PD - APPENDIX B - BALL TRANSFER CONVEYOR.pdf

APPENDIX B

FOR

BALL TRANSFER CONVEYOR

AT

JOINT BASE CHARLESTON, SOUTH CAROLINA

BUILDING 2194 & 2196

CSN: BCH105

DATE: 18 NOVEMBER 2022

PREPARED BY:

Megan Blackwell

MEGAN BLACKWELL

PROJECT ENGINEER

AFLCMC/EZPAE

Emmanuel Parel

EMMANUEL PAREL

REVIEWER

AFLCMC/EZPAE

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JB Charleston – Appendix B - Page i

Table of Contents

1. SCOPE

1.1. GENERAL SCOPE

2. APPLICABLE DOCUMENTS

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. BALL TRANSFER CONVEYOR

3.2.1.1. BALL TRANSFER UNITS

3.2.1.1.1. BALL TRANSFER UNIT CAPACITY

3.2.1.1.2. BALL TRANSFER UNIT LOAD BEARING COMPONENTS

3.2.1.1.3. BALL TRANSFER UNIT DEBRIS HOLES

3.2.1.1.4. BALL TRANSFER UNIT MARKING

3.2.1.1.5. BALL TRANSFER UNIT INSTALLATION

3.2.1.1.6. BALL TRANSFER UNIT CERTIFICATION

3.2.1.2. BALL TRANSFER DECK

3.2.1.3. TRANSFER FRAME AND TREADPLATE

3.2.1.4. STEEL SKIRTS AND GUARD RAILS

3.2.1.5. STOPPING CAPABILITIES

3.2.1.6. CONVEYOR LEVELNESS

3.2.2. MANUAL OPERATION

3.2.3. SPARE PARTS

4. QUALITY CONFORMANCE

4.1. INSPECTIONS

4.2. TEST

4.3. CERTIFICATIONS

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JB Charleston – Appendix B – Page 1

1. SCOPE

1.1. GENERAL SCOPE

This appendix establishes the minimum performance, design, fabrication, installation, orientation, and test requirements for a ball transfer conveyor systems for the 437th Aerial Port Squadron (APS) in Building 2194 and 2196 at Joint Base (JB) Charleston, South Carolina. All work shall be completed in accordance with this appendix, the Cover Purchase Description (PD), and Air Force (AF) Drawing BCH105-01. This appendix covers all equipment, materials, and labor necessary to complete installation of the system.

2. APPLICABLE DOCUMENTS

Applicable documents shall be in accordance with Section 2 of the Cover PD.

3. REQUIREMENTS

3.1. SYSTEM DESCRIPTION

Ball transfer conveyor systems shall be provided as shown on AF Drawing BCH105-01. The ball transfer conveyor shall provide smooth and easy manual transfer, rotation, and orientation of pallets in any direction. Pallets are manually pushed across the ball transfer conveyor. The ball transfer conveyor system shall interface with the gravity roller conveyor (Appendix A).

There shall be no areas where the frames/ball transfers cause the pallets to bind or not move freely between the conveyor systems. The conveyor system shall store and convey loads without damage or permanent deformation to the conveyor system or the pallets.

3.2. PHYSICAL AND PERFORMANCE CHARACTERISTICS

3.2.1. BALL TRANSFER CONVEYOR

The ball transfer conveyor system shall consist of ball transfers, ball transfer frames/treadplates, and frame skirts/guard rails. The ball transfer conveyor system shall be configured and located as shown on AF Drawing BCH105-01.

3.2.1.1. BALL TRANSFER UNITS

The ball transfer units shall be Alwayse model number 805-30- Type16 or 806-30-Type16, Kietek model number KO1A0, B&T model

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JB Charleston – Appendix B – Page 2 number BT/CS6030M, RBC Bearings model number 8749VN356XBF73, or equal meeting the requirements specified herein. The type of ball transfer unit used shall be approved by the COTR prior to ordering. The ball transfer unit manufacturer shall have been manufacturing ball transfer units for a minimum of 5 continuous years. Ball transfer units shall be the drop-in type that is supported and restrained in place by a hole in the conveyor treadplate.

3.2.1.1.1. BALL TRANSFER UNIT CAPACITY

Each ball transfer unit shall have a minimum load capacity of 500 pounds.

3.2.1.1.2. BALL TRANSFER UNIT LOAD BEARING COMPONENTS

Ball transfer units shall consist of a machined metal housing containing a minimum 1.18-inch diameter main load ball. All rolling elements shall be SAE 420 or SAE 440 stainless steel and shall be Grade 200 or better. The race shall have a hardness of Rockwell 55C or harder and the race shall be softer than the balls. The main ball and smaller balls shall be manufactured of the same material and shall have the same hardness. The smaller balls shall be manufactured in the United States unless approval is obtained from the COTR to use balls manufactured in another country. All load bearing components shall be hardened steel.

Components of the ball transfer units shall not corrode, rust, or deteriorate due to condensation.

3.2.1.1.3. BALL TRANSFER UNIT DEBRIS HOLES

Each ball transfer unit shall have debris holes on the bottom with a minimum area of 0.023-square inches.

3.2.1.1.4. BALL TRANSFER UNIT MARKING

Each ball transfer unit shall be marked with the manufacturer’s name and model number in a location that is visible from above when installed in the ball transfer treadplate.

3.2.1.1.5. BALL TRANSFER UNIT INSTALLATION

Ball transfer units shall be installed on maximum 7-1/4 inch centers. Ball transfers and the spacing shall not damage pallets stored or transferred on the conveying surface. The conveying surface shall extend a minimum of 0.50 inch above the ball transfer treadplate. The conveying surface shall be level with the conveying surface of the adjacent gravity roller

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JB Charleston – Appendix B – Page 3 conveyor sections. Each individual ball transfer unit shall be removable without removing the ball transfer treadplate. The ball transfer units shall be retained in place to prevent horizontal shifting or movement during pallet transfer.

3.2.1.1.6. BALL TRANSFER UNIT CERTIFICATION

The contractor shall certify the load capacity of the ball transfer units, that the housing is machined, and the material and hardness of the main ball and the smaller balls. If the ball transfer unit is not listed in 3.2.1.1., the Contractor shall certify the country of origin of the smaller balls.

3.2.1.2. BALL TRANSFER DECK

The ball transfer conveyor shall be capable of transferring and storing a variety of loaded ISUs and 463L pallets weighing up to 10,000 pounds (fully loaded) without deformation. The ball transfer deck consists of ball transfer units mounted in a frame with a treadplate for personnel to walk on, and pallet guard rails.

3.2.1.3. TRANSFER FRAME AND TREADPLATE

The ball transfer frames and treadplates shall be a combined single unit constructed of structural steel and shall support all loads without permanent deformation. The transfer frames and treadplates shall be minimum 0.12-inch thick steel. All treadplates shall form a single, integral walking area that provides a safe walking surface for personnel who manually transfer pallets on the ball transfer conveyor. Treadplates shall provide a non-skid surface with high traction even when wet. Holes for the ball transfers shall not create a gap larger than 0.03 inch between the ball transfer and the treadplate.

Transfer frames and treadplates shall be designed, installed, and sized to be easily removable by one person. Transfer frames and treadplates shall not be welded in place. If drains or cleanouts that require access are present, a small cover plate shall be provided so entire transfer frames and treadplates do not have to be removed for access. Pallets being transferred on the ball transfer conveyor shall not contact the treadplates.

Treadplates shall not deflect more than 0.12 inch when supporting a 250-pound person.

3.2.1.4. STEEL SKIRTS AND GUARD RAILS

A steel skirt shall extend from the treadplate surface to within 1/8 inch of the floor on all exposed sides of the ball transfer

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JB Charleston – Appendix B – Page 4 conveyor. The skirt and guard rail may be combined and installed as a single unit. Guard rails shall extend a minimum of 2 inches above the conveying surface. Each rail section shall be standard 10-foot sections where possible. Rail sections shall be anchored to the warehouse floor on maximum 5-foot centers. Additionally, the rails shall be anchored within 6 inches of the end of each section. Each rail section shall be mounted to the floor in a minimum of two places. Rail sections shall be mounted flush end to end to prevent snag points. All guard rails shall be painted safety yellow.

3.2.1.5. STOPPING CAPABILITIES

All guard rails located adjacent to ball transfer conveyor shall be designed to withstand repeated impacts of pallet loads up to 10,000 pounds moving at 40 feet per minute.

3.2.1.6. CONVEYOR LEVELNESS

The conveying surface shall be level along its entire length and width. All conveyors shall be level to within 1/8 inch over 10 feet and 1/2 inch over the entire conveyor along both the length and width of the conveyor. The conveyor shall provide a smooth surface for transporting palletized loads. The contractor shall verify the existing floor slope and condition prior to conveyor installation. The Contractor is responsible for all costs of providing a level conveying surface for areas where the floor is within 3 inches of level over the entire conveyor area.

Levelness shall be maintained regardless of the weight or positioning of the load on the conveyor. Levelness shall be maintained before, during, and after all manual transfer operations so the load does not become too difficult to push and to prevent pallets from moving away from operators.

3.2.2. MANUAL OPERATION

All ball transfers shall be free spinning without binding during all operations. The force required to start and maintain pallet transfer shall not exceed 25 pounds per 1,000 pounds of load.

The force requirements shall apply for all pallet loads weighing between 2,000 pounds and 10,000 pounds. The force to move a pallet weighting less than 2,000 pounds shall not exceed 50 pounds. The force requirements apply for pallet transfer in any possible direction. The force requirement shall be met by manual transfer without using tools for leverage. The force shall be applied 48 inches above the conveying surface at the edge of the pallet.

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JB Charleston – Appendix B – Page 5

3.2.3. SPARE PARTS

The spare parts listed below shall be provided with the system.

Manufacturer, model number, and contact information for a distributor shall be included with the spare parts so ordering information is available for future use. All spare parts shall be new items with a full manufacturer’s warranty. The Contractor shall replace any parts used during the warranty period at no cost to the Government.

A. Ball Transfer Units: Provide 3 percent of the number of ball transfer units in the conveyor system, rounded up to the next integer, to a maximum of 75 ball transfer units.

4. QUALITY CONFORMANCE

4.1. INSPECTIONS

The system shall be inspected to verify that it meets all the requirements of sections 1, 2, and 3 of this appendix and the Cover PD. These inspections shall be completed as part of the system checkout test and again as a part of the quality conformance test.

4.2. TEST

The following tests shall be performed on the system as part of the system checkout test and again as a part of the quality conformance test.

No. Paragraph Description

1. 3.1. Interface test. Move a 10,000 pound 463L pallet across each gravity roller conveyor and ball transfer conveyor interface in both directions.

If pallets snag or bind along a conveyor or at interfaces between conveyors, if any conveyor has damage or permanent deformation, or if any pallet contacts the building or any building component the conveyor fails the test.

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JB Charleston – Appendix B – Page 6

2. 3.2.1.1. Test to ensure all conveyor frames, bearings, ball transfers, and guard rails are capable of withstanding repeated impacts from on/off-loading and transfer of fully loaded pallets without suffering any permanent deformation.

Move a fully loaded pallet over every ball transfer. Repeat five times. If any deformation is present or if the pallet would not transfer the conveyor fails this test.

3. 3.2.1.2.

Load capacity test. Position two fully loaded 463L pallets (gross weight of 10,000 pounds each) on the ball transfer conveyor and leave for two hours. Push the loads off the conveyor. Inspect the conveyor for any deformation and individually spin each ball transfer to determine if it is still free rolling. Inspect the bottom of the 463L pallets before and after the test. If any deformation is present, if any ball transfers are not free rolling, or if the bottom of the pallet is damaged, the conveyor fails this test.

4. 3.2.1.4. Guard rail impact test. Using a 463L pallet weighing 10,000 pounds, impact the guard rail while the load is moving at 30 feet per minute.

Repeat on each span of guard rail. Inspect all guard rails and supporting structures for damage and deformation. If the pallet load, supporting structure, or any conveyor component including the guard rail suffers damage, permanent deformation, or decreased performance as a result of this test, the conveyor fails the test.

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JB Charleston – Appendix B – Page 7

5. 3.2.1.6.

Levelness test. Test to ensure that the conveyor is level along its entire length and width providing a smooth surface for transporting loads. Using a level, verify levelness at a minimum of 10 different locations along the conveyor. Using a level verify levelness at a minimum of 10 different locations at conveyor frame interfaces. If the conveyor is not level to within 0.06-inch over 10 feet at all locations measured, the conveyor fails this test.

6. 3.2.2. Manual operation test. Measure the force required to start and maintain pallet transfer of a 463L pallet weighing 10,000 pounds in 5 areas on the ball transfer conveyor. Repeat with a 2,000 pound pallet. Stop the pallet on the conveyor, rotate the pallet 90 degrees, stop movement, and continue pallet transfer in the original direction during each test. If the force required to start and maintain motion for the 10,000 pound pallet exceeds 250 pounds or if the force required to start and maintain motion for the 2,000 pound pallet exceeds 50 pounds, the conveyor fails the test.

4.3. CERTIFICATIONS

The Contractor shall provide certification that the following requirements have been met. All certifications shall be provided in accordance with the Contract Data Requirements List.

No. Paragraph Certifications

1. 3.2.1.1.1. Certify each ball transfer unit has a minimum load capacity of 500 pounds.

2. 3.2.1.1.2. Certify each ball transfer unit housing is machined steel.

3. 3.2.1.1.2. Certify rolling elements on the ball transfer units are SAE 420 or SAE 440 stainless steel and are Grade 200 or better.

4. 3.2.1.1.2. Certify the country of origin of the smaller balls (only if the ball transfer unit is not listed in 3.2.1.1.).

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TECHNICAL PURCHASE QUESTIONNAIRE

FOR

JB Charleston – Ball Transfer Conveyor TPQ – Page 1 of 3

BALL TRANSFER CONVEYOR

Solicitation Number: FA8604- -R- Project Title: Conveyor System Base: JB Charleston, SC CSN: BCH105 Appendix B – Ball Transfer Conveyor, 18 November 2022

The Offeror shall complete this questionnaire. All entries to this questionnaire shall be typed. The questionnaire will be used to determine the Offeror's understanding of the requirements and acceptability of the proposed equipment.

Please attach any exceptions to the Purchase Description as detailed below.

No. Paragaph Characteristics

1. AF Drawing

BCH105-01

How many square feet of ball transfer conveyor will be provided? ____________________________

2. 3.2.1.1. Who is the manufacturer and what is the model of the ball transfer units being provided?

3. 3.2.1.1.1. What is the minimum load capacity for each ball transfer unit? __________________________

4. 3.2.1.1.2. What is the diameter of the main ball?

5. 3.2.1.1.2. Are ball transfer unit rolling elements SAE 420 or SAE 440 stainless steel and Grade 200 or better?

YES NO

6. 3.2.1.1.3. What is the total size of the debris holes on the bottom of the ball transfer unit?

7. 3.2.1.1.5. What is the center-to-center spacing of the ball transfer units? _________________________

8. 3.2.1.1.5. How far above the tread plate is the conveying surface? _____________________________________

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JB Charleston – Ball Transfer Conveyor TPQ – Page 2 of 3

9. 3.2.1.1.5. Is each individual ball transfer removable without removing the tread plate and retained in place to prevent movement during pallet transfer?

10. 3.2.1.3. Will ball transfer frames and treadplates shall be a combined single unit constructed of structural steel?

11. 3.2.1.4. Will a steel skirt/guard rail be provided on all exposed sides of the ball transfer conveyor system?

12. 3.2.1.4. Will each guard rail section be anchored in a minimum of two places?

13. 3.2.1.5. Will guard rails be capable of withstanding repeated impacts of 10,000 pounds moving at 40 feet per minute?

14. 3.2.1.6. Will the conveyor be level within 1/8 inch over 10 feet and 1/2 inch over the entire conveyor?

15. 3.2.2. How many pounds of force per 1,000 pounds of load for all pallets over 2,000 pounds will be required to start and maintain pallet transfer? ____________________________________

16. 3.2.3. Will spare parts be provided as specified?

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JB Charleston – Ball Transfer Conveyor TPQ – Page 3 of 3

EXCEPTIONS

Attach any exceptions taken to the Purchase Description Appendix. Please outline those concerns in detail. Your exceptions will be reviewed to determine acceptability.

Are exceptions taken? YES NO Number of pages attached: ____________________________________

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