Fairlead Beam Modification SOW_2021.pdf

Statement of Work

Fairlead Beams

General requirements

1. Performing modifications to the Fairlead Beam (FLB) in accordance with drawings, procedures, and material specifications. Reference files titled “Fairlead Beam Upgrade Fabrication Drawings”. Only certified welders may perform welding on the beams.

Certificates must be provided with quotes. Follow American Welding Society D1.1, table 3.1 for welding requirements on ASTM A36 steel. Minimum yield strength 36Ksi, minimum tensile strength 58Ksi.

2. Use ONLY Sherwin Williams Zinc Clad IV. For Zinc Clad IV primed surfaces, paint standard for steel will be one coat of Zinc clad IV (3.0-5.0 mils dry film thickness) followed by two coats of Sherwin Williams Acrolon 218 HS polyurethane topcoat (3.0-6.0 mils dry film thickness). Refer to Fed Color description #595 14052, RGB Hex Code 373D2F for the topcoat color (Green). The vendor shall follow the manufacturer’s recommendations for surface preparation and coating application. Note: For painting purposes, the Fairlead Beams are approximately 15ft x 3ft x 1ft.

3. CETSC shall be contacted for a First Completed Beam Inspection after the first FLB is modified, assembled, and painted to ensure contract compliance. If accepted, modification and painting on the remaining FLB’s can continue.

Anticipated Work Sequence

1. Degrease and power wash units as necessary to prepare for media blasting, welding, & painting.

2. Each existing fairlead beam will come with four (4) lifting rings. Remove lifting rings and ground beam surface smooth. The lifting rings shall be re-installed at similar location on new top plate, by attaching with the newly fabricated bent plates (as indicated in Fig. 5-17). Bent plates sizing should replicate existing.

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Figure 5-17: Exploded view of new hand hole covers (Detail -1), a new 0.25-ln top plate (Detail -2), 12 new side plate gussets (Detail -3) and a standard falr1ead beam (Detail -4) prior to modification to meet 75 kip wheel loads from the 17 Nov 09 edition of UFC 3-60-01, Airfield and Heliport planning and Design

3. Media blast all paint coating down to the bare metal to ensure a strong bond is obtained between the metal and new paint coating; CETSC is aware of certain areas on the FLB that may limit the accessibility to fully meet this requirement. The top surfaces of the existing FLB that will be receiving the top plate cover does not require media blasting and can remain as is.

NOTE: Some of the existing paint may contain lead.

Figure 1 shows 2 beams that are typical of disassembled configuration, which will be sent for modifications.

Figure 1 - Disassembled Fairlead Beams

Additional accessories are being sent for each beam requiring media blasting, painting and coating. They include the following:

Note: Retainer cover plate and main fairlead beam are mated and are required to remain together. Items will be marked with identical numbers by CETSC personnel.

Retainer cover plate as shown in Figures 2.

Figure 2 - Retainer Cover Plate

Brush holders and Retainer Ring shown in Figure 3.

Figure 3 - Brush Holder and Retainer Ring

End Roller Housing shown in Figures 4-6.

Figure 4 - End Roller Housing

Figure 5 - End Roller Housing

Figure 6 - End Roller Housing

4. Fabrication of top plate as shown in Fig 5-20a thru 5-20c.

NOTE: Fairlead Beams can vary in length. Should the top plate have excess length on the back side it’s okay as long as the bolt holes and lifting rings line up. Should the front (area closest to the head of beam) have excess length, it needs to be ground flush with the edge of the beam.

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Figure 5-20b: FLB Top Plate Upgrade Drawings

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Figu re 5-20c: FLB Top Plate Upgrade Drawings

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5. Drill 28 each 0.81 inch holes in new top plate using Fig. 5-20b.

6. Drill 28 correlating holes in original fairlead beams to allow mounting of plate to original fairlead beam using nut, washers and bolt.

7. Drill 10 each 2.00 inch holes in new top plate using Fig. 5-20b.

8. Drill 10 correlating holes in original fairlead beam to allow access to fairlead beam mounting nuts.

9. Drill 4 each 0.16 inch holes using Fig. 5-20a to allow installing of serial plate. (Installed by ANG personnel)

10. Hand hole covers as shown in Figure 5-19.

11. Side gusset plate shown in figure 5-21.

NOTE: Weld gussets so they are flush with outside top and bottom edge of fairlead beam.

Note: Plate B is welded around its perimeter to Plate A

12. Assemble top plate side gussets and hand holds by bolting and welding in accordance with Figure 5-17 (shown earlier). A 3/8” course nut will need to be welded onto the bottom side of the fairlead beam hand hold in line with existing mounting holes. Note that the top of existing beam and bottom of the new top plate do not require painting prior to assembly.

13. Contact CETSC for First Completed Beam Inspection after paint has been applied.

See Figure 7 as a visual image for reference showing a completed product. Note that the completed product image includes work not required in this statement of work.

Figure 7 - Completed Product