FINAL Synopsis 6913G623Q300047 NWS Earle Boxcar Q 22.pdf

US DOT, The Volpe Center DRAFT Pre-Sol 6913G623Q300047

Performance Work Statement

50 Foot Damage Free (DF-Type) Railway Boxcars for Naval Weapons Station Earle Colts Neck, NJ

June 23, 2023

Office of the Secretary, U.S. Department of Transportation

Volpe National Transportation Systems Center Infrastructure Engineering and Deployment

CONTENTS

DESCRIPTION

1. GENERAL

1.2. REFERENCE DOCUMENTS

1.3. ORDER OF PRECEDENCE

2. 50-FOOT DAMAGE FREE (DF-TYPE) BOXCARS

2.1. DIMENSIONS and LIMITS

2.2. DESIGN/ENGINEERING/FABRICATION

2.3. PERIOD OF PERFORMANCE

2.4. DELIVERY REQUIREMENTS

2.5. DOORS

2.6. TRUCKS

2.7. BRAKES

2.8. MECHANICAL DUNNAGE SYSTEM

2.10. DRAFT GEARS AND COUPLERS

2.11. PAINTING AND STENCILING

2.11.1. PAINT SPECIFICATIONS

2.12. QUALITY CONTROL

2.13. DRAWINGS AND DOCUMENTATION

2.13.1. Parts/Service Manual

2.13.2. Operator's Procedure Manual

2.13.3. Documentation Package

2.14. INSPECTION PROCEDURE

2.14.1. Inspection

2.14.2. Tests

DESCRIPTION

This is a pre-solicitation for commercial items prepared in accordance with (IAW) the format in Federal Acquisition Regulation (FAR) Part 13.5, Simplified Procedures for Certain Commercial Products and Commercial Services, and the solicitation will be issued as a Firm-Fixed-Price purchase order, as supplemented with additional information included in this notice. The applicable North American Industry Classification System (NAICS) Code is 336510, Railroad Rolling Stock Manufacturing, with a small business size standard of 1,000 employees. This pre-solicitation document and incorporated provisions and clauses are those in effect through Federal Acquisition Circular (FAC) 2005-77.

The U.S. Department of Transportation, Volpe National Transportation Systems Center (Volpe Center), Cambridge, MA, 02142, is seeking to acquire general purpose railway boxcars as described herein. All boxcar deliveries shall be FOB DESTINATION and therefore Offers must consider any shipping costs in the CLIN price. All boxcar deliveries shall be within timeframe specified. It is noted upon delivery/acceptance for each railway boxcar the standard commercial warranty will begin.

CLINs Description Quantity Delivery Unit Price Total Price

00100 50-Foot Railway Boxcars, Delivered

22 365 Calendar Days After Award

1. GENERAL

The contractor shall provide the following items:

1. The contractor shall provide a quantity of twenty-two (22) 50-foot double-door damage free (DF –Type) railway boxcars with wood floors and belt rail equipped, with a load capacity of no less than 80-tons and a service life of 40-years or newer according to AAR when manufactured new. The design shall be based on a gross rail load (GRL) of 263,000 pounds. All boxcars shall be delivered to U.S. Naval Weapons Station (NWS) Earle, Colts Neck, New Jersey.

Disclaimer: To provide the best value to the Government, the Government is accepting new and/or used railway boxcars for this effort. All railcars in this procurement are specified to be manufactured with either new components or components dated up to ten years old at the time of this pre-solicitation date. The government will also take into consideration proposals offering options for cost saving solutions such as reutilized components. Paint and finish shall be fresh and railcar decks shall be newly fabricated under any circumstances.

1.2. REFERENCE DOCUMENTS

The railroad boxcars must satisfy all the following documents in effect at the time of this procurement:

1. Association of American Railroads (AAR) Manual of Standards and Recommended Practices

2. AAR Interchange Rules

3. The Official Railway Equipment Register

4. Code of Federal Regulations (CFR) 49, Transportation

5. American Society for Testing and Materials (ASTM) A53

6. American Welding Society (AWS) D15.1

7. American Society of Mechanical Engineers (ASME), Boiler and Pressure Code Section IX, Welding

Qualifications.

8. American Iron and Steel Institute (AISI) Standards

9. MIL-STD-1320D

10. NAVSEA SW023-AK-SAF-010

11. Existing Crossmember Exhibits (1) through (4)

1.3. ORDER OF PRECEDENCE

The Order of Precedence is established in FAR 52.212-4. In addition to the Order of Precedence set in FAR 52.212-4, if there is a conflict between the text of this document and the references cited above, the text of this document takes precedence.

2. 50-FOOT DAMAGE FREE (DF-TYPE) BOXCARS

All boxcars offered shall be newly manufactured or may have a remaining life of 40-years according to AAR interchange rules. This includes all dated components. All cars proposed must meet the requirements of this PWS. The 40-year remaining life is calculated at the time this pre-solicitation is posted on a normal 50-year lifespan, without increased life status applied. The following specifications are applicable to the 50-foot boxcars. The Government is seeking boxcars similarly sized and configured to the boxcars identified in this specification. The dimensions presented in this document, unless otherwise stated, are dimensions taken from the existing boxcars for reference. Any proposed lengths and distances that are different from the dimensions specified in this document must be presented for review and approval prior to award. External dimensions have a greater need of being the same as the dimensions provided herein.

2.1. DIMENSIONS AND LIMITS

1. Length over end sills: 50’ - 9 ½“ (+/- 1 inch)

2. Length over pulling face of couplers (overall length nominal): 55’ - 5”

3. Extreme width: 9’ – 11” (119 inches)

4. Extreme height: 14’ – 3” (171 inches)

5. Deck (platform) Height (empty car, from top of rail): 3’ – 10” (46 inches)

6. Wheel/axle truck center pin to center pin distance: 40’ - 10”

7. Truck assembly axle to axle distance: 66 inches

8. Coupler Height: 2’ - 10 ½” (34.5 inches) from top of rail to the coupler.

9. Minimum Gross Rail Load: 263,000 pounds

10. Capacity requirement for new cars: 80 Ton (160,000 pounds)

11. Light Weight (LT WT): determined by design

12. AAR Mechanical Designation: XL

13. AAR Car Equipment Type Code: A330

14. Minimum coupled curve negotiation: 23-degree

2.2. DESIGN/ENGINEERING/FABRICATION

1. The boxcars shall be manufactured from materials conforming to AAR and ASTM specifications.

2. All boxcars must satisfy all AAR Interchange requirements at time of delivery.

3. The boxcars shall be commercial standard 56-½ inch rail wheel gauge and shall meet or exceed AAR design specifications and Code of Federal Regulations, 49CFR Part 231 – Railroad Safety Appliance Standards).

4. The boxcar inside walls shall have thirty-two (32) anchor belt rails permanently attached. See Belt Rail Section below. Wood wall lining fabricated from ¾-inch external commercial grade plywood on inside walls and between belt rails is required.

5. All boxcars offered shall be similar by size, type, deck height, doors, age, and volume.

6. Prior to any work/re-work, the Government reserves the right to inspect and accept or reject previously manufactured boxcars planned for this procurement.

7. All work to be accomplished for the deliverables associated with this work statement shall be performed by an AAR certified rail shop with these current active certificates: AAR M-1003 Quality Assurance certificate and AAR S-2034 Car Builder Certification.

8. The Vendor shall provide a Quality Assurance Plan which identifies the process used to assure product quality as it relates to this effort.

9. All boxcars shall be tested for water tightness and all leaks must be repaired prior to delivery.

2.3. PERIOD OF PERFORMANCE

All boxcars shall be delivered within one-year (365 days) from the date of award.

2.4. DELIVERY REQUIREMENTS

Delivery of boxcars to destination shall be by railroad. Each boxcar shall be prepared for delivery in accordance with AAR requirements for Interchange Service. The USN car ID Road Numbers will be provided at a later date. The contractor shall be responsible for temporary registering the cars in the AAR UMLER (Universal Machine Language Equipment Register) for delivery and delivering all boxcars.

Final acceptance of boxcars will be at U.S. Naval Weapons Station Earle (NWS) Colts Neck, New Jersey. Acceptance will require inspection for carrier damage and proper operating condition of doors and other functions at the destination prior to any payment to the contractor. The delivery destination is:

Conrail Interchange, at Receiving Yard on board U.S. Naval Weapons Station (NWS) Earle, Colts Neck, New Jersey

Receiving Customer Address:

NMCLANT DET EARLE

201 Highway South BLDG C-9 NWS Earle Colts Neck, NJ 07722-5017

2.5. DOORS

1. All boxcars shall have sliding doors centered on both sides of the superstructure.

2. The minimum door opening shall be 10’ – 2” (122 inches) but no more than 12’ (144 inches) maximum.

3. Closed doors shall repel water from entering the boxcar.

2.6. TRUCKS

1. Each boxcar superstructure shall be mounted on two 2-axle trucks.

2. The trucks and truck components shall be suitable for a gross rail load (GRL) of at least 263,000 pounds on four axles per boxcar. Trucks shall have manganese steel vertical liners.

3. Wheels shall be new, one wear, 36-inch diameter, heat-treated, curved plate, cast or wrought steel and appropriate for the truck capacity. Used wheels may be acceptable depending on the remaining tread thickness and overall condition. Under any circumstances, wheels must satisfy acceptance inspection criteria at destination.

4. Axles and roller bearings for each boxcar shall be of appropriate size and capacity for each boxcar type and meet all AAR requirements.

5. The spring travel shall be in accordance with truck capacity and deck height desired.

6. Each car shall be equipped with AAR approved constant contact or constant contact/roller combination side-bearings adjusted to AAR specifications.

7. Truck center bowl horizontal surface shall be lubricated with an AAR approved non-metallic liner.

Center bowl diameter to be appropriately sized for gross rail load of boxcar per AAR.

2.7. BRAKES

1. Air brakes, single capacity, providing constant braking force. The control valve shall be ABDX or newer design approved for use by the AAR and shall incorporate a four-port receiver for an automated single-car test. High friction composition brake shoes shall be used in accordance with latest AAR requirements.

2. The car brake piping system shall conform to ASTM A-53 schedule 80 or latest revision and shall meet the requirements of AAR and shall be installed in a location protected from accidental damage during side loading operations.

3. Boxcars shall pass testing as specified in AAR Standard S-486 Single Car Testing Device - Code of Tests for Freight Car equipment.

4. Net air brake and hand brake force, as determined by a static brake test, shall conform to AAR standard S-401.

5. The hand brake shall be end-mounted and comply with 49CFR 231.27.

6. Brake beams shall be of the unit type and brake head to reject cast iron shoes.

7. Brake air reservoirs shall conform to AAR requirements.

8. Boxcar brake cylinders having 12” total travel shall have travel of 7 1/2” +/-1/4” travel at acceptance.

Automatic double acting slack adjusters shall be used.

9. Chains used in the braking system shall be confined only to the handbrake linkage.

10. Cars shall be equipped with AAR approved air brake hoses long enough to safely negotiate curves and coupler travel. The air hose and end arrangement shall be in accordance with AAR standards.

2.8. MECHANICAL DUNNAGE SYSTEM

1. DF System shall be comparable with MIL-STD-1320D and compatible with existing dunnage bars currently in use at U.S. Naval Weapons Station Earle.

2. The inside dimensions of the DF Type boxcar are: length, 50 feet 6 inches between end walls; width, 8 feet 11 inches between wall members; and height, 10 feet at the eaves. Each car contains, as standard equipment, thirty-two (32) horizontal permanently mounted steel rails along the length of the boxcar from the door opening to the end wall.

3. Each rail shall be one continuous length.

4. Height of each rail shall be 10, 24, 30, 36, 48, 60, 72, and 84 inches above finished floor height.

5. Rails shall accommodate crossmember bar adjustment in one (1) inch increments along the horizontal plain of each rail.

6. Existing crossmember is adjustable from 105 inches to 109 inches.

7. Note: Reference 11 - photos of existing crossmember bar.

2.9. BOXCAR FLOORING

1. Flooring shall consist of 2 - 3/8 inch thick, 5 – 1/16 wide tongue and groove yellow pine or similar (not hardwood) that can be used for nailing and fastening blocking material and in conformance with AAR Manual of Standards and Recommended Practices, Section A, Part II, Specification M-907, Group IV.

Wood decking material shall be applied to the steel subfloor by stud welding fasteners.

2. Floor Minimum Load Rating 50,000 pounds per square foot, (50K).

2.10. DRAFT GEARS AND COUPLERS

1. Couplers shall be AAR approved Type-E bottom shelf design.

2. Cars shall have manganese steel coupler carrier wear plates (no nonmetallic wear plates allowed). The uncoupling arrangement shall be such that an AAR-approved replacement coupling rod can be applied without modification to the car body or uncoupling device support brackets.

3. Cars shall be equipped with fixed couplers. No end-of-car hydraulic valve cushioning devices are to be installed on the boxcars.

4. Knuckles shall be of reduced slack design. Articulated connectors shall be of cast steel incorporating parts to take up slack; the design shall provide for the compensation of wear on mating parts to maintain a slack-free condition.

2.11. PAINTING AND STENCILING

1. Contractor shall follow AAR Requirements for surfaces that are not to be painted.

2. Ferrous metal surfaces to be painted shall be cleaned to bare metal by sandblasting, commercial grade grit blasting, or mechanical or chemical means. Surfaces to be painted shall be coated with a primer pretreatment coating within 24 hours prior to the application of the primer. Ferrous surfaces requiring finish painting shall be primed with one coat of rust inhibiting high build urethane or equal, dry film thickness to be in accordance with the paint manufacturer's instructions. All surfaces to be painted which will be inaccessible after assembly shall have primer applied before assembly, except in weld area. Finish coat paint shall be two coats of high-build urethane or equal, dry film minimum thickness of each coat to be 1.2 +0.6 -0.0 mils, or in accordance with the paint manufacturer's instructions. The color of the painted car body including the underframe structure and the attached components, except as otherwise specified below or by AAR Section L, shall be gray. The paint system total VOC shall be less than 3.5lbs/gal.

3. Trucks shall be fog painted with a 0.5-mil maximum dry film thickness application of black enamel.

The paint coating shall not prevent detection of flaws or cracks in ordinary inspections. In the event pre-painted trucks are supplied, the paint shall be applied in accordance with the paint manufacturer's standards. All painting must meet Federal, State, and local compliance and permitting for painting processes.

4. Placards, four per railcar, permanently fixed as specified in NAVSEA SW023-AK-SAF-010 and 49 CFR part 172.510 (one on each A & B End, and one each side). No less than 13.5 inches square in size. Each placard shall have seven metal flip indicator signs on white background identifying the following: Explosive 1.1, Explosive 1.2, Explosive 1.3, Explosive 1.4, Dangerous, Empty, Inert (an example of the type is: Labelmaster Style 81SF-7).

2.11.1. PAINT SPECIFICATIONS

1. Paint Specifications shall conform to AAR Standard M-1001 Section C, Part II, Section 5.2

2. Paint classification shall be Urethane or equal and follow the Federal Color Standard: 595B

White # 27886 Black # 17038 Gray # 26270 Yellow # 13591

3. Primer shall be urethane compatible Substrate: Primed Steel Pre-treatment: Sandblasted Compliance Status: 3.5 lb. /gal volatile organic compound (VOC) mixed (maximum)

4. Application to Boxcars Car body: White Underframe: Gray Trucks: Black (fog coat only) Ladders, handholds, steps, brake wheels and levers: Black Alkyd Enamel (TT-E-1 593 B or equivalent) Stenciling: Black “United States Navy” located on both sides of boxcar on one side of the sliding door and “USN (followed by Road Number that will be provided at a later date)” on both sides of car on the other side of the sliding door.

5. Reflective surfaces applied to A and B ends, and on both sides extending from the ends at least 8-feet towards the center.

6. A consolidated stencil with appropriate brake maintenance information shall be attached to the cars.

7. Paint thickness: 4-mil minimum dry thickness combined system of primer and final coat.

8. Grab irons, uncoupling levers, and sill steps shall be painted yellow. Only component supplier will paint telescoping portions of uncoupling lever.

9. An anti-skid deck-covering compound shall be applied to the bare metal, steel deck plate before painting. Decks made of wood or anti-skid material do not require anti-skid coating.

10. Stenciling and markings shall be done with AAR approved contrasting-color materials. White paint stenciling must be of a consistency to cover black background thoroughly and provide a sharp contrast that will remain legible for a minimum period of 96 months. Stenciling on each end of car shall be done with black paint and will include but not be limited to identification of couplers, wheels, end-of-car cushioning, springs, and snubbers. "JACK HERE" and "LIFT HERE" stencils shall be applied at the appropriate places. Additional markings including loading and weight dimensions (LT WT and LD LMT) shall be in accordance with AAR Section L– Lettering and Marking of Cars, as applicable.

Adhesive backed film markings must be applied at surface temperatures between 40- and 100-degrees Fahrenheit.

11. In addition to the markings identified by the AAR, there shall be twenty-eight (28) reflective markers (quantity of 14 red color and 14 amber color) attached to each boxcar with the following characteristics:

a) Have a minimum reflective diameter of 4-inches

b) Be of armored/protected type by enclosed in a steel or aluminum housing

c) Four markers to be install on each end of the boxcars and ten markers installed on each side of each boxcar superstructure (see reference pictures)

Pictures provided for reflective marker reference locations

2.12. QUALITY CONTROL

1. Structural members shall be free of notch sensitive areas and discontinuities that could result in highly localized stress concentrations.

2. Welding shall be in accordance with AWS D15.1 and AAR section C, part II, volume 1 -

Specifications for Design, Fabrication, and Construction of Freight Cars, M-1001. The surface of parts to be welded shall be free from rust, scale, paint, grease, and mill scale or other foreign matter that can be removed by chipping and wire brushing. Spot, tack, or intermittent welds for strength will not be permitted. Weld penetration shall be such as to provide transference of maximum design stress through the base metal juncture. Fillet welds shall be provided to reduce stress concentration.

3. Unless otherwise specified in the contract or purchase order, the contractor is responsible for the performance of all inspection requirements (examinations and tests) as specified herein. Except as otherwise specified, the contractor may use his own or any other facilities suitable for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any of the inspections set forth in the specification where such inspections are deemed necessary to ensure supplies and service conform to prescribed requirements.

4. The contractor is responsible for ensuring that components and materials used are manufactured, examined, and tested in accordance with referenced specifications and standards or for providing evidence that AAR has previously approved the components.

2.13. DRAWINGS AND DOCUMENTATION

The boxcar design shall be provided with a Parts/Service Manual, Operator’s Procedure Manual, and Documentation Package. The following shall be submitted to the contracting officer upon delivery:

2.13.1. Parts/Service Manual

The boxcar parts/service manual shall be designed to provide quick access to information for the experienced and novice user. The parts/service manual will provide parts pages and component illustration pages and shall provide a description for all mechanical assemblies and all special tools required to perform repairs if failure occurs. Safety will be announced when describing procedures that have the capability to cause damage to equipment or harm personnel. This description shall describe and illustrate the assembly and/or subassemblies contained in all main assemblies. The subassemblies will be illustrated in exploded view style and the breakout of parts will be cross-referenced by item number to provide identification by name and part number and quantity required. The part number is the manufacturer's number for the component. The manual will also contain a description and part number for special tools required for the removal/replacement of assemblies and sub-assemblies.

Manual quantities are described in the following Sections.

2.13.2. OPERATOR'S PROCEDURE MANUAL

The Contractor shall supply a stand-alone Operator's Procedure Manual. The boxcar Operator's Procedure Manual will contain a step-by-step process to operate all systems and assemblies. This shall include all safety warnings and safety related operations. Manual quantities are described in the following sections.

2.13.3. DOCUMENTATION PACKAGE

The documentation package to be submitted shall consist of two hard copies and two electronic copies of the following:

1. Component (part) identification

2. Maintenance Manual (including troubleshooting guide)

3. Operator's Procedure Manual (described above)

4. Parts/Service Manual (described above)

5. Identification and results of all certifications, tests, repairs and inspections

NOTE: All electronically formatted documentation shall be compatible with Adobe Acrobat Reader and can be electronically reproduced for Government use.

2.14. INSPECTION PROCEDURE

2.14.1. INSPECTION

Each boxcar shall be examined for, but not limited to, the following characteristics:

1. AAR M-1003 Certification for Activity Code A20 (Manufacturer of Freight Cars) and AAR S-2034 Car Builder Certification from Vendor performing the boxcar construction.

2. Boxcars shall safely negotiate track curvature as specified.

3. All boxcar’s dimensions and paint as specified.

4. Materials resistant to corrosion and deterioration or treated to be resistant to corrosion and deterioration in the applicable storage and operating environments.

5. Contractor provides required manuals and documentation identifying materials, material finishes or treatment.

6. Load limit for car design not to exceed 263,000 pounds gross rail load (GRL)

7. Safety appliances as required per AAR.

8. Painting and markings.

9. Design and construction in accordance with AAR/FRA requirements.

10. Brake equipment as specified.

11. Wheels with unacceptable defects. In this situation, the car will not be acceptable until repaired.

2.14.2. TESTS

1. Any tests required by AAR shall be in accordance with AAR specifications, and as specified herein.

No specific order of testing is required. All tests listed below will be conducted at the contractor’s designated location.

2. The entire air brake system shall be tested to ensure correct functioning of all components. The boxcar shall be tested with a single car-testing device in accordance with AAR Standard S 486 Single Car Testing Device Code of Tests for Freight Car Equipment. The brake cylinder piston travel shall be as specified in S 400, Specification No.2518 Freight Car Brake Equipment, and Installation Specifications and shall be tested for interference and correct travel. Nonconformance to AAR requirements shall constitute failure of this test. A braking force test in accordance with AAR requirements shall be conducted to determine brake shoe pressure at each wheel.

3. The hand brake shall be tested in accordance with AAR requirements to determine the brake shoe pressure at each wheel. Nonconformance shall constitute failure of this test.

4. The side bearings shall be tested with the car on level tangent track and the car body level. Side bearing clearances shall be measured at each bearing. Nonconformance to manufacturer's, AAR or CFR Title 49 clearance limits shall constitute failure of this test.

End of DRAFT PWS