Amend_0002_Replacement_Pages.pdf

CONTINUATION SHEET FOR:

STANDARD FORM 1449

REFERENCE NO. OF DOCUMENT BEING CONTINUED REPLACEMENT

PAGE

00002 RFP: HSCG84-16-R-AA9485

BASE PERIOD: FEBRUARY 1, 2016 (or date of contract award) – JANUARY 31, 2017

CLIN DESCRIPTION

EST

QTY

U/I

UNIT

PRICE

TOTAL

00001 OVERHAUL SERVICES

00001A 1CR, 1NR 3 EA $ $

00001B 2CR, 2NR 3 EA $ $

00001C 3CR, 3CI, 3NI, 3NR 35 EA $ $

00001D 5CR, 5CI, 5NI 3 EA $ $

00001E 5X11 LCR/5X11 LNR 20 EA $ $

00001F 6X20 LR 20 EA $ $

00001G 7X17 LR 5 EA $ $

00001H 7X20 LI 7 EA $ $

00001I 8X26 LR 5 EA $ $

00001J 9X20 BR/GR 2 EA $ $

00002 ADDITIONAL SERVICES

00002A Replace buoy body plating beyond overhaul 100 SF $ $

00002B Replace Mooring Arm 4 EA $ $

00002C Permanently Close Battery Pocket 10 EA $ $

00002D Install new wires and electrical components 2 BUOY $ $

00002E Install Bell 2 EA $ $

00002F Install Gong 2 EA $ $

00002G Install Bell / Gong Stand 2 EA $ $

00002H Install New Towers for 6X20, 7X17, 8X26, and

9X20 Buoys

2 EA

00002I Install New “odd” Lifting Eye/Bail 6 EA $ $

00002J Install New Counterweight Tubes 1 EA $ $

00002K Composite Labor Rate 10 HR $ $

00003 SHIPMENTS / TRANSPORTATION

00003A From Milwaukee, WI to Contractor’s Facility /

From Contractor’s Facility to Milwaukee, WI

2 TRK $ $

00003B From Sturgeon Bay, WI to Contractor’s Facility /

From Contractor’s Facility to Sturgeon Bay, WI

2 TRK $ $

00003C From Essexville, MI to Contractor’s Facility /

From Contractor’s Facility to Essexville, MI

2 TRK $ $

00003D From Sault Ste Marie, MI to Contractor’s Facility /

From Contractor’s Facility to Sault Ste Marie, MI

8 TRK $ $

00003E From Detroit, MI to Contractor’s Facility /

From Contractor’s Facility to Detroit, MI

18 TRK $ $

00003F From Cheboygan, MI to Contractor’s Facility /

From Contractor’s Facility to Cheboygan, MI

22 TRK $ $

00003G From Port Huron, MI to Contractor’s Facility /

From Contractor’s Facility to Port Huron, MI

2 TRK $ $

00003H From Buffalo, NY to Contractor’s Facility /

From Contractor’s Facility to Buffalo, NY

2 TRK $ $

00003I From Duluth, MN to Contractor’s Facility / From

Contractor’s Facility to Duluth, MN

6 TRK $ $

ESTIMATED BASE PERIOD TOTAL $

OPTION YEAR ONE: FEBRUARY 1, 2017 – JANUARY 31, 2018

EST

QTY

U/I

UNIT

PRICE

TOTAL

10001 OVERHAUL SERVICES

10001A 1CR, 1NR 3 EA $ $

10001B 2CR, 2NR 3 EA $ $

10001C 3CR, 3CI, 3NI, 3NR 35 EA $ $

10001D 5CR, 5CI, 5NI 3 EA $ $

10001E 5X11 LCR/5X11 LNR 20 EA $ $

10001F 6X20 LR 20 EA $ $

10001G 7X17 LR 5 EA $ $

10001H 7X20 LI 7 EA $ $

10001I 8X26 LR 5 EA $ $

10001J 9X20 BR/GR 2 EA $ $

10002 ADDITIONAL SERVICES

10002A Replace buoy body plating beyond overhaul 100 SF $ $

10002B Replace Mooring Arm 4 EA $ $

10002C Permanently Close Battery Pocket 10 EA $ $

10002D Install new wires and electrical components 2 BUOY $ $

10002E Install Bell 2 EA $ $

10002F Install Gong 2 EA $ $

10002G Install Bell / Gong Stand 2 EA $ $

10002H Install New Towers for 6X20, 7X17, 8X26, and

9X20 Buoys

2 EA

10002I Install New “odd” Lifting Eye/Bail 6 EA $ $

10002J Install New Counterweight Tubes 1 EA $ $

10002K Composite Labor Rate 10 HR $ $

10003 SHIPMENTS / TRANSPORTATION

10003A From Milwaukee, WI to Contractor’s Facility /

From Contractor’s Facility to Milwaukee, WI

2 TRK $ $

10003B From Sturgeon Bay, WI to Contractor’s Facility

/ From Contractor’s Facility to Sturgeon Bay, WI

2 TRK $ $

10003C From Essexville, MI to Contractor’s Facility /

From Contractor’s Facility to Essexville, MI

2 TRK $ $

10003D From Sault Ste Marie, MI to Contractor’s Facility /

From Contractor’s Facility to Sault Ste Marie, MI

8 TRK $ $

10003E From Detroit, MI to Contractor’s Facility /

From Contractor’s Facility to Detroit, MI

18 TRK $ $

10003F From Cheboygan, MI to Contractor’s Facility /

From Contractor’s Facility to Cheboygan, MI

22 TRK $ $

10003G From Port Huron, MI to Contractor’s Facility /

From Contractor’s Facility to Port Huron, MI

2 TRK $ $

10003H From Buffalo, NY to Contractor’s Facility /

From Contractor’s Facility to Buffalo, NY

2 TRK $ $

10003I From Duluth, MN to Contractor’s Facility / From

Contractor’s Facility to Duluth, MN

ESTIMATED OPTION YEAR ONE TOTAL $

OPTION YEAR TWO: FEBRUARY 1, 2018 – JANUARY 31, 2019

EST

QTY

U/I

UNIT

PRICE

TOTAL

20001 OVERHAUL SERVICES

20001A 1CR, 1NR 3 EA $ $

20001B 2CR, 2NR 3 EA $ $

20001C 3CR, 3CI, 3NI, 3NR 35 EA $ $

20001D 5CR, 5CI, 5NI 3 EA $ $

20001E 5X11 LCR/5X11 LNR 20 EA $ $

20001F 6X20 LR 20 EA $ $

20001G 7X17 LR 5 EA $ $

20001H 7X20 LI 7 EA $ $

20001I 8X26 LR 5 EA $ $

20001J 9X20 BR/GR 2 EA $ $

20002 ADDITIONAL SERVICES

20002A Replace buoy body plating beyond overhaul 100 SF $ $

20002B Replace Mooring Arm 4 EA $ $

20002C Permanently Close Battery Pocket 10 EA $ $

20002D Install new wires and electrical components 2 BUOY $ $

20002E Install Bell 2 EA $ $

20002F Install Gong 2 EA $ $

20002G Install Bell / Gong Stand 2 EA $ $

20002H Install New Towers for 6X20, 7X17, 8X26, and

9X20 Buoys

2 EA

20002I Install New “odd” Lifting Eye/Bail 6 EA $ $

20002J Install New Counterweight Tubes 1 EA $ $

20002K Composite Labor Rate 10 HR $ $

20003 SHIPMENTS / TRANSPORTATION

20003A From Milwaukee, WI to Contractor’s Facility /

From Contractor’s Facility to Milwaukee, WI

2 TRK $ $

20003B From Sturgeon Bay, WI to Contractor’s Facility

/ From Contractor’s Facility to Sturgeon Bay, WI

2 TRK $ $

20003C From Essexville, MI to Contractor’s Facility /

From Contractor’s Facility to Essexville, MI

2 TRK $ $

20003D From Sault Ste Marie, MI to Contractor’s Facility /

From Contractor’s Facility to Sault Ste Marie, MI

8 TRK $ $

20003E From Detroit, MI to Contractor’s Facility /

From Contractor’s Facility to Detroit, MI

18 TRK $ $

20003F From Cheboygan, MI to Contractor’s Facility /

From Contractor’s Facility to Cheboygan, MI

22 TRK $ $

20003G From Port Huron, MI to Contractor’s Facility /

From Contractor’s Facility to Port Huron, MI

2 TRK $ $

20003H From Buffalo, NY to Contractor’s Facility /

From Contractor’s Facility to Buffalo, NY

2 TRK $ $

20003I From Duluth, MN to Contractor’s Facility / From

Contractor’s Facility to Duluth, MN

ESTIMATED OPTION YEAR TWO TOTAL $

OPTION YEAR THREE: FEBRUARY 1, 2019 – JANUARY 31, 2020

EST

QTY

U/I

UNIT

PRICE

TOTAL

30001 OVERHAUL SERVICES

30001A 1CR, 1NR 3 EA $ $

30001B 2CR, 2NR 3 EA $ $

30001C 3CR, 3CI, 3NI, 3NR 35 EA $ $

30001D 5CR, 5CI, 5NI 3 EA $ $

30001E 5X11 LCR/5X11 LNR 20 EA $ $

30001F 6X20 LR 20 EA $ $

30001G 7X17 LR 5 EA $ $

30001H 7X20 LI 7 EA $ $

30001I 8X26 LR 5 EA $ $

30001J 9X20 BR/GR 2 EA $ $

30002 ADDITIONAL SERVICES

30002A Replace buoy body plating beyond overhaul 100 SF $ $

30002B Replace Mooring Arm 4 EA $ $

30002C Permanently Close Battery Pocket 10 EA $ $

30002D Install new wires and electrical components 2 BUOY $ $

30002E Install Bell 2 EA $ $

30002F Install Gong 2 EA $ $

30002G Install Bell / Gong Stand 2 EA $ $

30002H Install New Towers for 6X20, 7X17, 8X26, and

9X20 Buoys

2 EA

30002I Install New “odd” Lifting Eye/Bail 6 EA $ $

30002J Install New Counterweight Tubes 1 EA $ $

30002K Composite Labor Rate 10 HR $ $

30003 SHIPMENTS / TRANSPORTATION

30003A From Milwaukee, WI to Contractor’s Facility /

From Contractor’s Facility to Milwaukee, WI

2 TRK $ $

30003B From Sturgeon Bay, WI to Contractor’s Facility

/ From Contractor’s Facility to Sturgeon Bay, WI

2 TRK $ $

30003C From Essexville, MI to Contractor’s Facility /

From Contractor’s Facility to Essexville, MI

2 TRK $ $

30003D From Sault Ste Marie, MI to Contractor’s Facility /

From Contractor’s Facility to Sault Ste Marie, MI

8 TRK $ $

30003E From Detroit, MI to Contractor’s Facility /

From Contractor’s Facility to Detroit, MI

18 TRK $ $

30003F From Cheboygan, MI to Contractor’s Facility /

From Contractor’s Facility to Cheboygan, MI

22 TRK $ $

30003G From Port Huron, MI to Contractor’s Facility /

From Contractor’s Facility to Port Huron, MI

2 TRK $ $

30003H From Buffalo, NY to Contractor’s Facility /

From Contractor’s Facility to Buffalo, NY

2 TRK $ $

30003I From Duluth, MN to Contractor’s Facility / From

Contractor’s Facility to Duluth, MN

ESTIMATED OPTION YEAR THREE TOTAL $

OPTION YEAR FOUR: FEBRUARY 1, 2020 – JANUARY 31, 2021

EST

QTY

U/I

UNIT

PRICE

TOTAL

40001 OVERHAUL SERVICES

40001A 1CR, 1NR 3 EA $ $

40001B 2CR, 2NR 3 EA $ $

40001C 3CR, 3CI, 3NI, 3NR 35 EA $ $

40001D 5CR, 5CI, 5NI 3 EA $ $

40001E 5X11 LCR/5X11 LNR 20 EA $ $

40001F 6X20 LR 20 EA $ $

40001G 7X17 LR 5 EA $ $

40001H 7X20 LI 7 EA $ $

40001I 8X26 LR 5 EA $ $

40001J 9X20 BR/GR 2 EA $ $

40002 ADDITIONAL SERVICES

40002A Replace buoy body plating beyond overhaul 100 SF $ $

40002B Replace Mooring Arm 4 EA $ $

40002C Permanently Close Battery Pocket 10 EA $ $

40002D Install new wires and electrical components 2 BUOY $ $

40002E Install Bell 2 EA $ $

40002F Install Gong 2 EA $ $

40002G Install Bell / Gong Stand 2 EA $ $

40002H Install New Towers for 6X20, 7X17, 8X26, and

9X20 Buoys

2 EA

40002I Install New “odd” Lifting Eye/Bail 6 EA $ $

40002J Install New Counterweight Tubes 1 EA $ $

40002K Composite Labor Rate 10 HR $ $

40003 SHIPMENTS / TRANSPORTATION

40003A From Milwaukee, WI to Contractor’s Facility /

From Contractor’s Facility to Milwaukee, WI

2 TRK $ $

40003B From Sturgeon Bay, WI to Contractor’s Facility

/ From Contractor’s Facility to Sturgeon Bay, WI

2 TRK $ $

40003C From Essexville, MI to Contractor’s Facility /

From Contractor’s Facility to Essexville, MI

2 TRK $ $

40003D From Sault Ste Marie, MI to Contractor’s Facility /

From Contractor’s Facility to Sault Ste Marie, MI

8 TRK $ $

40003E From Detroit, MI to Contractor’s Facility /

From Contractor’s Facility to Detroit, MI

18 TRK $ $

40003F From Cheboygan, MI to Contractor’s Facility /

From Contractor’s Facility to Cheboygan, MI

22 TRK $ $

40003G From Port Huron, MI to Contractor’s Facility /

From Contractor’s Facility to Port Huron, MI

2 TRK $ $

40003H From Buffalo, NY to Contractor’s Facility /

From Contractor’s Facility to Buffalo, NY

2 TRK $ $

40003I From Duluth, MN to Contractor’s Facility / From

Contractor’s Facility to Duluth, MN

ESTIMATED OPTION YEAR FOUR TOTAL $

C-5.2.6 QUANTITIES OF BUOYS. Historical workload data for the period of 2012 through 2015 are listed in TE-5. This data is provided for informational purposes only, and does not constitute any commitment or guarantee that the Contractor shall receive a similar quantity of work.

C-5.2.7 WORK RECEPTION RESPONSIBILITIES.

a. Government Responsibilities. When buoys are returned from station the Government will scrape away the loose marine growth, remove the mooring equipment, remove all batteries, power assembly clamps and solar panels, remove the lantern package, RACON and/or electronic horn if installed, and vent valves and reducers. This work will be done prior to pick up by the Contractor.

b. Contractor Responsibilities. Upon receipt of a buoy, and after transport to the Contractor’s facility, the

Contractor shall remove all wiring, pocket cover(s), pocket gasket(s), damaged tappers, retro reflective materials, bird springs, if any of this equipment is installed on the buoy to be overhauled. Tappers and sound signals shall be removed from the buoy during overhaul.

c. Contractor’s Storage of GFE/GFP. Any removed equipment is considered Government Furnished

Equipment (GFE) or Government Furnished Property (GFP) and shall be held in safe storage by the

Contractor. A complete list of GFE/GFP is found in TE-1. The Contractor shall keep records of any

GFE/GFP removed/stored and shall submit a written quarterly report to the COR listing the quantities of the various GFE/GFP on hand. Any removed GFE/GFP shall be used to outfit other buoys. If inadequate GFE/GFP is on hand to meet routine work requests, the Contractor shall notify the COR or

COR in writing within 3 days of the receipt of the task order. If inadequate quantities of GFE/GFP are on hand to meet emergency requests the Contractor shall immediately give verbal notification to the

COR, and follow up with written notice.

C-5.3 OVERHAUL

C-5.3.1 OVERHAUL consists of repairing damaged or worn areas, making required structural modifications, preparing the surface of the buoy, painting the buoy with primer coatings and testing the watertight and structural integrity of the buoy body and battery pockets.

C-5.3.2 REPAIRS TO LIGHTED BUOYS. The following paragraphs outline the detailed repairs that must be made to lighted buoys being overhauled. Some of these buoys may be used without lighting equipment.

C-5.3.3 BUOY BODY. All dents in the buoy body larger than one foot in diameter or 4 inches deep shall be repaired. The repair shall return the buoy shell to the approximate original shape. Heating of the surface to facilitate removal of the dent is acceptable. Leaks in seams or pit holes shall be closed by welding. Any cracks in the buoy body shall be closed by welding. Pits deeper than 1/8 inch shall be filled by welding and ground to within 1/16 inch of the original contour of the plate. The junctions of the lifting and mooring eyes to the buoy body shall be closely examined and any weld defects found shall be repaired.

a. After all repairs, the buoy must be airtight. Buoy body shall be retrofitted if necessary with a second air test coupling 180 degrees from existing coupling on the buoys hull to facilitate the gas free testing.

Leaks shall not be patched with epoxy, paint, glue, sealant or any other filler compound. As per

CIM16500.3A Chapter 2.E.4 Gas Free Testing is required prior to beginning any work on the buoy.

C-5.3.4 MOORING FITTINGS.

C-5.3.5 MOORING EYES. Mooring eyes and welds shall be inspected for wear, cracks, and distortion. The inside surface of all mooring eyes shall be built up to the original size and shape using welding or the eye replaced. Buoys that have mooring eyes with sleeve bushings shall have the bushing removed and a new one fitted in place. If damage is found CFR will be submitted to replace mooring eye.

C-5.3.6 MOORING ARMS. On 7X17 and 5X11 buoys, mooring arms that are bent to within three inches of the buoy counterweight shall be straightened to the original shape or replaced. The holes in both ends of the mooring arm shall be built up to their original size and shape using welding. The pins on which the arm is attached to the buoy body that are worn down more than 5/8 of an inch shall be built up to original size and shape by welding or replaced. The mooring arm attachment pad shall be built up to original size and shape or replaced.

C-5.3.7 LIFTING EYE/ BAIL ON LIGHTED BUOY. Lifting eyes/ bails and welds shall be inspected for wear, cracks, and distortion. If damage is found, the Contractor shall submit a CFR to the COR.

C-5.3.8 CHAFING BLOCKS. Chafing blocks shall be replaced on 8X26 buoys. The steel bolts that hold the chafing block in place shall be replaced when the new block is installed. All steel surfaces under the chafing block shall be painted with required primer and anti fouling coats prior to installation of the chafing block.

C-5.3.9 COUNTERWEIGHT TUBES. Cracks, pit holes and other holes in the counterweight tube shall be repaired by welding. Pits that are greater than 1/8 inch deep shall be filled by welding and ground flush. The junction of the counterweight tube to the buoy body shall have all cracks, holes, pits and other defects repaired by welding.

C-5.3.10 BATTERY POCKETS. Lighted buoys have been built with three different types of battery pocket closures; swing bolts, V-band and bolted. 22 inch diameter V-band flanges shall be replaced with a swing bolt flange per United States Coast Guard (USCG) Ocean Engineering Drawings Numbered 121102 and 121104.

24 inch diameter V-band flanges shall be replaced with a swing bolt flange per USCG Ocean Engineering

Drawings Numbered 121102, 121143 and 121162. Damaged bolts and swing bolt flanges that require replacement shall be replaced with the appropriate (24" or 22") swing bolt flange, per the above USCG Ocean

Engineering Drawings. In the past 4 years no V-band pocket covers have been found.

C-5.3.11 BATTERY POCKET COVERS. Battery pocket covers that are warped, cracked, pitted or have other defects shall have the flange or cover repaired or replaced to achieve watertight integrity, as demonstrated by successfully passing the air test required in Section C-5.3.35. If damaged beyond practical repair (as determined by COR) the Contractor shall replace the battery pocket cover as provided as GFP

(USCG Ocean Engineering Drawing Number 121162).

C-5.3.12 GASKETS. All gaskets shall be replaced with new gaskets as part of the overhaul. Gaskets will be provided as GFP (USCG Ocean Engineering Drawing Numbers 121143 and 121104).

C-5.3.13 CLOSURE DEVICE. All swing bolts shall be inspected for proper operation. Any swing bolt that has damaged threads such that the nut does not move freely, is bent, cannot swing freely into position, is damaged in any way that impairs its operation, or is not of the standard type listed on drawing 121102 shall be replaced. Replacement swing bolts and nuts shall be of the same size and dimension listed on the drawing

121102 and shall be made of stainless steel, any 300 Series. The clevis pin assembly shall also be examined for damage. Any bent pin shall be replaced with a stainless steel pin, any 300 Series of the same size (3/4 inch diameter) and length. Missing or damaged cotter pins shall be replaced with stainless steel cotter pins. Clevis pin washers can be reused if in good condition and shall be made of stainless steel, any 300 series. All V-band closure devices shall be converted to Swing bolt closure devices as depicted in drawings noted in Section C-

5.3.10. The T-bolt assembly shall be examined for proper operation and repaired or replaced if damaged. The bolts on all bolted flanges shall be inspected. Any bolt that is damaged so that the nut does not move freely, is bent, or has sustained other damage that impairs its operation shall be replaced. Replacement bolts and nuts shall be 3/4 inch diameter, 10 threads per inch, National Course threads, 4 inches long, stainless steel and shall be installed in the flange as shown in USCG Ocean Engineering Drawings Numbered 121143 and 121104.

C-5.3.14 VENT LINES. All buoys with battery pocket(s) must be equipped with stainless steel vent lines.

Single pocket buoys shall have two vent lines on the pocket with one line equipped with a plastic hose that runs to the bottom of the pocket. Two pocket buoys shall have one vent line per pocket with a crossover pipe running between the bottoms of the pockets. The vent line shall be schedule 40 stainless steel pipe, 3/4 inch diameter. The crossover tube shall be schedule 40 galvanized steel pipe, 2 inch diameter. If the crossover tube is less than 2 inch diameter, the Contractor shall notify the COR and an additional line item will be added to convert the buoy to a 2 inch crossover tube. The Contractor shall install any section of the vent line system that is missing. The vent line shall extend to within 4-12 inches of the uppermost portion of the lower panel of the radar reflector. The vent line system shall be inspected during each overhaul for breaks, cracks, pinched portions, loose fittings, missing or damaged plastic hose, plugged crossover tube, or other damage that impairs the performance of the vent line system. All damage shall be repaired by welding or replacement as appropriate. Vent lines shall be tested as part of the air test of the battery pockets required by Section C-

5.3.37. Problems identified during this testing shall be repaired. Vent lines shall be secured to the tower legs every thirty (30) inches using vent line retainer clips (item 22 on drawing 170320). Vent lines shall be continuous. Threaded unions shall only be used on 5x11 and 3.5x8 buoy vent lines. If found any other vent lines they shall be replaced with stainless steel coupling and welded into place.

C-5.3.15 BATTERY POCKET CYLINDERS. When equipped with the interior portion of each battery pocket shall be inspected for cracks, holes, pits, or other defects. These shall be repaired by welding. The junction of the crossover tube to the battery pocket cylinder shall be inspected for the presence of excess slag or other welding material or defects that could impair the function of the crossover tube. All foreign matter shall be removed from the pocket prior to surface preparation and painting.

C-5.3.16 BUOY TOWERS

C-5.3.17 RADAR REFLECTOR. Radar reflector plates bent more than three degrees from a right angle shall be repaired to a tolerance of plus or minus one degree. Holes, pits, cracks and any other structural defects shall be repaired by welding. Any areas of the reflector that are badly corroded and cannot be repaired by welding shall be replaced with sheet steel of the same thickness. These plates shall be installed to plus or minus one degree tolerance on all right angle intersections. Aluminum alloy 5086 or 6061 shall be used on 5X11 LR buoys. The radar reflector will be provided as GFP (USCG Ocean Engineering Drawing Number 121024 &

120316).

C-5.3.18 TOWER LEGS AND MEMBERS. Tower legs or feet broken away from the buoy body shall be re-attached by welding. Tower legs bent more than 3 inches from a straight line over a two foot length shall be straightened. If necessary, the tower shall be straightened so that the center line of the tower is not more than two degrees from perpendicular to the waterline of the buoy when it is floating in calm water.

C-5.3.19 LANTERN RING. The steel lantern ring shall be straightened if it obstructs the light of a properly installed lantern. Any ring that is bent, broken, cracked, missing or damaged in any other way shall be repaired or replaced. The lantern mounting plate shall be inspected for any damage from corrosion or collision and repaired by welding, or replaced, if it will not support a standard 155mm lantern. If outfitted with bent, broken or missing guano bars shall be repaired or replaced with 1/8 inch by ¾ inch steel bars.

C-5.3.20 TOWER INSPECTION. Any 9 x 20, 8X26, 7X17 or 6X20 buoy provided for overhaul that is completely missing its cage or has a cage determined by the COR to be too badly damaged to repair shall have a new cage installed. The new cage shall be installed in the same manner as the previous cage by welding the new cage to the buoy body. These replacement cages will be provided as GFP (USCG Ocean Engineering

Drawing Numbers 121021, 121022, & 121023). On 1965 type 5X11LR and 3 ½ X8LR buoys the radar reflector bolts to a battery pocket cover assembly. Buoys of this class that are provided for overhaul without the radar reflector and/or the battery pocket assembly shall have these items replaced. The radar reflector will be provided as GFP (USCG Ocean Engineering Drawing Number 121024). The battery pocket assembly onto which this reflector mounts shall be provided by the Contractor. The assembly shall be fabricated per USCG

Ocean Engineering Number 107377 or 107379 as applicable.

C-5.3.21 TAPPERS. Tappers on all sound buoys shall be inspected for proper operation and condition. Metal hinge tappers shall be replaced when the hinge bar is worn to 3/4 inch diameter, or the hinge support ring is worn to a thickness of 1/16 inch. The tapper must swing freely on its hinge or be repaired. Tappers bent more than 3 inches from a straight line over a 2 foot distance shall be straightened. On tappers with adjustable balls, the tapper ball shall be turned to an unworn area. When it can no longer be turned to an unworn area, the ball shall be replaced. When installing tapper hinge plate to cage flat washers made of stainless steel, any 300 series shall be placed under both the head of and the nut of the bolt. When tapper has been properly adjusted a tack weld shall be made on the tapper to prevent the lower adjusting nut from backing off. Replacement tappers will be provided as GFP (USCG Ocean Engineering Drawing Number 120382). The Contractor shall request in writing from the COR these replacement tappers. The Contractor shall be required to demonstrate that the tappers are to replace ones on buoys that were damaged or worn beyond the limits described above.

C-5.3.22 BELL, GONG, AND WHISTLE FLANGES. Shall be inspected for wear, cracks, and distortion.

Bent flanges shall be repaired or replaced. If replacement is required and not specified on the Task Order, then a CFR shall be submitted to the COR.

C-5.3.23 REPAIRS TO UNLIGHTED BUOYS.

C-5.3.24 BUOY BODY. All dents in the buoy body larger than one foot in diameter or four inches deep shall be repaired. The repair shall return the buoy shell to the approximate original shape. Heating of the surface to facilitate removal of the dent is acceptable. Leaks in seams or pit holes shall be closed by welding. Any cracks in the buoy body shall be closed by welding. Pits deeper than 1/8 inch shall be filled by welding and ground flush. The junctions of the lifting and mooring eyes to the buoy body shall be closely examined and any weld defects found shall be repaired. Buoy body shall be retrofitted if necessary with a second air test coupling 180 degrees from existing coupling on the buoys hull to facilitate the gas free testing. After all repairs the buoy must be airtight. Leaks shall not be patched with epoxy, paint, glue, sealant or any other filler compound. As per CIM16500.3A Chapter 2.E.4 Gas Free Testing is required prior to beginning any work on the buoy.

C-5.3.25 MOORING FITTINGS.

C-5.3.26 MOORING EYES. Mooring eyes and welds shall be inspected for wear, cracks, and distortion. The inside surface of all mooring eyes shall be built up to the original size and shape using welding or the eye replaced. Buoys that have mooring eyes with sleeve bushings shall have the bushing removed and a new one fitted in place. If damage is found, the Contractor shall submit a CFR to the COR.

C-5.3.27 RADAR REFLECTOR. Radar reflector plates bent more than three degrees from a right angle shall be repaired to a tolerance of plus or minus one degree. Holes, pits, cracks and any other structural defects shall be repaired by welding. Any areas of the reflector that are badly corroded and cannot be repaired by welding shall be replaced with sheet steel of the same thickness. These plates shall be installed to plus or minus one degree to all right angle intersections. The radar reflector will be provided as GFP (USCG Ocean Engineering

Drawing Number 121024 & 120316).

C-5.3.28 STRUCTURAL MODIFICATION. Lighted and unlighted buoys shall be modified as requested in the task order. Modifications may include installation or removal of hardware on the buoy.

C-5.3.29 REMOVAL OF HARDWARE. When requested in the task order, lighted and unlighted buoys equipped with solar mounting hardware, RACON mounting hardware or a topmark shall have the hardware removed. The hardware that is removed shall be returned to the Government or held by the Contractor in storage as directed in the task order. The Government may direct the Contractor to install this used hardware on buoys being overhauled per Section C-5.2.4.

C-5.3.30 LIFTING EYE/ BAIL ON LIGHTED BUOY. Lifting eyes/ bails and welds shall be inspected for wear, cracks, and distortion. If damage is found, the Contractor shall submit a CFR to the COR.

C-5.3.31 Paragraph Deleted.

C-5.3.32 WELDING BOTH LIGHTED AND UNLIGHTED. Welding shall conform to the requirements of

TE-3.

C-5.3.33 HULL PREPARATION AND PAINTING BOTH LIGHTED AND UNLIGHTED. The Contractor shall re-paint the buoys in accordance with the requirements listed in TE-4.

C-5.3.34 TESTING BOTH LIGHTED AND UNLIGHTED.

C-5.3.35 AIR TEST. Each buoy shall be subjected to an air test to determine the watertight integrity of the buoy. The buoy internal spaces shall be temperature stabilized to the ambient air temperature prior to the conduction of the air test. All welding shall be completed prior to the air testing. Any welding on the buoy body after completion of the air test shall require re-testing. Separate air tests shall be performed on the buoy body and on the buoy battery pocket(s). At no time during testing shall both the buoy body and battery pockets be under pressure. While the buoy body is undergoing testing, the battery pocket cover(s) shall be removed from the buoy. While the battery pocket(s) is/are undergoing testing, the buoy body test plug shall be removed from the buoy. A test record shall be kept as to the date tested, buoy identification number, and the results of the test. A calibrated pressure gauge shall monitor the test pressure. A gauge range shall be selected such that a pressure of 2 psi is not less than 10 percent of the scale. The gauge shall have 1 percent accuracy at the test pressure and a 1 oz. per square inch sensitivity. The date of the air test (successful) shall be written on the outside of the buoy near the fitting.

C-5.3.36 BUOY BODY AIR TEST. The air test of the buoy body shall be made through the test plug provided in the buoy. If a buoy does not have a test plug the Contractor shall install a 3/4 inch diameter stainless steel coupling in the buoy for performance of the test. This coupling shall be located on the buoy deck approximately 3 inches from the side of the buoy. After testing it shall be sealed with a stainless steel pipe plug. An air pressure of 3 psi shall be built up in the buoy body, the inlet air turned off, and observed for

10 minutes after pressure stabilization. Any drop in pressure shall cause the buoy to fail the test. If the buoy fails the test, the cause of the air leak shall be found and repaired, and the test performed until successful.

C-5.3.37 BUOY BATTERY POCKET AIR TEST. The air test of the battery pockets shall be made through the battery pocket vent lines. Prior to the test the buoy body test plug must be removed. An air pressure of 2 psi shall be built up in the buoy battery pockets and vent lines, the inlet air turned off, and observed for five minutes after pressure stabilization. Any drop in pressure is a battery pocket air test failure. If the battery pockets and vent lines fail the test, the cause of the air leak shall be found and repaired, and the test performed until successful. The air pressure shall be vented off by releasing it out the vent line opposite of the pressure gauge. While doing so monitor the air pressure gauge to see that air pressure is dropping. If pressure does not drop it may be an indication of a plugged crossover tube.

C-5.3.38 WELD TESTS. All weld tests shall be performed after all hot work is complete and prior to application of the primer. Welds in and around the lifting eyes, mooring eyes and/or mooring arm point of attachments to buoy body shall be 100% tested using magnetic particle method. Nondestructive tests shall be in accordance with AWS D1.1.

C-5.3.39 PAINT THICKNESS TEST. A nondestructive paint thickness test shall be performed on each buoy to ensure that the proper thickness of coating has been applied.

C-5.4 ADDITIONAL WORK ITEMS

C-5.4.1 REPLACE BUOY BODY PLATING BEYOND OVERHAUL. For repair to body plating that is in addition to overhaul or requested by the government (CLIN X0002A). Renew buoy body outer steel plating where dents, pits, and cracks are too extensive to be repaired, or where plating is wasted 25 percent or more of original thickness. The plate installed shall be of equal thickness to the surrounding steel plate. The edge of the plate shall not overlap the original shell and must be faired into the original shape of the buoy. Prior to finishing the repair of the outer steel plates, any part of the internal structure of the buoy that was also damaged or removed when the shell was cropped out must be repaired. This may require cutting a temporary access port in the buoy hull. This is an acceptable procedure. This port shall be repaired by filling the hole with new plate, or the plate that was removed, and welding it in place. After all repairs, the buoy must be airtight. Buoy body shall be retrofitted if necessary with a second air test coupling 180 degrees from existing coupling on the buoys hull to facilitate the gas free testing. Leaks shall not be patched with epoxy, paint, glue, sealant or any other filler compound. As per CIM16500.3A Chapter 2.E.4 Gas Free Testing is required prior to beginning any work on the buoy.

C-5.4.2 REPLACE MOORING ARMS . If unable to repair damage to mooring arms on 7x17 or 5x11 buoys, they will be replaced. On 5x11 buoys built prior to 1992 the mooring arm will be upgraded to shorter arm if not previously completed. These mooring arms will be considered GFE and supplied to the contractor. The

Coast Guard will determine if the upgrade is required (CLIN X0002B).

C-5.4.3 PERMANENTLY CLOSE BATTERY POCKETS. With LED lighting and growing technology, the government may request that vent lines be removed and sealed and battery pockets to be welded shut. This shall be completed by removing the batty pocket flange and welded shut to achieve watertight integrity. Vent

Valves and Cap Vent Lines with a 3/4 inch Stainless Steel Pipe Cap Flanges should be removed and equal thickness metal replaced. Metal should not over overlap and provide a smooth weld with the top of the buoy.

This will be on Task Order when required by the Coast Guard (CLIN X0002C).

C-5.4.4 INSTALL NEW WIRES AND ASSOCIATED ELETRICAL COMPONENTS. This will be on Task

Order when required by the Coast Guard (CLIN X0002D).

C-5.4.5 INSTALL BELL. The Task Order will indicate if a buoy must be outfitted with a bell. Each bell shall have four properly adjusted tappers. The tapper balls shall be adjusted so that the balls centerline is located 1-

1/4 inch above the bell’s lower edge. Rubber tapper stops shall be installed in the buoy cage. This will be on

Task Order when required by the Coast Guard (CLIN X0002E).

C-5.4.6 INSTALL GONG. The Task Order will indicate if a buoy must be outfitted with a gong. Each gong set shall have four properly adjusted tappers. The tapper ball shall be adjusted so that the ball’s centerline is located 1/4 inch above the lower lip of the individual gong. On three gong units the lowest gong shall have two tappers mounted on opposite sides of the cage. One tapper shall be adjusted to the middle gong and one tapper to the top gong. Four gong units shall have one tapper adjusted to strike each individual gong. Rubber tapper stops shall be installed in the buoy cage (CLIN X0002F).

C-5.4.7 INSTALL BELL OR GONG STAND. On buoy hulls requiring the addition of a bell or gong, CLIN

X0002G will be used for the installation of a bell or gong stand. If this is required, it will be included on the

Task Order.

C-5.4.8 INSTALL NEW TOWER. Any 9X20, 8X26, 7X17 or 6X20 buoy provided for overhaul that is completely missing its cage or has a cage determined by the COR to be too badly damaged to repair shall have a new cage installed. The new cage shall be installed in the same manner as the previous cage by welding the new cage to the buoy body. These replacement cages will be provided as GFP (USCG Ocean Engineering

Drawing Numbers 121021, 121022, & 121023) (CLIN X0002H).

C-5.4.9 COUNTERWEIGHT TUBES. Bent counterweight tubes shall be straightened or replaced. A bent counterweight tube is one that has sustained a structural deformation such as a fold or buckle. Damaged sections may be cut out and replaced in lieu of replacement of the whole tube. For 8x26 and 6x20 buoys requiring the replacement of the entire counterweight tube, CLIN X0002J will be used on the Task Order. For dents or damage to counterweight tube beyond overhaul but not requiring a total replacement CLIN X00002A will be used. If a counterweight tube or portion thereof is replaced, it shall be replaced with a pipe of equal thickness, diameter and length. If the counterweight tube being replaced was outfitted with gussets, the replacement tube shall also be outfitted with gussets of the same size and in the same location. The cast iron counterweight shall be removed from the damaged counterweight tube and installed in the same manner on the new tube. The surface of the counterweight tube that is covered by the counterweight shall be coated with asphalt enamel meeting the requirements of MIL-P-1227 prior to installation of the counterweight on the counterweight tube. A new counterweight tube shall be equipped with chafing blocks if the one being replaced was so equipped. The location and manner in which the chafing block is installed shall be the same as on the original counterweight tube. (Note that some counterweight tubes are of sealed construction and some are open.) A counterweight tube shall be replaced with the same type of tube.

C-5.4. 10 LIFTING EYE / MOORING EYE ON LIGHTED BUOY. If not already installed, all lighted buoys shall have an “odd” lifting eye installed. If a lifting eye or mooring eye needs to be replaced, the contractor shall submit a CFR with additional line item (CLIN X00002J) .

C-5.4.11 COMPOSITE LABOR RATE. Hourly compensation to cover work not outlined in the schedule. This will be on Task Order when required by the Coast Guard (CLIN X0002K).

C-5.5 TRANSPORTATION OF BUOYS

C 5.5.1 TRANSPORTATION. The Contractor shall provide transportation for buoys from the specified pick-up location to the Contractor’s facility. The Contractor shall drop-off buoy shipment from Contractor’s

Facility to designated Coast Guard drop-ff location. These would be considered two shipments. Specific pick-up and drop-off locations will be specified in each task order. As noted in the Schedule, buoys shall be shipped and charged to the government by the truck load. A truckload is defined as a 48 foot flatbed truck. A list of the amount of buoys per truck load can be found in TE-8.

Possible U.S. Coast Guard locations and addresses are provided below.

U.S. Coast Guard Sector Lake Michigan

2420 S. Lincoln Memorial Drive

Milwaukee, WI 53207-1997

Coast Guard Moorings

CGC MOBILE BAY

Municipal Pier

Sturgeon Bay, WI 54235-0287

U.S. Coast Guard ANT Saginaw

2405 Weadock Road

Essexville, MI 48732-9602

U.S Coast Guard Sector Sault Ste Marie

337 Water Street

Sault Ste Marie, MI 49783-9501

U.S. Coast Guard Sector Bufflo

1 Furhmann Blvd.

Buffalo, NY 14203-3189

CGC MACKINAW

632 Coast Guard Drive

Cheboygan, MI 49721-9999

U.S. Coast Guard Sector Detroit

110 Mt. Elliott Ave

Detroit, MI 48207-4380

Coast Guard Moorings

CGC HOLLYHOCK

Foot of Lincoln Ave.

2700 Omar St

Port Huron, MI 48060-0786

CGC ALDER

1201 Minnesota Ave

Duluth, MN 55802-2492

C-5.5.2 Technical Exhibit 2 lists approximate buoy shipping weights and volumes. The Contractor shall load and transport buoys and equipment in accordance with the standard safe load configurations provided in TE-8.

Note: The Contractor remains responsible for loading buoys, securing and configuring loads in such a manner that transport and delivery can be accomplished safely. The Government is providing information on past loading practices which have proven successful, however this is solely for informational and reference purposes, and the Contractor shall be completely responsible to ensure that all loads are configured safely.

C-5.5.3 At the time the buoy or GFP is picked up, the Contractor shall sign a Requisition and

Invoice/Shipping Document (DD Form 1149, included as part of TE-7). This document shall account for the transfer of custody of the buoy or GFP to the Contractor. After successful inspection, the Contractor shall deliver the buoy or GFP to its final destination and use a DD Form 1149 to account for transfer of the buoy or

GFP back to the Government.

C-5.5.4 SAMPLE BUOY OVERHAUL SCENARIO. An 8x26 buoy is dropped by a Coast Guard Buoy

Tender at USCG SECTOR DETROIT. The Buoy Manager at Sector Detroit sends a request to the 9 th District

COR representative . The Work request is reviewed and a Procurement Requests is generated and sent the

Contracting Officer who subsequently issues an Optional Form 347 (Task Order) to the Contractor to pick up the buoy at Sector Detroit to "Overhaul and Install New Bell with a finished color of Green with a final destination of Coast Guard Cutter HOLLYHOCK Port Huron, MI within 60 days of receipt of task order”.

The Task Order will list CLINS X0001I, X0002E,X0003E, and X0003G. The Contractor picks up the buoy in

Detroit, transferring custody with a DD-1149. The Contractor performs the required work at their facility.

After successful inspection, and/or clearance to proceed, the Contractor transports the buoy to the CGC

HOLLYHOCK, transferring custody with a DD-1149.