N0017326Q0007 - Attachment 1

STATEMENT OF WORK

Corrosion Control, Coating, and Reflector Panel Fabrication for AN/FSC-78 Terminal in Guam

1.0 INTRODUCTION

The NRL Code 8124 requires the corrosion control, coating, and reflector panel fabrication for one AN/FSC-78 terminal in Guam.

2.0 SCOPE OF WORK

This Statement of Work (SOW) defines the work effort associated with the required corrosion control, coating, and reflector panel fabrication for one AN/FSC-78 terminal in Guam.

The contractor shall independently perform all work and furnish all labor, materials, supplies, equipment, and services to perform the services detailed in Sections 2.1 through 3.0.

2.1 CORROSION CONTROL AND COATING

The scope of work defined in this document is limited to removing any contaminants from the exterior surfaces of the antenna structure including mildew, grease, oil, algae, and other deleterious foreign matter in accordance with SSCP-SP 12 / NACE No. 5, as applicable, repairing superficial damage to those surfaces, and applying a coating system that will protect the antenna surfaces for an extended period of time. In this Statement of Work, superficial surface damage is defined as surface rust and/or peeling paint. It also includes the severely corroded sections of the antenna drum which shall be removed and replaced with new sheet metal where required. This SOW does not address structural corrosion. Structural corrosion is defined as corrosion affecting the integrity of the structure, and logically would require repair or replacement of the structurally corroded portion, itself.

The contractor will be responsible for shipping and handling of all tools, equipment, and potentially hazardous materials required to complete all work on-site.

The place of performance for the corrosion control and coating shall be the location of the one AN/FSC-78 terminal in Guam.

2.1.1 AN/FSC-78 TERMINAL

The exterior surfaces of the AN/FSC-78 terminal include, and are limited to:

1. Reflector support assembly (quadripod, crow’s nest, reflector hub),

2. Ring Girder,

3. elevated Equipment Room (EER) exterior and interior

4. Elevation Wheel and Yoke Assembly,

5. Ladders, stairways, and platforms,

6. Azimuth cone assembly and concrete base. The antenna reflector shall be cleaned, but not painted.

The scope of work is that which would be expected of antenna refurbishment and painting. It does not include “fixing” or repairing any components on the antenna. An example would be the repair or replacement of structurally corroded fasteners or electrical boxes, this is not the requirement.

The scope of work is however to include those tasks described in Section 2, “Surface Preparation Tasks.”

Since surface preparation is limited to preparing the surfaces for painting, as opposed to entirely removing previous coatings, an epoxy mastic system is specified in this SOW. This SOW also specifies the contractor apply a brushed epoxy coating to all deteriorated areas (most commonly found on sharp edges, crevices, weld seams, back-to-back angles and hardware). The process is described in Section 2.1.3.

2.1.2 SURFACE PREPARATION TASKS

1. The contractor shall perform the following surface preparation activities prior to touch-up painting:

a) Initially pressure wash all exterior surfaces to remove accumulated mildew, grease, oil, algae, and loose paint, and use a surface cleaner product to provide a clean surface prior to touch-up painting.

b) Removal of any remaining surface corrosion and loose paint by mechanical means, which may include sanding, grinding, or other similar methods.

c) Removal of all evidence of the exterior surface corrosion and recoat as necessary.

2.1.2 a REMOVAL OF PAINT CHIPS

The subcontractor shall be responsible for the containment, collection, removal, and disposal of paint chips and other debris, or otherwise, as directed by the on-site NRL Code 8124 representative. All paint chips and residue will be vacuumed, placed and contained in marked 55-gallon drums for disposal.

Contractor shall provide a plan, to be approved by NRL Code 8124, for their intended methods of surface preparation, application of all coatings including all materials and products to be used, as well as containment, collection, removal, and disposal of paint chips and other debris.

2.1.3 CORROSION CONTROL AND COATING PROCESS DESCRIPTION

1. This process shall be designed to ensure the following results:

a) Removal of compromised material and application of corrosion control finish to the existing damaged material and finish.

b) Compatibility with the existing finish such that the applied finish will adhere to the existing finish and not bubble or peel off.

c) Applicability to steel, aluminum, hot-dip galvanized steel surfaces and concrete surfaces.

d) A durable finish that will not require a full recoating for at least 4 years.

e) Non heavy metal, oil, or lead based finish.

2. Surface Preparation

a) The contractor shall pressure wash to remove dirt, dust, mold, mildew, loose paint, oil, grease, and other contaminants in accordance with SSPC-SP 12 / NACE No.5, as applicable.

Corrosion control utilizing SSPC-SP 15 (Bare Metal Power Tool Cleaning). SSPC-SP 14 / NACE No. 8 (Industrial Blast Cleaning) where feasible based on physical access to surface. Cleaning and surface treatment shall be inspected and approved by the on-site NRL Code 8124 representative prior to all painting operations. Cleaning shall be done with solvents, detergents, and processes that have no deleterious effect on the surface and that produce a surface satisfactory for receiving subsequent paint finishes. Loosely adhered paint and superficial rust shall be removed by pressure washing.

b) Dirt, grease, loose chalky paint, or other foreign material that have accumulated on the previously painted or galvanized surfaces shall be removed with a pressure washing or steam cleaning apparatus, which shall precede all other phases of cleaning. It is not intended that sound paint be removed using this process. Any paint that becomes loose, curled, lifted, or loses its bond with the preceding coat or coats after pressure washing shall be removed to sound paint or metal surface level by other means. Hand and power tool cleaning should then be used to abrade remaining intact coatings and establish an anchor profile suitable for subsequent coatings.

c) Application of a Sealer Coat.

(1) A epoxy penetrating sealer shall be applied to prepared surfaces as necessary to assure compatibility with the existing coatings and to seal all damaged areas.

This sealant shall be applied by brush only.

d) Application of a two part Epoxy.

(1) Application of a Direct-to-Rust (DTR) fast-cure polyamide epoxy primer, approximately 7 mils DFT, on all compromised metals to ensure corrosion protection. All sharp edges, weld seams, skip welds, bolts, crevices, and back-to-back angles where the existing coating has deteriorated will be brushed coated.

Once DTR is applied a Direct-to-Metal (DTM) acrylic topcoat paint is used. The application of this coat shall be all that is required to provide adequate finish protection to the touchup areas for at least four to five years.

e) Topcoat application.

(1) The application of a Direct to Metal (DTM), white, high-performance acrylic topcoat, approximately 5-7 mils DFT, to all exterior antenna surfaces excluding the reflector, by whatever means suitable to the site conditions.

2.1.4 CORROSION CONTROL AND COATING PRODUCT DATA

a) The following is a suggested list of products. The contractor shall be allowed to use alternate paints, primers, or washes, as long as they are equal or better in quality, environmental conformance, and properties to the items specified here.

(1) Surface Cleaner

Carboline “Surface Cleaner 3” concentrate is a biodegradable cleaning agent for degreasing and cleaning contaminated surfaces prior to painting. This is recommended for painted and unpainted steel, stainless steel, other non-ferrous metals, and concrete surfaces. May be diluted up to 10 parts water to 1 part cleaner, but can be used full-strength for difficult contaminant removal.

Application of Carboline Surface Cleaner 3 is limited to combined air, product and surface temperatures above 40°F.

(2) Epoxy Coating (Applications by brush only)

Pittsburgh Paint Ref. 95-245, 95-249 series two part “Pitt-Guard Rapid-Coat Direct-To-Rust (DTR) Epoxy Mastic Coating, an identifying gray color to be used for “Stripe” coating and white for top coatings. Performs equally well on steel, concrete, hot dip galvanized steel, and aluminum. Its excellent wetting properties allow application and good performance over tightly adherent rust. Product is self-priming and has a very low VOC (2.8 lbs. /gal.). Thinning up to 10% is permitted, using a PPG proprietary thinner equivalent to zylene or xylol.

Application of PPG “Pitt-Guard Rapid-Coat Direct-To-Rust (DTR) Epoxy Mastic Coating is limited to air, product, and surface temperatures above 32°F (0°C), and surface temperature of at least 5°F (3°C) above the dew point. This product may be applied on damp surfaces, but without frost or ice present.

Drying Schedule at 77°F (25°C)

• Dry to touch: 3-4 hours

• Dry to handle: 7-8 hours

• Dry to recoat: 3 hours, minimum

(3) Top Coat

Carboline “3359 DTM” (Direct-to-Metal) is an acrylic coating designed for both direct-to-metal and finish-coat applications. It provides excellent resistance to flash rusting, greatly reduces overspray due to its dry-fall properties, and has low odor. Product is self-priming and has a very low VOC (0.96 lbs./gal). Thinning up to 5% with water is permitted. Application of Carboline 3359 DTM is limited to air product and surface temperatures above 50°F (10°C), and a surface temperature at least 5°F (3°C) above the dew point. Top coat color shall be white.

Drying Schedule at 75°F (24°C) To touch: 6 hours To recoat: 2 hours

2.2 REFLECTOR PANEL FABRICATION

Contractor shall work with the original panel manufacturer to fabricate new 18m reflector panels for one AN/FSC-78 antenna in Guam, in accordance with industry-accepted standards custom tailored for the specifications detailed in Sections 2.2.1 through 2.2.2.

The place of performance for the panel fabrication shall be at the contractor’s fabrication facility only.

The anticipated period of performance for the panel fabrication shall be 1 September 2026 – 1 September 2027.

2.2.1 FULL REFLECTOR MAIN SPECIFICATIONS

Reflector size of 18.3m (60 ft)

Shape Profile of a true parabola, no taper. Prior to fabrication, contractor shall confirm shape profile with NRL Code 8124 including all applicable design drawings which shall be approved by NRL Code 8124.

Complete reflector accuracy: <0.50 mm [0.02 in] RMS after on-site photogrammetry/theodolite alignment

2.2.2 CONFIGURATION & TECHNICAL SPECIFICATIONS

Configuration: Four rows of panels for a total of 96 panels

Row 1: 16 panels Row 2: 16 panels Row 3: 32 panels Row 4: 32 panels

Panel requirements/specifications:

• Quadra-pod cut-outs as required by design.

• Access hatch: one panel shall have an access door to enter the dish.

• Fabrication process: bonded panels, all parts anodized, completed in environmentally controlled room for bonding and assembly.

• Reflective skin: 1.5mm thickness.

• Radial zee profile: 50x80x50mm.

• Transversal zee profile: 50x76x40mm.

• Backup plates (only in the 4 edges): 40x3mm.

• Material: aluminum alloy 6082-T6 or equivalent (6061-T6).

• Fabrication surface accuracy: <0.25 mm RMS (measured by photogrammetry).

• Panels RMS verification method: digital photogrammetry system from GSI; shall be measured for first five panels per row, then one every five produced.

• Panel RMS shall be measured relative to the panel support points at 30-40 deg of inclination RMS reading grid: 40x40mm MAX.

• Edges & sides: 3mm +/- 1.5mm straight

• Panel gaps: 3mm +/- 1.5mm

• Shape Profile: per specifications of AN/FSC-78 terminal original documentation and to be confirmed by NRL Code 8124.

• Attachment hole locations: Qty of four points of support for each panel per original specifications.

• Finish of front and rear sides:

o 1x coat of epoxy primer for a total thickness of 40-50 microns o 2x cross coats of polyurethane topcoat white RAL 9010 40 glass, total thickness of 60-70 microns

• Total dry paint thickness at the end of painting operations (primer + topcoat): 100-120 microns Identification and Marking: Each panel shall have a label containing the following information:

o Serial Number o Ring Number o Measured RMS value o Date of Manufacture

• Reflector Panel Supports: Four supports, per reflector panel, shall be fabricated as follows:

Painted, zinc-plated steel.

o Stainless steel adjusting screw.

o Stainless steel, shims, spacers, & square washers. Stainless steel hardware.

o Reflector panel support design to be approved by NRL Code 8124 prior to fabrication Reflector panel supports shall be delivered fully assembled.

QC Documentation shall be provided as follows:

o Certificate of Compliance for the materials Panel RMS verification FG tolerance sheet.

o Panel dimensional verification Check-out Datasheet Attachment hole location check-out datasheet Painting thickness & adhesion Check-out Operations.

Packing and Shipping:

o The reflector panels shall be packed in one 40’ container with a valid Convention for Safe Containers plate.

3.0 SUBMITTALS/DELIVERABLES

As a minimum, the contractor shall provide the following information to the NRL Code 8124 Government POC:

1. Schedule

Careful consideration shall be given to appropriate times when site representative may be able to inspect work in progress for quality and completeness, and those times shall be clearly depicted in the schedule. The work shall be planned so that only a minimum amount of downtime shall be scheduled, which must be mutually agreed and coordinated with NRL Code 8124 during schedule development.

2. Deliverable Due Dates:

The contractor shall provide weekly status reports to NRL Code 8124, due on the first day of the following work week. The reports shall include, at a minimum:

a. weekly accomplishments;

b. the following weekly schedule activities;

c. items of interest/concern. The status report can either be written or via telecon.

3. Quality Control

The contractor shall outline their quality control plan as part of their proposal. Contractor will provide photo evidence, within 48 hours of request of products and completion of objectives, as requested by the on-site NRL Code 8124 representative.

4. Safety

The contractor shall outline their safety plans to NRL Code 8124. All contractor personnel used on site will have undergone safety training for working at heights and provide Certification thereof to NRL Code 8124.

5. Program Logistics and Support

The contractor shall outline how he intends to support this program logistically. A brief description of the contingencies the contractor has in place shall be provided.

6. Key Personnel

The subcontractor shall provide a list of the key personnel to be associated with the program.

All on-site personnel are to have previous experience in refinishing and upgrading heavy, medium and small, full motion parabolic antennas.

3.1 EXECUTION PHASES AND MILESTONE PAYMENTS

The contractor shall plan for a milestone based payment structure for the corrosion control and coating task and the reflector panel fabrication task based on the execution phases detailed Sections 3.1.1. and 3.1.2.

3.1.1 CORROSION CONTROL AND COATING

The contractor shall execute the corrosion control and coating task in five Phases as follows:

Phase 1- Pre-Deployment Planning and Mobilization o Final review of SOW o Procurement of abrasives, blasting media, coatings, and consumables o Packaging and shipment of tools, blasting equipment, and hazardous materials Coordination of personnel travel, site access, and safety requirements Confirmation of heavy equipment (HE)

Phase 2- Deployment to Site Team deployment o Site Safety and Hazard Awareness Brief Receipt of HE o Commence work

Phase 3- Reflector Backup Assembly Surface Preparation and Coating o Pressure washing and cleaning of the reflector, quad, and backup structure o Corrosion control using SSPC-SP 15 and SSPC-SP 14 methods, as applicable Application of epoxy primer to exposed metal and previously corroded areas Application of a high-performance acrylic topcoat (approximately 5-7 mils DFT), excluding the reflector

Phase 4- EER and Elevation Deck Structure Surface Preparation and Coating o Corrosion control and coating of the EER and elevation decks o Replacement of hardware beyond restoration within expected quantities o Installation of temporary protective shrouds for power enclosures o Metal fabrication as needed to restore operational reliability to the EER drum assembly Application of a high-performance acrylic topcoat (approximately 5-7 mils DFT), excluding the reflector

Phase 5- Lower Deck, Pedestal, and Closeout o Corrosion control and coating of the lower deck, concrete pedestal, and stairway o Final quality assurance inspection and demobilization

Milestone invoicing shall be in alignment with the following percentages:

Corrosion Control & Coating

Milestone Estimated Timing

Invoice Percentage

Receipt of Order/Project Start Day 0 15% Phase 1 - Pre-Deployment Complete PO + 3-4 weeks 15% Phase 2 - Deployment to Site PO + 8 weeks 5% Phase 3 - Reflector Backup Assembly PO + 24 weeks 10% Phase 4 - EER and Elevation Deck Structure PO + 28 weeks 20% Phase 5 - Panel Manufacturing Complete/Delivery PO + 60 weeks 20%

3.1.2 REFELCTOR PANEL FABRICATION

The contractor shall execute the reflector panel fabrication task in Phases as follows:

Phase 1- Engineering, Planning, and 90% Drawing Review o Final review of SOW o 90% drawing review o Award manufacturing of reflector panels and panel supports Schedule of manufacturing process

Phase 2 - Receive material at manufacturer and begin manufacturing Prepare tooling o Receipt and accounting of materials o Begin fabrication of reflector panel o Begin fabrication of reflector panel supports

Phase 3 - Quality Assurance Visit to Manufacturer SME deployment to manufacturer o QA the first set of reflector panels and first set reflector panel supports as applicable Continue reflector panel and associated hardware fabrication

Phase 4 - 50% Completion of Production o Continue reflector panel and panel support fabrication o Using photogrammetry, measure Panel RMS of the first five panels of each row and every five produced thereafter

Phase 5 - Reflector Panel Surface Coating, Completion of Manufacturing, Package and Ship Deliverables o Coating of reflector panels as specified in SOW Section 2.2.2 100% drawing review o Identify, mark, and quality control of reflector panels as specified in SOW Section 2.2.2 o Pack all deliverables in one 40’ container and coordinate with NRL Code 8124 for shipping (NRL shall handle shipping)

Milestone invoicing shall be in alignment with the following percentages:

Reflector Panel Fabrication

Milestone Estimated Timing Invoice Percentage Receipt of Order/Project Start Day 0 15% Phase 1- Engineering/Drawing Complete PO + 8 weeks 15% Phase 2- Receive Materials at Manufacturer PO + 20 weeks 20% Phase 3- Quality Assurance Check PO + 24 weeks 10% Phase 4- 50% Production Complete PO + 28 weeks 20% Phase 5- Panel Manufacturing Complete/Delivery PO + 60 weeks 20%

4.0 FINAL ACCEPTANCE

Upon completion of the corrosion control and coating, the contractor will perform a walk-through with NRL Code 8124 and any discrepancies will be noted on a checklist and corrected.

Final acceptance shall constitute satisfactory acceptance of the work and a Letter of Acceptance or Certificate of Conformance, to be generated by the contractor, shall be signed by the contractor and NRL Code 8124.

Final acceptance of the reflector panels and panels supports shall be performed after delivery of the reflector panels and panel supports and their satisfactory inspection and acceptance upon unpacking.

Final acceptance shall constitute satisfactory acceptance of the deliverables and a Letter of Acceptance or Certificate of Conformance will be signed by the contractor and NRL Code 8124.

5.0 SPECIAL INSTRUCTIONS

The contractor is required to have hands-on experience with the Subject AN/FSC-78 Terminal in Guam and be able to source the panels to be fabricated from the original manufacturer.