NRL_composite_panel_rebuild_sow_6_23_15_rg_input.docx

Draft Statement of Work

COMPOSITE PANEL CORROSION RECONDITIONING EFFORT

Sources Sought N00173-15-LO01

1.0 Introduction

Material Chemistry Branch 6120/Polymers Physics Code 6126 The Chemistry Division staff consists of full-time employees, full-time military employees, and intermittent employees. A number of other personnel work on site in the Division, including Research Associates of the National Research Council and the American Society for Engineering Education, academic scientists and faculty on sabbatical leave or in a part-time status, summer students, exchange students, cooperative programs, Junior Fellows, gifted and talented high school students, research apprentices, and contract scientists. This broad spectrum of scientific talent completes the total complement of approximately 200 personnel who work daily in the Division. Their diverse technical backgrounds include not only chemistry and chemical engineering, but also physics, mathematics, computer science, environmental science, materials science, biochemistry, microbiology, and electrical engineering. The numerous awards reflect the scientific quality and productivity of this rich mixture of talent and recognition accorded members of the Chemistry Division.

1.1 Mission

The basic research program of the Polymer Physics Section involves study of the molecular basis for the mechanical, electrical, optical, and thermodynamic properties of materials and the development of novel polymeric systems. Current areas of focus include relaxation properties and rheology of polymers and their blends, liquid crystalline materials, and molecular liquids.

1.2 Background

The DoD currently has external structures that have been exposed to environmental elements causing rapid corrosion of exterior wall components. A study was performed by NRL to identify a new coating that would enable protection for the exterior modular walls exposed to corrosive environments. The external walls are a composite system which incorporate two separate steel plates with an insulating polymer (vulcanized rubber) in between. Due to internally generated vibrations within the structure, the vibrations will propagate to the composite walls causing motion within the two steel plates. The relative motion of the two external plates causes traditional paints and coatings to fail through cracking where minimal elongation of the coating is allowed. The crack locations enable exposure of the steel to the elements causing corrosion. An investigation was performed to identify coatings that will enable protection from corrosion and provide high elongations. Within the study polymers including marine paints, epoxy paints and polyureas were studied.

From a previous government study only one coating was able to meet all aspects of corrosion resistance. This coating was a polyurea designated as K5 with ultrabond (UB) additive.

In addition to the protection requirements, the DoD will rebuild existing damaged panels where corrosion is observed to only occur on the mild steel side. In addition to applying a final coating of the K5 polyurea with UB a rebuild effort to replace the mild steel back side of the composite structure. The rebuild effort requires the separation of both the vulcanized rubber and mild steel from the harder steel panel. The separation process must completely remove all rubber from the hardened steel without elevating the temperature of the hardened panel above 300 deg Fahrenheit. Once separated the surface of the hardened panel must be sandblasted on all exposed surfaces. Once the harder steel panel is prepared, the reconstruction process will incorporate the placement of an expanding polyurea foam and the application of pressure to maintain a specific standoff distance between the two metal panels as the foam during curing will create an outward force.

Through government investigations X2 polyurea foam was identified to be capable of providing both the material strength and adhesion between the two panels. The X2 foam in addition to the material properties will expand enabling all voids between the two steel plates to be filled.

Once the X2 foam is allowed to cure under external pressure for thirty minutes the remaining foam is removed through the application of a sharp knife to remove remaining foam material from the sides, reassembling all previously installed hardware and encapsulation the entire panel system with the K5 polyurea.

1.3 Scope

The purpose of this contract is to provide a facility, personnel and equipment to perform research for the DoD/Material Chemisrtry Branch/ Polymers Code 6126 in the areas described below:

The a qty of 10 structural sets (A structural set incorporates 28 edge varying side panels and 42 flat side panels [each panel consists of dimensions of 20” x 48” <varying side panels> and 18” x 24” ,side panels>]) to be reconditioned. The process of reconditioning the structural panels includes:

1) Separating the existing mild steel structural panel and vulcanized rubber from the hardened steel panel

· The separation process must not exceed 300 deg Fahrenheit

2) Removal of any remaining polymers from the cryogenic separating process

· All rubber must be removed from the hardened steel and all exposed surfaces of the hard steel plate must be sand blasted

3) Fabricating the new steel backing plates and sandblasting

· All mild steel plates used to rebuild the composite panel will be provided by the government

4) Applying the polyurea X2 foam as the interface polymer to bond the two metal layers

· The X2 polyurea foam must be applied based on all manufacturers specification including storage requirements, temperature, humidity, surface preparation and specified approved application equipment

· All applications will be inspected for all required application conditions and overall application quality

· If application is not found to meet required quality the X2 will be removed and the process will be repeated (any damage to the mild steel material will be replaced at the contractors cost)

5) Provide pressing to hold the two steel plates, with X2 polyurea sandwiched in between, together for a period of thirty minutes

· A pressing system must be developed to enable uniform pressure across both the multi angled and flat plates capable of pressures of 2 tons spread across an area of 24” x 18”

· The pressing system must be capable of providing pressure consistently for a period of 30 minutes.

6) Trim excess X2 polyurea foam after pressing process along edges

· All excess foam protruding from the edges and any foam on either exposed panel face must be removed

7) Bolt any external hardware prior to final encapsulation

· All original hardware must be sandblasted or equivalent to remove any painted surface and/or rust before fastening back onto composite panel

8) Encapsulate entire panel

· The K5 polyurea must be applied based on all manufacturers specification including storage requirements, temperature, humidity, surface preparation and specified approved application equipment

· All applications will be inspected for all required application conditions and overall application quality

· If application was not performed properly the K5 material will have to be removed and re-sprayed

Based on the 8 required steps, the Offeror shall complete all steps necessary to deliver 10 sets of reconditioned composite panels. The offeror must provide all required polymer materials, specifically SPI K5 polyurea and X2 polyurea foam. In addition, the awarded Offeror shall provide Qty 1 high pressure/temperature spray unit (PMC Classic PHX-25) and Qty 1 low pressure spray unit (SPI LPG with accessory kit) (purchased new) which will remain in the government’s possession after completion of the 10 sets.

In addition all equipment and chemicals to separate and remove the residual polymers on the steel must be provided by Offeror (mechanical devices, chemicals, heaters, cleaning supplies). The Offeror shall provide all Material Safety Sheets (MSDs) for all chemicals.

1.4 Facility Location

The physical location of where the rebuilding process is to be performed must be within a 30 mile radius of Quantico VA.

2.0 Tasks

The process of reconditioning the composite structural panels includes:

2.1 Separating the existing mild steel structural panel and vulcanized rubber from the hardened steel panel

· The separation process must not exceed 300 deg Fahrenheit

2.2 Removal of any remaining polymers from the cryogenic separating process

· All rubber must be removed from the hardened steel and all exposed surfaces of the hard steel plate must be sand blasted

2.3 Applying the polyurea X2 foam as the interface polymer to bond the two metal layers

· The X2 polyurea foam must be applied based on all manufacturers specification including storage requirements, temperature, humidity, surface preparation and specified approved application equipment

· All applications will be inspected for all required application conditions and overall application quality

· If application is not found to meet required quality the X2 will be removed and the process will be repeated (any damage to the mild steel material will be replaced at the contractors cost)

2.4 Provide pressing to hold the two steel plates, with X2 polyurea sandwiched in between, together for a period of thirty minutes

· A pressing system must be developed to enable uniform pressure across both the multi angled and flat plates capable of pressures of 2 tons spread across an area of 24” x 18”

· The pressing system must be capable of providing pressure consistently for a period of 30 minutes.

2.5 Trim excess X2 polyurea foam after pressing process along edges

· All excess foam protruding from the edges and any foam on either exposed panel face must be removed

2.6 Bolt any external hardware prior to final encapsulation

· All original hardware must be sandblasted or equivalent to remove any painted surface and/or rust before fastening back onto composite panel

2.7 Encapsulate entire panel

· The K5 polyurea must be applied based on all manufacturers specification including storage requirements, temperature, humidity, surface preparation and specified approved application equipment

· All applications will be inspected for all required application conditions and overall application quality

· If application was not performed properly the K5 material will have to be removed and re-sprayed

2.6 Personnel Administration

The Offeror shall assign a single point of contact, also known as the Program Manager (PM), who must work closely with the government Contracting Officer and Contracting Officers Representative (COR), as applicable.

The Offeror PM must ultimately be responsible for ensuring that the Offeror’s performance meets all government contracting requirements within cost and schedule. PM must have the requisite authority for full control over all company resources necessary for contract performance. As appropriate, the role of PM may be a full time management position, or a collateral duty assigned to a technical team member.

The Offeror shall maintain the adequacy of their employees by providing initial and refresher training to meet the SOW requirements.

The Offeror shall make necessary travel arrangements for employees.

2.6.1 Contract Administration

The Offeror shall establish processes and assign appropriate resources to effectively administer this contract.

The Offeror shall respond in writing to Government requests for contractual actions within five work days.

2.6.2 ProgramManagement Plan (PMP)

The Offeror must submit a Program Management Plan (PMP) defining the Offeror's approach to implementing the contract. The PMP provides the Government insight to the systems, processes, and structure within which the Offeror operates. The PMP should include, as applicable and if not defined in a separate plan: quality control, risk management, systems engineering, software development, configuration management, and subcontract management.

A draft PMP must be delivered with the Offeror’s proposal. Three copies of the complete version must be submitted to the KO and COR 30 days after contract award, and within 5 working days when changes are made thereafter.

2.6.3 Intellectual Property

The Offeror shall create source data where source data is not available or the existing data is determined by the Government to be inadequate for use. The Offeror shall present data requirements for Government approval as part of the Integrated Product and Process Development (IPPD). All source data shall be created or modified using commercially available non-proprietary tools. All Government rights shall be unlimited unless otherwise stated.

2.6.4 Contractor Acquired Equipment, Materials, Subcontracts and Supplies Equipment and unexpended materials and supplies purchased by the Offeror under this contract become the property of the Government at the end of the performance period, including all options.

The Offeror shall provide supplies for Offeror personnel.

The Offeror shall provide any other equipment, material, and supplies, not furnished by the Government, but required to perform the work defined under Section 3, Performance Requirements, below.

The Offeror shall be responsible for any subcontract management necessary for performing efforts described in Section 3, Performance Requirements, below.

Vendor Item Control Drawings The Offeror shall prepare vendor item control drawings for commercial item(s) approved for use in the design and not covered by Government or nationally recognized industry association specifications and standards. The parts must comply with the requirements of the applicable part documentation. Existing test data (such as supplier originated objective evidence of compliance or Government/Industry Data Exchange Program (GIDEP) reports shall be used to the maximum extent practicable.

Shipping The Offeror shall be responsible for the management and movement of all Government and SSC-LANT -Acquired Property required for this effort. The Offeror shall plan, coordinate, and provide for all transposition either shipped or received.

Lifecycle Support The Offeror shall deliver to the Government any and all manufacturing processes, jigs, tooling, software, molds, models, or other equipment used in the developmental, integration and manufacturing for future production.

2.7 Location and Hours of Work

Accomplishment of the results contained in this SOW requires work at various Naval Research Laboratory facilities in the National Capital Region. Normal workdays are Monday through Friday except US Federal Holidays. NRL workers typically work eight (8) hours per day, 40 hours per week. Flextime workers start not earlier than 0600 and not later than 1000. Core hours of work are from 1000-1100 and 1300-1400 daily. All employees are expected to be available during core hours Additional information on work hours is provided in Section 1. (c), NRL HOURS OF OPERATION AND HOLIDAY SCHEDULE, in the NRL ROSC.

2.8 Travel / Temporary Duty (TDY)

Travel to other government facilities or Offeror facilities may be required for conduct of experimental research or attendance at government reviews or scientific meetings and seminars.

The Offeror shall maintain the capability to arrange the travel of Offeror personnel to locations in CONUS often on short notice.

The Offeror shall submit all travel requirements (including plans, agenda, itinerary and dates) for pre-approval to the Government and is on a strictly cost reimbursable basis.

The Offeror shall bill costs for travel in accordance with FAR 31.205-46 Travel Costs (subject to local policy & procedures).

3.0 Performance Requirements

The following section specifies the Performance Objectives/Performance Elements for the contract.

The Offeror shall perform the listed seven tasks and provide all required equipment, facilities, resources and materials, specifically SPI K5 polyurea and X2 polyurea foam. In addition, the Offeror shall provide Qty 1 high pressure/temperature spray unit (PMC Classic PHX-25) and Qty 1 low pressure spray unit (SPI LPG with accessory kit) (purchased new) which will remain in the government’s possession after completion of the tasks. The Offeror To complete all ten sets of the structural panels.

In addition all equipment and chemicals to separate and remove the residual polymers on the steel must be provided by Offeror (mechanical devices, chemicals, heaters, cleaning supplies..).

The process of reconditioning the composite panels includes:

1) Separating the existing mild steel structural panel and vulcanized rubber from the hardened steel panel

· The separation process must not exceed 300 deg Fahrenheit

2) Removal of any remaining polymers from the cryogenic separating process

· All rubber must be removed from the hardened steel and all exposed surfaces of the hard steel plate must be sand blasted

3) Fabricating the new steel backing plates and sandblasting

· All mild steel plates used to rebuild the composite panel will be provided by the government

4) Applying the polyurea X2 foam as the interface polymer to bond the two metal layers

· The X2 polyurea foam must be applied based on all manufacturers specification including storage requirements, temperature, humidity, surface preparation and specified approved application equipment

· All applications will be inspected for all required application conditions and overall application quality

· If application is not found to meet required quality the X2 will be removed and the process will be repeated (any damage to the mild steel material will be replaced at the contractors cost)

5) Provide pressing to hold the two steel plates, with X2 polyurea sandwiched in between, together for a period of thirty minutes

· A pressing system must be developed to enable uniform pressure across both the multi angled and flat plates capable of pressures of 2 tons spread across an area of 24” x 18”

· The pressing system must be capable of providing pressure consistently for a period of 30 minutes.

6) Trim excess X2 polyurea foam after pressing process along edges

· All excess foam protruding from the edges and any foam on either exposed panel face must be removed

7) Bolt any external hardware prior to final encapsulation

· All original hardware must be sandblasted or equivalent to remove any painted surface and/or rust before fastening back onto composite panel

8) Encapsulate entire panel

· The K5 polyurea must be applied based on all manufacturers specification including storage requirements, temperature, humidity, surface preparation and specified approved application equipment

· All applications will be inspected for all required application conditions and overall application quality

· If application was not performed properly the K5 material will have to be removed and re-sprayed 4 Special Requirements This section describes the special requirements for this effort. The following sub-sections provide details of various considerations on this effort.

4.1 Security

This work is “Unclassified”. All documents developed must be documented as “Distribution Statement D”.

4.1.1 DD Forms 254

Not required

4.2 Transition

The Offeror shall follow the transition planning submitted as part of the Offeror's Program Management Plan and keep the Government fully informed of status throughout the transition period.

This plan should describe the Offeror's transition in to service at the beginning of the contract, and how work would be transitioned to a different Offeror or contract vehicle at the end of the contract. It should include a staffing and training plan for new personnel. The Offeror should plan for the transfer of work control and information, addressing any security issues, the transfer and accountability of GFE, inspections and acceptance, and delineating the method for processing and assigning tasks during the phase-in/phase-out periods. The plan should address how the Offeror will implement adequate measures to coordinate communications with the incumbent Offeror and NRL staff in order to ensure uninterrupted workflow and minimal mission impact during the transition process.

5 Deliverables The Offeror shall provide deliverables with the schedule and format as described in section 5.0 of this contract.

DELIVERABLE SUMMARY CHART