M00146-16-T-9006_Amendment_0009.pdf

N6592316SU00068

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83)

Prescribed by GSA

FAR (48 CFR) 53.243

The purpose of this modification is to revise the Specification Section 3.6.1 for Data Rights. The quotation due date has been extended to 01

August 2016, at 10:00 AM EST. See Summary of Changes for details.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 26

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 27-Jul-2016

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X M00146-16-T-9006

X 9B. DATED (SEE ITEM 11)

25-Jan-2016

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE

RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

27-Jul-2016

CODE

CHERRY POINT SATELLITE CONTRACTING OFF.

ATTN: CHRISTINE PISTOCHINI

PSC BOX 8018

BLDG. 159, MCAS

CHERRY POINT NC 28533

M00146 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

M00146-16-T-9006

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION A - SOLICITATION/CONTRACT FORM

The required response date/time has changed from 28-Jul-2016 02:00 PM to 01-Aug-2016 10:00 AM.

SECTION C - DESCRIPTIONS AND SPECIFICATIONS

The following have been modified:

Specification

For an Upgrade of

An Existing Cold Spray System

1. SCOPE. This specification describes the minimum performance requirements for design, manufacture, delivery, installation, and acceptance testing of a new Cold Spray System Upgrade. The upgrade shall include a new booth, robot, turntable, and jib crane. The existing cold spray equipment is a CGT cold spray system with a

Oerlikon Metco Kinetiks 4000 spray gun and is located in Shop 93202, Building 4225 of the Fleet Readiness Center

East, MCAS Cherry Point NC.

2. APPLICABLE DOCUMENTS. The following specifications, standards, drawings and other publications of the issue in effect on date solicitation, or request for quotes, form a part of this specification to the extent specified herein. Unless otherwise noted the contractor shall ensure the latest edition is used.

2.1 Government Documents.

FLEET READINESS INSTRUCTION (FRCEASTINST)

FRCEASTINST 5090.1 – Environmental Compliance

FRCEASTINST 5000.1A, enclosure (1) – Visitor/Contractor Site Specific Rules and Compliance

Brochure

PE-21565 Rev A – Cold Spray Site Plan

(A copy of this instruction can be acquired by contacting the contracting office.)

MIL STANDARDS

MIL-STD-1472G - Human Engineering

MIL-STD-3021 – Materials Desposition, Cold Spray

(Copies may be ordered online at http://dodssp.daps.dla.mil/ or from DODSSP, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094)

NAVAL AIR SYSTEMS COMMAND (NAVAIR)

NAVAIR 17-35TR-04 - Requirements for Preparation of Instrument Calibration Procedures http://dodssp.daps.dla.mil/

(A copy of these instructions can be acquired by contacting the contracting officer.)

NAVAL FACILITIES COMMAND (NAVFAC), NAVY CRANE CENTER

NAVFAC P-307 Management of Weight Handling Equipment

(Copies available online at: https://portal.navfac.navy.mil/portal/page/portal/docs/doc_store_pub/p-

307%20december%202009.pdf)

US ARMY CORPS of ENGINEERS

EM 385-1-1 - US Army Corps of Engineers Safety and Health Requirements Manual

(A copy of this instruction can be acquired at http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-

1_2008Sep_Consolidated_2011Aug.pdf)

U.S. DEPARTMENT OF LABOR

29 CFR 1910 – Occupational Safety and Health Standards

29 CFR 1910.147 – Control of Hazardous Energy (Lockout/Tagout)

29 CFR 1910.331-335 – Safety-Related Work Practices

29 CFR 1926 – Safety and Health Regulations for Construction

29 CFR 1926.500 – Fall Protection

(U.S. Department of Labor, OSHA Publications, P.O. Box 37535, Washington, D.C. 20013-7535 www.osha.gov)

UNITED FACILITIES CRITERIA (UFC)

UFC 1-200-01 - General Building Requirements

UFC 3-410-04N – Industrial Ventilation

UFC 3-600-01 – Fire Protection Engineering for Facilities

(Whole Building Design Guide, National Institute of Building Sciences, 1090 Vermont Avenue NW, Suite 700, Washington, DC 20005 or www.wbdg.org)

U.S. NAVY

OPNAVINST 5100.23 – Navy Safety and Health Program Manual (Ashore)

(“www.safetycenter.navy.mil/instructions/default.htm” or Commander, Naval Safety Center 375 A Street, Norfolk, VA 23511)

NAVAL FACILITIES COMMAND (NAVFAC), NAVY CRANE CENTER

NAVCRANECENINST 11450.2 – Design of Navy Shore Weigh Handling Equipment https://portal.navfac.navy.mil/portal/page/portal/docs/doc_store_pub/p-307%20december%202009.pdf https://portal.navfac.navy.mil/portal/page/portal/docs/doc_store_pub/p-307%20december%202009.pdf http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1_2008Sep_Consolidated_2011Aug.pdf http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-1_2008Sep_Consolidated_2011Aug.pdf http://www.osha.gov/ http://www.wbdg.org/

(Copies available online at:

http://www.navfac.navy.mil/content/dam/navfac/Specialty%20Centers/Navy%20Crane%20Center/PDFs/Downloads

/navcranece-instruction-11450.2.pdf)

2.2 Non-Government Documents.

AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL, INC. (AMCA)

AMCA 99-0401 – Classification for Spark Resistant Construction

(Address application for copies to the AMCA International, 30 W. University Dr., Arlington Heights, IL 60004 or www.amca.org)

AMERICAN CONFERENCE OF GOVERNMENTAL INDUSTRIAL HYGEINISTS (ACGIH)

American Conference of Governmental Industrial Hygienists Industrial Ventilation Manual

(American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Cincinnati OH, 45240-

1634 or www.acgih.org)

AMERICAN INSTITUTE OF STEEL CONSTRUCTION (AISC)

AISC Manual of Steel Construction – Allowable Stress Design

(American Institute of Steel Construction, One East Wacker Drive Suite 700, Chicago, IL 60601-1802 or www.aisc.org)

AMERICAN NATIONAL STANDARDS INSTITUTE, INC. (ANSI)

ANSI A10.32 – Personal Fall Protection

ANSI B11/STD 11.19 - Machines-Performance Criteria for Safeguarding

ANSI MH27.1 – Standard for Patented Track Underhung Crane and Monorail Systems

(Address application for copies to the American National Standards Institute, Dept. 969, 1430 Broadway, New

York, NY 10018)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME A13.1 – Scheme for the Identification of Piping Systems

ASME B30.11 – Monorails and Underhung Cranes

ASME B30.16 – Overhead Hoists (Underhung)

ASME B31.1 – Power Piping Code

ASME HST-2 – Performance Standard for Hard Chain Manually Operated Chain Hoists

ASME Y14.100 – Engineering Drawing Practices, Engineering Drawing and Related

Documentation Practices

ASME Y14.34 - Associated Lists, Engineering Drawing and Related Documentation Practices

(American Society of Mechanical Engineers, Three Park Avenue, New York, NY 10016 or www.asme.org)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A-36 – Standard Specification for Carbon Structural Steel

(American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 or www.astm.org)

AMERICAN WELDING SOCIETY (AWS)

AWS D14.1 – Welding of Industrial and Mill Cranes and Other Material Handling Equipment

(American Welding Society, 8669 NW 36 Street, #130, Miami, FL 33166-6672 or www.awsnow.org)

Crane Manufacturers Association of America (CMAA)

CMAA 74 – Specifications for Top Running &, Under Running Single Girder Electric Traveling

Cranes Utilizing Under Running Trolley Hoist

CMAA 78 – Standard and Guidelines for Professional Services Performed On Overhead and

Traveling Cranes and Associated Hoisting Equipment

(Crane Manufacturer’s Association of America/The Material Handling Institute (MHI), 8720 Red Oak Blvd. Ste

201, Charlotte, NC 28217-3996 or www.mhi.org/cmaa)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA ICS-1 – Industrial Control and Systems General Requirements

NEMA ICS-6 – Industrial Control and Systems Enclosures

NEMA MG-1 – Motors and Generators Errata

NEMA 250 – Enclosures for Electrical Equipment (1000 Volts Maximum)

(National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1752, Rosslyn, Virginia 22209 or www.nema.org)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 70 – National Electrical Code (2014 Edition)

NFPA 70E – Standard for Electrical Safety in the Workplace (Current Edition)

NFPA 79 – Electrical Standard for Industrial Machinery

NFPA 101 – Life Safety Code

NFPA 484 – National Fire Protection Association Standard for Combustible Metals

NFPA 654 – National Fire Protection Association Standard for the Prevention of Fire and Dust

Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids http://www.astm.org/ http://www.awsnow.org/

(NFPA, 1 Batterymarch Park, Quincy, Massachusetts 02169-7471)

NORTH CAROLINA STATE BOARD OF EXAMINERS OF ELECTRICAL

CONTRACTORS

North Carolina Board of Examiners of Electrical Contractors in accordance with the provisions and requirements of Chapter 87, Article 4 of The General Statutes of North Carolina.

(A copy of this instruction can be acquired by World Wide Web at: http://www.ncbeec.org/)

2.3 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained. The listed documents in this specification are a minimal list but not limited to regulations for industrial safety pertaining to industrial equipment design and installation. Under no circumstance shall these regulations not be applied to the manufacture and installation of the equipment.

3. REQUIREMENTS.

3.1 General. All equipment items shall be new and current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being quoted for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

3.1.1 Intended Use. The equipment shall be used to perform high pressure cold spray on various structural and nonstructural aircraft components to include the H-53 gearbox, H1 combining gearbox, AV-8B landing gear housings, and V-22 canopy tracks. Cold spray powders to be used include 2000 series (aluminum copper alloys), 5000 series (aluminum magnesium alloys), 6000 series (aluminum magnesium silicon alloys), 7000 series

(aluminum zinc alloys), aluminum oxide blended powders, and a copper blended powder. In addition, one chamber will be used to texture the surface in preparation of the cold spray application via 54 to 80 grit aluminum oxide blast media. The requirements contained in this specification are detailed to clarify what is required.

3.1.2 Measuring and Indicating Device Graduations. All measuring and indicating devices on the equipment shall be graduated in the inch/pound system as required.

3.1.3 Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the equipment, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29

CFR 1910.

3.1.3.1 Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.19. The safety devices shall not interfere with the operation of the equipment. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts.

3.1.3.2 Human Engineering. The equipment shall be ergonomically designed in accordance to MIL STD 1472G, as to reduce/eliminate injury to the operator while operating the equipment. All points of operation shall be easily accessible to the operator with minimal motion and there shall be no overextending conditions. The equipment shall be designed and manufactured to minimize the possibility of human error or injury (i.e. back injury) and to ensure human/machine compatibility. Adequate access to support maintenance functions and personnel shall be provided as part of the design.

3.1.4 Noise Restriction. Noise transmitted from the equipment furnished shall not exceed 85 dBA at the source in accordance with OPNAVINST 5100.23. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 85 dB requirements.

3.1.5 Environmental Protection. The equipment shall meet all applicable US Environmental Protection Agency

(EPA) and OSHA restrictions for materials classified as hazardous to the environment in effect on the date of contract. During the operation of the machine at the final location, the equipment shall comply with all applicable

US EPA and OSHA regulations in effect on the date of contract regulating the emission of materials hazardous to the environment.

3.1.5.1 Mercury Restriction. The equipment shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture. Fluorescent light bulbs shall be excluded in this restriction.

3.1.5.2 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the equipment.

3.1.5.3 PCB Restriction. Equipment or materials containing polychlorinated biphenyl (PCB) shall not be used in the equipment.

3.1.5.4 ODS Restriction. Equipment or materials containing Class 1 Ozone Depleting Substances (ODS) shall not be used except when approved in writing and a copy attached with the quote, by the Navy Senior

Acquisition Executive, Assistant Secretary of the Navy for Research, Development, and Acquisition.

3.1.6 Hazardous Material: Contractors shall comply with FRCEASTINST 5090.1, before introducing to, or removing any hazardous materials from the FRC East. The contractor shall submit all MSDS sheets prior to bringing any hazardous materials on site at the FRC East.

3.1.6.1 The contractor shall inform the designated facility representative of all contractor used Hazardous

Material (HM) and the contractor shall provide MSDSs for those materials to the facility representative.

Contractor shall develop two (2) binders for MSDS for HM used on-site. The contractor shall maintain one

(1) MSDS binder on the job site in close proximity of work being done. The second MSDS binder shall be provided to the environmental office to include the project number and name, contractor company name, contractor emergency Point of Contact (POC) and phone number. The contractor shall ensure all personnel on site have knowledge of the on-site binder and are able to retrieve, without barriers, a MSDS when needed. At no time shall the contractor perform any work without all copies of all MSDSs being maintained on site at all times and in the contractor's on site office or in the contractor's work truck (if used as a field office). These MSDSs are required in the event of emergency or spill incident. (Regulatory

Reference 29 CFR 1910.1200) All HM left on site, shall be stored in accordance with the MSDS.

3.1.6.2 Within five (5) days of the start of the project, the Contractor shall provide to the Government the amount of HM inventory on site. Form FRCE 5090/20 shall be used for this purpose (Contact the FRC East

Project Manager for a copy). The form shall be completed in its entirety except for Column "Quantity

Used". This form shall also be provided monthly to the FRC East Environmental Division or at the completion of the job, whichever occurs first. (Regulatory Reference 29 CFR 1910.1200)

3.2 Equipment Components & Structure. The equipment shall be assembled of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the equipment to its maximum rating and capacity without distortion.

3.2.1 Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

3.2.2 Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.3 Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

3.2.4 Materials. Direct contact between dissimilar metals, especially brass, copper, or steel in contact with aluminum or magnesium, shall be avoided. When dissimilar materials are used a dielectric barrier is required preventing the metals from contacting each other.

3.2.5 Painting. The equipment shall be painted in accordance with the manufacturer’s standard commercial practice. Prior to painting, surfaces shall be properly prepared and primed. All paint and coatings used shall not degrade or be susceptible to chemical reactions of the machine processes. Manufacturer’s standard color shall be used. Machine guards shall be painted yellow. The inside of electrical panel doors shall be painted white and inside the electrical panels shall be painted white.

3.2.6 Workmanship. Workmanship of the equipment shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this specification.

3.2.7 Standard Equipment. All standard equipment normally provided with the equipment shall be furnished.

3.2.8 Operating Conditions. The equipment shall be capable of 16 hours of continuous, efficient and safe operation in a factory environment of 80 degrees Fahrenheit ±20 degrees, atmospheric pressures between 25.5 and

30.5 inches of mercury, and relative humidity of 95% or less without exceeding the designed operating limits of any of its components.

3.3 Essential System Components. The cold spray system shall consist of, at a minimum, the following components:

a. Booth (lights, doors, windows, etc.) with two (2) chambers

b. Dust Collector(s) with heated make-up air and facilities controls monitoring.

c. Robot

d. Turn Table

e. Monorail

f. Electrical systems, Fire Alarm Connections to building fire alarm panel.

g. Software

h. Fire Suppression

3.3.1 Booth. The contractor shall supply a new cold spray booth to include all necessary Industrial Ventilation, Heating Ventilation and Air Conditioning (HVAC)(heated makeup air), fire suppression, lights, etc.

3.3.1.1 The booth shall include two (2) chambers. Each chamber shall have minimum interior dimensions of 13 feet wide by 20 feet deep by 15 feet 6 inches high. Maximum exterior dimensions shall be 14 feet wide by 21 feet deep by 16 feet 6 inches high. One chamber will be used for high pressure cold spray application and the other chamber will be used for surface preparation prior to cold spray application.

However, the new booth height shall in no way encroach within 18” of the existing fire sprinklers.

3.3.1.2 Each chamber shall have one (1) double leaf door with a clear opening of at least 84 inches wide by

96 inches tall. Each leaf shall have a 16 inch by 16 inch viewing window.

3.3.1.3 Each chamber shall have at least one (1) shaded view window near the operator console 40 inches wide by 36 inches high. The center of the window shall be five (5) foot above the finished floor.

3.3.1.4 Each chamber shall have a minimum of five (5) light fixtures mounted in the ceiling of appropriate rating in accordance with (IAW) the NFPA 70 for the environment inside the enclosure.

3.3.1.5 Items inside the spray booth shall be placed to allow for the most open area inside for loading material to be processed. All hard piping inside the enclosure shall be run along the walls of the spray booth. All flexible hoses inside the spray booth shall be mounted to tool counterbalances to suspend them from the ceiling of the booth but allow for free movement of the robot. The hoses shall be securely attached to the counterbalances and protected from damage.

3.3.1.6 Booth fabrication and installation shall meet UFC 1-200-01, NFPA 654, and NFPA 484. The contractor shall design the booth/enclosure/chamber and all dust collection systems for a Dust Explosion

Class of St3, a Deflagration Index of >500 Kst (bar.m/s), and/or a Maximum Explosion Pressure (Pmax) of

17.5 (bar g).

3.3.1.7 Space Constraints. The equipment shall be designed to require the minimum amount of floor space possible. The equipment shall be designed and positioned allowing access to all serviceable components. The contractor shall provide a preliminary equipment layout showing length, width, and height as well as how the equipment fits within the allowed floor space with their proposal. Before any installation work, the contractor shall provide for review and comments all installation drawings (including all contract installed equipment/parts, roof equipment, and ventilation accessories) showing length, width, and height as well as how the equipment fits within the allowed floor space.

3.3.1.8 The booth shall not have any equipment mounted on the top. However, if access is required to the top of the booth then a properly design access ladder, per OSHA 29CFR1910 shall be installed.

Additionally, the contractor shall provide fall protection in the form of either a fall arrest points, fall restraint points or a fall protection railing system.

3.3.1.9 The booth shall be provided with piping penetration locations identified on the contractors drawings for the Government to drill holes and install pipe into the booth at three (3) separate locations for industrial gas pipes of 1 ½” Diameter. Additionally, the contractor shall provide the Government with a suggested path of travel for interior piping within the booth to connect industrial gases to the Government owned high pressure cold spray equipment that will be mounted on the contractor provided robot.

3.3.2 Dust Collector(s) (Heated Make-up Air and Controls). Each chamber shall have a dust collector and heated make-up air system. The dust collector shall interface with the FRC East existing Johnson Controls Facilities

Management System. The dust collectors, ducting, and overall Industrial Ventilation system design shall meet the requirements of the NFPA 484 and NFPA 654 in regards to using aluminum and aluminum alloys metal powders for the spray chamber and 54 to 80 grit aluminum oxide blast media for the surface preparation chamber. These include but are not limited to the 2000 series (aluminum copper alloys), 5000 series (aluminum magnesium alloys), 6000 series (aluminum magnesium silicon alloys), 7000 series (aluminum zinc alloys), aluminum oxide blended powders, and a copper blended powder. The contractor is responsible for performing capture velocity point calculations and providing them to the Government. The contractor shall provide the Industrial Ventilation system mounted to either the robot or free standing as to provide the most open area, inside each chamber, as possible. The dust collection system shall have enough velocity to capture the dust from the point of application in accordance with ACGIH

Industrial Ventilation Manual. The contractor shall provide fan curve details of the proposed dust collector system.

The dust collector may or may not have a HEPA filter prior to emission based on the contractor’s most efficient design. The contractor is responsible for connecting the exhaust plenum and dust collector. The dust collector shall meet the requirements of UFC 1-200-01 and UFC 3-600-01 for overall design and manufacture.

a) The high pressure cold spray chamber may utilize either a cyclone separator or water filtration dust collection unit. The contractor shall provide a dust collector designed to be installed on the exterior of the building. However, if a wet collection system is deemed appropriate then it may be installed on the interior of the space. If a cyclone separator is selected, as the contractor’s choice, then the dust collector shall have capability to collect dust into a 55 gallon drum and shall be easily modified to accommodate a 5 gallon drum.

b) The surface preparation chamber shall use a downdraft system and the dust collector shall be a cyclone separator type dust collector. The contractor shall provide a dust collector designed to be installed on the exterior of the building. The cyclone separator dust collector shall have capability to collect dust into a 55 gallon drum and shall be easily modified to accommodate a 5 gallon drum.

3.3.2.1 Industrial Ventilation. The contractor shall design and install all Industrial Ventilation systems.

The contractor shall provide all engineering details, calculations and drawings with the Site Preparation and

Installation Plan (Paragraph 3.6.2). The contractor shall provide exhaust ducting material and exhaust ducting size. The contractor shall provide all instructions to install the exhaust venting, venting material, which shall include pipe size, weights, dimensions, material, and calculations. A note shall be placed in the calculations that states the following “The exhaust system shown was designed for (Example: Varsol) contaminant, minimum control velocity (Example 2000) FPM hazard potential (A-D) rate of evolution (1-

4).” The contractor shall provide, on the equipment, a single point connection for each contaminate source a vent discharge location. The contractor shall design and install the ventilation discharge to eliminate re-entrainment of exhaust air into existing heating, ventilation and air conditioning supply air intakes. Install the exhaust vent ducting through Government provided wall penetrations. The exhaust vent installation shall meet or exceed the current Department of Defense construction criteria as defined in UFC 1-200-01.

The contractor shall use an offset stack and design the ventilation stack as identified in the ACGIH, “Industrial Ventilation, A Manual of Recommended Practice” current edition. All new industrial ventilation systems shall conform to UFC 3-410-04N. The new dust collector shall be equipped with a broken filter alarm.

3.3.2.2 Fans shall meet spark resistance classification A per AMCA 99-0401. Hydraulic lubrication fittings shall be in accordance with SAE J534. Where use of high pressure lubricating equipment, 1000 psi or higher, will damage grease seals or other parts, a suitable warning shall be affixed to the equipment in a conspicuous location.

3.3.2.3 Explosion Protection. The contractor shall provide explosion or deflagration vent piping design information to be the same as that for dust collector. Information shall include the pipe size, pipe thickness, piping material, and piping maximum length to contain and direct explosive or deflagration gases/vapors to the atmosphere. Additionally, the contractor shall include any additional manufacturer requirements for piping and piping accessories.

3.3.2.4 Equipment Labeling. The contractor shall provide a placard that will label the use of the equipment for the type of dust it will collect. Placard mounting location shall be prominent. The placard shall be easily removed and replaced without the use of any tools. Placard shall be designed to be seen from all approach angles at a distance of 35 feet for persons with 20/20 vision. Placard colors shall be in accordance with NFPA 484.

3.3.2.5 Capture Velocity. Capture velocity shall be 200 feet per minute at 48 inches from the booth face opening or slots.

3.3.2.6 Overall Filtering Efficiency. Equipment shall capture a minimum of 99% of particles one (1) micron and larger. The manufacturer shall attain and provide tests conducted by an approved testing organization that prove that the collector’s efficiency will capture 99% of particles one (1) micron and larger.

3.3.2.7 Filter Monitoring. Each filtering system shall have an easily readable magnehelic differential pressure monitoring gauge for each filter bank. The controls and differential pressure gauge indicators shall be capable of directly interfacing with FRC East's existing Johnson Controls Facilities Management System

(FMS). Verification of new equipment’s integration into the existing Johnson Controls FMS system shall be conducted with an FRC East representative prior to project closeout. Controls graphics shall show the building and relative building locations of the equipment to closely match the drawings and as-built locations.

3.3.2.8 Make-up Air. The make-up air intake hood shall be located on the exterior of the building. The make-up air shall be heated utilizing SCR electric duct mounted heat strips. Winter design conditions for

Cherry Point, NC is 24 degrees F. Make-up Air shall be designed to maintain 50 degrees F inside each chamber. The outside hood shall be designed to prevent water entrainment into the air stream.

3.3.2.9 Duct Construction. The duct construction and installation shall conform to SMACNA round industrial duct construction and SMACNA industrial duct construction standards. The make-up air duct shall be equipped with a silencer to meet Paragraph 3.1.4. The intake shall be sized to make-up air removed by the new dust collector installed as part of this project.

3.3.2.10 Duct Access Door. Where the air contaminant includes particulates that may settle in the duct, clean-out doors shall be provided in horizontal runs, near elbows, junctions, and vertical runs. The spacing of the clean-out doors shall not exceed 12 feet for ducts of 12 inches diameter and less but may be greater for larger ducts. Removable Caps should be installed at all terminal ends and the last branch connection should not be more than six (6) inches from capped ends.

3.3.2.11 Water Condensation. Where condensation may occur in the duct, the duct system shall be liquid tight and provisions made for proper sloping and drainage.

3.3.2.12 Duct Labeling. Label the duct with content and direction of flow. Label the system every 10 feet and at all changes in direction and elevation. Label shall completely wrap the duct so that label is readable from all directions. Stencil on the system using black paint in block letter with a minimum letter height of three (3) inches.

3.3.2.13 Dust Collector Filters. If the new collectors require or are allowed to have filters then the contractor shall provide two (2) sets of all filters needed for the dust collector. One set shall be installed in the dust collector and the other set shall be provided to the Government for storage.

3.3.2.14 Facilities Controls Connection. All new Heating, Ventilation, and Air Conditioning equipment, Industrial Ventilation equipment, and all filter differential pressure gauge indicators shall be directly interfaced with FRC East's existing Johnson Controls (JCI) Facilities Management System (FMS). All

Direct Digital Control (DDC) field controllers/devices shall be network configurable, using existing government owned software: JCI Metasys ADX, version 7.X and JCI CCT(Controller Configuration

Tool) version 10.X. All DDC filed controllers shall communicate using the BACnet MS/TP protocol. The contractor shall field verify the existing conditions to include the existing controls. Upgrade existing controls graphics to match new equipment labeling. Controls graphics shall show the building and relative building locations of the equipment to closely match the drawings and As-built locations. Verification of the new control(s) operations and functionality shall be conducted with an FRC East representative prior to project closeout. Examples of equipment to be connected to the FMS system are dust collectors, makeup air units, thermostats, exhaust fans, and chillers.

3.3.3 Robot. The contractor shall provide a Fanuc M710iC/50 or equivalent six-axis robot with a R-30iB or equivalent controller for proper integration with the spray system.

3.3.3.1 The robot shall incorporate an extended axis turntable for spray process.

3.3.3.2 The robot shall be mounted on a motorized trolley attached to an overhead gantry system. The gantry shall move north/south through the booth with lockable positions every one (1) foot. The gantry shall also be able to move up to four (4) feet to the east with lockable positions every one (1) foot.

3.3.3.3 The J-1 axis (i.e. where the robot swivels) shall be located 10 foot from floor height.

3.3.3.4 The robot and spray system shall communicate and shall be able to disable each other when a problem is sensed by either system. The robot shall attempt to travel to a safe home position after any alarm, unless an event occurs that would deem robot movement undesired, unsafe, or destructive.

3.3.3.5 The robot shall be programmed with positions for “out of the way” as well as a position to attach or work on the end effector (spray gun).

3.3.3.6 A full robot controller image shall be made and provided by the contractor to the Government at the completion of final acceptance before the contractor leaves the facility.

3.3.3.7 Original robot manufacturer disks shall be provided by the contractor. This includes manuals and robot software.

3.3.3.8 The robot shall have a minimum capable work envelope of five (5) foot in diameter and four (4) foot in height.

3.3.3.9 The robot arm shall have a mounting bracket capable of holding a Kinetiks 4000 spray gun.

3.3.4 Turntable. The contractor shall supply a new turn table.

3.3.4.1 The turn table shall have a full 90 degree tilt capability about its horizontal axis. The turn table shall be cable of operating at 45 degree and 90 degree tilt with a minimum 1000 pound part attached. Part is approximately four (4) feet high by four (4) feet wide.

3.3.4.2 The turn table shall rotate a full 360 degrees about its vertical axis.

3.3.4.3 The turn table diameter shall be four (4) foot minimum.

3.3.4.4 The turn table shall have a minimum capacity of 2000 pounds.

3.3.4.5 The turntable shall be capable of a minimum of 10 RPM while tilted with part attached. In addition, the contractor shall design the system so that FRC East may add a second smaller turntable in the future.

The turntable would be located within the new robots limits. The intent of the Government is for the second turntable to operate at a much higher RPM than the larger turntable being installed by this contract. The part recipe created by the operator shall have a field for "large" or "small" turntable and RPM.

3.3.4.6 Controls for the turn table shall be integrated with the robot controls.

3.3.5 Weight Handling Equipment. The steel frame supporting the cold spray robot (Section 3.3.3.2) shall be designed to incorporate a weight handling monorail system utilizing a 1 (one) ton manual chain fall to assist in the loading of the turn table.

3.3.5.1 Monorail Beam. The beam shall be of the patented track type. It shall be permanently mounted on the cold spray robot steel frame and be designed in compliance with CMAA 74, ANSI MH27.1, ASTM A-36 and AWS D14.1.

3.3.5.2 Trolley. The trolley shall be rated for 2,000 pounds. It shall be manually operated with non-coasting drive, compatible with the selected patented track beam, have machined steel wheels (stamped steel or cast iron is prohibited), safety lugs (drop stops) or a functionally equivalent feature to prevent derailment in the event of wheel or axle failure, and rubber bumpers.

3.3.5.3 Hoist. The hoist shall have a rated lifting capacity of 2,000 pounds, be in compliance with ASME

B30.16 and ASME HST-2. It shall be equipped with a mechanical load brake suitable to stop and hold 131.25% of its rated capacity, an overload limiting device, and a chain stop or dead-end connection to prevent the load chain from running out of the hoist at its fully extended position. It shall be lug mounted to the trolley, and have an easily removable unplated forged steel hook with a safety latch. In addition, the hoist shall come with documentation from the manufacturer certifying it’s capability to be periodically load tested to 131.25% of its rated capacity. The minimum clear hook height shall be 8'-6".

3.3.6 Electrical System. The machine shall conform to NFPA 79. The existing source voltage available at the facility is 480 VAC, 3 phase, 60-hertz power service. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete. This shall include any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated and fused single disconnect device shall be utilized on the machine with means of lockout in the off position only. Graphic symbols for logic diagrams shall be in accordance with applicable requirements of NEMA

ICS-1.

3.3.6.1 Electrical Enclosures. Electrical enclosure shall conform to all applicable standards NEMA ICS-

6. The enclosure shall be a NEMA 250 Type 12, providing ventilation utilizing an A/C unit for cooling of components. All electrical enclosures shall be marked for arc flash hazard per NFPA 79.

3.3.6.2 Motors. Motors shall be rated for continuous duty and shall have ball or roller bearings of the sealed and permanently lubricated type. Alternating-current (AC) motors shall be designed to operate on

60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1. Each motor shall have an identification plate to identify manufacturer, model identification, serial number, voltage, amperage, horsepower, phase, and frequency.

Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and drawing(s).

3.3.6.3 Fail-Safe Operation. All electrical systems shall be designed for fail-safe operation and shall be insulated, isolated, shielded, and grounded for operating safely.

3.3.6.4 Interlock Switches. The equipment shall be provided with door interlock switches, which instantly remove power from equipment where a hazard exists when doors/panels providing access to those hazardous areas are opened (i.e. electrical cabinet, etc.).

3.3.6.5 Emergency Stop. The equipment shall include several emergency stop buttons throughout the system, within the reach of the operator to remove all energy sources in a safe manner for the termination of the operation, per NFPA 79.

3.3.6.6 Lockout/Tagout. A single point disconnect for lockout/tagout shall be provided for the equipment per 29 CFR 1910.147. A written procedure including pictures of the actual location where each lock and tag is intended to be placed for locking out all energy sources shall be provided in accordance with 29 CFR

1910.147. See Paragraph 3.6.4.

3.3.7 Software. The following are requirements for a particular type of software that may be used in the control system provided by the contractor. Any commercial software shall be licensed to Fleet Readiness Center East. All licenses shall be permanent.

3.3.7.1 Robot Software.

3.3.7.1.1 Teach Pendant. The robot shall include a wireless teach pendant for programming robot movement. It is understood that each part to be sprayed is to be programmed by FRCE artisans as needed after initial start-up via this teach pendant.

3.3.7.1.2 Robot Memory Image. The contractor shall provide an image of the robot software on Compact

Disk media. This image shall be made during Final Acceptance Testing.

3.3.7.1.3 Factory Supplied Software. The contractor shall provide any factory software that comes with the robot on original factory media.

3.3.7.2 PLC Software.

3.3.7.2.1 Factory Software. The contractor shall supply a licensed copy of any software required to communicate with any PLC used in the control system. The contractor shall also supply a licensed copy of project editing software for any PLC used in the system.

3.3.7.2.2 Cables. All appropriate PC-to-Control System communication cables not already owned by the

Government shall be supplied by the contractor.

3.3.7.2.3 Communications Software. Often, communications protocols such as DeviceNet are used to connect devices within a control system. All software and hardware necessary for troubleshooting this protocol and the devices using it shall be provided by the contractor.

3.3.7.2.4 Project Software. The machine-specific PLC project file or files shall be provided by the contractor on Compact Disk media. This copy of the software shall be fully commented and labeled for ease of troubleshooting the system.

3.3.7.3 PC Software.

3.3.7.3.1 Backup Hard Drive. A clone hard drive shall be made of any PC used in the control system. This hard drive shall be provided by the contractor. No form of RAID shall qualify as a backup hard drive. No form of RAID shall be used on the control PC.

3.3.7.3.2 System BIOS. A list of BIOS settings for the industrial PC shall be provided by the contractor and included in the software binder.

3.3.7.3.3 Factory Software. All factory software provided with the computer shall be provided to the

Government.

3.3.7.4 Software Quality Assurance. All software media, manuals, BIOS settings listing, hardcopy of

PLC logic, settings for all communications protocols, communications block diagram of connected devices, and any other helpful baseline settings, such as passwords, user names, calibration data, for the system shall be organized in a software binder. This will be the software baseline for the system.

3.3.8 Fire Suppression. The contractor shall provide a fire suppression system, designed for the interior of the new booth, in accordance with UFC 3-600-01 and the 2012 International Building Code (IBC). The fire suppression system shall be installed in accordance with UFC 3-600-01 and the 2012 IBC. If a conflict exists between UFC 3-

600-01 and the 2012 IBC including any NFPA referenced documents, UFC 3-600-01 shall take precedence. Fire suppression located within the booth shall be designed and installed to provide a single point connection. Location of the single point connection shall be coordinated with the Government. Consideration shall be applied to the area exterior to the booth footprint to maintain proper fire suppression to the surrounding area. A registered professional fire protection engineer or an individual that has obtained National Institute for Certification in Engineering

Technologies, Level III certification (minimum) in accordance with NFPA 72, must prepare fire suppression system design, construction (shop) drawings, plans, and calculations. The contractor shall submit the fire suppression system design, construction (shop) drawings, plans, and calculations to the Government. The Government shall submit contractor fire suppression design, construction (shop) drawings, plans, and calculations to Authority Having

Jurisdiction (AHJ) for approval. Contractor shall submit all documentation to the Government within 90 calendar days after contract award. The Government will require 90 calendar days to provide a response.

3.3.9 Fire Alarm Connection. Any new fire suppression system installed shall be interfaced into the existing

Building fire alarm panel. Verification of new fire suppression systems integration and proper operation shall be observed by the MCAS Fire Department and a FRC East representative prior to final payment and project closeout.

Field verify the existing conditions to include the fire alarm system and wiring.

3.4 Marking on Instruments, Control Panels, and Plates. All alphanumeric symbols on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked in boldface on a contrasting background and shall be clearly and legibly marked for function and identification on a corrosion resistant material.

3.4.1 Lubrication Chart or Plate. A corrosion resistant lubrication chart or plate shall be permanently attached to the equipment. The following information as a minimum shall be furnished: points of lubricant application, servicing interval, type of lubricant, viscosity, military or federal specification for each lubricant (if applicable), and size and type of each lubricant filter.

3.4.2 Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records. The nameplate shall contain the following information: nomenclature, manufacturer's name, manufacturer's model designation, manufacturer's serial number, power input (volts, total amps, phase, and frequency), contract number, and date of manufacture.

3.5 Post Award Conference. The Post Award Conference (PAC) shall be held at customer facility no later than 30 days after contract award. Representative(s) from the contractor’s plant who are familiar with both the equipment to be furnished and the requirements of the specification shall attend the PAC. During the PAC a Plan of Action and

Milestone (POA&M) (see Sect 3.6.5) chart shall be submitted to the Government in hard copy and electronic format. During the PAC, the contract and all requirements regarding regulatory compliance, equipment, layout, delivery, demolition, installation, disposal, training, and warranty shall be discussed.

3.6 Technical Data. Technical data shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data, drawings, and prints shall be legible and written in the English language. Documents shall be fully legible. Poor quality copies and materials with hole punches obliterating the text or drawings will not be accepted.

3.6.1 Data Rights: The Government requires unlimited rights to all technical data and drawings for the entire system. Unlimited data rights will be limited to items designed for this specific installation. Commercial Off The

Shelf (COTS) items shall be provided with all vendor literature and drawings typically provided to the private industry with the same data rights typically provided. These unlimited rights will allow it to maintain and upgrade the items throughout the planned lifecycle. In addition, the Government's license to the technical data rights, license, and drawings if the Government chooses to do so, will allow future competitive procurement of replacements and upgrades. When an upgrade or re-procurement is contemplated, the Government will have the right to provide drawings and technical data to vendors. These data rights shall pertain to all documentation and drawings pertaining to the system to be acquired through this procurement.

3.6.2 Manuals. Two (2) complete printed sets and one (1) electronic copy (CD-ROM) of the Operation, Software, and Maintenance manuals shall be provided. Documentation shall include at a minimum, operations, installation, maintenance, routine service schedule, calibration, preventive maintenance, lockout/tagout procedures, illustrated parts break down, recommended spare parts list including part numbers, vendor’s literature, mechanical design drawings, pneumatic schematics, and electrical/electronic schematics.