N6833519R0332_Attachment_01_SOW.docx

N68335-19-D-XXXX

NAVAL AIR SYSTEMS COMMAND

NAVAL AIR WARFARE CENTER AIRCRAFT DIVISION LAKEHURST

Attachment 01

STATEMENT OF WORK

For

REPAIR AND REFURBISHMENT OF AM2 MATTING

For Contract # N68335-19-D-XXXX

Prepared by:

Naval Air Systems Command Naval Air Warfare Center Aircraft Division Lakehurst, New Jersey 08733-5109

Date: 16 April 2019

DISTRIBUTION STATEMENT D: Distribution authorized to DoD and U.S. DoD Contractors only for Critical Technology Use, 12 December 2017. Other requests for this document shall be referred to NAVAL AIR WARFARE CENTER, AIRCRAFT DIVISION, HIGHWAY 547, LAKEHURST, NJ 08733, CODE 1.3.3.9.1.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. Sec 2751 et seq.), or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App2401, et seq. Violations of these export laws are subject to severe criminal penalties.

DESTRUCTION NOTICE: Destroy by any method that shall prevent disclosure of contents or reconstruction of the document.

Table of Contents

DESCRIPTION OF WORK

(a) All AM2 Matting Repair and Refurbishment activities in CLINs 0001-0031 and 0033-004 shall be completed in accordance with the following drawings (Attachment 03), and this Statement of Work (SOW) - (Attachment 01)

Nomenclature Drawing Number

(b) All reporting for CLIN 0032 shall be completed in accordance with Contract Data Requirements List (CDRL) (Exhibit A).

EFFECTIVE DATES FOR SPECIFICATIONS AND STANDARDS

Unless otherwise specified, the revision level and date for each specification and standard cited within this solicitation/contract (including any specifications of standards cited in any drawing, handbook or referenced specification or standard contained within this solicitation) shall be that listed in the Assist Web Site: “https://assist. dla.mil/online/start”.

CONTRACTOR NOTIFICATION TO QUALITY ASSURANCE (QA)

(a) Due to the critical application of the matting required for this contract a representative of the EAF Program Office, Lakehurst NJ, AM2 Matting Subject Matter Expert (SME), is available to furnish technical assistance on quality assurance matters and shall have the option of conducting quality assurance surveillance for the first lot, and all subsequent lots of matting produced under this contract.

(b) The Contractor Quality Assurance (QA) surveillance function shall be performed in conjunction with the Quality Assurance Representative (QAR) from the cognizant Defense Contract Management Agency (DCMA). The joint QA function does not abrogate the authority of the DCMA QAR.

(c) The Contractor shall maintain QA responsibility for the finished products. The Contractor shall notify, in writing or email, the Procuring Contracting Officer (PCO) when the matting is scheduled to be presented to the DCMA QAR for Government inspection and acceptance. This notification shall afford the QA representative the option of being present during the inspection.

(d) Notification may be provided via telephone to the PCO, immediately followed by written request or email. A minimum of fourteen (14) working days’ notice is required after receipt of the notification to arrange for the QA representative visit.

CONFIGURATION MANAGEMENT

Any Engineering Change Proposal (ECP) and any Request for Variance (RFV), affecting any item being procured under this contract shall be in accordance with Configuration Management best practices contained in SAE-EIA-649B and CDRLs A005 and A006, respectively. The Contractor shall submit one copy of each ECP or RFV to the Contract Administration Office, Naval Air Warfare Center, Aircraft Division, Lakehurst (NAWCADLKE). ECPs and RFVs shall be submitted to the IPT Leader, and reviewed by NAWCADLKE Engineering Code 4.8.2.2., prior to approval by the PCO. If any such modification or superseding document affects the cost or performance of this contract, an equitable adjustment will be evaluated in accordance with the procedures of the “Changes” Clause of this Contract (FAR 52.243-1) and the PCO.

(CDRL A005, Engineering Change Proposal (ECP)) (CDRL A006, Request for Variance (RFV))

PRE-AWARD/POST-AWARD SURVEY

A Pre-Award Survey is requested to evaluate prospective Contractor’s production and quality control capabilities (i.e. current production schedules, effects of unforeseen production delays). A Post-Award Survey will aid in the resolution of any production problems (drawings, matting specs, sources of supply, etc.) The Government may choose to waive the Pre and Post Award Surveys as necessary.

QUALIFIED PRODUCTS LIST (QPL)

The Contractor shall use only coating systems approved by NAVAIR Lakehurst Code 4.3.4.2. Approved Coating System sources are listed in SOW Section 9, Paragraph 7.7.3.1.

GOVERNMENT FURNISHED MATERIAL (GFM) FOR REFURBISHMENT

The Government will provide Government owned, used AM2 matting to the Contractor, supplied in 6 and 12-foot-long sheets. GFM may or may not be bundled, supplied in single sheets or packaged with end frames of approximately 18 sheets per package. End frames may be supplied as part of the matting bundles or as separate stand-alone shipments. The Contractor shall supply all other material as described below in SOW Paragraph 8.

Upon receipt of GFM, the Contractor shall sort AM2 mat and end frames by point of origin and site designation (e.g. Site 3-11, 29 Palms). The Contractor shall inspect the AM2 matting for damage in accordance with SOW Section 9, Paragraph 4.2 of this statement of work “Damage Classification” and SOW Section 9, Paragraph 4.3., “Damage Inspection”. The Contractor shall also inspect the end frames in accordance with SOW Section 9, Paragraph 5. The inspection shall determine if the AM2 matting and end frames are ready for refurbishment, require repair or cleaning, or are beyond repair (scrap). The Contractor shall submit the sorting results to the Government on completion of sorting GFM from a particular site as part of the weekly Government Furnished Material (GFM) Status Report, CDRL A00D. The Contractor shall retain GFM sorting data as records under this contract.

(CDRL A00D, Government Furnished Material (GFM) Status Report) and Attachment 02, GFP Items List

The Contractor shall provide an inventory of all AM2 matting, end frames and locking bars to the Government on a weekly basis. The Contractor shall prepare the inventory counts by type (e.g. F71, F72) and categorized as follows: inventory available for refurbishment (unsorted); inventory requiring repair or cleaning; inventory repaired and available for refurbishment; inventory refurbished waiting to be shipped; inventory that is beyond repair or considered (scrap). The Contractor shall submit the inventory for the reporting period as part of the weekly Government Furnished Material Status Report, CDRL A00D. The Contractor shall retain inventory data as records under this contract.

(CDRL A00D, Government Furnished Material (GFM) Status Report) and Attachment 02, GFP Items List

The Government shall provide and the contractor shall maintain enough material in order to maintain a daily production schedule of eight (8) AM2 matting packages per day. If contractor chooses to produce more than this quantity, the contractor may do so, however, the Government will only be liable for providing enough Matting to maintain this stated quantity. Any production in excess of eight packages per day shall not be cause for equitable adjustment to the Contract.

The Government will supply end frames P/N 621555-_ as GFM in various configurations and refurbished per the SOW. Aluminum end frames supplied may be new, require refurbishment and repair, or may be Ready For Issue (RFI). If the amount of GFM end frames supplied is inadequate to package the refurbished AM2 matting, the Government will supply additional end frames, either new, requiring refurbishment and repair, or RFI, as required. The Contractor shall not refurbish large window end frames (P/N 621555-20) and shall consider the large window end frames as scrap.

Scrap material, which is all aluminum, is defined as AM2 matting beyond repair, end frames beyond repair, all large window end frames and all locking bars received. The Contactor shall also consider as scrap, if received, AM2 matting accessories such as key locks, H-connectors, Y-connectors, cruciform stakes and edge clamps.

The Contractor shall sell all matting that is determined as scrap under the authority and guidance of the cognizant DCMA office. The Contractor shall ensure that the proceeds are used to purchase additional refurbished AM2 matting packages. This includes any material configuration or line item. The Contractor shall ensure that all proceeds from the sale of scrap material is placed in an interest-bearing escrow account and expensed solely at the discretion of the PCO.

The Contractor shall demilitarize the scrap AM2 matting (“De-Mil”) prior to be being sold as scrap by any method that prevents the matting from being used for its intended purpose. The choice of the “de-mil” method is at the discretion of the Contractor. The Governments’ intent for the scrap material, which shall be all aluminum, is to have it recycled by a smelter into new aluminum stock and not to be used for its intended purpose or for any other purpose.

The Contractor shall dispose of unusable packaging, dunnage, steel strapping, and steel end frames. These items are considered to be without value and not for sale.

The Contractor shall not sell any individual piece or package of AM2 matting or aluminum accessories as scrap until so identified and confirmed in writing with the Expeditionary Airfield IPT Leader.

CONTRACTOR SUPPLIED MATERIAL (CSM) FOR REFURBISHMENT

The Contractor shall supply the following items as required:

(a) End sheets where applicable. The Contractor can anticipate 70 percent of the packages will need end sheets.

(b) Locking bars (three types)

(c) Component parts for end frames

(d) Edge Tool, P/N 510827-1 (Contractor’s use for repair of bent AM2 mat connectors)

DETAILED SPECIFICATIONS FOR AM2 MATTING REFURBISHMENT AND REPAIR

The following describes the Process for the Refurbishment and Repair of AM2 mat. The Contractor shall adhere to the specifications outlined below:

1. AM2 matting consists of Landing Mat (F71 and F72), Heavy-Duty Mat (F73) and Spacer Mat (F78). The Contractor shall refurbish Government-owned AM2 matting by disassembling, sorting, cleaning, repairing, resurfacing and repackaging the matting in accordance with the latest revisions of NAVAIR Lakehurst Drawings: 626578 Revision J, (F71); 626577 Revision J, (F72); 622536 Revision J, (F73); 622392 Revision K, (F78) and instructions provided in this SOW.

2 DELETED

2.1 DELETED

2.2 DELETED

3 AM2 Matting Packages Refurbishment

3.1 The Contractor shall disassemble existing matting packages or bundles and consider any locking bars (P/N 320660-1,-5,-6) received as scrap. The Contractor is not required to sort any of the locking bars received for serviceability.

3.1.1 The Contractor shall supply all locking bars that are required for repackaging as new material and manufactured in accordance with NAVAIR Lakehurst Drawing 320660, Revision Y.

3.1.2 The Contractor shall dispose of all packaging material and steel end frames in accordance with SOW Section 7. All aluminum scrap shall remain the property of the Government and disposed/sold in accordance with the GFM requirements in SOW Section 7 and applicable contract clauses.

3.2 The Contractor shall inspect and repair the aluminum end frames (P/N 621555-_), either packaged with the matting or supplied separately in accordance with SOW Section 9, Paragraph 5 of this document.

If present, the Contractor shall remove Tie-Down Rings (P/N 621555-12) on end frames considered for repair. The Contractor is prohibited from repairing large window end frames (P/N 621555-20), and should classify them as scrap.

3.3 The Contractor shall consider all end sheets received as scrap. The Contractor shall supply end sheets (P/N 425139-1) and coat the end sheets as specified in SOW Section 9, Paragraph 7.7.8.5.

4 AM2 Matting Damage Classification, Inspection and Repair

4.1 The Contractor shall inspect and repair AM2 matting prior to resurfacing, in accordance with Section 9 Paragraph 4.

4.2 Damage Classification

4.2.1 Holes

4.2.1.1 Surface holes weaken the matting structure and allow water to enter and then freeze and bulge the matting. Holes also allow the entry of spilled fuel inside the matting and possibly cause a safety hazard.

4.2.2 Dents

4.2.2.1 Dents weaken the matting structure. The most critical dent condition is where multiple dents exist in a concentrated area.

4.2.3 Bulges

4.2.3.1 Bulges are caused by water freezing inside the matting. Small bulges should not create any operational, packaging, or installation problems. However, bulges with cracks on the top surface can become a tail hook hazard and are an indication of skin separation from the ribs.

4.2.4 Connectors

4.2.4.1 Connectors may have bent, broken, or missing portions of lips. These types of damages can impede the safe interlocking of matting sheets.

4.2.5 Corrosion

4.2.5.1 Corrosion is distinguished by pockmarks or pits on the surface, and is usually encountered on the bottom surface. The area affected by corrosion will vary. Corrosion may have been severe enough in some areas to result in perforation of the surface.

4.2.6 Bow/Twist

4.2.6.1 Severely bowed or twisted matting can be difficult to assemble with other matting and greatly increases field installation time.

4.2.7 Cracks

4.3.1 Holes

4.3.1.1 The Contractor shall consider as scrap, matting that contains surface holes with dimensions greater than 3 inches, with the one exception of SOW Section 9, Paragraph 4.3.1.3.

4.3.1.2 The Contractor shall repair holes up to 3 inches in any dimension by welding in accordance with the welding procedures of SOW Section 9, Paragraph 4.4.1 of this document.

4.3.1.3 The Contractor shall repair holes indicative of forklift tine damage by welding. These holes are rectangular with maximum dimensions of 1.5 inches wide by 10 inches long.

4.3.1.4 The Contractor shall repair holes that pass through either the male or female connector, into the matting core, under the same guidelines and restrictions of SOW Section 9, Paragraphs 4.3.1.1, 4.3.1.2 and 4.3.1.3 of this document.

4.3.1.4.1 Heavy-Duty Matting

4.3.1.4.1.1 The Contractor shall repair holes that pass through the prongs-up or prongs-down connector, into the matting core, under the same guidelines and restrictions of SOW Section 9, Paragraphs 4.3.1.1, 4.3.1.2 and 4.3.1.3 of this document.

4.3.2 Dents (See Figure 1)

4.3.2.1 A dent is defined as a depression in the matting surface that is greater than 1/8 inch in depth.

4.3.2.2 Individual dents shall not be larger than 9 inches in length or width.

4.3.2.3 A 4-inch band established across the matting surface (measured perpendicular to the long dimension and inward from the end connectors) shall not contain more than 13 dents. For Spacer Matting, a 4-inch band established across the matting surface (measured perpendicular to the long dimension and inward from the end connectors) shall not contain more than 7 dents.

4.3.2.3.1 Heavy-Duty Matting

4.3.2.3.1.1 A 4-inch band established across the matting surface (measured perpendicular to the long dimension and inward from the end connectors) shall not contain more than 10 dents.

4.3.2.4 The remaining matting surface (inward from the 4-inch bands) shall not contain more than 6 dents in any 1 square-foot area.

AM2 MAT

FIGURE 1

4.3.3 Bulges

4.3.3.1 Matting shall not contain more than 4 individual bulges in any 1 square-foot area.

4.3.3.2 The core section next to the male/female connector shall not contain bulges.

4.3.3.2.1 Heavy-Duty Matting

4.3.3.2.2 The core section next to the prongs-up or prongs-down connector shall not contain bulges.

4.3.3.3 Individual bulges in the top skin shall not contain cracks or tears, or be more than 1/8 inch in maximum height.

4.3.3.4 Individual bulges in the bottom skin shall not contain cracks or tears larger than 9 inches. The Contractor shall repair cracks/tears in accordance with SOW Section 9, Paragraph 4.3.8 of this document.

4.3.4 Connector Damage

4.3.4.1 Landing Mat

4.3.4.1.1 Cracked or missing prongs-up or prongs-down connector lips shall not exceed 3 inches in length in any one area, or a cumulative 6 inches on each lip of the connector. For Spacer Matting, cracked or missing prongs-up or prongs-down connector lips shall not exceed 1½ inches in length in any one area, or a cumulative 3 inches on each lip of the connector.

4.3.4.1.2 For 12-foot matting cracked or missing male/female connector lips shall not exceed 6 inches in length in any one area, or a cumulative 12 inches on each lip of the connector. For 6-foot matting, cracked or missing male/female connector lips shall not exceed 3 inches in length in any one area, or a cumulative 6 inches on each lip of the connector.

4.3.4.2 Heavy-Duty Matting

4.3.4.2.1 Cracked or missing male/female connector lips shall not exceed 2 inches in any one area, or a cumulative 5 inches on each lip of the connector.

4.3.4.2.2 Cracked or missing prongs-up or prongs-down connector lips shall not exceed 3 inches in length in any one area, or a cumulative 6 inches on each lip of the connector.

4.3.5 Surface Corrosion

4.3.5.1 Corrosion pitting which has not perforated the surface is acceptable.

4.3.5.2 The Contractor shall repair corrosion pitting that perforated the surface in accordance with SOW Section 9, Paragraph 4.3.1 of this document if all of the following conditions are met:

4.3.5.2.1 The individual areas where the corrosion pitting has perforated the matting are less than or equal to 1 square foot.

4.3.5.2.2 The individual square-foot areas are bounded on all sides by sound, non-corroded metal, and do not overlap.

4.3.5.2.3 The Contractor shall inspect and repair corroded prongs-up or prongs-down connectors or male/female connectors in accordance with SOW Section 9, Paragraph 4.3.4 of this document, as if the corroded areas were "cracked or missing".

4.3.6 Bow/Twist

4.3.6.1 The Contractor shall correct bowed matting to within 3/8 inch over the length of a 12-foot sheet, 3/16 inch over the length of a 6-foot sheet, 1/16 inch over the 2-foot and 19-inch widths of a matting, and 1/32 inch over the 1-foot width of the matting. The Contractor shall repair the bow in accordance with SOW Section 9, Paragraph 4.4.3 of this document.

4.3.6.2 The Contractor shall correct twisted matingt to within 1/4 inch on a 12-foot sheet and 1/8 inch on a 6-foot sheet. A twist is measured relative to a level plane established by two perpendicular edges.

4.3.7 AM2 Matting Containing Fluids

4.3.7.1 The Contractor shall completely drain any matting that contains any fluids.

4.3.7.2 A maximum of 1 hole may be drilled into each core, as needed, to completely drain an individual sheet.

4.3.7.3 The Contractor shall ensure that drainage holes shall not exceed 1/4 inch in diameter.

4.3.7.4 The Contractor shall drill drainage holes through the locking bar slot, or the bottom surface of the matting.

4.3.7.5 The Contractor shall repair all drainage holes by welding in accordance with SOW Section 9, Paragraph 4.4.1 of this document.

4.3.8 Cracks

4.3.8.1 The Contractor shall reject any crack in an end connector weld.

4.3.8.2 The Contractor shall reject cracks that exceed 9 inches in length.

4.3.8.3 The Contractor shall repair all cracks less than 9 inches in length by welding in accordance with SOW Section 9, Paragraph 4.4.1 of this document.

4.3.9 Damage Separation Distances

4.3.9.1 The Contractor shall ensure the minimum acceptable distance between adjacent holes shall be 3 inches for holes larger than 1/2 inch in diameter.

4.3.9.2 The Contractor shall ensure the minimum acceptable distance between adjacent areas of missing lips shall be 3 inches on an individual lip.

4.4 Damage Repair

4.4.1 Weld Repair

4.4.1.1 The Contractor shall perform all welding procedures in accordance with AWS D1.2. The Contractor shall utilize material meeting the requirements of ASTM B209, Alloy 6061, Temper T6 for all patch repairs. The Contractor shall qualify welding procedures in accordance with AWS B2.1. The Contractor shall ensure welds shall be 100% penetrant inspected in accordance with ASTM E 1417, Type I, Method A, Sensitivity Level 2. The Contractor shall ensure welds meet the following requirements: The Contractor shall ensure that all welds and at least 1/2-inch of the adjacent base metal on each side are free of linear indications greater than 1/16-inch in length. The total indication area for non-linear indications shall not exceed 0.75% of the weld surface area. The Contractor shall ensure that all weld repairs are ground flush with the base metal.

4.4.2 Connector Repair

4.4.2.1 The Contractor shall repair bent male, female, prongs-up and prongs-down lips using an Edge Tool (P/N 510827-1). The Contractor shall straighten bent lip areas to ensure proper interlocking of matting sheets and proper insertion of locking bars. Areas of lips that are badly bent may be cut out, provided that the repaired connector still conforms to the guidelines of SOW Section 9, Paragraph 4.3.4 of this document.

4.4.3 Bow/Twist Repair

4.4.3.1 The Contractor shall repair matting determined to be bowed using the abrasive blasting machine specified in SOW Section 9, Paragraph 7.7.7.2.1.1. of this document. Blast wheel speed on one side of the machine is adjusted, or turned off, allowing for higher or lower abrasive blasting on the bowed side of the matting. The side blasted will normally be the bowed, or convex, side. The Contractor shall determine the feed rate, which will depend on the severity of the bow. The Contractor shall re-inspect the matting after blasting and if the bow is acceptable under the applicable criteria it shall be acceptable for resurfacing in accordance with SOW Section 9, Paragraph 7.7 of this document. The Contractor shall re-blast the matting if it is not within criteria. The Contractor shall reject the matting if after two attempts at repairing an individual sheet of bowed matting, the matting is still out of tolerance, it will be rejected. The Contractor shall ensure that this repair will not damage or destroy the matting. The Contractor shall submit any proposed alternative repair procedure for bowed matting to NAWC 4.3.4.2 for approval prior to its use, in accordance with Request for Variance, CDRL A006.

4.4.4 The Contractor shall segregate for future disposition; all inspected AM2, Heavy-Duty and Spacer Matting that exceeds the repair criteria stated in SOW Section 9, Paragraph 4 of this document.

5 End Frame Damage Classification, Inspection and Repair

5.1 The Contractor shall inspect and repair end frames in accordance with the following criteria:

5.2 Damage Classification

5.2.1 Weld Cracks

5.2.1.1 Cracks in the end frame fabrication welds weaken the structure.

5.2.2 Surface Cracks

5.2.2.1 Surface cracks in the end frame sheet material weaken the structure.

5.2.3 Broken/Missing Stacking Extrusions

5.2.3.1 Broken and missing stacking extrusions prevent the matting packages from being stacked safely.

5.2.4 Broken/Missing Foot Extrusions

5.2.4.1 Broken and missing foot extrusions prevent the matting packages from being handled safely.

5.2.5 Broken/Missing Banding Loops/Ears

5.2.5.1 Broken and missing banding loops/ears prevent the matting packages from being strapped and assembled.

5.2.6. Bent Top Flange

5.2.6.1 A Bent Top Flange of the end frame prevents the insertion of the wood dunnage and will prevent the proper assembly of the mat packages.

5.3 Damage Inspection

5.3.1 The Contractor shall set aside "large window" end frames (P/N 621555-20) for scrap.

5.3.2 The Contractor shall repair any crack, up to 6 inches in length.

5.3.3 The Contractor shall reject any crack longer than 6 inches in length.

5.4 Damage Repair

5.4.1 The Contractor shall perform all welding in accordance with AWS D1.2. The Contractor shall qualify all welding procedures in accordance with AWS B2.1. The Contractor shall visually inspect weldments to ensure that the welds meet the requirements of AWS D1.2. The Contractor shall grind down all weld repairs flush with the base metal.

5.4.2 The Contractor shall use only weld material to repair damaged end frames, no patch plates shall be used.

5.4.3 The Contractor shall replace broken or missing stacking extrusions, foot extrusions and banding loops/ears in accordance with the end frame drawing 621555, Revision V.

5.4.4 The Contractor shall repair bent top flange damage by the Contractors’ preferred method. If the depth of the bend is larger than 1 inch, the end frame shall be rejected as scrap. The repaired bent flange need not be perfectly straight, but it shall be able to accommodate a minimum of ¼-inch thick wood dunnage when assembled with a matting package. If the end frame cracks during the bend repair process, the Contractor shall then determine if the crack or cracks can be weld repaired based on the criteria stated in SOW paragraph 5.3.

5.4.5 The Contractor shall ensure that all repaired end frames shall meet the configuration requirements of NAVAIR Lakehurst Drawing 621555, Revision V.

5.4.6 The Contractor shall segregate as scrap all inspected end frames that exceed the repair criteria stated in SOW Section 9, Paragraph 5 of this document.

5.5 Anticipated End Frame Damage

6.1 The Contractor can anticipate five percent of the 12-foot matting received will require some type of repair in accordance with SOW Section 9, Paragraph 4 and 1.5 percent shall be rejected as beyond repair. The Contractor can anticipate that four percent of the 6-foot matting received will require some type of repair in accordance with SOW Section 9, Paragraph 4 and 1.5 percent shall be rejected as beyond repair. The Contractor shall be responsible for any matting determined to be distorted or damaged. The Government will replace any matting determined to be distorted or damaged by the Contractor during the abrasive blasting process, through no fault of their own. A Government representative will be available to assist in the determination of the serviceability of the matting. The Contractor shall resurface the quantity of matting specified in the contract.

6.2 The Contractor can anticipate that 20 percent of the matingt will be excessively dirty or require additional cleaning. The Contractor shall not reject excessively dirty matting unless agreed upon directly by the Government. The Contractor shall clean the matting, including removing tar, asphalt, paint coatings, dirt and any other foreign matter or substance that has adhered to the matting. The Contractor shall be responsible in every instance, for cleaning the matting prior to it entering the resurfacing process.

6.3 The Contractor can anticipate that 10% of the matting will require hole repair.

6.4 The Contractor can anticipate that 10% of the matting will require crack repair.

6.5 The Contractor can anticipate that 20% of the matting will require straightening of bent lips.

6.6 The Contractor can anticipate that 20% of the matting will require straightening of bow or twist.

6.7 The Government will provide additional matting for the rejected matting. The Contractor shall resurface the number of mats specified in the contract.

7 Resurfacing of AM2 Matting

7.1 The Contractor shall resurface the matting. This task consists of cleaning and removing existing coating, and application of new coatings in accordance with SOW Section 9 Paragraph 7.7 of this document.

7.1.2 The Contractor shall use only approved coating systems listed in Table 1, or as otherwise approved by the Government. The Contractor shall provide the ASTM F 718 data sheets required for all products utilized in the coating process.

7.2 The Contractor shall ensure that the resurfacing process satisfies all local safety and environmental regulations.

7.3 DELETED

7.4 The Contractor shall ensure that the resurfacing process, including surface preparation by grit blasting, shall not increase the distortion or bowing of any matting, nor remove any substrate matting material.

7.5 The Contractor shall implement an inspection/acceptance procedure for the matting entering and exiting the resurfacing process. The Contractor shall verify that the matting is not being further distorted or bowed by the resurfacing process.

7.7.1 Scope

7.7.1.1 This process instruction defines the material, surface preparation and application requirements for coating Marine Corps AM2 Matting and associated packaging components (end frames and end sheets). Any changes to this process instruction require approval from NAVAIR Lakehurst Code 4.3.4.2. prior to implementation.

7.7.2 Documents

7.7.2.1 The following documents shall form a part of this process requirement:

7.7.3 Material Requirements

7.7.3.1 A coating system consists of a primer and a nonskid coating. The Contractor shall use coating systems approved by the Government. Table 1 provides the currently approved coating systems:

TABLE 1: APPROVED COATING SYSTEMS

Coating System

American Safety Technology 565 Eagle Rock Avenue Roseland, NJ 07068 800-631-7841 MS-3C Primer MS-5C Primer

FD 300

Milamar Coatings 311 N.W. 122nd Street, Suite 100 Oklahoma City, OK 405-755-8448

Gryphin Company 3501 Richmond St.

Philadelphia, PA 19134

(215) 426-5976 G-350 Chelating Coating G-250 Chelating Primer G-249 Epoxy Primer

G-2216LM

7.7.3.1.1. The Contractor shall obtain an ASTM F 718 format data sheet from the coating manufacturer for each of the coatings in the coating system. The ASTM F 718 data sheet is a source for physical and technical properties of the coatings, including mixing, application, and environmental requirements and limitations for the coatings.

7.7.3.1.2. The Contractor shall ensure that the ASTM F 718 format data sheets shall be included and be an integral part of the Production Plan (CDRL A007). Refer to SOW Section 9, Paragraph 7.7.4 of this document.

7.7.3.1.3. The Contractor shall document and include any changes to the coating system or to the ASTM F 718 format data sheets into the Production Plan (CDRL A007).

7.7.3.1.4. In the event of a conflict between the requirements of this process instruction and the Contractor's ASTM F 718 format data sheet, this process instruction shall take precedence.

7.7.3.2. The Contractor shall apply primer and nonskid coating as a "system". A system consists of primer and nonskid coating produced by the same manufacturer and that have the manufacturer’s assurance of compatibility.

7.7.3.3. The Contractor shall use coating within their designated shelf life as identified by the coating manufacturer.

7.7.3.4. The Contractor shall mix in the proper ratios, and as required by the coating manufacturer on the ASTM F 718 data sheet multi-component coatings, for example, those that consist of a separate resin and hardener.

7.7.3.4.1. The Contractor shall mix the entire contents of coating “kits” at one time.

7.7.3.4.2. The Contractor is authorized bulk delivery systems ("totes" or plural component spray systems). The Contractor shall utilize calibrated metering equipment that is adjusted to achieve the coating manufacturer's required mixing ratio.

7.7.3.4.2.1. The Contractor shall ensure proper mix ratios are achieved by a manual method when automatic metering equipment is not utilized for the measurement of component volumes.

7.7.3.4.2.2. The Contractor shall develop a process to qualify a manual method of component addition, and include this process in the Production Plan (CDRL A007).

7.7.3.5. The Contractor shall develop a process to ensure that mixing ratios, induction times, permissible thinner additions, pot life, and any other special instructions for each of the coatings are maintained. The Contractor shall develop this information in accordance with the coating manufacturer’s requirements and ASTM F 718 data sheet guidance. The Contractor shall incorporate this information into the Production Plan (CDRL A007).

7.7.4. Production Plan Requirement

The Contractor shall document a Production Plan for the Repair and Refurbishment of AM2 matting; following the procedures as directed in SOW Section 9 paragraphs 7.7.4.1 through 7.7.4.3 of this document.

(CDRL A007, Production Plan)

7.7.4.1. This Process Instruction presents guidance for the Contractor to satisfactorily resurface AM2 mat. The Contractor shall develop a Production Plan based on this guidance that details the entire manufacturing process. The Contractor shall ensure that the Production Plan is a detailed step-by-step description of all the process steps involved for the repair and refurbishment of AM2 matting. The Contractor shall ensure that the Production Plan addresses all materials used in the resurfacing process. The Contractor shall ensure that the Production Plan addresses all equipment required for the process, to include calibrations or certifications needed for test or inspection. The Contractor shall ensure that the Production Plan addresses all deficiencies found during the production process.

7.7.4.2. The Contactor shall ensure that the Production Plan is readily available for review by Government representatives when visits to the Contractor’s facility for inspections, site visits and other official business occur.

7.7.4.3. The Contractor shall maintain and update the Production Plan regularly to reflect current processes being utilized and to incorporate changes to the materials or processing.

7.7.5. Environmental Impact.

7.7.5.1. This process requires the use of Volatile Organic Compound (VOC) containing materials. Most states, and some pollution control districts within the United States, limit both the VOC of the coatings as well as the amount of VOC emitted per hour, day, month, or year. The Contractor shall contact the cognizant agency to determine what requirements or restrictions exist in their specific area to determine the applicable requirements and restrictions and further and to comply with those requirements or restrictions.

7.7.5.2. This process may generate waste which is classified as hazardous. The Contractor shall contact the cognizant agency to determine proper requirements for disposing of the hazardous waste generated.

7.7.5.3. Surface preparation is preceded by the requirement to clean or degrease the surface of the item for coating. The Contractor is responsible for determining the process and materials for cleaning the matting and ensuring that no substance used for cleaning the matting is listed as a Class 1 Ozone Depleting Substance.

7.7.6. Safety

7.7.6.1. The Contractor shall be responsible for the occupational safety of personnel involved with this process, and shall provide personal protective equipment for the personnel. The personal protective equipment shall be in conformance with OSHA and local regulations. The Contractor shall ensure that protective equipment is utilized as necessary to reduce personnel exposure to abrasive blasting dust (which may contain silica), and chemicals contained in the coatings.

7.7.6.2. The Contractor shall obtain, read, understand and comply with the Material Safety Data Sheets requirements for all products used as part of this resurfacing process. The Contractor shall consult local Occupational Safety and Health officials or an Industrial Hygienist for evaluation and guidance if doubt exists regarding exposure of personnel to substances present or produced by this process.

7.7.7. AM2 Matting Resurfacing

7.7.7.1. Matingt Inspection

7.7.7.1.1 The Contractor shall inspect the matting for resurfacing suitability. The Contractor shall refer to SOW Section 9, Paragraph 4 of this document for specific inspection requirements and repair procedures.

7.7.7.1.1.1. Water Filled Matting

7.7.7.1.1.1.1. The Contractor shall drain matting filled with water as thoroughly as possible prior to entering the resurfacing process. Refer to SOW Section 9, Paragraph 4.3.7 of this document. for acceptable water draining methods. Any matting indicating leaking water during processing may be rejected if the conditions in SOW Section 9, Paragraphs 7.7.7.6.10. and 7.7.7.7.1.9.5 are not met.

7.7.7.1.1.2. Pre-Cleaning

7.7.7.1.1.2.1. The Contractor shall remove any accumulations of tar, asphalt, and similar contaminates prior to surface preparation.

7.7.7.1.1.2.2. The Contractor is responsible for and shall choose the method of removal of these accumulations. The Contractor shall ensure the pre-cleaning process does not damage the matting. The Contractor shall include this process in the Production Plan (CDRL A007).

7.7.7.2. Surface Preparation

7.7.7.2.1. The Contractor shall prepare AM2 matting by abrasive grit blasting or may propose a suitable alternative method which must first be submitted to and approved by NAVAIR.

7.7.7.2.1.1. Abrasive Blasting Machine

7.7.7.2.1.1.1. The Contractor shall perform the abrasive blasting process using a centrifugal wheel-driven abrasive blast machine. The Contractor shall ensure that the abrasive blasting machine is comprised of the following components: a cabinet to contain the blast and dust; centrifugal wheels to propel the abrasives; a separator to remove blasting residues from grit; a dust collector to collect and remove dust; a work conveyor to move the matting through the blast machine; a reclamation system to return the grit to the separator; and an air knife, blower or vacuum to remove excess dust from the matting surface. The Contractor shall ensure that all components are integral within the blast machine.

7.7.7.2.1.1.2. Abrasive blasting dust may contain silica which is known to be hazardous to the health of personnel from repeated exposure. The Contractor shall ensure that all dust collection equipment is functioning properly, has sufficient capacity to prevent dust from escaping the blast enclosure, and that all personnel involved with the abrasive blast machine wear the appropriate respiratory protection.

7.7.7.2.1.2. Blasting Media

7.7.7.2.1.2.1. The following blast media are permissible: Steel Grit Mesh G-16 to G-40 in accordance with SAE J1993, size 16 to 40 per SAE J444; Aluminum Oxide Grit, mesh 16 to 50 Grade A, Coarse (Grit no. 36, Sieve no. 25) per A-A-59316 Type I Grade A. The Contractor shall ensure that any other blast media chosen for this process is approved by the Government prior to its use.

7.7.7.2.1.2.2. Blasting Media Cleanliness

7.7.7.2.1.2.2.1. The Contractor shall test the abrasive for oil contamination prior to the start of abrasive blasting and during production. The Contractor shall test the abrasive for contamination during production a minimum of three times per blasting shift and record the results.

7.7.7.2.1.2.2.2. This test shall consist of removing one (1) 8-ounce volume cup of grit from the machine and placing it into a clean glass container filled with one gallon of clean water. The appearance of an iridescent film on the water’s surface indicates grit contamination that requires remediation.

7.7.7.2.1.2.2.3. The Contractor shall discard contaminated grit. The Contractor shall ensure that the abrasive blasting process will not start or continue until the source of contamination is identified and corrected.

7.7.7.2.1.3. Heavy Accumulations

7.7.7.2.1.3.1. The Contractor shall remove heavy accumulations of previous coatings, such as runway marking lines or overlapped nonskid, not removed by passing through the abrasive blasting machine. The Contractor shall develop a process to clean these materials from the matting. The Contractor shall ensure the process does not damage the matting.

7.7.7.3. Surface Cleanliness

7.7.7.3.1. Following all surface preparation, the top and bottom surfaces shall be "near white" defined as: A near white blast cleaned surface, when viewed without magnification, shall be free of all visible oil, grease, dirt, corrosion products, foreign matter, and shall only show slight residues from previously applied coatings. Slight residues from previous coatings are those that are visible in discrete specs, and cannot be removed with reasonable pressure with a sharp probe or knife. The required surface profile shall be present. Refer to SSPC-SP-10. A near white surface shall be maintained on the top and bottom surfaces, and the end connectors of the matting.

7.7.7.3.1.1. The Contractor shall remove previous coatings from the contours of the male and female edge connectors, and end connectors. It is permissible for coating residue in these areas only to be denser than “discrete specks”, however, the coating which remains shall not be easily removable with a sharp knife or probe. Coating accumulations that have adhered properly in the connectors are permissible provided the interlocking capability of the connector is not impaired.

7.7.7.4. Surface Profile

7.7.7.4.1. The Contractor shall ensure that a 3 to 6 mil surface profile is produced on the top and bottom matting surfaces from abrasive blasting. The Contractor shall check the surface profile for compliance a minimum of three times per blasting shift and record the results.

7.7.7.5. Dust Residue

7.7.7.5.1. The Contractor shall clean the matting of blasting dust on exiting the abrasive blasting machine. The Contractor shall ensure that when a white lint-free cloth rubbed over the matting exiting the machine shows no more than a slight grey discoloration from dust residue and a "track" be visible on the matting where it was wiped with the cloth. The Contractor shall check the surface dust residue for compliance with a white lint-free cloth a minimum of three times per blasting shift and record the results.

7.7.7.5.2. The Contractor shall ensure that any matting with excessive dust residue shall be blown clean with dry, oil-free compressed air, vacuumed, or brushed to remove this dust. If compressed air is used, the contractor shall check the compressed air for oil contamination a minimum of three times per blasting shift and record the results.

7.7.7.6. Primer Coating Application

7.7.7.6.1. The Contractor shall ensure that the entire matting is primed within one hour following abrasive blasting.

7.7.7.6.2. The Contractor shall ensure that primer is from Approved Coating Systems listed in Table 1.

7.7.7.6.3. The Contractor shall refer to and comply with the ASTM F 718 format data sheets for temperature and humidity requirements and limitations for primer application and curing. The Contractor shall monitor and record both matting surface temperatures and ambient temperatures. The Contractor shall measure and record relative humidity in the proximity of the primer application booth and curing area. The Contractor shall ensure that systems are in place that allow the temperature and the relative humidity to be directly controlled in order to maintain climatic conditions in accordance with the ASTM F 718 format data sheet. The Contractor shall ensure that the temperature and humidity readings shall be taken and recorded at a minimum of one time per hour during the primer application process. Primer pot life shall be adjusted as required to compensate for any temperature and humidity fluctuations during the workday.

7.7.7.6.3.1. The Contractor shall apply all coatings indoors in a temperature controlled environment in accordance with the requirements of the requisite ASTM F 718 format data sheets.

7.7.7.6.4. Thickness

7.7.7.6.4.1. The Contractor shall comply with the range for primer film thickness as specified in the manufacturer's ASTM F 718 format data sheet.

7.7.7.6.4.2. The Contractor shall maintain the primer film thickness range as specified in the manufacturers’ ASTM F 718 format data sheet across the entire top and bottom surfaces of the matting.

7.7.7.6.4.2.1. The Contractor shall assess primer film thickness on all male/female and end connector surfaces that can be touched by a "comb-type" wet film thickness gauge. One (1) film thickness check shall be performed for every batch of 18 mats and the total number of “comb-type” wet film readings/checks performed per hour shall be recorded.

7.7.7.6.4.2.1.1. The Contractor shall reject heavy accumulations of coating application in the contours of the male and female edge connectors. Heavy accumulations of coating prevent interlocking of the matting.

7.7.7.6.4.2.1.2. The Contractor shall limit the locking bar slot in the end connectors to mist coating. Build-up of any thickness of coating in this slot may prevent the insertion of the locking bar and hamper matting assembly. The slot may be masked from coating accumulations.

7.7.7.6.5 Coverage

7.7.7.6.5.1. The Contractor shall apply primer by spraying in a single application and ensuring that it is cross-coated to ensure complete and even coverage. Cross-coating for the matting is defined as coating in the long (longitudinal) direction first, completely coating the matting and then coating in the side-to side (transverse) direction second.

7.7.7.6.6. Matting Placement

7.7.7.6.6.1. The matting may be hung vertically for primer application provided the coating does not sag or run upon application.

7.7.7.6.7. Matting Hangers

7.7.7.6.7.1. The Contractor shall touch up areas covered by conveyor fixtures with primer prior to packaging the matting. The one-hour time limitation between abrasive blasting and primer application does not apply for touch up of these areas. The Contractor shall ensure that the conveyor fixtures do not overlap either top or bottom matting surfaces.

7.7.7.6.7.2. The Contractor shall refer to and comply with the ASTM F 718 format data sheet for minimum and maximum recoating times. The minimum recoat time may be defined by test, or a time/temperature relationship. The Contractor shall ensure that the maximum recoat time is limited to 72 hours (if the maximum expressed on the ASTM F 718 format data sheets exceeds 72 hours.) The Contractor shall re-blast and re-prime the matting if the primer dry time has exceeded either the manufacturer’s maximum recoat time, or 72 hours, whichever is less.

7.7.7.6.8. Cure and Force Cure

7.7.7.6.8.1. The Contractor shall ensure that primed matting shall ambient cure (air cure) for the time period, temperature and humidity conditions as specified on the requisite ASTM F 718 format data sheet and as specified in 7.7.7.6.7.2. The minimum dry time for ambient cure primed matting shall be strictly enforced and shall be such that there are no large fluctuations in the cure area of the temperature and humidity during the ascribed dry times. Temperature and humidity recordings shall be recorded hourly in the primed matting cure area. Temperature and humidity gradients are not permitted in the primed matting cure area; different elevations within this area shall not be at differing temperatures and relative humidities.

7.7.7.6.8.2. The Contractor shall ensure that force curing requirements are included in the coating manufacturers’ ASTM F 718 format data sheets. The Contractor shall ensure that any force cured primer is accomplished in accordance with the requirements specified by the coating manufacturer.

7.7.7.6.9. Contamination

7.7.7.6.9.1. The Contractor shall ensure that any primed matting surface that has become contaminated with oil, oily fingerprints, or other similar or any contaminants, is cleaned with solvent prior to any subsequent coating.

7.7.7.6.9.2. The Contractor shall ensure that the matting contamination cleaning…