SOW F-22 Work Stand 1-7-21.pdf

Statement of Work

For

F-22 Maintenance Work Stands

In Support of the 309th Aircraft Maintenance Group (309 AMXG)

574th Aircraft Maintenance Squadron (574 AMXS)

07 January 2021

Table of Contents

1. GENERAL INFORMATION………………………………………………..……………

2. APPLICABLE DOCUMENTS……………………………………………….……….….….. 4

3. DESIGN...………………………………………..……………………….………………….. 4

4. PROGRAM MANAGEMENT…….……………….…………………………………..……. 5

5. SYSTEMS ENGINEERING……..…………………………...…………………………..….. 5

6. WARRANTY……………………………………………………………….….....………….. 9

7. TECHNICAL DATA DELIVERABLES……………….…………………………………... 10

8. GENERAL BASE REQUIREMENTS………………………...……………………….…... 11

APPENDIX A: PERFORMANCE SPECIFICATION…………….…………………………… 12

1. GENERAL…………………………………………………………………………..….. 12

2. EXTENT OF STANDS…………………………………………………………………. 13

3. STRUCTURAL REQUIREMENTS……..……………………………………………... 15

4. ELECTRICAL………………………………………………………………………….. 19

5. COMPRESSED AIR……………………….…………………………………….…..…. 21

1. GENERAL INFORMATION

1.1. Scope

New F-22 work stands are required to support coatings application and maintenance operations on the aircraft at the 574 Aircraft Maintenance Squadron (574 AMXS). The contractor shall be responsible for providing new work stands that improve upon and replace the existing arrangements utilized at the F-22 depot shown in Figures 1, 2, and 3.

This statement of work provides the minimum requirements for the design, construction, assembly, functional verification, functional demonstration, and operator training for new maintenance work stands for the F-22 at Hill Air Force Base (Hill AFB). The contractor shall provide three different configurations of work stand to the F-22 depot:

• Configuration I shall be for work stands in Building 674

• Configuration II for work stands in Building 680

• Configuration III shall be a Platform Stand for accessing the outboard sides of the aircraft vertical stabilizers.

The contractor shall also provide full documentation, including drawings and full bills of materials, for all work stand configurations (CDRL A003). Upon delivery and acceptance of the new work stands, the contractor shall dispose of the old work stands at no cost to the government.

1.2. Background

When the 574 AMXS and the F-22 depot were first established at Hill AFB, work stands were delivered to facilitate maintenance to the aircraft. Over the years hence, the work stands have had multiple modifications made to them and are no longer in the same configurations. In addition, several of the work stands have fallen into a state of disrepair, and can no longer be maintained due to a lack of available documentation. Furthermore, new safety stipulations established by the Occupational Safety and Health Administration (OSHA) and process changes at the F-22 depot, mandate that new work stands be designed and fabricated for the F-22 Maintenance Depot.

The current work stand arrangement used at the 574 AMXS can be seen in Figure 1 with the aft Tail Stand Section removed. A representation of the current Tail Stand used by the F-22 depot can be found in Figure 2. The current Tail Stand used by the 574 AMXS interfaces to the aft end of the aircraft in between the vertical stabilizers. Figure 3 represents a separate Platform Stand used by the F-22 depot to work on and access the outboard sides of the vertical stabilizers.

Figure 1: Existing F-22 Work Stand Arrangement (Tail Stand Removed)

Figure 2: Current F-22 Tail Stand Arrangement

2. APPLICABLE DOCUMENTS

2.1. Issues of Documents

The following documents shall be used based on the latest revision available on the date of the request for proposal, unless otherwise specified, and form a part of this Statement of Work (SOW) to the extent specified herein. When documents revisions conflict, this SOW shall govern.

2.2. Documents

Table 1: Safety Standards and Specifications OSHA 29 CFR 1910 Occupational Safety and Health Standards1

NFPA 70 National Electric Code (NEC)

3. DESIGN

The contractor shall design F-22 maintenance work stands meeting all requirements of the Performance Specification (Appendix A) maximizing the use of commercial items as defined in Federal Acquisitions Regulations Section 2.101. The goal is to supply the commercial or modified commercial equipment and/or components, with a production history and proven track record to the Government.

1 See Standards for Work Platforms and Fall Protection Subpart D: Walking Working Surfaces

Figure 3: Platform Stand

4. PROGRAM MANAGEMENT

Upon request by the government, the contractor shall provide cost, schedule, and technical risk updates throughout the life of the contract. These requests may include but are not limited to:

• Contract Status, Progress Tracking, and Reporting of Milestones

• Risk Management

• Technical Reviews

• Product Drawings/Models and Associated Lists Status

• Configuration Management

• Review of Critical Application Items (CAI) and Critical Safety Items (CSI)

• Subcontract management activity status (if applicable)

• Quality and Corrective Action Plan Status

• Action items

In addition the contractor shall hold a status meeting once every two weeks via teleconference with the 309 AMXG/EN and 574 AMXS to update the government on their progress. These bi-weekly meetings will be held until initial delivery of the work stands. After initial delivery, the contractor shall hold meetings with the government on a monthly basis to provide manufacturing and delivery updates. The contractor is exempt from holding status meetings if they overlap with the scheduled dates and times of the requirements reviews mandated by this statement of work.

The contractor shall be responsible for scheduling and organizing all status meetings. The status meetings will cease once the government and contractor agree that all stipulations of this statement of work have been met.

5. SYSTEMS ENGINEERING

A standard systems engineering process shall be used during the performance of this contract.

The contractor shall support the following:

5.1. System Requirements Review (SRR)

The SRR is to ensure the contractor and Government teams understand and agree that the contract requirements, including the Performance Specification, SOW, etc. have been completely represented in the contractor’s proposal and can be executed within cost, schedule and technical constraints. The understanding of technical requirements and verification methods shall be characterized in a technical risk assessment by the contractor to comply with the Performance Specification. The contractor shall establish a date and time for the SRR to be held via teleconference or in person within 21 calendar days of contract award.

5.1.1. SRR Entrance Criteria

• Initial Risk Management Plan that addresses the following:

o Delivery Risk o Safety Risks to Personnel o Aircraft Damage Risk

5.1.2. SRR Exit Criteria

• Completion of action items that come as a result of the SRR

• A document containing agreed upon system design requirements and the proposed work stand layout around the aircraft (CDRL A001)

5.2. Critical Design Review (CDR)

The CDR is a technical assessment that ensures the system under review has a reasonable expectation of being judged operationally effective and suitable. The CDR shall be conducted within 60 calendar days of the SRR. The CDR will be conducted at a location agreed upon by the Government and the Contractor. Design changes after the CDR must be authorized in writing by the 309th AMXG/EN (F-22) Government Subject Matter Expert (SME). Upon Government approval of the CDR the contractor shall produce and deliver the fixtures IAW paragraph 5.4. The contractor shall include in the CDR (CDRL A001):

• Draft product drawings, models, and associated lists. Drawings and lists shall be provided in an adobe pdf format and models shall be provided in a Solidworks 2019 or earlier format. All electronic files shall be provided to the government on a CD-R/DVD-R. In addition, the contractor shall deliver all drawings and parts lists in a printed, bound, or stapled book.

• Analysis/write-up justifying how the design meets or exceeds the Performance Specification requirements. This shall be in the form of one (1) CD-R/DVD-R digital copy containing the analysis/write-up file(s) in Microsoft Office or PDF format.

• Present cost, schedule, and performance risks as well as risk mitigation plans.

This shall be in the form of one (1) CD-R/DVD-R digital copy containing the risk presentation file(s) in Microsoft Office or PDF format.

5.2.1. CDR Entrance Criteria

• Completion of SRR

• Draft Product Drawings/Models and Associated Lists (CDRL A001)

• Updated Risk Management Plan (CDRL A001)

5.2.2. CDR Exit Criteria

• Updated Product Drawings/Models and Associated Lists (CDRL A001)

• Completion of any Action Items that result from the CDR

• Government approval of successful CDR milestone

5.3. Physical Configuration Audit (PCA)

A PCA is a technical audit consisting of a direct comparison of the characteristics of a production unit with the characteristics specified on the applicable Product Configuration Identification (drawings, associated lists, specifications, etc.). The objective of the PCA is to verify that the final drawing package matches the Configuration Item (production unit) being produced.

The contractor shall support a PCA of the F-22 work stands by fabricating validation work stand sets for each configuration of work stand. The contractor shall have the validation work stand sets available for a PCA within 90 calendar days of CDR completion. In addition, the contractor shall coordinate with the government to conduct the PCA on each validation set at the contractor’s manufacturing facility. The contractor shall also prepare a document listing the key performance parameters (KPPs) of the work stands as a guide for the PCA. The document shall also be used by the contractor and the government to sign off that each KPP has been met and satisfied2. If discrepancies or non-compliance issues are discovered with the validation stands, the contractor must correct them within 30 calendar days. Furthermore, the contractor must ensure that all work stand documentation to include drawings, lists, and computer models are also updated within 30 calendar days.

Subsequently delivered full rate production work stands must also address any of the identified non-compliance issues or discrepancies encountered with the validation stands.

(CDRL A004)

5.4. Delivery and Acceptance

5.4.1. Delivery Costs

Work stand shipping and delivery to Hill AFB shall be at no cost to the government. The contractor shall be responsible for all delivery and shipping costs incurred. If the work stands are damaged during shipping, the contractor shall be responsible for all repairs at no cost to the government.

2 Some KPPs may need to be verified onsite at Hill AFB once the validation work stands are delivered to the Air Force. For example, interfaces to the aircraft can only be checked with an available F-22 at the depot. These KPPs will be checked and signed off by the government after the validation work stands are delivered to Hill AFB. If non-compliance issues are encountered with KPPs that can only be checked at Hill AFB, the contractor shall be responsible for addressing them on-site at Hill AFB at no cost to the government.

5.4.2. Delivery Schedule

Upon completion of the PCA at the contractor’s facility, the contractor shall deliver the validation work stand sets to the Hill AFB F-22 depot according to the schedule outlined in Table 2. The validation stand sets for each configuration shall be delivered first to provide the F-22 depot with an evaluation period. These validation stand sets will be evaluated by HAFB engineering, production, and safety for compliance to the statement of work. The 574 AMXS production has thirty (30)-business days to complete their evaluation and acceptance of each configuration of validation work stand set. The contractor shall send a technical representative or representatives to accompany the delivery of the validation work stand sets and to participate in the government evaluation of the validation stands. The contractor representative shall be present at Hill AFB for the first eighteen (18)-business days following initial delivery of the validation stands. If compliance issues are encountered, the contractor shall correct the issues within 30 calendar days. The full rate production stands shall reflect the configurations established by the validation stand sets.

Once, the first set of validation work stands are accepted by the government, the remaining sets of work stands shall be produced, assembled, and delivered to 574 AMXS/309 AMXG at a rate of one set per configuration every 60 calendar days. If the 574 AMXS discovers further compliance issues with a work stand set, the contractor shall correct them within 30 days.

Table 2: Work Stand Delivery Schedule Configuration I – Initial Validation Work Stand Set

90 calendar days after CDR exit criteria have been met

Configuration I – Full Rate Production Work Stands

Every 60 days after acceptance of the Validation Work Stand Set by the F-22 Depot

Configuration II – Initial Validation Work Stand Set

90 calendar days after CDR exit criteria have been met

Configuration II – Full Rate Production Work Stands

Every 60 days after acceptance of the Validation Work Stand Set by the F-22 Depot

Configuration III – Initial Validation Set 90 calendar days after CDR exit criteria have been met

Configuration III – Full Rate Production Set

60 days after acceptance of the Validation Work Stand Set by the F-22 Depot

5.4.3. Government Acceptance

The government will have an eighteen (18)-business day period to perform a quality audit of each delivered work stand set. The eighteen (18)-business day period will begin once an aircraft becomes available at the depot and the work stands can be installed around the aircraft. The contractor shall deliver the same document used during the PCA on the validation work stand sets along with the full rate production work stand sets to facilitate the audit of each delivered unit. If all KPPs are met, the government shall sign the PCA document and accept the work stands using DD Form 250.

The contractor shall be responsible for correcting any failures to meet the requirements of the Performance Specification (Appendix A). This shall include, but is not limited to, design changes along with associated work stand modifications, documentation updates, and shipping and/or travel required to correct deficiencies. The contractor shall correct these deficiencies within 30 calendar days of identification at acceptance, unless otherwise agreed upon by the Government. The contractor shall not be paid for the delivery of a work stand set until all compliance issues have been rectified and the work stand set has been accepted by the government in writing.

5.5. Quality Assurance

The contractor shall continually manage and improve the quality of all products and services delivered under this contract and the processes by which they are realized. The system used by the contractor to manage quality shall be compliant with all requirements of, and at a minimum be functionally equal to, a current active version of the ANSI/ISO/ASQ Q9001, Quality Systems - Model for Quality Assurance in Design, Development, Production, Installation and Servicing. The Government shall have the right to audit the contractor's quality system for ANSI/ISO/ASQ Q9001 compliance.

5.6. Obsolete Work Stands

The contractor shall be responsible for the disposal of obsolete work stands at the F-22 depot at no cost to the government. Obsolete work stands shall be defined as the old work stand sets currently in use at the F-22 depot and all ancillary equipment that accompanies them.

Obsolete work stands shall be disposed of piecemeal as new work stand sets arrive and are accepted at the depot. The contractor may recycle or scrap the old work stands as they see fit to offset disposal costs.

6. WARRANTY

6.1. Warranty Commencement

The warranty for all work stands shall commence upon written final acceptance of the final delivery of work stands to the F-22 depot.

6.2. Length of Warranty

The work stands shall come with a written industry standard one year warranty starting at the date of final acceptance.

6.3. Replacement of Defective Parts

During this warranty period, the contractor shall be responsible for the replacement of any defective parts or systems, the failure of which is due to faulty materials, workmanship, design or inadequate service life. The contractor shall provide replacement parts to the depot within seven (7) calendar days. Shipping costs will be at the expense of the contractor.

Consumables are expected to be excluded from this warranty requirement.

7. TECHNICAL DATA DELIVERABLES

7.1. Operation and Maintenance manual

Work Stand Operation and Maintenance manuals shall be prepared and delivered on electronic media via the latest MS Office (Power Point, Excel, or Word) or PDF format and on bound/stapled 8 ½ by 11 inch bond paper. (CDRL A002) The contractor shall provide three hardcopy O&M manuals for the provided work stands and one CD-R ROM/DVD-R digital copy. The technical data shall be delivered with the first set of work stands. No additional copies need to be delivered with the second or subsequent sets of stands. The manual shall include, but is not limited to, the following:

• A full bill of materials (BOM) with items used, part numbers, and associated vendors

• Maintenance Instructions. Maintenance instructions for items that will require sustainment to include all materials used for maintenance and step by step instructions to complete required tasks.

• Operating Instructions. Clear and easy to follow instructions for fully and safely operating the work stands.

• Recommended preventative maintenance schedule

7.2. Design Drawings/Models and Associated Lists (CDRL A003)

The contractor shall deliver the Product Drawings/Models and Associated Lists that provides the Government with unlimited data rights. This data shall include everything that is required to reproduce or modify the work stands.

The contractor shall deliver draft drawings/models and associated lists to support the CDR in accordance with paragraph 5.2, as well as the finalized drawings/models and associated lists in conjunction with the first work stand delivery. The finalized drawings/models and associated lists shall be delivered with the first set of work stands as follows:

• 2 CD-R/DVD-R digital copies of the drawings and models containing a PDF version of drawings and the SolidWorks 2019 compatible model files.

• 1 Printed copy of the drawings in a bound or stapled book.

8. GENERAL BASE REQUIREMENTS

8.1. Delivery

Trucks delivering equipment to Hill AFB must use the Roy gate for entry onto the base.

8.2. Badging

Due to the short duration of the delivery of each set of stands, permanent base access badges will not be provided to the contractor. Temporary base access will be authorized for the duration of the delivery.

The contractor shall provide a list to the 309 AMXG Engineering representative not less than 7 business days prior to the date access to the base is required. The list will be computer generated or typed and organized alphabetically by the visitor’s last name. The list will include last name, first name, driver’s license number, and state listed on license of all guests that will need access.

The contractor shall be provided a temporary visitors badge by the 309 AMXG Security Office, authorizing escorted access to the industrial area within the flight line. This badge will be provided each day the contractor enters the flight line and shall be returned to the 309 AMXG Security Office by the end of the work day.

8.3. Escorts

The contractor shall be escorted at all times within the flight line by an authorized government representative. The contractor shall coordinate schedule and escorting services with 309 AMXG Engineering office. A point of contact will be identified at the time of contract award.

8.4. Normal Hours of Operation

The contractor shall have access to the facility during the following normal hours of operations from 6am to 5pm Monday thru Friday and after hour access approval is at 309 AMXG/EN’s discretion.

8.5. Observed Holidays

Holidays observed at Hill AFB are New Year’s Day, Martin Luther King Day, Presidents Day, Memorial Day, Independence Day, Labor Day, Columbus Day, Veterans Days, Thanksgiving Day and Christmas Day. If the holiday falls on Saturday, it is observed on Friday. If the holiday falls on a Sunday, it is observed on Monday.

Appendix A

Performance Specification: Work Stand Design Requirements

1. GENERAL

1.1. Configurations

Three different configurations of work stand are desired at the 574 AMXS and Hill AFB.

Configuration I shall be for operations within Building 674, Configuration II for operations within Building 680, and Configuration III shall be a platform stand capable of accessing the outboard sides of the aircraft vertical stabilizers.

1.2. Quantities

The 574 AMXS desires a quantity of seven (7) work stands for Configuration I, ten (10) work stands for Configuration II, and two (2) for Configuration III.

1.3. Safety Standards and Specifications

The design and construction of the work stands shall meet safety requirements and stipulations set forth in the following standards and specifications:

Table 3: Safety Standards and Specifications Applicable to Each Work Stand Configuration OSHA 29 CFR 1910 All configurations

NFPA: NEC 70 All configurations

NFPA: NEC Class 1 Division 1 Configuration I and III

1.4. 309 AMXG Foreign Object Damage Control Program

All work stand components in any configuration must meet all requirements of the 309 AMXG foreign object damage (FOD) control program. Provisions must be made for all fasteners, pins, or other removable items on the work stands to be attached with tethers or other features to prevent the introduction of “FOD” into the work environment.

• All pinning features shall utilize commercially off the shelf T-Handle Locking Quick- Release Pins or equivalent with an attached lanyard.

• All pinning features shall meet a Class 9 running and sliding fit (RC 9) according to the clearances and tolerances established in ANSI B4.1.

1.5. Outdoor Storage

All stand sections must be capable of enduring long term outdoor storage in all-weather without becoming water damaged or rusting.

• The work stands shall have drain holes on all deck areas and structural members to prevent water from building up on or inside the work stands.

• All electrical components must meet a NEMA 3R rating.

• All work stands shall be protective coated to prevent rust.

1.6. Commercially Available Items

Where possible, commercially available off the shelf components and materials shall be used to construct the work stands.

2. EXTENT OF STANDS

2.1. Fall Protection

The stands shall provide fall protection meeting all parts of OSHA 29 CFR 1910 around the aircraft, for personnel on top of the aircraft, and for personnel on top of the stands.

• There shall be no point from which personnel on top of the aircraft or on top of the stands could fall to the floor.

• The work stands in all configurations shall provide fall protection in the areas indicated in Figure 4.

• The contractor may leverage the design and construction of the original F-22 work stands as much as possible.

• Computer models of the original work stands can be provided to the contractor upon request.

2.2. Symmetrical About the Aircraft Centerline

The work stand sets for Configuration I and II shall fully enclose the aircraft and be symmetrical about the aircraft centerline. The stand sets shall be identical (mirrored) for both the left and right side of the aircraft.

2.3. Removal of Flight Surfaces

Flight surfaces may be removed during maintenance operations performed on the aircraft.

The flight surfaces in question are the flaperons, ailerons, leading edges of the wings, trailing edges of the wings, horizontal stabilizers, vertical stabilizer leading edges, rudders, and the integrated fore body (IFB). The work stands shall provide fall protection in these areas when the flight surfaces are removed.

• The work stand sections surrounding the aforementioned flight surfaces shall have pull outs to provide fall protection when those flight surfaces are removed from the aircraft.

• Configuration III of the work stands shall also have pullouts that interface to the outboard sides of the vertical stabilizers.

• Design specifications for the pullouts shall be fully defined along with structural requirements for the work stands further on in this appendix.

• Gates, fencing, or other barriers shall be present to prevent fall hazards when the horizontal stabilizers are removed.

2.4. Configuration III - Platform Stand

Configuration III shall be a Platform Stand that interfaces to the outboard sides of the aircraft vertical stabilizers on both sides of the aircraft. Configuration III shall be a single work stand section that is completely separate from the other configurations of work stand requested by the 574 AMXS and 309 AMXG.

• Configuration III shall match the current Platform Stand arrangement and methodology at the depot represented in Figure 3.

• The Configuration III work stands must provide full access to the outboard sides of the aircraft vertical stabilizers on both sides of the aircraft and at any height.

• Configuration III must be able to access the outboard sides of the vertical stabilizers when the Horizontal Stabilizers are installed on the aircraft and removed from the aircraft.3

3 The current work stands used at the F-22 depot do not meet this requirement. The new Configuration III work stands must meet this requirement.

• Design modifications to the original Platform Stand arrangement are permitted to account for additional requirements within this statement of work.

3. STRUCTURAL REQUIREMENTS

3.1. Work Stand Sections

The work stands shall be designed in separate sections to facilitate maintenance on the aircraft while simultaneously providing fall protection in all areas described previously.

• The work stands shall be designed in separate sections such that no more than two (2) persons are needed to easily move, join, and separate all stand sections into place from any direction.

• All stand sections shall align to one another to ensure proper setup.

• Configuration I and II work stand sections surrounding the nose of the aircraft shall allow full access to the IFB. This shall be accomplished by having two separate work stand sections split down the centerline of the aircraft.

• Configuration I and II shall have identically arranged work stand sections that are dimensionally and structurally the same unless specified otherwise in the following requirements.

• The contractor shall deliver tail stands for Configuration I and II that match the current tail stand arrangement and methodology at the depot.

• Design modifications to the original tail stand arrangement are permitted to account for additional requirements within this statement of work.

• All stand sections shall have locking casters with brakes and a method for towing.

• All stand sections shall be designed, and the towing points located, such that when the sections are towed, they are stable and not easily tipped over.

• The work stands shall be designed such that they do not tip over when inclined at a maximum angle of 15 degrees as mandated by OSHA 29 CFR 1910.

• The stands shall be capable of being towed over the ground level "railroad tracks" used with aircraft hangar doors without becoming damaged.

• All stand sections shall have lift points suitable for fork truck lifting. These points shall be identified with "Lift Here" labels and the approximate weight of the stand section.

• The Configuration I work stands shall take into account the Inlet Coating Repair (ICR) robots in paint booths LO5, LO6, and LO7. When the robots are idle and not in use, they are stored against the walls on the North side of the paint booths. The work stands cannot interfere with or infringe upon the storage space of the robots.

• The Configuration II work stands must take into account space available on the hangar floor in Building 680. The work stands cannot interfere with work stands surrounding aircraft in an adjacent maintenance dock.

• The aircraft may be on jacks during certain maintenance operations. All configurations of work stand must take into account the aircraft nose jacks and main jacks and cannot infringe on their footprint. The 574 AMXS utilizes a 20-Ton Hydraulic Tripod Jack with model number 42L7528 for the nose and a 20-Ton

Hydraulic Tripod Jack with model number 59J6185 or 42L7528 for the main landing gear at the aft of the aircraft.

3.2. Work Stand Deck Structure

The work stand deck structure shall provide ample space for personnel to comfortably and safely work on the aircraft.

• Each configuration of work stand shall be designed to support four (4) workers, each weighing 250 lbs. and each with 50 lbs. of tools.

• The overall dimensions of the work stand deck sections shall be a minimum of sixty

(60) inches and a maximum of seventy two (72) inches wide. The same overall deck dimensions of the original F-22 work stands is desired.

• The Configuration I and II work stand decks shall be nominally level with the chines/strakes, leading edges of the aircraft wings, and horizontal stabilizers.

Adjustable leveling jacks shall be used to provide up to one (1) foot of up and down movement to facilitate adjustment of the work stand deck hieght.

• All work stand deck areas shall me made of a metal slip resistant surface.

• Work stands for Configuration II shall be constructed with a diamond plate deck surface and work stands for Configuration I shall be constructed with a metal grating surface.

• The grating surface for Configuration I must be open enough to allow for the passage of foam and water from the Building 674 fire suppression system.

• Configuration III shall also be constructed with the same grating surface as Configuration I.

• The maximum permitted deflection of the deck plating and grating over a 25 sq. ft.

area shall be no more than ½.” Extra structural support members are permitted beneath the deck grating for the Configuration I and III work stands to achieve the deflection requirement.

• The under deck support structure of the Configuration I and Configuration II stands shall be as open as possible to allow for easy access under the aircraft.

• All support columns and/or sections of the work stands shall be located such that it allows full access and openings to all aircraft internal component access panels. The number of stringers and girders should be limited.

• The under deck support structure of the Configuration I and II work stands shall have storage shelving for consumable items such as drip pans, pads, paper towels, etc.

• Hose racks shall also be incorporated into the under deck structure to provide storage for shop air hoses, breathing air hoses, vacuum hoses, and electrical extension cordage.

• Each work stand section shall have three (3) two (2) foot by five (5) foot tables attached to the support structure or safety railings that are accessible from the stand deck areas.

• The under deck support structure shall also have built in work tables meeting the same dimensions as the tables above the deck structure.

• All work stand deck edges and/or surfaces that may come in contact with the aircraft shall be padded to prevent damage to the aircraft. Rubber bumpers attached to the edges of the work stand sections are required.

• The rubber bumpers attached to the work stands shall be fully serviceable and easily replaced if damaged or worn excessively.

• The Configuration I work stands shall have hooks or hangars attached to various areas above the work stand decks and below for hanging disposable suits, booties, breathing masks, and other personal protective equipment (PPE).

3.3. Leveling Jacks

The Configuration I and II work stands shall be nominally level with the chines/strakes and leading edges of the aircraft wings and horizontal stabilizers. However, the deck structure of each individual work stand section may have to raise and lower to facilitate maintenance operations on the aircraft. Each work stand section shall have leveling jacks to facilitate raising and lowering the work stand decks.

• The leveling jacks shall allow for up and down movement of one foot (1 ft.) of travel to facilitate the install of flight surfaces in various aircraft configurations.

• The leveling jacks shall have flat pads only to ensure that the work stand sections sit firmly on the floor and cannot move once the leveling jacks are in use.

• The leveling jacks shall be operable without the use of tooling and provide clearly visible height indications.

3.4. Safety Railings, Stairways, and Gates

The work stands shall have a combination of stairways, gates, and safety railings to facilitate maintenance access to the aircraft while providing fall protection.

• The work stand safety railings shall be designed to support two (2) workers each weighing 250 lbs. and each with 50 lbs of tools.

• Work stand stairways shall be designed to support four (4) workers, each weighing

250 lbs. and each with 50 lbs. of tools.

• The maximum allowed deflection of any railing will be ½” over 5 ft.

• The maximum allowed deflection of any stairway step shall be ½” over 25 sq. ft.

• When an entire work stand section or a work stand platform are removed, a hinged gate shall cover open areas and walkways to prevent fall hazards. The gate shall have a latching mechanism to keep it in place when deployed. The same mechanism shall keep the gate stowed away, folded against the work stand support structure when not in use.

• Provisions shall be made for work stand stairways to self-adjust as the work stands are raised and lowered with the leveling jacks.

• Work stand stairways shall be parallel to the overall work stand structure, rather than perpendicular to it, to minimize the overall footprint surrounding the aircraft.

• Stairways shall be permanently affixed to the work stand sections and shall not be removable.

• The work stand safety railings shall be removable to allow for easier access to the work stand deck area. The safety railings shall also be easily pinned into place when in use. Each removable safety railing must be light enough to be easily moved by two (2) people.

• All work stands shall be provided with toe kick protection to keep tools from being accidentally kicked off of the aircraft and/or stand deck surfaces. Toe kick protection shall be present on all stairways. OSHA CFR 1910 provides dimensions for toe kick protection.

• All hand railings shall be painted gloss safety yellow. Deck surfaces shall be gray in color and all other surfaces shall be painted blue.

3.5. Sliding Pullouts

When the flaperons, ailerons, leading edges of the wings, trailing edges of the wings, and the integrated fore body (IFB) are removed from the aircraft there will be a gap between the deck structure of the work stands and the aircraft. This gap will present a fall hazard. Sliding pull outs are required on the Configuration I and II work stands to bridge the gap and provide fall protection. Additionally the angle of the vertical stabilizers will present a gap between the Configuration III work stand deck and the outboard sides of the vertical stabilizers. Pullouts shall also be required on the Configuration III work stand.

• All three configurations of work stand shall require pullouts near the aforementioned commonly removed flight surfaces and outboard sides of the vertical stabilizers.

• The pullouts shall be free sliding and easily moved in and out by one mechanic while he or she is working on top of the work stand deck structure.

• The pull outs shall utilize a robust low friction bearing surface capable of long term outdoor storage and heavy use such as PTFE or Teflon.

• Each sliding pullout shall be 12” wide and of varying length depending on the gap width to be covered.

• The pullouts shall have a locking mechanism that securely fastens each pullout section in place without the use of tools. The locking mechanism or methodology utilized shall provide clear indications to the operator when the pullout is properly or improperly locked in place.

• The pullouts shall be covered with the same diamond plate or grating used on the work stand deck structure. Configuration I work stand pull outs shall use the same grating surface as the deck structure and Configuration II work stand pull outs shall use the same diamond plate surface as the deck structure.

• Each pullout shall be able to support two (2) workers each weighing 250 lbs. and each with 50 lbs. of tooling.

• The maximum permitted deflection of the pullouts shall be no more than ½.”

• Rubber bumpers shall be attached to the ends of the pullouts to protect aircraft surfaces from damage.

4. ELECTRICAL

4.1. NFPA 70 NEC: Class 1 Division 1

The Configuration I and III work stands will be used in specialized explosion proof paint booths in the presence of flammable vapors. All electrical components on the Configuration I and III work stands must meet all NEC Class 1 Division 1 stipulations.

• The Configuration I work stands shall have provisions to be electrically bonded together and grounded for dissipation of static electricity. The stands shall be provided with grounding and bonding reels, fitted with “gator” clips and bayonets.

• Grounding cable shall be 50 ft. long and mounted onto a retractable reel. CoxReels model number SDHL-200 is required.

• One grounding reel per work stand section shall be installed on the Configuration I work stands.

• The Configuration III stands shall be grounded in the same manner as the Configuration I work stands.

• The Configuration II work stands will be used in a different work area and are not in the presence of flammable vapors. The Configuration II work stands do not need to meet Class 1 Division 1 safety stipulations.

• The Configuration II work stands do not require grounding reels.

4.2. Electrical Network

The Configuration I and II work stands shall be fabricated with a separate electrical network on each half of the aircraft to supply power to lighting and electrical outlets. The Configuration III work stand shall have a basic electrical network providing power to an outlet accessible from the stand deck structure.

• The Configuration I and III work stand electrical networks, per aforementioned requirements, must meet Class 1 Division 1 requirements. The Configuration II work stands do not need to meet Class 1 Division 1 requirements, but must meet other stipulations of NFPA 70: NEC.

• The electrical networks shall supply 120 V.A.C. 60 Hz 20 Amp power to the work stands.

• NEMA 5-20 male plugs and their equivalent female receptacles shall be used exclusively throughout the electrical networks on the work stands. Configuration I and III work stands must use NEMA 5-20 male plugs meeting Class 1 Division 1 requirements.

• All internal and external wiring within the work stand electrical networks shall use 12 gauge wiring.

• The Configuration I work stands shall interface to electrical power in Building 674 on the left and right sides of the aircraft at the work stand sections nearest the wing tips.

• The Configuration II work stands shall interface to Building 680 electrical power at the forward end of the aircraft at the work stand sections surrounding the aircraft’s nose.

• The Configuration III work stand shall interface to building power at the base of its access stairway.

• The work stands in all configurations shall interface to building power using a male plug attached to a fifty (50) length of extension cord. The Configuration I and II work stands shall have two such extension cords. One for each half of the work stand electrical network. The Configuration III work stands shall have only one extension cord.

• The extension cords for the Configuration I work stands shall be stowed away on a hook or other feature near the aircraft wing tips. The extension cords for the Configuration II work stands shall be stowed in a similar fashion at the nose of the aircraft. The Configuration III work stand extension cords shall be stowed in the same fashion near the base of the stand’s access stairway.

• To ensure electrical safety, the Configuration I work stands shall have 20 Amp breaker boxes in line with the 50 foot extension cords providing building power to the Configuration I work stand networks. The Configuration II and III work stands shall also have 20 Amp breaker boxes in line with the extension cords.

• Each Configuration I and II work stand section electrical network shall begin with a male plug attached to a tether and terminate with female receptacle attached to a tether. The Configuration I and II work stand sections shall “daisy chain” to each other using the male plugs and female receptacles attached to tethers. The tethers shall be long enough to reach each adjacent work stand section.

• The Configuration I and II work stands shall have eight duplex receptacles per aircraft side, no more than ten feet between each receptacle. Four of the duplex receptacles shall be accessible from the work stand deck structure and four of the outlets shall be accessible from below.

• The Configuration III work stand shall have one duplex receptacle accessible from the work stand deck structure.

• Per aforementioned outdoor storage requirements all electrical components must meet a NEMA 3R rating.

4.3. Electric Lighting

Each work stand section shall provide sufficient lighting beneath the aircraft to provide a well-lighted work environment.

• The Configuration I work stands shall be built using lighting and outlets rated for fueled aircraft hangars under NFPA 70: NEC Class 1 Division 1.

• The Configuration II work stands do not need to meet NFPA 70: NEC Class 1

Division 1 requirements.

• Lighting shall not be installed on the Configuration III work stands.

• The Configuration I and II work stands shall have between two (2) and four (4) LED lights per work stand section depending on its size. Large stand sections with sufficient space shall have four (4) lights and smaller sections shall have two (2) lights.

• The lighting shall be evenly spaced, mounted at the lower sections of the stands close to floor level, face towards the aircraft, and provide full illumination of the lower aircraft surface.

• Each light shall have adjustable up and down rotation and be provided with individual on/off switches.

• All LED lighting must provide 4000 Kelvin white light and be fully serviceable.

5. COMPRESSED AIR

5.1. Shop Air Network

The work stand arrangement around the aircraft shall contain an interconnected shop air network capable of providing air to pneumatic tooling available at the 574 AMXS. All configurations of work stand shall be capable of connecting and interfacing to the shop air system within Building 674 and 680 and be rated to 500 psi.

• The Configuration I and II work stands shall have two separate air networks for the left and right sides of the aircraft. The Configuration III work stands shall have a single air network leading to the work stand deck.

• The Configuration I work stands shall interface with Building 674 shop air at the wing tips of the aircraft and the Configuration II work stands shall interface with Building 680 shop air at the nose of the aircraft. Configuration III work stands shall interface to building shop air at the base of the stand’s access stairway.

• The shop air network shall use “industrial” style quick disconnects unless specified otherwise.

• The Configuration I work stands shall have a 50 ft. hose at each wing tip used to connect the work stand arrangement to building shop air. The hose shall use ½” quick disconnects.

• The Configuration II work stands shall have two 50 ft. hoses at the nose of the aircraft and ½” quick disconnects to interface to building shop air.

• The Configuration III work stand shall connect to building shop air using ½” quick disconnects and a 50 ft. hose mounted to the base of the stand’s access stairway.

• The pressurized air network for each work stand section shall utilize piping and each Configuration I and II work stand section shall “daisy chain” to the next adjacent work stand section with ½” quick disconnects.

• The Configuration I and II work stands shall have four 50 ft. air hose reels with ¼” quick disconnects mounted to the work stand sections closest to the junction between the forward wing tips and the aircraft fuselage. Two of the air hose reels shall be above the work stand deck and two shall be below. The same arrangement shall be on both sides of the aircraft.

• Each work stand section in each configuration shall have the capability to be capped off to allow for work stand arrangements that do not utilize each section.

• All shop air hose reels shall be a CoxReels reel with model number P-LP-135 or an equivalent reel available through a different vendor or manufacturer.

• The air network installed on all work stand configurations must be grounded to prevent static electric discharge.

• All shop air hoses used in the system shall be red in color to distinguish them from other pneumatic lines used on the work stands.

5.2. Central Vacuum System Network

Building 674 has a central vacuum system used for cleaning debris and dust left over from aircraft coatings removal. The Configuration I work stands shall have a central vacuum network capable of interfacing with that system.

• The work stand vacuum system network shall interface at the aircraft wing tips with the main 4” diameter vacuum lines entering each paint booth in Building 674.

• The Configuration I work stands shall have two separate networks. One network for the right side of the aircraft and the other for the left side.

• The vacuum system network shall also be compatible with the 2” diameter Clayton

Associates combination vacuum and pressurized air hoses used at the 574 AMXS.

• The Configuration I work stand central vacuum network shall “daisy chain” together in a fashion similar to the shop air using piping and 2” diameter hose. Each work stand section shall connect together using 2” diameter hose and connectors available through Clayton Associates or equivalent.

• Each work stand section shall have the capability to be capped off to allow for work stand arrangements that do not utilize each section.

• Each Configuration I work stand section shall have four (4) ports per aircraft side available for plugging in vacuum hoses and other vacuum equipment or tooling. Four

(4) of the ports shall be available above the work stand deck structure and four (4) shall be available below. The ports shall be evenly spaced apart across the aircraft.

• Provisions must be made to ensure that the central vacuum network is properly grounded to prevent static electric spark hazards.

• The central vacuum system work stand network shall also include a “filter” to catch debris greater than ½” in size to prevent it from clogging the Building 674 central vacuum system.

• All central vacuum hoses shall be black in color to distinguish them from other pneumatic lines used on the work stands.

• The Configuration II and III work stands do not need to interface to the central vacuum system.

5.3. 20 inHg Vacuum System Network

Building 674 has an additional and distinct vacuum system that is used for pulling a vacuum on materials bonded to the aircraft. The system provides a 20 inHg vacuum pressure to all paint booths within Bldg 674. The Configuration I work stands must also have an interconnected network available for the 20 inHg vacuum system.

• The Configuration I work stands shall have two separate 20 inHg vacuum networks.

One network for the right side of the aircraft and a second for the left side.

• The 20 inHg vacuum network shall use “industrial” style quick disconnects unless specified otherwise.

• The Configuration I work stands shall have a 50 ft. hose at each wing tip used to connect the work stand arrangement to the 20 inHg vacuum system. The hose shall use ½” quick disconnects.

• The vacuum system shall “daisy chain” together in the same fashion as the shop air system. Piping shall be used along with ½” quick disconnects to construct the networks for the Configuration I work stands.

• Each side of the aircraft shall have four 50 ft. retractable hose reels for the 20 inHg vacuum system with ¼” quick disconnects. The 20 inHg vacuum system reels shall be mounted to the work stand sections closest to the junction between the forward wing tips and the aircraft fuselage. Two of the reels shall be above the work stand deck structure and two shall be below. The same arrangement shall be on both sides of the aircraft.

• All 20 inHg vacuum system lines shall utilize quick disconnects capable of interfacing to tooling and equipment available at the depot.

• Each work stand section shall have the capability to be capped off to allow for work stand arrangements that do not utilize each section.

• Provisions must be made to ensure that the central vacuum network is properly grounded to prevent static electric spark hazards.

• All 20 inHg vacuum system lines shall be made from blue Flexeel Polyurethane 3/8” diameter inner coil hose to distinguish them from other pneumatic lines used on the work stands.

• All 20 inHg vacuum system hose reels shall be a CoxReels reel with model number P-LP-135 or an equivalent reel available through a different vendor or manufacturer.

• The Configuration II and III work stands do not need to interface to the 20 inHg

5.4. Manifolds

In addition to the various configurations of hose reel, the shop air system, central vacuum system, and 20 inHg vacuum system shall all interface to manifolds above and below the various configurations of work stand deck structure. The manifolds will provide personnel with additional access locations for the various pneumatic and vacuum systems used at the

574 AMXS.

• The manifolds shall be compatible with “industrial” style quick disconnects unless specified otherwise.

• The Configuration I, II,…