HSCG38-15-Q-010002-Statement_of_Work.docx

HC-144A AIRCRAFT REMOVABLE COMPOSITE STRUCTURAL PANEL

REPAIR AND MODIFICATION

STATEMENT OF WORK

1.0 BACKGROUND

Inspections of HC-144A removable structural panels routinely show evidence of corrosion of the rivets and dimpled washers. Corrosion is caused by dissimilar material where foil or screen used as lightening and static protection comes in contact with the original manufacturers (OEM) washers or poor installation of washers during panel construction. It is the intention of the United States Coast Guard (USCG) to have these panels repaired, and where applicable replace the existing CASA installed cup washers part numbers (P/Ns) CAN44114C10-0.4 or CAN44114A10-0.4 and CAN44100C4X0.4 or CAN44100A4X0.4) with cup washers P/N NAS1169DD10L where installed.

The vertical stabilizer’s trailing edge panels listed in section 3.2 shall be inspected, repaired and modified accordingly IAW section 2.7.

2.0 REQUIREMENT

2.1 The repair source shall be an OEM or a Federal Aviation Administration (FAA) Part 145 authorized repair center certified to perform composite repairs and/or modifications to provide complete, ready-to-install components listed in section 3.0.

2.2 Repairs, material type, and ply direction shall be in accordance with (IAW) previously approved USCG processes. Alternate repair processes, such as the Military Technical Orders listed in paragraph 4.2, or Advanced Composite Repair Procedures for Aerospace, are acceptable. Repairs may only be completed by OEM approved or USGC approved capable, repair facilities.

2.3 Deviations From OEM Specifications

2.3.1 Designated Engineering Representative (DER) or contractor developed repair procedures that comply with FAA Advisory Circular AC 43-214, Repair and Alterations to Composites and Bonded Aircraft Structure may be acceptable upon review and approval by USCG MRS Engineering. Deviations in ply layup or material shall be approved by the USCG’s ALC MRS Engineering Division prior to commencement of work.

2.3.2 Contractor shall submit any proposed repair scheme to the USCG Contracting Officer for MRS Engineering Division review and approval. Work shall not commence until contractor receives USCG approval. Contractor generated repair schemes will be treated as proprietary data by the USCG.

2.4 Contractor shall have the equipment, tooling, and expertise required to repair these components. The technical data for repair of these panels is proprietary to the OEM, EADS/CASA. The USCG does not own, nor can it provide the data.

2.5 Replace damaged wire screen or foil used for lightening and anti-static protection with material that meets OEM specifications as applicable for the panel undergoing repair. Prepreg materials; such as Astrostrike® or SynSkin® is authorized providing screen or foil meets OEM material characteristics.

2.6 Cup Washer Replacement

2.6.1 Inspect panel for washer type, size, and location. Identifying location and type of washer is important for washer replacement in steps 2.6.1 and 2.6.2.

2.6.2 Replace OEM washer P/N CAN22114C10-04 with NAS1169DD10L washers.

2.6.3 Replace OEM washer P/N CAN44100C4X0.4 or CAN44100A4X0.4 with NAS1169DD10L washers. Ream washer hole to 0.251 to 0.261 inch diameter to allow installation of a 0.250” fastener. Alodine with 1201 after reaming.

2.6.4 Install and blend washers into existing surface to allow for a flush exterior surface and a smooth transition. If necessary increase perimeter thickness on interior side of panel to allow for washer installation. Thickness shall not exceed 0.060 inches. Blend additional thickness to existing material.

2.7 Repair/Modify Vertical Stabilizer Trailing Edge Panel Repair/Modification (Reference Paragraph 3.2 for P/Ns)

2.7.1 Repair

2.7.1.1 Inspect/repair lower panel P/N 35-33235-0001.

2.7.1.2 Replace existing washers with NAS1169DD10L cup washers.

2.7.1.3 Paint see paragraph 2.8.4.

2.7.2 Modify

2.7.2.1 Inspect, repair and modify P/Ns 35-33236-0003, 35-33237-0003, 35-33238-0003, and 35-33239-0003.

2.7.2.2 Install dimple washers NAS1169DD10L at every other hole. Holes will be drilled using a number 10 drill by USCG technicians. Washers shall be installed to allow for a flush and smooth exterior surface. The perimeter thickness on the panel interior side may be increased for washer installation. Thickness shall be kept to a minimum, not to exceed 0.060 inch. Blend additional thickness to existing material.

2.7.2.3 Plug marked unused rivet holes. Holes will be identified by the USCG with a black sharpie.

2.7.2.4 Paint see paragraph 2.8.4.

2.8 Paint

2.8.1 Do not paint the washer dimples.

2.8.2 Apply conductive coating BMS10-21 Type III or equivalent.

2.8.3 Prime with MIL-PRF-23377 Class 1 type N or equivalent.

2.8.4 Vertical stabilizer panels shall have conductive coating and epoxy primer applied per paragraphs 2.8.2 and 2.8.3 followed by polyurethane CG ORANGE, FEDSTD 595, COLOR# 12250, MIL PRF 85285.

2.8.5 Horizontal stabilizer panels P/Ns 35-31331-0005 and 35-31331-0006 shall have a conductive coating, epoxy primer applied per paragraphs 2.82 and 2.83 followed by polyurethane CG White, FEDSTD 595 color #17860, MIL-PRF-85285.

Note: The HC144 is top coated with Sherwin Williams Jet Glo Express. The product numbers for CG Orange is Z05411, and CG White Y05412.

2.8.6 All coatings shall be applied IAW paint manufacturer’s instructions.

2.9 Electrical Conductivity Checks

2.9.1 Panels with screen or wire mesh shall have a continuity of 300 milliohms or less between washers.

2.9.2 Panels without wire screen or mesh with conductive coating shall have a conductivity not to exceed 50,000 ohms per square inch.

2.10 Provide FAA 8130-3 Airworthiness document or a certificate of conformance (COC) for repaired panels. FAA Form 8130 is preferred.

3.0 PANEL PART NUMBERS

3.1 P/N’s For Repair

3.2 P/Ns Vertical Stabilizer Panels (Repair/Modify)

4.0 APPLICABLE DOCUMENTS

4.1 Military Technical Orders

4.1.1 AFTO 1-1-690, General Advanced Composite Repair Process Manual

4.1.2 NAVAIR 01-1A-21, General Composite Repair

4.2 Data Availability

4.2.1 OEM drawings, Component Manuals are proprietary and cannot be provided by the Coast Guard. The Coast Guard does not own nor can it provide this data. The contractor shall obtain their own OEM component maintenance manuals, drawings and specifications. The Original Equipment Manufacturer for the HC-144A is 0117B EADS Construcciones Aeronautic, Avenida Aragon, 404, Madrid, Spain 28022.

4.2.2 Military Technical Orders: The USCG will not furnish the tech orders listed in paragraph 4.2. The contractor shall obtain their own.

5.0 DELIVERABLES

5.1 The Contractor shall provide a Federal Aviation Administration airworthiness form 8130-3 or Certificate of Conformance (COC) for each component repaired. One copy of the airworthiness tag or COC shall be included with each panel. FAA Form 8130 is preferred.

5.2 The Contractor shall provide the Coast Guard Contracting Officer with a statement describing the work accomplished, parts replaced and a cost breakdown for labor/materials. (ex. Teardown/Inspection Report)

5.3 The contractor shall provide DER or contractor develop repair schemes which deviate from the CN-235 SRM and LCM for USCG MRS Engineering approval prior to commencement of work, if applicable.

6.0 ENVIRONMENTAL REQUIREMENTS

All parts must be thoroughly cleaned IAW applicable Component Maintenance Manuals or FAA Advisory Circular 43-205, Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of Aircraft and Aviation Products, to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc., prior to being returned to ALC. ALC may take random samples of parts to ensure they are free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and Health Standards 1910.1025 (lead), 1910.1026 (Hexavalent Chromium) and 1910.1027 (Cadmium).

7.0 PACKAGING AND PRESERVATION

Packaging/preservation: Unless otherwise specified packaging/preservation shall be IAW ASTM D 3951-2010. Components shall be packaged sufficiently, which will afford maximum protection from damage in transit and corrosion. Packaging material shall not consist of popcorn, shredded paper, Styrofoam of any type, or peanut style packaging. Any deviation from ASTM D 3951-2010 requires prior approval of ALC’s Contracting Officer.

8.0 INSPECTION AND FINAL ACCEPTANCE

Final inspection and acceptance will be performed by ALC quality assurance personnel for kind, count and condition only. Unless special inspections are otherwise specified by the USCG, the contractor shall perform the inspections and tests required to substantiate that the supplies and services provided conforms to this contract.

9.0 THE USCG POINT OF CONTACT (POC)

For questions concerning this solicitation or submission of contractor developed repair schemes the USCG POC is ALC’s MRS Division Contracting Officer Terence Blucker, Terence.L.Blucker@uscg.mil , voice (252) 334-5203.