PWS 07 RFAAP Maintenance_12_2025_Draft.docx

RADFORD ARMY AMMUNITION PLANT

PERFORMANCE WORK STATEMENT (PWS)

PWS 7: Maintenance of Active Facilities November 2025

1. GENERAL INFORMATION

1.1. INTRODUCTION

1.1.1. This PWS outlines the contractor's requirements for the maintenance of Government Furnished Property (GFP) (Real Property and Personal Property/General Equipment), as defined in PWS 4, including but not limited to land, buildings, structures, rail, infrastructure, vehicles, and equipment as prescribed by FAR 52.245-1. This PWS also outlines documentation of maintenance efforts performed and associated metrics to track efficiency and effectiveness. Government oversight will be focused on the Contractor’s achievements, performance, and overall execution of this PWS.

1.2. BACKGROUND

1.2.1. The contractor shall be responsible for maintenance of the entire facility, both the Main Plant (Montgomery/Pulaski County) and the New River Unit (Dublin), covering approximately 6,900 acres in total. Maintenance of GFP shall be conducted and documented such that property requirements prescribed by PWS 4 and the FAR are met.

1.3. SCOPE

1.3.1. The scope of this PWS includes normal and routine maintenance of the following elements and all associated personnel and processes:

1.3.1.1. Land: all grounds contained within and including the perimeter fencing of the Main Plant and New River Unit sites (approximately 6,900 acres total). This includes personnel walkways, roadways, vegetation, and land. The perimeter fencing shall be maintained in accordance with PWS 6 requirements.

1.3.1.2. Buildings: all facilities in an ‘Active’ status per the Government’s General Fund Enterprise Business System (GFEBS), maintained and updated by the contractor per PWS 4. Facilities in any status other than ‘Active’ are unauthorized for use of any kind.

1.3.1.3. Rail: railroad trackage, ties, ballasts, and all components of the railroad system, including bridges, crossings, and signals used for transportation by railcar, railcar storage, or any track that is intersected by roadway or footpath. All active track shall be maintained under this PWS and IAW UFC 4-860-03.

1.3.1.4. Bridges: any structure built to span a physical obstacle without blocking the way underneath, constructed for the purpose of providing passage over the obstacle.

1.3.1.5. Infrastructure: any physical structures not previously mentioned that support the functionality of the facility to include, but not limited to, water lines, steam lines, compressed air lines, electrical systems, fiber, and sewage systems.

1.3.1.6. Vehicles: all General Service Administration (GSA) vehicles and other non-tactical vehicles (NTVs) that support personnel and product transportation, including but not limited to, railcars, locomotives, powder vans, trucks, heavy equipment, ambulance, and fire engines.

1.3.1.7. Equipment: any apparatus that directly or indirectly supports production, including but not limited to mixers, presses, compressors, motors, turbines, and HVAC systems.

1.3.1.8. Note that all fire equipment systems inspections, test, and maintenance shall be performed IAW NFPA Standards and Codes and PWS 3 requirements.

1.3.2. Maintenance requirements under this PWS are inclusive of Tenant usage of GFP. The contractor shall ensure that all tenants comply with these requirements per the Tenant Use Agreement (TUA) between the contractor and Tenant.

1.3.3. The contractor shall ensure that all individuals or companies contracted to perform work and support adherence to the requirements (i.e. subcontractors) comply with these requirements per the contract between the contractor and subcontractor.

1.3.4. Abnormal Maintenance (defined in section 1.4.2.3) and Maintenance of Inactive Facilities (MIF) both fall outside the scope of this PWS. Maintenance requirements of inactive facilities are outlined in a separate Task Order (TO 0008).

1.3.4.1. Any building pending deactivation (i.e. request for deactivation is awaiting approval) must be maintained as an active building until the process and documentation for layaway to Caretaker status is fully complete.

1.4. DEFINITIONS

1.4.1. Radford Army Ammunition Plant (RFAAP) Maintenance Plan (MP): The governing document written by the contractor to describe how the Facilities Maintenance Team shall meet the requirements outlined in this PWS.

1.4.2. Corrective Maintenance: Any action required to preserve, repair, or replace active facilities and active equipment in such condition that it may be safely and effectively utilized for its designated purpose.

1.4.2.1. Normal Maintenance: Inclusive of but not limited to periodic, day-to-day requested care of production and all elements outlined in section 1.3.1.

1.4.2.2. Major Maintenance: Rare or infrequent, yet substantial repairs, replacement, rehabilitation, and/or upgrades to GFP that are deemed too critical or urgent for the PBS process. Major Maintenance is typically project-oriented and shall not be used in emergency situations (e.g. safety/environmentally critical failures or an urgent repair supporting production). Major Maintenance shall not be used for maintenance described by regulations and/or PWS requirements herein. More details regarding the Major Maintenance process can be found in section 2.1.10.

1.4.2.3. Abnormal Maintenance: Substantial purchases, repairs, and/or upgrades exceeding $250,000 that may be attributed to severe weather events (acts of God, tornadoes, earthquakes, floods, etc.) and/or an isolated/peculiar event. The Government may fully fund the cost per each event for all active GFP impacted, subject to the availability of funds, Government determination that Abnormal Maintenance is appropriate, and determination of need by the Government. If it is determined that the contractor failed to maintain or operate the property IAW this PWS, the approved Maintenance Plan, or operating procedures, the contractor shall be responsible for the full repair or replacement.

1.4.3. Deferred Maintenance: Any maintenance tasks that are not performed within the defined timeframes for completion (see section 2.1.2.4.3).

1.4.4. Preventative Maintenance (PM): Methodical and proactive approach to reduce or prevent unplanned maintenance downtime and ensure safe and environmentally compliant operation through regularly scheduled maintenance (e.g. lubrication, inspection, rotation, etc.). PM schedule may be time-based or usage-based.

1.4.4.1. Delinquent PM: PM that is scheduled for completion within a certain timeframe and not completed within that timeframe.

1.4.5. Predictive Maintenance (PdM): Tools and techniques (e.g. vibrational analysis, ultrasonic testing, laser alignment, etc.) used to determine the condition of equipment to forecast when maintenance should be performed prior to failure.

1.4.6. Computerized Maintenance Management System (CMMS): Software that centralizes all maintenance information and facilitates maintenance processes. It helps optimize the utilization and availability of physical equipment and other elements of section 1.3.1 through prioritizing and scheduling maintenance activities.

1.4.7. Work Order (WO): Any request for corrective work, preventative maintenance, or predictive maintenance generated and tracked within the CMMS.

1.4.8. Planned Maintenance Downtime: Scheduled time for preventative maintenance or corrective work (excluding equipment failure) that is coordinated with appropriate personnel.

1.4.9. Unplanned Maintenance Downtime: Any downtime caused by equipment failure until equipment is repaired and available for production.

1.4.10. Subcontractor: Individuals or companies contracted to perform work.

1.4.11. Mechanical Integrity (MI): The process of managing equipment to ensure it is designed, installed, operated, and maintained properly.

1.4.12. Key Performance Indicator (KPI): Measurable and quantifiable metrics used to evaluate and assess the contractor’s performance and effectiveness of maintenance strategies.

1.4.12.1. Backlog – On the last day of any month, the total estimated time to complete the number of open work orders for each maintenance category (CM, PM, PdM), with respect to safety and/or production impact.

1.4.12.2. Water Break Data – The number of water breaks reported and completed in a given month and the end-of-the-month backlog.

1.4.12.3. Steam Leak Data – The number of steam leaks reported and completed in a given month and the end-of-the-month backlog.

1.4.12.4. Mean Time to Repair (MTTR) – The average time to perform a work order (from time reported to time completed) categorized by both maintenance category (CM, PM, PdM) and with respect to safety and/or production impact.

1.4.12.5. Mean Response Time – The average time to respond to a maintenance request (from time reported to time work began) categorized with respect to safety and/or production impact.

1.4.12.6. Planned Maintenance Percentage (PMP) – For all non-emergency maintenance, the percentage of work orders scheduled in the CMMS.

1.4.12.7. Schedule Compliance – Percentage of scheduled WOs completed IAW the schedule. This KPI is tied to PMP. Work that is not completed IAW the schedule will be considered deferred maintenance at the Government’s discretion.

1.4.12.8. Estimated vs. Actual Man-Hours – For all completed WOs, provide the ratio of estimated hours to actual hours. Estimated and actual hours must be available on a per WO basis in the CMMS.

1.4.12.9. Worker Utilization Percentage – Delineate the breakdown of man-hours between CM, PM, PdM, and idle time.

1.5. KEY PERFORMANCE INDICATORS (KPIs)

1.5.1. The contractor’s performance will be monitored and measured through recurring submissions of a monthly KPI Report for RFAAP. While the Government reserves the right to assess contractor compliance with specific requirements of this PWS, the primary measure of the contractor’s success in performing the PWS will be determined by KPI goal attainment.

1.5.2. The monthly KPI Report shall demonstrate efficiencies of maintenance work performed at RFAAP by tracking the following KPIs and be submitted to the PCO by the 5th business day of each month. (CDRL A07-001):

1.5.2.1. Backlog

1.5.2.2. Water Break Data

1.5.2.3. Steam Leak Data

1.5.2.4. Mean Time to Repair (MTTR)

1.5.2.5. Mean Response Time

1.5.2.6. Planned Maintenance Percentage (PMP)

1.5.2.7. Schedule Compliance

1.5.2.8. Estimated vs. Actual Man-Hours

1.5.2.9. Worker Utilization Percentage

1.5.3. In addition to the KPIs specified in section 1.5.1.1, the contractor shall identify a minimum of three (3) KPIs that measure performance, timeliness, and/or effectiveness of maintenance efforts at RFAAP. The initial submission of the KPIs shall be submitted with the KPI Report to the PCO 60 calendar days after operational control and monthly thereafter.

1.5.3.1. The contractor shall define the calculation method for each KPI and any sub-KPIs in the first submission of the PWS 7 KPI report ACA for Government approval.

1.5.3.2. The PWS 7 KPI Report shall provide targets for improvement for each KPI, with justification as to why the target was determined. Targets may be based on industry standards or baseline data acquired in the first quarter of performance tracking. Targets may be adjusted on an annual basis or sooner if necessary, with Government approval.

1.5.3.3. When KPIs are trending negative or consistently below target (for at least three consecutive months), the contractor shall provide a plan or strategy adjustment to work back towards the target. The plan and/or strategy shall include details on actions to be performed, timeline for improvement and personnel responsible to achieve the target.

1.6. APPLICABLE DOCUMENTS OR CITATIONS

1.6.1. The contractor shall utilize the below Army Regulations (AR) and Unified Facilities Criteria (UFC) for guidance and shall be held accountable to these requirements:

1.6.1.1. AR 420-1 Chapter 5: Buildings and Structures

1.6.1.2. AR 420-1 Chapter 7, Section III: Pavements

1.6.1.3. AR 420-1 Chapter 7, Section IV: Railroads

1.6.1.4. AR 420-1 Chapter 7, Section V: Bridges

1.6.1.5. AR 420-5 Chapter 9: Fire Protection

1.6.1.6. AR 420-5 Chapter 10: Equipment and Apparatus

1.6.1.7. UFC 4-860-03 Railroad Track Maintenance Standards

1.6.1.8. UFC 3-430-07 Operations and Maintenance: Inspection and Certification of Boilers and Unfired Pressure Vessels

2. WORK REQUIREMENTS

2.1. TECHNICAL REQUIREMENTS

2.

2.1.

2.1.1. The contractor shall support production and utilities by extending the life cycle of facility assets through control of planned and unplanned downtime and maintenance of installation equipment and facilities. Maintenance activities shall be in accordance with (IAW) the approved Facilities Maintenance Plan.

2.1.2. Unless otherwise prescribed herein, maintenance shall be performed in accordance with chemical industry best practices for a complex industrial environment where equipment reliability and asset integrity play a crucial role in ensuring safety and efficiency. Given the nature of operations, maintaining asset integrity long-term requires robust operational maintenance strategies. The contractor shall ensure that all subcontractors and tenants comply with these requirements.

2.1.2.1. The contractor shall annually develop and administer a Maintenance Plan for RFAAP. Initial submission of the RFAAP Maintenance Plan (MP) shall be provided no later than 90 calendar days prior to operational control and by 30 January of each year thereafter. Each MP will be reviewed and approved by the Government. (CDRL A07-002)

2.1.2.2. The MP shall describe in detail the strategy and work processes (from problem identification through execution) for maintenance of 100% of active Government furnished property at RFAAP (land, buildings, structures, rail, infrastructure, vehicles, and equipment).

2.1.2.3. The MP shall describe in detail the strategy for regular and recurring maintenance of the grounds at RFAAP (both the Main Plant and the New River Unit), including but not limited to controlling vegetation to achieve a safe, neat and professional appearance, management of pests, and removal of snow, when applicable.

2.1.2.3.1. The contractor shall work with the Army Staff Natural Resources Manager to determine annual project areas (combined 30 acres minimum per year) that have been overcome by invasive species. This includes cutting down existing plants, properly disposing of the debris, and applying an approved herbicide to all stumps to prevent resprouting. Follow-up treatment of any new sprouts may be required to achieve effective control.

2.1.2.4. The contractor shall maintain all firebreak trails on RFAAP and NRU property. The primary purpose of the trails is to create a physical barrier that slows or stops the spread of wildfires by reducing available fuel and providing access for firefighting personnel and equipment. Maintenance activities shall include clearing vegetation, removing debris and invasive species, repairing erosion, and ensuring the trails remain accessible for a variety of emergency response vehicles.

2.1.2.5. The MP shall mitigate the risk of failure of equipment at RFAAP that supports production manufacturing through the inclusion of PdM and PM processes and the implementation of a Mechanical Integrity (MI) Program IAW PWS 9 and applicable OSHA standards. Unexpected service requests and other maintenance-related needs shall be addressed through the corrective maintenance process.

2.1.2.6. The MP shall describe in detail the strategy and procedure for all maintenance activities (including preventative, predictive, and corrective maintenance) to ensure outages are scheduled to minimize impact on production manufacturing.

2.1.2.7. The contractor shall maintain a CMMS that installs and utilizes all applicable modules and data fields (both searchable and exportable) for tracking maintenance trends and KPIs. The MP shall describe in detail how 100% of maintenance activities will be captured in the CMMS, to include subcontracted work.

2.1.2.7.1. The CMMS shall be capable of resource planning and allocation for RFAAP, which includes, but is not limited to, executing the strategy and work processes as defined in the MP and coordinating and integrating maintenance efforts between facilities, production, engineering, safety, environmental, and procurement.

2.1.2.7.2. The contractor shall analyze available resources (i.e. workforce) and adjust allocation strategy based on the current and forecasted demand for those resources. The contractor shall develop and report at least one KPI to address this requirement and report data monthly (see section 2.1.5).

2.1.2.7.3. The CMMS shall include complete electronic documentation for 100% of work performed – Corrective Maintenance (CM), PM and PdM – to allow for complete and transparent auditability. This includes work performed by subcontractors. All non-emergency work shall be scheduled in the CMMS, and work included in the CMMS shall be completed as specified in timeframes defined within the MP. Work that is not completed within these specified timeframes will be considered deferred maintenance at the Government’s discretion.

2.1.2.7.4. CM, PM, and PdM documentation shall, at minimum, document work performed (what was accomplished), labor required (personnel and time-on-job), materials used, and all associated costs.

2.1.2.7.5. The contractor shall provide the Government access to 100% of the information included in the CMMS with a unique username and password for the system.

2.1.2.7.6. If a new defect is discovered while performing CM, PM or PdM then the work performed to correct that deficiency shall be documented in the CMMS (create new work order or document within existing work order).

2.1.2.7.7. The MP shall describe in detail how the contractor will develop and maintain a comprehensive Spare and Repair Parts Management System for RFAAP that minimizes downtime and includes 100% of spare and repair parts for Government furnished property at RFAAP.

2.1.2.7.8. The Spare and Repair Parts Management System shall include a list of assets, prioritized based on criticality, life expectancy, and/or redundancy. The Spare and Repair Parts Program shall include stock of spare parts for all assets or a contingency plan that mitigates downtime if the assets were to fail.

2.1.2.7.9. The Asset List shall be provided upon request within five (5) business days.

2.1.2.7.10. The Spare and Repair Parts Management System shall demonstrate effectiveness by identifying trends and areas of improvement through tracking of relevant KPIs.

2.1.3. The contractor shall conduct quarterly Life Cycle Cost Analysis (LCCA). The data shall be processed as independent quarters of the year (i.e. not the aggregate YTD data). The contractor shall submit the data to the PCO no later than fifteen calendar days after the end of the quarter. (CDRL A07-003)

2.1.3.1. The LCCA shall, at a minimum, include life cycle costs of the top 10 assets with the largest associated repair costs.

2.1.3.2. Life cycle costs include cost for replacement parts, direct labor, subcontractor, and estimated lost cost from production downtime per asset. Analysis of direct repair costs shall be separate from estimated lost cost from production downtime (i.e. two separate lists of the top 10 costliest assets).

2.1.3.3. The LCCA shall include assessments for each specific quarter and total costs for the lifespan of the asset starting at contract award. For example, if the contract starts on 1 JAN 2028, the total costs for an asset would include all replacement parts, labor, subcontractor costs and lost cost from production downtime from 1 JAN 2028 to the time of CDRL submission (rolling summation).

2.1.3.4. The contractor shall identify at least one asset from the LCCA, to analyze the root cause(s) of costliness and develop a short and long-term solution for reducing cost.

2.1.4. The contractor shall submit monthly PM Completion Reports showing scheduled PMs for the month compared to actual results to the PCO on the first business day of each month. (CDRL A07-004). The Report shall include the following:

2.1.4.1. PMs completed (specifying scheduled and unscheduled).

2.1.4.2. Delinquent PMs (in a given month and the overall backlog).

2.1.4.2.1. Delinquent PMs with a frequency greater than one month shall be included in the overall backlog until PMs are completed or superseded.

2.1.4.3. PMs that were generated or revised with reason for generation/revision.

2.1.4.4. Any cancelled or inactivated PMs with adequate justification for cancellation.

2.1.4.5. Scheduled PMs for the upcoming month.

2.1.5. The contractor shall diagnose and analyze equipment failures at RFAAP, with the goal of understanding the factors that contributed to and/or resulted in failure and implementing identified actions to prevent future failures.

2.1.5.1. As long as criteria are met, at least one follow-up analysis per category shall be conducted and submitted monthly by the 10th business day (CDRL A07-005):

2.1.5.1.1. Repeat failures that occur within a one-month timeframe or an asset with low mean time between failure

2.1.5.1.2. Failure that impacted production for greater than 24 hours

2.1.5.1.3. Near miss or safety event that involved maintenance personnel or processes

2.1.5.2. Each submission shall include the following:

2.1.5.2.1. Detailed description and explanation of failure

2.1.5.2.2. Root cause of failure

2.1.5.2.3. Analysis of solutions to address the failure, both in the short-term and long-term

2.1.5.2.4. Execution plan and associated action log

2.1.5.2.5. Estimated cost of each solution

2.1.5.2.6. CM, PM, and/or PdM data, as applicable (develop performance-based metrics, planning/scheduling upgrades, etc.)

2.1.6. The contractor shall provide additional analysis or diagnosis when notified of unsatisfactory performance by the Contracting Officer (PCO and/or ACO), Contracting Officers Representative (COR), or other Regulatory Agency (EPA, OSHA, VDEQ, etc.).

2.1.7. The contractor shall expedite completion of work that is directed by the RFAAP Commander to correct a security, environmental, or safety concern.

2.1.8. The contractor shall hold recurring meetings (monthly, at minimum) with local Army Staff technical personnel to discuss any CDRLs, KPIs, Work Orders, or any other maintenance inquiries or concerns.

2.1.9. Major Maintenance

2.1.9.1. The contractor shall execute a minimum of $5,000,000 (excluding profit and G&A of the Contractor) per year at RFAAP for Major Maintenance, for contracts years 1-5. For contract year 6 and onward, the contractor shall execute a minimum of $6,000,000 (excluding profit and G&A of the Contractor) per year at RFAAP for Major Maintenance.

2.1.9.1.1. The contractor shall submit Major Maintenance Projects to the Government for review and approval prior to execution of the project. (CDRL A07-006)

2.1.9.1.2. Major Maintenance shall generally exceed $150,000 per repair/replacement/inspection/action. The contractor shall not aggregate maintenance requirements in an effort to reach the $150,000 threshold. In all cases, Major Maintenance funding shall be used solely for the purpose of Major Maintenance. These funds shall not be used to fulfill any other facility contract requirements (e.g., facility infrastructure maintenance) that are already required in any above section of this PWS. In the event of a disagreement with regards to the legitimacy of a Major Maintenance project, the PCO shall make the final determination.

2.1.9.1.3. The contractor shall maintain a list of all Major Maintenance projects identified (1-N), both approved and pending approval, to provide the Government visibility into the total estimated project workload and value over the contract POP. The first execution period for Major Maintenance shall begin when the contractor takes operational control of RFAAP. Cost estimates for each project shall be provided and based on engineering estimates, project comparisons, and vendor quotes if available. The contractor shall provide justification on the need for each project and the rationale of their proposed prioritization to the PCO. Comments, approval, and/or disapproval shall be provided to the contractor by the PCO.

2.1.9.2. Prior to the execution of each project, the contractor shall review all proposed costs to ensure that they are allowable, allocable, fair, and reasonable. If there are any questions, the contractor shall consult with the PCO. If at any time before or during the execution of any project, it is determined that the cost is substantially different from the original estimate, the PCO shall be notified.

2.1.9.3. The Major Maintenance Committee, consisting of both contractor and Government personnel, shall meet on an agreed upon frequency (e.g. biweekly) to review the 1-N List and expenditures of all projects in execution. The contractor shall capture actual cost data for all Major Maintenance projects and provide the data to the PCO by 31 December each year. (CDRL A07-007)

2.1.9.4. The Government may direct fund additional Major Maintenance projects on a case-by-case basis, but this shall not be assumed. Additional direct funded Major Maintenance projects shall be executed via the standard Major Maintenance process described herein.

2.1.9.5. The contractor shall apply annual unused funding/credits to the following year. Major Maintenance credits carried forward may be used for Major Maintenance projects in subsequent years in the contract period. Should the contractor incur costs over and above the annual allotment, it shall be deducted from the following calendar year. At the end of the contract, the contractor shall return any unused Major Maintenance funding to the Government via a means provided by the PCO.

2.1.9.6. All Major Maintenance Projects satisfying this requirement become Government Property at time of purchase and/or upon execution, IAW PWS 4.

2.1.9.7. Major Maintenance shall be scheduled to minimize impact on production. Major Maintenance can be scheduled with other maintenance activities or building shutdowns, but the contractor shall consider the urgency and all impacts of waiting to perform Major Maintenance.

2.2. DELIVERABLES

CDRL A07-001 Key Performance Indicator Report (monthly, 5th business day)

CDRL A07-002 RFAAP Maintenance Plan (annually)

CDRL A07-003 Life Cycle Cost Analysis (quarterly, 15th calendar day after quarter ends)

CDRL A07-004 Preventative Maintenance Completion Report (monthly, 1st business day)

CDRL A07-005 Follow-Up Analysis to Failure (monthly, 10th business day)

CDRL A07-006 Major Maintenance Project Submission (as required)

CDRL A07-007 Major Maintenance Funding Report (annually, based on the CY, submission due by every 31 December)