SOW_for_Bond_Assemblies.pdf

ATTACHMENT 1

STATEMENT OF WORK (SOW) FOR THE

OVERHAUL OF MH-60T BOND ASSEMBLIES

HSCG38-17-Q-J00098

Scope

The United States Coast Guard (USCG) Aviation Logistics Center (ALC), Medium Range Recovery (MRR) Product Line Division located in Elizabeth City, North Carolina has a requirement to overhaul the following component(s) installed on the Coast Guard’s MH-60T aircraft.

Overhaul to like new condition on an as needed basis;

Nomenclature National Stock Number (NSN) Part Number (P/N) Bond Assembly 5935-01-HS2-4435 70207-22201-057

The Contractor shall provide all necessary parts, material, labor, tooling, overhaul/repair manuals, test equipment, engineering services, management, and facilities to test, and evaluate the component(s) in accordance with (IAW) this SOW. USCG aircraft operate primarily in a saltwater environment and are subject to corrosion. The Contractor is advised to expect corrosion on the component(s) to be overhauled under this order. The component(s) shall be overhauled and returned by the Contractor in an airworthy condition suitable for installation on MH-60T aircraft.

ALC MRR Engineering has the sole responsibility to certify overhaul agents for components unique to or maintained exclusively by the Coast Guard. The Bond Assembly is unique to the MH-60T model and only ALC MRR Engineering approved sources shall be authorized as an approved overhaul facility.

Approval of new overhaul facilities requires a site visit by MRR Engineering. Award of this requirement will not be delayed pending approval by MRR Engineering. However, this is a recurring requirement and only approved overhaul facilities may be eligible for future requirements.

The contractor shall know the makeup of the bond assembly and have the ability to overhaul them. The bond assembly is comprised of the following materials: composite, aluminum core, and fiberglass. The contractor shall use best commercial practices to overhaul the bond assembly as approved by MRR Engineering. The overhaul of the bond assembly specified herein shall be performed only by MRR Engineering approved contractors.

Applicable/Compliance Documents

The Coast Guard does not own nor can it provide the required directives for this requirement (except where stated below).

Overhaul services must be performed IAW the procedures established in the documents referenced in Applicable/Compliance Documents section of this SOW. The documents are listed in order of precedence. Latest revisions of all manuals shall apply. The information contained in this section is not intended to be all inclusive nor to detract from or modify procedures outlined in the manuals. If the applicable technical manual does not cover a procedure, the Contractor shall utilize the original equipment manufacturer (OEM) overhaul/repair manual. If the OEM manual does not cover a procedure, the Contractor shall utilize the best commercial business practice. Where an application of “best commercial practice” is in conflict with these manuals, the Contracting Officer (KO) may approve deviation from requirements. When applicable, each Manual will specify if the Export Control Act applies.

All OEM shop, inspection, overhaul, repair, or other OEM Component Maintenance Manuals (CMM) and revisions as applicable

All OEM service bulletins, amendments, modifications, and specifications as applicable

Federal Aviation Administration (FAA) Advisory Circular 43-205, Guidance for Selecting Chemical Agents and Processes for Depainting and General Cleaning of Aircraft and Aviation Products

Coast Guard Aviation Logistics Center Instruction 4100.1A, Aviation Logistics Center Material Disposal Procedures (included as a separate attachment to this Federal Business Opportunities (FBO) notice under CG ALCINST 4100.1A)

Coast Guard Aviation Logistics Center Instruction 4855.4, Policy and Quality Assurance Procedures for the Receipt Inspection of New, Repaired, and Overhauled items from Vendors (included as a separate attachment to this FBO notice under CG ALCINST 4855.4)

Coast Guard Aviation Logistics Center Instruction 4200.3B, ALC Spare Parts Breakout/New Product Development (included as a separate attachment to this FBO notice under CG ALCINST 4200.3A)

The Coast Guard has the sole responsibility for the development of internal procedures for the Aviation Logistics Command’s Spare Parts Breakout Program. Any commercial Contractor that manufactures, repairs, overhauls, reverse engineers, or the like any Coast Guard component is subject to Coast Guard Aviation Logistics Center Instruction 4200.3A, ALC Spare Parts Breakout/New Product Development.

Occupational Safety and Health Standards (OSHA) 1910.1025 (Lead)

OSHA 1910.1026 (Chromium VI)

OSHA 1910.1027 (Cadmium)

Military Standard (MIL-STD) MIL-STD-129R, Military Marking For Shipment and Storage

MIL-STD-2073-1E, Standard Practice For Military Packaging

Overhaul Services

The bond assembly shall be overhauled using best commercial practices and commercial composite manufacturing and overhaul techniques. The contractor shall develop their own overhaul schemes to overhaul the bond assembly and submit for approval by MRR Engineering. The overhaul procedures shall include step-by-step instructions or procedures on how the contractor intends to accomplish the overhaul.

Once overhaul procedures are approved, the bond assembly must undergo a Form, Fit, and Function (FFF) verification process. MRR Engineering will approve or disapprove the bond assemblies within 60 days of receipt. The contractor shall be notified by MRR Engineering, if any discrepancies are found.

The contractor shall have 30 days to correct minor discrepancies, as determined by MRR Engineering.

Major discrepancies shall be corrected within 60 days upon notification by MRR Engineering.

The Government shall not furnish any drawings, specifications, tooling, fixtures, jigs or any other overhaul documents to overhaul the bond assembly. The Government will not authorize funding for the fabrication of any jigs, fixtures or tooling to facilitate this work nor will award be delayed pending receipt of specifications or any required tooling.

The overhaul of the bond assembly consists of partial tear-down to remove outer skin, fiberglass end caps, removing the latch hole area, blanking the latch hole area, as well as replacing the outer skin and fiberglass end caps. The following actions are to be performed:

All skins and structural parts shall have bond primer applied prior to installation and shall also be epoxy primed (MIL-P-23377 TYPE 1 Class C) after completion.

When the bond assembly is re-skinned or refurbished any corners or voids will be required to be sealed up with BR 624 to reduce water intrusion.

The inserts for the forward edge of bond assembly (seal) will need to be wet installed and closed up on the back to reduce the amount of water entering the door.

Bond 2”Wx0.020”T 301 SS doubler to top of the bond assembly, underneath extrusion.

Replace 38010-70032 extrusion at the top of the door during this process.

The following requirements apply to the latch area in order to ensure proper latch installation on site:

a. Remove section of interior doubler on original bond assembly where latch holes are drilled (approximate area to be removed is 0.5” Wide x 1.85” Length).

b. Replace section of interior doubler removed with same thickness and approximate size.

c. Add 0.020” doubler patch to inside of the bond assembly, approximate size is 7” x 7”.

d. Hot bond all three layers of T6 aluminum (new exterior skin, replaced interior doubler material, and doubler patch) with AF 163-2K adhesive.

e. Latch holes are to be left blank to allow for correct latch installation on site due to variances in OEM door dimensions.

Changes to closed back inserts/rivnuts on leading edge of bond assembly:

a. Part Numbers (P/N) to be used are 445SE1032-08-1 insert (or 495SE1032-08-1 as equivalent substitute) in all areas of leading edge where core is directly behind fiberglass end cap and a NAS1330S3KB116 rivnut A/R on fiberglass areas without core on inside surface, including two each seal attach points on each side of latch area. Fiberglass is to be reinforced inside cap in those areas as required to secure the

NAS1330S3KB116.

b. Locate attach points (inserts locations) on leading edge of the bond assembly using template created from USCG - supplied door seal (NSN 5330-01-419-1347).

c. Leave additional 1 to 2 inches of interior skin near latch area opening for USCG to trim net for proper latch fit on installation.

d. Replace parts IAW MIL-A-8625(series) Type I, Class 1.

e. Where closed back rivnuts/inserts are compression installed, inject hole with sealant prior to installation in order to seal edges.

f. Fiberglass cap to be installed with two-part adhesive EA9309 or EA9320 and seal edges.

g. Open area of latch bottom – adhesive bleedout will not be removed in this area to reduce potential leakage areas, area to be sealed with additional AF 163-2K strip, if needed.

h. Adhesive bleedout on part – minimize removal of adhesive bleedout in order to limit removal of bond prime.

All bond assemblies overhauled by the contractor shall have an identification (ID) plate attached to the bottom of the bond assembly.

The ID plate requirements shall be as follows:

Size: 3x5 anodized aluminum data plate

The ID plate shall include; contractor’s name and cage code, date of repair, and reference the contract number of the overhaul bond assembly. No sharpie markers allowed.

Data plate shall be bonded to the bottom skin of the bond assembly.

Special Tooling

The contractor shall have an autoclave in their possession. The autoclave must be used to overhaul the Bond assemblies. The autoclave shall be large enough to accompany the size of the Bond assemblies as well as the ability to cure all Bond assemblies after overhaul/repair.

Overhaul Specific Requirements

The Contractor shall perform overhaul services IAW the SOW and Federal Aviation Regulations Parts 43 and 145. The Contractor shall perform a thorough visual and technical inspection of each component requiring overhauled and correct all deficiencies found. This shall include replacement of broken parts and the removal of any foreign matter or corrosion. Parts found to be defective shall be replaced with new parts. A form DD1577-2 – Unserviceable (Reparable) Tag-Materiel or a form CG-1577-B – Product Quality Deficiency Report (PQDR ) Tag will be attached to each not ready-for-issue (NRFI) component describing faults. Once the component has been overhaul to like new condition, the Contractor shall remove the unserviceable tag from the component.

Corrosion Issues

USCG aircraft operate primarily in a saltwater environment and are subject to corrosion. Corrosion may be on the component(s) to be overhauled under this order. During inspection and functional test, the presence of corrosion in a component or subcomponent thereof shall constitute reason for a more thorough disassembly and inspection. Should corrosion be found, disassembly shall be made only to the extent necessary to remove corrosion or replace the part(s) affected. Corroded parts shall be replaced unless removal of corrosion from a part will NOT impair the efficiency or safe operation of the part.

Corrosion removal and treatment of affected areas shall be accomplished IAW the applicable technical manual specifications and drawings.

Replacement Parts

Parts shall be replaced as required by the applicable technical manual. Parts found to be defective shall be replaced as specified in the applicable technical manual or as otherwise authorized in writing by the KO.

All parts replacing defective parts shall be new. A copy of the Contractor's work order, listing all replaced parts, shall be provided for each component. The Contractor shall maintain documentation on all replacement parts for a minimum of twenty-four (24) months after delivery and provide this documentation to the USCG upon request.

Environmental Requirements

All parts must be thoroughly cleaned in accordance with applicable CMM 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 the USCG. The USCG may take random samples of parts to ensure they are as free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and Health Standards 1910-1025 (Lead), 1910.1026 (Chromium VI) and 1910-1027 (Cadmium).

Service Bulletins, Modifications, Engineering Change Proposals (ECP), Local Engineering Change Proposals (LECP), and Time Compliance Technical Orders (TCTO)

The KO shall notify the Contractor in writing of components requiring incorporation of a service bulletin, modification, ECP, LECP, or TCTO. Upon receiving such notice, the Contractor shall submit, within thirty (30) calendar days, a firm fixed price (FFP) quote for an incremental charge to be assessed each time the service bulletin or change is incorporated. The quote shall contain a breakdown of material and labor costs based upon the FFP labor rates and material factors. The incremental charge agreed upon for incorporation of a service bulletin shall apply only to those components for which the Contractor has incorporated a required service bulletin, not those for which the service bulletin has been previously incorporated. Upon agreement of an incremental charge and issuance of an order modification to reflect this change, the service bulletin shall be incorporated into each subsequent component received at the repair facility if the service bulletin has not already been incorporated. When incorporation of a service bulletin changes the P/N of the component contained in the schedule, the new P/N and NSN (if applicable) will be added to the order via modification.

Changes to Applicable/Compliance Documents and Obsolete Parts/Processes

The Contractor shall notify the KO in writing when changes are made to the applicable/compliance documents referenced in section Applicable/Compliance Documents of this SOW. Such notification shall include the nature of the changes and details sufficient for the USCG to evaluate the scope and impact of the change. In addition, when the Contractor receives a component for which certain parts or processes have become obsolete, the Contractor shall, within thirty (30) calendar days after receipt of the component, notify the KO in writing and submit rationale and verification of any specification change or obsolete part or process, and a written estimate of the effort required to accomplish the overhaul. Such estimates shall include nomenclature, NSN, P/N, cost, quantity of replacement parts, and the number of hours at the labor rate specified in the schedule for the applicable period. The Contractor shall substantiate the cost of parts with invoices or catalog pricing. The Contractor’s delivery obligation for the components identified shall be suspended as of the date of notice to the KO. The KO will, within thirty

(30) calendar days after receipt of the Contractor’s written estimate, make a written determination as to the disposition of the component. A new delivery date will be negotiated. Written approval to perform IAW the revised specifications or drawings and obsolete part processes must be obtained from the KO prior to commencement of work. The USCG reserves the right to waive any specifications.

Condemned Parts and Material

All non-repairable parts, including parts replaced during the overhaul process, shall be scrapped (i.e., rendered unusable to the point they cannot be returned to service) IAW Aviation Logistics Center Instruction 4100.1, Material Disposal Procedures.

Beyond Economical Repair (BER)

In the event a component cannot be overhauled to like new condition and is found to be BER, the Contractor shall immediately stop working on the component and notify the KO in writing. The Contractor’s written notification shall include, at a minimum, the following information: Order Number, Contract Line Item Number (CLIN), Nomenclature, NSN, P/N, S/N, and a brief description supporting the determination. The KO will provide disposition instructions via modification within thirty (30) calendar days after receipt of notification. The Contractor shall be entitled to compensation for the established scrap price only.

Place of Performance

The place of performance will be the Contractor’s facilities.

Urgent Requirements/Aircraft on Ground (AOG)

In the event an AOG status occurs as a result of a lack of component(s), the Contractor will be notified and requested to provide a response within twenty-four (24) hours of the notification. The Contractor’s response shall provide status of the component needed to satisfy the AOG situation and the requirements to expedite shipment.

An AOG situation may require that the Contractor ship directly to a specified Coast Guard field unit. The component shall be shipped by the fastest traceable means (i.e., air freight, next day delivery). The KO may issue an order modification authorizing additional funding as agreed upon by the Government and the Contractor to accomplish the expedited overhaul. The Contractor shall mark the outside of the shipping container “AOG” in letters not less than 2” high.

Delivery

Induction shall take place no later than fifteen (15) calendar days after receipt of the component(s) at the Contractor’s facility. Government requires a maximum delivery of 60 days.

Material Inspection and Receiving Report

At the time of each delivery of services under this order, the Contractor shall prepare and furnish to the Government a properly completed DD Form 250 – Material Inspection Receiving Report which will be used as a packing slip. The packing slip shall include the following information: (1) NSN; (2) P/N; (3) Nomenclature; (4) S/N; (5) Contract Number; (6) Order Number; (7) CLIN; and (8) Quantity. Two copies of the packing slip shall be submitted with the shipment. One copy shall be inside the shipping container and one copy shall be attached to the outside of the shipping container.

Contract Administration Data

Only warranted KOs are authorized to issue and modify any order, approve changes in any of the requirements, or obligate funds. Notwithstanding any term or condition contained elsewhere in the order, the authority to modify the order remains solely with the KO. If the Contractor makes any order changes at the direction of any person other than the KO, the change will be considered to have been made without authority and no adjustment will be made in the order to cover any increase in costs that may result. The KO has the authority to perform any and all post-award functions in administering and enforcing an order IAW its terms and conditions.

Laws and Regulations

The Contractor shall be knowledgeable of and comply with all applicable federal and state laws and regulations and any local laws and ordinances regarding environmental protection. In the event environmental laws and/or regulations change during the term of this order, the Contractor is required to comply as such laws come into effect.

Government Furnished Resources

The Government will not furnish any resources to the Contractor in support of this order.

Contractor Furnished Property

The Contractor shall furnish all necessary parts, material, labor, tooling, overhaul/repair manuals, test equipment, engineering services, management, and facilities to test, evaluate, and overhaul the component(s) IAW this SOW to fulfill the requirements of this order.