFORMANCE

4.1. INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the Cover 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. TEST

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

No. Paragraph Description

Cannon AFB, NM – App B - Page 9

1. 3.2.1. 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.

2. 3.2.2. 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.

3. 3.2.3.3. 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.

4. 3.2.8.

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 at a speed of 40 feet/minute. Inspect all pallet stops for deformation. If any deformation is present, the system shall fail.

Cannon AFB, NM – App B - Page 10

5. 3.2.3.2. 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.

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

2. 3.2.5.2. Certify that the conveyor roller bearings are nonprecision, dust-tight, oil lubricated, zinc-plated, antifriction ball type.

TECHNICAL PROPOSAL QUESTIONNAIRE

FOR

Cannon AFB, NM – 463L Pallet Conveyor TPQ - Page 1 of 4

463L PALLET GRAVITY ROLLER CONVEYOR

Offeror:

Solicitation Number: FA8604- -R- Project Title: Storage Aid System Base: Cannon AFB, NM CSN: ZCN102 Appendix B, 463L Pallet Gravity Roller Conveyor, 17 January 2023

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 Purchase Description Appendix as detailed below.

Roller Manufacturer, Model Number: _____________________________ Bearing Manufacturer: _______________________________________ Conveyor Manufacturer: ______________________________________

No. Paragraph Characteristics

1. 3.1. Will the conveyor allow the transfer of 463L pallets and ISU containers from a 10K forklift to the existing lane of conveyor as specified?

YES NO

2. 3.2.1. Will the conveyor withstand repeated impacts from on/off-loading of pallets and transfer of pallets without suffering permanent deformation?

3. 3.2.2. What is the minimum load capacity of each roller? ____________________________ pounds

4. 3.2.3.1. Will pallets transfer between adjacent conveyor frames without snagging or binding?

5. 3.2.3.2. Are all roller conveyor sections within a conveyor lane at the same elevation along both length and width, plus or minus 1/8 of an inch?

Solicitation Number: FA8604-__-R-____

Cannon AFB, NM – 463L Pallet Conveyor TPQ - Page 2 of 4

6. 3.2.3.4. Force required to start pallet transfer:

___________ pounds per 1,000 pounds of load

Force required to maintain pallet transfer:

___________ pounds per 1,000 pounds of load

7. 3.2.5. What is the roller spacing, center to center?

____________________________ inches

8. 3.2.5. What is the minimum distance between the conveying surface of the rollers and the frame?

_____________________________ inches

9. 3.2.5. What is the diameter of the roller tubes?

____________________________________ inches

10. 3.2.5. Will roller tubes have electro-deposited zinc coatings?

11. 3.2.5.1. Does the roller tube plating comply with ASTMB633, Service Condition 2, Type I?

12. 3.2.5.1. What type and size of axles will be provided?

How are roller axles retained? ____________

13. 3.2.5.2. What type of bearings are being provided?

What is the bearing load rating?

____________________________________ pounds

14. 3.2.6. What size of channel will be used for the frames?

_______ inches at _________ pounds-per-foot

15. 3.2.6.1. Will the conveyor be anchored on maximum 5 feet centers?

Cannon AFB, NM – 463L Pallet Conveyor TPQ - Page 3 of 4

16. 3.2.7. Will crossties be provided as specified?

17. 3.2.8. How many fixed pallet stops will be provided?

18. 3.2.8. Are all pallet stops designed to withstand impact without damage as specified?

19. 3.2.8. How far above the conveying surface do pallet stops extend? _______________ inches

20. 3.2.9. Are guiderails provided in locations specified?

Are the guiderails structural steel angle?

Size of the guiderails:

______ inches x ______ inches x ______ inch

21. 3.2.9. Are guide rails anchored separately from the conveyor frames?

YES NO

Are guide rail sections mounted flush end to end to prevent snag points?

22. 3.2.11. Are frame protectors provided where specified?

Will the frame protectors not be damaged or suffer permanent deformation from tine impacts?

23. 3.2.12. Will spare rollers be provided as specified?

Cannon AFB, NM – 463L Pallet Conveyor TPQ - Page 4 of 4

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?

Number of pages attached: ____________________________________