SP3300-15-R-0013_SOW.pdf

Draft Statement of Work For

VLM Storage System Bldg. 1331

Defense Distribution Depot Albany, GA

Apr 30, 2014

DLA Installation Support for Distribution DS-FDI; Building 1-2 S Avenue

New Cumberland, PA 17070-5000

TABLE OF CONTENTS

1.0 SCOPE -------------------------------------------------------------------------------- 3

1.1 SITE ----------------------------------------------------------------------------------- 3

1.2 SYSTEM LAYOUT AND FUNCTION (EXISTING SYSTEM) ------------ 3

1.3 SYSTEM LAYOUT AND FUNCTION (NEW SYSTEM) ------------------- 3

1.4 REQUIRED SYSTEM THROUGHPUT ----------------------------------------- 3

1.5 CONTRACT LINE ITEMS -------------------------------------------------------- 4

2.0 APPICABLE SPECIFICATIONS, STANDARDS AND CODES ----------- 5

2.1 GOVERNMENT DOCUMENTS -------------------------------------------------- 5

2.2 STANDARDS AND CODES ------------------------------------------------------ 6

3.0 REQUIREMENTS ------------------------------------------------------------------- 7

3.1 GENERAL REQUIREMENTS ---------------------------------------------------- 7

3.2 EQUIPMENT SPECIFICATIONS ------------------------------------------------ 15

3.3 TRAINING ---------------------------------------------------------------------------- 21

4.0 QUALITY ----------------------------------------------------------------------------- 24

4.1 LAYOUT ------------------------------------------------------------------------------ 24

4.2 SYSTEM MAINTENANCE ------------------------------------------------------- 24

4.3 SYSTEM CHECKOUT ------------------------------------------------------------ 25

4.4 INSPECTION AND TEST --------------------------------------------------------- 25

SECTION 1

1.0 SCOPE

This specification covers the necessary services, labor, material, equipment and control components required to supply a new Vertical Lift Module (VLM) Storage System (here to after called system) for an existing storage and order processing area in Bay 1 of Building 1331.

1.1 SITE

The system shall be installed in Bldg. 1331 at DLA Distribution Albany, GA (DDAG) located at 814 Radford Blvd., Building 1331, Albany, GA

1.1.1 SITE DESCRIPTION

Bldg. 1331 is concrete storage/processing building. The building has 5 bays with nominal dimensions of 200 ft. long, 200 ft. wide and 18 ft. clear stack height. Bay 1 currently contains pallet racking with binnable and pallet materials and 7 vertical carousels. Bay 2 currently houses pallet racking with pallets and binnable material. Bay 3 currently houses a processing area, 15 vertical carousels, and pallet racking with binnable material. Bay 4 houses pallet racking. The bin material currently stored in the vertical carousels will be relocated to the new VLM Storage Systems provided under this contract. The future warehouse layout conditions are depicted in Attachment DS-FDI Drawing No. 2015-1331-2-1. All rack work will be performed by a separate contract.

The scope of this contract is to provide 11 each Vertical Lift Modules (VLMs) and install the VLMs and demolish and remove the existing 22 vertical carousels. It also includes an option to buy additional VLM features, ergonomic workstations and an enhanced warranty.

1.2 SYSTEM LAYOUT AND FUNCTION (EXISTING SYSTEM)

The existing storage systems in Building 1331 can be seen during the pre-bid site visit.

There are no current drawings of the existing layout. The function of the system is to store binnable materials on racking and in 22 existing vertical carousels.

1.3 SYSTEM LAYOUT AND FUNCTION (NEW SYSTEM)

The new storage system for Building 1331, bays 1 and 4 for storage of binnable material are shown on Attachment DS-FDI Drawing No. 2015-1331-2-1. The system will consist of new pallet rack, package rack and eleven (11) vertical lift modules located in Building 1331,. Pallet and package rack will be provided by others. Requirements for the Vertical Lift Modules are detailed in this SOW.

1.4 CONTRACT LINE ITEMS

The offeror shall bid the system with separate prices for each contract line item. The Government shall reserve the right to award each contract line item together or separately in order to match budget allocations with the maximum system capability. If the Government does not award all the contract line items during the initial award, the

Government reserves the right to award CLINS 0005 and 0006 up to 180 days from the initial contract award. CLINs 0001 and 0002 are the base bid. CLINs 0003, 0004, and 0005 are optional CLINs. The performance period for CLIN 0001 is 270 days. The performance period for CLIN 0002 is 90 days, which begins 120 days after the acceptance of the new VLM system. The performance period for CLIN 0003, if awarded, is 270 days from original award. The performance period for CLIN 0004, if awarded, is 120 days. The performance period for CLIN 0005 will be for one year after acceptance of the entire new system.

1.4.1 CLIN NO. 0001 VLM STORAGE SYSTEM

QTY DESCRIPTION

11 ea. Vertical Lift Modules

1.4.2 CLIN NO. 0002 DEMOLITION OF EXISTING VERTICAL CAROUSELS

22 Demolition, Removal, and Disposal of Vertical Carousels

1.4.3 CLIN NO. 0003 OPTIONAL VLM FEATURES

11 ea Dual Tray Delivery Feature

1.4.4 CLIN NO. 0004 OPTIONAL WORKSTATIONS

11 ea. Ergonomic workstations

1.4.5 CLIN NO. 0005 OPTIONAL 1 Year ENHANCED WARRANTY

1 Yr Preventive and Corrective Maintenance Tasks and Defined

Warranty Repair Response Timelines

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

The following list of specifications, standards and codes shall apply to the work covered within this document. The offeror shall be responsible to ensure that all such applicable regulations are satisfied. Special attention shall be given to federal state and local requirements. The issue in effect of the following documents on the date of the solicitation forms a part of the specification to the extent specified herein:

2.1 GOVERNMENT DOCUMENTS

2.1.1 FEDERAL SPECIFICATIONS

NN-P-71 Pallets, Material Handling, Wood Stringer Construction, 2 way and 4 way (partial) TT-P-645 Primer, Paint, Zinc Chromate, Alkyd Type TT-E-489 Enamel, Alkyd, Gloss, Low Voc Content Aluminum W-F-408 Fittings for Conduit, Metal, Rigid (thick wall and thin wall (EMT) type

2.1.2 MILITARY SPECIFICATIONS

MIL-C-83286 Polyurethane Paint MIL-P-514 Plates, Identification, Instrumentation, and Marking DOD-P-15328 Pretreatment Primer

2.1.3 FEDERAL STANDARDS

FED-STD-595 Federal Standard 595, A (9), Colors

2.1.4 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

STANDARDS

29 CFR 1910 Occupational Safety and Health Standards

2.1.5 U. S. ARMY CORPS OF ENGINEERS MANUAL

EM-385-1-1 General Safety Requirements

2.1.6 MILITARY STANDARDS

MIL-PRF-61002 Identification Marking of U.S. Military Property MIL-STD-248 Welding and Brazing Procedures and Performance MIL-STD-1474 Noise Limits for Army Material

2.1.7 DRAWINGS

DS-FDI Drawing No. 2015-1331-1-1 VLM Storage System, DDAG Building

1331(EXISTING)

DS-FDI Drawing No. 2015-1331-2-1 VLM Storage System, DDAG Building 1331

(NEW SYSTEM)

2.2 STANDARDS AND CODES

Standards of the National Electrical Manufacturer’s Association (NEMA) American Welding Society Standards Code of the American Society of Mechanical Engineers Standards of the American Institute of Electrical Engineers American Society for Testing Materials (ASTM) Standards

ASTM 53

ASTM 120

American National Standards Institute (ANSI) B20.1 Safety Standards for Conveyors and Related Equipment

National Fire Protection Association (NFPA) Publications National Electrical Code (NEC) Underwriters’ Laboratories, Inc., Publication Standards

ANSI/UL-558 - Standards for Safety for Internal Combustion Engine UL-583 - Standards for Safety Power Operated Industrial Trucks

American Iron and Steel Industrial Standards (AISI) Factory Mutual System (FM) Publications

Federal Specification TT-E-489H Federal Specification TT-P-645B

MIL-STD-1472

MIL-STD-130

FAR 52-236-7

DLA Form 1591 SY 91a (motor vehicle)

ANSI Z49.1 (1975)

SECTION 3

3.0 REQUIREMENTS

3.1 GENERAL REQUIREMENTS

The general requirements cited herein shall apply to any system or equipment proposed by the contractor. The final design of the system and the capability of the designed system to meet the firm performance requirements of this contract are the responsibility of the contractor Alternate equipment and system architecture may be proposed by the contractor provided all firm performance requirements specified in Sections 1.3 through

1.4 and 3.1 through 3.4 are satisfied by the proposed design. The contractor shall provide all equipment, material, control components, engineering and labor necessary to provide completely installed systems ready for operation. The system shall be tested by the contractor prior to performance testing by the Government. All equipment (each whole product with its integral software) shall be the manufacturer’s current, commercially designed and available or a commercial product that has been slightly modified to fit the proposed system. The commercial product must have proven, successful field application for at least two years immediately preceding the issue date of this solicitation.

The field experience of each specific equipment product shall have been gained by an identical or previous model to the one being offered. The design of the specific equipment product offered must be fully defined. Also, any design changes during the two year period of field experience shall be identified by the offeror. These design changes must be minor and insignificant or be demonstrated reliable through commercial application.

3.1.1 MATERIALS AND OPERATING CONDITIONS

Unless otherwise specifically stated, all material shall be new and of the most suitable grade for the intended purpose. All parts shall be manufactured to such standards as will permit replacement or adjustment without modification to system components. All system equipment must be capable of operating in an industrial environment with temperatures from 50 to 100 degrees Fahrenheit and from 5 to 95 percent relative humidity (non-condensing). Dust and other airborne particle shall be filtered by a replaceable air filter. Electronic components will be equipped with cooling fan to protect the systems from heat damage.

3.1.2 TREATMENT AND PAINTING

All surfaces not yet painted but suitable for painting, with the exception of plated surfaces, shall be thoroughly cleaned to provide a clean, dry surface, free of all mill scale, oil grease, dirt, rust or other inhibiting material, and shall be painted with paint conforming to Federal Specification TT-E-489H, consisting of one coat of base primer conforming to Federal Specification TT-P-645B and one coat of enamel applied in accordance with standard commercial practices to assure complete coverage and durability of finish. An alternative painting process which will also be acceptable is an on-line metal cleaning process, then a blown dry or baked dry preparation prior to painting. The dry metal material is painted using an electrostatic spray paint process. The pre-wash cleaning process deposits an iron phosphate coating which is then covered with an alkyd baking enamel. The finish coat, when dry, shall be a smooth, even surface, free of runs, sags, drips or other defects. Color of the finish coat shall be the manufacturer’s standard commercial color.

3.1.3 STATE-OF-THE-ART COMPONENTS

The systems supplied by the contractor shall embody features that represent the current commercially available state-of-the-art products. Such features as plug-in electrical or electronic modules, solid state circuitry, trouble detection lights, and electronic diagnostic systems shall be utilized when practical to do so. Automatic or lifetime lubrication shall also be utilized where applicable.

3.1.4 MATERIAL TO BE HANDLED

Material to be handled consists of non-uniform packages of mixed stock. Individual items, packages and cartons shall range in size from 1 inch long by 1 inch wide x 1 inch high to 6 inches long by 6 inches wide by 6 inches high and in weight from 1 ounce to 50 lbs.

3.1.5 LUBRICATION AND ADJUSTMENT

All equipment shall be greased, oiled or lubricated and properly adjusted by the contractor when installing equipment to insure satisfactory operation. Lifetime lubrication shall be utilized wherever possible.

3.1.6 DIMENSIONS

Dimensions required to design and install equipment for use in facilities shall not be obtained from drawings, but shall be taken from measurement of the site location.

3.1.7 NOISE LEVELS

No single item of equipment shall produce an operating noise level in excess of 70 decibels within 4 feet of the equipment and no combination of operating elements of equipment shall exceed an 8 hour time weighted average sound level of 84 decibels measured on the A scale, when measured in accordance with section 1910.95 (“Occupational Noise Exposure”) of 29 CFR 1910 (OSHA Safety and Health Standards).

Noise levels shall also be in compliance with MIL-STD-1472.

3.1.8 ELECTRICAL POWER SOURCE

All electrical equipment shall be taken from the main electrical panel in Bay 3 which is 480 volt, 1200 amp, 3 phase, 60 Hz. All conduit, wire, electrical power distribution equipment, including transformers, and other electrical hardware, and labor necessary to provide power to the contractor installed equipment shall be contractor furnished and installed in accordance with the National Electrical Code (NEC), National Fire Protection Association (NFPA), and other applicable state and local codes. All wiring runs shall be enclosed in heavy walled rigid conduit or thin-wall electrical Metallic Tubing (EMT) with threaded fittings. Conduit runs shall not obstruct personnel, vehicle, or other material flow patterns. All electrical work shall be in accordance with the NEC. The contractor shall also remove all conduit from the existing vertical carousels, back to the nearest electrical panel, beyond the vertical carousel disconnect.

3.1.9 SWITCHES AND CONTROLS

All start buttons, switches, selection buttons, and other control devices shall be marked with a permanent identifying label. All wires used in control circuits shall be identified at each junction or end with a wire number which corresponds to the number used in the contractor’s electrical control drawings specified in CDRL A008) of this document.

Wiring terminal strips shall be used to the maximum extent practicable.

3.1.10 STANDARDIZATION OF COMPONENTS

Corresponding units and replaceable assemblies, subassemblies and parts in this specification shall be physically and functionally interchangeable as complete items without modification thereof or of other articles with which items are used. Where dimensions, ratings and characteristics are not specified herein, the manufacturer’s published design limits shall be used to determine compliance with the foregoing.

3.1.11 FASTENERS

Unless otherwise specified, all threaded fasteners, washers and cotter pins required to fabricate the components of the system (except those designed to be in contact with oil in reservoirs) shall be plated to resist corrosion. All fasteners for similar applications shall be identical. If torch cutting or welding is required permits must be obtained per paragraph 3.1.16.1.7.

3.1.12 METAL FABRICATIONS

Metals used in the fabrication of components shall provide original quality surface finish and shall be free from kinks and hard bends. Metals having corroded or pitted surfaces are not acceptable. Metal straightening or forming shall be done by methods that will not cause weakening or injury to the material. Burrs and sharp edges in holes and on sheets, plates and members shall be removed sufficiently to assure correct fits and to prevent loosening of fasteners and damage to components. Flame cutting with a tip suitable for the thickness of metal may be employed instead of shearing or sawing. Splatter and slag shall be removed and exposed cuts ground smooth. Heated metals shall be allowed to cool slowly, except in the performance of designed heat treatment and overheating shall be avoided in accordance with the recommendations of the metal manufacturer. All bends of a major character and all modular assembly fabrication shall be made with controlled means to ensure uniformity of size and shape.

3.1.12.1 WELDS

Welded joints shall be sound, thoroughly fused to the base metal, smooth, free from cracks, pits, holes, fissures, under cuts, rough projecting edges and sized to provide strength necessary to suit the intended purpose. All welds shall be smooth, continuous, with complete heat penetration and shall transmit stress without permanent deformation or failure when the equipment supplied is subjected to normal service and the testing in Section 4 of this statement of work. The contractor’s welders, welding operators and welding procedures shall be qualified to meet the requirements of MIL-STD-248, the American Welding Society (AWS) Standards or American Society of Mechanical Engineers (ASME).

3.1.12.2 BOLTED AND RIVETED CONNECTIONS

Holes in the sizes recommended in standard practice shall be accurately punched, drilled or formed and shall have burrs removed. Bolts, studs and cap screws shall be provided with washers or lock washers. Self-locking nuts are acceptable in lieu of standard nuts and lock washers. All fasteners shall be correctly tightened and shall have full engagement. Rivet heads shall be full, neatly made, concentric with rivet holes and in full contact with the surface of the member. Excessive upsetting of rivets to fill holes is not acceptable.

3.1.12.3 CASTINGS AND FORGINGS

Castings and forgings shall be of the best quality normally used in commercial practice and not produce any deleterious effects for the intended purpose.

3.1.12.4 MACHINE WORK

All parts shall be manufactured to gage through the use of correct jigs, fixtures, tape controlled machines or combination thereof.

3.1.13 FLOOR MOUNTING OF EQUIPMENT

All equipment shall be floor supported, except non-load bearing system components such as conduit, and shall be securely bolted to the concrete floor.

3.1.14 IDENTIFICATION MARKING

All equipment and major components shall have identification plates permanently attached. The information contained on the plates shall be as indicated herein and as specified in MIL-STD-130. Identification data shall include, as a minimum, contract number, manufacturer, serial number, model number and date of manufacture.

3.1.14.1 CONTROL IDENTIFICATION

Major items of electrical equipment and major components shall be permanently marked with an identification nameplate to identify the equipment by type or function and specific unit number as shown on the drawings and as required by NEC. All start buttons, selection buttons, switches and control devices shall each be marked with a permanent identification label. Hand lettering or marking is not acceptable.

3.1.15 SPECIAL PROVISIONS

3.1.15.1 INTERRUPTION OF WAREHOUSE OPERATIONS

The installation shall be phased to minimize downtime the warehouse operations shall not be curtailed nor suspended except as absolutely essential. Any required curtailment or suspension shall be coordinated with at least 5 days notice to the Government through the Contracting Officer’s Representative. Any interruption to warehouse operations greater than 15 minutes must be performed during non-duty hours (see paragraph 3.1.15.3).

3.1.15.2 INSTALLATION SEQUENCE

Installation of the system shall be in the following order.

a. Install VLMs

b. Demolish and remove existing VLM’s

3.1.15.3 WORKING HOURS

Normal working hours are 0600 through 1800 Monday through Friday excluding federal holidays. The contractor may be allowed, under extenuating circumstances, to perform work outside of regular hours. Where work is desired to be performed other than during regular hours, the contractor shall request permission from the Contracting Officer’s Representative (COR) at least 24 hours in advance to allow for the necessary arrangements to be made.

3.1.15.4 REMOVAL OF WASTE AND DEBRIS

All on-site waste and debris, and conduit generated in performing this contract shall be disposed of off-site at contractor arrangement and expense. The contractor shall comply with FAR 52-236-7. The contractor shall maintain the work site and premises in a clean and neat condition during the installation.

3.1.15.5 PENETRATION OF FIREWALLS

Firewalls may be penetrated for installation of electrical and communications cables and air lines pending inspection and approval by the Marine Corps Logistics Base Albany Fire Department. Cables shall be enclosed in rigid conduit completely through the wall.

The opening around the conduit/pipe shall be sealed with builder’s mortar and finished to original appearance.

3.1.15.6 WALL PENETRATIONS

The walls will be carefully cut to prevent undue damage. Penetrations shall be finished in a neat, quality workmanship like manner and any damage resulting to the walls or floors or any part of the warehouse shall be repaired with material of a kind, texture and quality to match existing materials. The contractor is required to obtain approval from the Contracting Officer’s Representative prior to making any permanent or temporary firewall or exterior wall penetrations other than those identified in this specification.

3.1.16 SAFETY REQUIREMENTS

3.1.16.1 GENERAL REQUIREMENTS

3.1.16.1.1 These safety provisions are only general in nature and are not intended to be all inclusive. The contractor shall follow and will not be excused from following the safety requirements of EM 385-1-1, appropriate safety standards or other requirements established by DLA, National Electric Code, OSHA, National Fire Code or other established safety requirements.

3.1.16.1.2 It is the responsibility of the contractor to be aware of the safety requirements for personnel, equipment, buildings and materials. All protective coverings, shields, protective barriers, barricades, warning signs, etc., will be furnished and installed in accordance with ANSI and OSHA Standards by the contractor where a hazard or potential hazard exists. Twenty-four (24) hours prior to the planned installation of protective barriers and barricades, the contractor will coordinate with the COR for concurrence and approval. The removal of barricades and barriers will be accomplished by the contractor at the completion of the work in the area.

3.1.16.1.3 All protective equipment must be approved by the safety and health manager or his designated authority. The contractor shall notify the COR and get approval before commencing work.

3.1.16.1.4 The contractor must comply with all OSHA standards for the storage, handling and application of flammable paints and liquids, combustibles and other hazardous materials. This includes the use of ventilation, personal protective equipment, respiratory protection, monitoring for air contaminants and requirements to convey to workers the hazards associated with the operation.

3.1.16.1.5 The contractor shall submit current material safety data sheets for all materials to be used on the project. This includes new materials selected and substitute materials.

3.1.16.1.6 The equipment and the controls, including any modifications and installation of same, shall conform to the requirements of ANSI/ASME B20.1-1984, Safety Standards for Conveyors and Related Equipment.

3.1.16.1.7 No torch cutting or welding work of any description shall be permitted within the installation boundaries until the site of the proposed work has been inspected by the base fire department, and a permit has been issued. Permits must be obtained on a daily basis by contractor personnel coordinating the request through Jon Peacock, (229) 376- 1780 jon.peacock@dla.mil and Marine Corps Logistics Base Albany Fire Department and identifying the location and type of work to be done.

3.1.16.1.8 All edges shall be beveled, ground smooth, or otherwise shaped to preclude sharp edges. Protruding parts will be designed to eliminate any hazards that could cause personal injury and will be installed only after approval by the contracting officer or his designated representative. The equipment and the controls, including any modifications and installation of same, shall conform to the requirements of ANSI/ASME B20.1-1984, Safety Standards for Conveyors and Related Equipment.

3.1.16.1.9 MISHAP REPORTING

A copy of the report on each job connected injury, property damage, or motor vehicle mishap will be submitted to the facilities engineer and the safety and health office.

This report may be made on either a contractor’s report form, a DLA Form 1591, mishap report, or SY 91a (motor vehicle). The estimated absence in days, if any, by employee due to injury and/or cost of property or vehicle damages shall be included.

3.1.16.2 INSTALLATION SAFETY PRACTICES

mailto:jon.peacock@dla.mil

3.1.16.2.1 Personal protective equipment such as hard hats, safety glasses, safety shoes, etc., shall be worn in all areas and on all jobs as required by the safety and health office. All hard hat areas shall be indicated by contractor furnished signs. Safety and health office personnel may inspect the work site at any time for compliance.

3.1.16.2.2 All contractor material shall be stored in a neat and stable manner so as to preclude leaning or falling stacks. Housekeeping will be maintained at a high level at all times.

Scrap material, such as empty cartons, wood crates, etc., will be removed by the contractor at the end of each work day.

3.1.16.2.3 Smoking is prohibited except in designated areas.

3.1.16.2.4 Gasoline operated equipment used in the building will be kept to a minimum to preclude the build-up of carbon monoxide and other hazardous fumes. For welding, electric motor driven arc welders are preferred. If gasoline or diesel engine welders are used, the welder will be kept outside the building with welding cables run inside, or the engine exhaust will be ducted to outside the building subject to the safety and health manager’s approval.

3.1.16.2.5 Only a one (1) day supply of flammable, combustible, corrosive and other hazardous materials is to be kept at the job site. All other stock of hazardous materials shall be stored in accordance with applicable OSHA Standards at a location remote from the job site and approved by the Government.

3.1.16.2.6 Safety markings shall be in accordance with 29 CFR 1910.144 and 145. Location of safety equipment shall be designated by alternating green and white stripes on the floor.

3.1.16.3 FIRE PREVENTION

The use of all fire hydrants will be controlled by this center’s fire department. No unauthorized use of fire hydrants will be permitted. Fifteen feet clearance is required around all fire hydrants at all times. Fire aisles, building entrances and building exits will be kept clear of obstructions at all times. A 24-inch clearance will be maintained at firewalls at all times.

3.1.16.4 FLAME CUTTING AND WELDING PROCESSES

3.1.16.4.1 Welding, cutting or use of flame devices require prior approval of the Fire Chief and shall be performed in accordance with ANSI Z49.1 (1975). A welding screen shall be used whenever welding is being done. The contractor shall have on duty at such times and as required by the Marine Corps Logistics Base Albany Fire Department Fire Chief when welding, cutting or using open flame devices, a fire watcher who shall be a qualified fire fighter with not less than three years consecutive experience.

3.1.16.4.2 At no time will contractor use or block installed fire equipment, valve houses, or post indicator valve unless authorized by the fire department.

3.1.17 CONTRACT DATA REQUIREMENTS

The contractor shall furnish contract data as required in DD Form 1423, Contract Data Requirements List, included with this specification. Contract data, outlined in Table 2, shall be prepared in accordance with this specification or data item descriptions attached thereto, and submitted in the quantities and at the times specified for approval.

Sequence Title DID ID. Number A001 Installation Schedule DI-S-SAT1

A002 Layout Drawings DI-E-SAT2

A003 As-Built Drawings DI-E-SAT2 A004 Operating Manual DI-E-SAT1 A005 Maintenance Manual DI-E-SAT1 A006 Contractor Technical Representative List DI-E-SAT11 A007 Training Material and Schedules DI-E-SAT A008 Power Requirements DI-P-SAT1 A009 Design Data Calculations DI-E-24040A A010 Certificate of Compliance DI-E-SAT14 A011 Test Plan DI-T-SAT1 A012 Software Documentation Manual DI-S-SAT-2

Table 1

3.2 EQUIPMENT SPECIFICATIONS

All mechanical/electrical equipment and components shall properly be interfaced to ensure all equipment supplied shall be designed and installed in compliance with seismic zone 2 requirements, providing a rigid/stable structure capable of handling all anticipated loads/stresses. Contractor shall ensure equipment design does not cause/result in build-up of static electricity, and install protective devices as required. Penetrations of firewalls shall be accomplished in accordance with the requirements of paragraph

3.1.15.5 and 3.1.15.6.

3.2.1.1 CONTROL PANELS

All control panels shall be located adjacent to the applicable VLM area. Control panels shall contain all control components/devices, and related equipment necessary for operation of VLMs in specified modes.

3.2.2 VERTICAL LIFT MODULE (VLM)

Eleven (11) VLMs shall be supplied and installed in Bay 4 for binnable material currently stored in the vertical carousels in Bays 1 and 3. During manual mode of operation, the employee reviews the paper pick(or stow) list and accesses the VLM operator control panel, and selects the desired VLM tray to be retrieved. The VLM then delivers the tray to the front of the VLM. The operator then picks (or stows) the desired material from(or

to) the tray. The operator then places the picked material in a tote for movement to the shipping area. Upon completing the pick(or stow), the operator selects the next tray to be retrieved from the VLM operator control panel. In response, the VLM returns the currently displayed tray to an appropriate storage location, and retrieves the next tray to the external tray delivery area.

3.2.2.1 SELF SUPPORTING STRUCTURE

The systems shall have a self-supporting structure with a load-bearing profile framework and steel modular exterior panels. Vertical Lift Module (VLM) has a weight capacity of 132,000 lbs. Outside cabinet dimensions, including external tray delivery station, of the VLM is approximately 18’ 0” tall x 15’0” wide x 13’6” deep. The storage tray dimensions must be at least 160” (13’ 4”) wide by 30.0” deep and offer a clear opening across the 160” width with no tray support components within the tray body. Vertical depth inside the tray must be at least 4.5”.

3.2.2.2 CENTRAL ELEVATING PLATFORM

The central elevating platform is to be located between the front and rear columns of vertically stored trays. System will deliver trays to the external delivery area as requested by the operator. All vertical tray movement is to be accomplished through the use of steel or Kevlar® reinforced toothed belt drive system and a self-braking gear motor controlled by an inverter. Vertical positioning of trays is to be controlled by a count encoder. Tray stability is maintained through the use of eight rollers on the elevator mechanism.

3.2.2.3 EXTERNAL TRAY DELIVERY SYSTEM

VLM to include automatic tray delivery that is outside the machine enclosure in a single-level tray configuration. The maximum height of stored material must be no more than 26”. The external tray delivery system must provide ergonomic and unobstructed overhead access outside the enclosed VLM to the materials stored inside the tray.

3.2.2.4 DUAL TRAY DELIVERY OPTION

Once the user has completed the actions required in the first tray, the second tray is delivered automatically to the external access delivery point while the VLM returns the first tray to its first available stored position.

3.2.2.5 UNIT PERFORMANCE PARAMETERS

Unit Performance Empty Tray Fully Loaded Tray # Trays delivered per hour 92 66 Average Tray time delivery 19 seconds 23 seconds Maximum Tray Time Delivery 28 seconds 33 seconds

3.2.2.6 TRAYS

Trays are to be manufactured from galvanized sheet metal, have a steel reinforced design and welded construction with NO welded reinforcements inside the tray. All trays are to be manufactured to accept slotted walls on approximately 1 inch centers for the installation of side-to-side tray partitions and front-to-back tray dividers. Trays without slotted internal walls will not be acceptable. There will be a total of 45 trays, each approximately 160”wide x 30” deep x 4.5” high. All trays will have a net load capacity of 1,653 lbs.

3.2.2.7 PARTITIONS AND DIVIDERS

Partitions and dividers are constructed of galvanized steel and are compatible with the manufacturers slotted wall trays. The partitions and dividers will provide compartmentalization for the trays in any multiples on 1” centers. Partitions and dividers shall be provided by the manufacturer of the VLM equipment so as to ensure compatibility with the supplied trays. Thirty-six (36) front to back dividers (i.e. 30” total length) per tray shall be supplied. Seven (7) left to right (i.e. 160” total length) dividers per tray shall be provided.

3.2.2.8 OPERATOR CONSOLE

Operator Console shall be an industrial PC design and include:

• Graphical touch screen LCD

• 10.4” TFT color touch screen with 800 x 600 resolution ( VGA compatible)

• Microsoft Windows 7 Operating system

• Diagnostics touch screen feature in the event of an error or malfunction

• Can be used either in manual or semi-automatic mode.

• Operator console must be adjustable and capable of being positioned anywhere across the side-to-side track of the machine opening.

3.2.2.9 ELECTRICAL CABINET

All of the electronic devices for powering and automatically controlling the VLM are located within the front drawer sliding electrical cabinet and shall include:

• REMIO input/output board

• Connection to the Operator Console by use of an Ethernet port

• Incremental encoder input

• Inverters used for both vertical and horizontal speed control via CAN/BUS

• Digital I/O interface boards

• Complete electrical cabling with all required sensors and connections

• Exterior Paneling- VLM exterior to be clad with high strength sheet metal panels that provide a high level of heat and sound insulation. These panels are easily removed to provide access for maintenance.

3.2.2.10 SAFETY FEATURES FOR VLM

• Product measurement light curtains, located at the rear of the delivery bay, are required to measure the height of items stored in the trays as they enter the VLM. If a product is over height, or if there is not sufficient space within the VLM, the tray is rejected and returned to the operator.

• Personal Protection light curtains, located in the front of the delivery bay area, are required to protect operators while they load and unload trays.

• Machine diagnostics automatically performed at start up.

• Continuous operation control monitoring

• Vertical axis encoder status control

• Axis overrun safety switch that opens contacts and enables motor brake

3.2.2.11 GREEN FEATURE:

The unit shall be equipped with “Green” features which will assist in offsetting electrical usage. The Green device, allows the energy generated by the downward movement of the elevator to be re-utilized which would otherwise be dissipated in the form of heat on the relative braking resistors. The fundamental principle that allows such regeneration utilizes the DC-BUS technology in common among the various inverters. The Green solution is a special inverter which, being placed between the machine’s main switch and electrical panel, functions both as an “energy stabilizer” when the motor of the vertical axis absorbs, and as a generator when the motor of the vertical axis generates, rerouting the electrical energy produced to the customer’s grid.

3.2.2.12 ELECTRICAL REQUIREMENTS

The contractor will provide electrical installation for each VLM.

3.2.2.13 SOFTWARE REQUIREMENTS

The VLM contractor will be responsible for providing the necessary software capability to meet the Government’s minimum requirements for the following:

(A) Allow user to retrieve trays by tray number. Bar code scanning and bar code reading capability/host interface capability shall be included.

(B) Allow user to perform VLM parameter modifications, manage fault diagnostics/ fault recovery and operate in manual or semi-automatic mode.

(C) Inventory management capability via open source interface(non-proprietary) of all customer inventories for all VLMs supplied.

The software will provide these basic services as standard features:

• Use of a modern relational data base

• Data backup and restoration in the event of software malfunction

• Customizable grid screen layout

• Advanced filtering options that allows customizable searches and orders

• Advanced user/operator rights management

• Hierarchal list management (kitting)

• Graphical location management for both the VLM as well as items stored in manual pick areas such as shelving and racks.

• Configurable integration with enterprise management systems via an ASCII files exchange.

• Data exchange via ODBC driver, XML files and Excel spreadsheets

• Packing List Management

• Capability to batch pick items picked from different locations

• Capability to manage internal material movement between different areas

• Capability to create custom reports with an intuitive report tool

• Automatic database maintenance that will optimize software performance

In addition to the above, the Software package provide by the VLM supplier will include these advanced capabilities:

• Advanced security management, with the capability to limit access to trays and items depending on the user’s role or area of responsibility.

• Associate images to items

• Group items into families to define common characteristics

• Group items into categories to improve search and filtering functionality

• Manage supplementary attributes for items and orders.

• Extend the systems basic movement management features by providing:

A) Packing list management

B) Assembly kit management

C) Batch picking management that will work in conjunction with the LED Indicator bar.

D) Transit material management for items such as boxes and totes

• VLM Manufacturer is to provide factory certified installation of the complete system, including, operator training and support for the operational software provided.

3.2.3 WORKSTATION EQUIPMENT FOR VLMs

The various pieces of equipment listed shall be installed by the contractor as necessary to create a work environment that will be conducive to worker productivity and efficiency.

All interfaces between the operators, the workload and the installed system shall be optimized to produce a layout using effective and approved ergonomic principles. The equipment will be used for Government operations of PC’s and printers in a material handling operation at a future date. All workstation equipment shall be submitted for approval in accordance with CDRL A002.

3.2.3.1 WORKTABLES

The contractor shall provide 1 assembled worktable for each VLM supplied. All non-painted surfaces shall be galvanized. The tables shall have the following features:

A. FORMICA TOP OVER STEEL TABLE TOP

The high density Formica top shall be attached directly over a fabricated 12 gauge steel top rated at 250 lbs. per sq. ft. The top shall be warp and splinter proof and resistant to impact, moisture and oils. Overall table top dimensions shall be 72 inches wide by 30 inches deep.

B. TABLE LEGS

Table legs with supports shall be fabricated from 16 gauge steel (minimum) and be adjustable from 30-3/4 in to 34 ¾ in. Cross support members are welded or bolted to vertical legs for strength and durability. The legs shall bolt to the table top and allow for mounting of a back stringer.

C. BACK STRINGER

Stringer shall be fabricated from 16 gauge steel (minimum) to 4 to 7 inches wide that will hold the legs rigid. It shall bolt to the back legs.

D. DRAWER

There shall be two drawers per worktable with all mounting hardware included. The drawers shall operate on ball bearing rollers within its own case. Automatic stops shall limit the drawer travel. Drawer size shall be nominal 17 ¼ in W x 20 in. D x 6 ½ in. H. Drawer shall also have a built in lock.

E. TOP SHELF, LIGHT AND CPU POCKET

The workstation shall also be supplied with a top shelf, a florescent light and a CPU pocket for a medium size desk top computer (16 D x 16 H x 7 W).

3.2.3.2 INDUSTRIAL CHAIRS

The contractor shall supply 1 assembled chair for each VLM worktable supplied for the Bldg. 1331 VLM Storage System. The chair shall provide functional ergonomic seating, be engineered to maximize comfort and increase productivity. It shall be built to withstand heavy industrial use. The seat height, back depth lumbar tilt and seat pan tilt shall be adjustable by the operator while seated to meet his requirements. The chair shall have automatic adjustments for height and a single control for automatic adjustment of seat tilt and back depth. Seat height adjustment will be at least from 24 to 32 inches.

Pneumatic lift shall provide at least 6 inches of Adjustment with a lever control. Center support column shall be adjustable at least 12 inches for high or low seating. Micro cellular, self-skinning polyurethane shall be molded over the seat, back and footrest. The large seat (minimum 17 in wide x 16 in deep) will have contoured support with waterfall front. The extra high back (minimum 15 in wide x 12 in high) tilts for lumbar support and adjusts for height. The chair shall have a five-legged base with three-level footrests of heavy gauge steel, finished with baked powder epoxy that offers durability and stability. The base shall have high impact, oil resistant glided.

3.2.3.3 FLOOR MATS

Floor mats shall be supplied with each workstation and will be antistatic, anti-fatigue, solid heavy-duty mats ½ in. to 5/8 in thick. The mats shall be sized to fit each workstation and will cover the area in front of the worktables. Edges shall be beveled to prevent trip hazards.

3.3 TRAINING

Training shall be provided in the operation and maintenance of all equipment provided by the contractor. All training media such as visual aids, diagrams and drawings shall be furnished as required per sequence A007. All training shall be conducted by individuals well qualified in training matters, and the operation and maintenance of the contractor furnished equipment.

3.3.1 OPERATOR TRAINING

Two classes, four hours each on-site training shall be conducted by the contractor in the operation of contractor supplied system components. Government personnel shall generally be experienced in warehouse operations. Operator training shall be conducted on a scheduled basis with class size not to exceed ten persons each. Operator training shall be completed prior to performance testing (paragraph 4.4.4). Operational training shall provide employees a complete knowledge of operation of the system and shall include a handout booklet containing pertinent information regarding equipment operation. Specific areas of operator training shall include, but are not limited to:

a. Familiarization with the system capacity, operating characteristics and performance parameters, including operation of manual controls.

b. Familiarization with location, purpose and function of all controls.

c. Hands-on training under expected operating conditions including simulation of emergency/error situations.

3.3.2 ONSITE MAINTENANCE TRAINING

Two classes, eight hours each, onsite maintenance training shall be conducted by the contractor in the maintenance of the installed system provided by the contractor.

Maintenance training shall be conducted on a scheduled basis with class size not to exceed 10 persons each. Onsite training shall provide a working knowledge of preventive maintenance, troubleshooting, diagnostics, and correction of malfunctions including repair, adjustment, disassembly, inspection, and overhaul and reassembly of system components. Specific areas of training shall include, but are not limited to, the following:

a. An overview of manufacturing processes and techniques employed in constructing the systems components.

b. Diagnostic techniques required to isolate defective components using test equipment that is listed by the contractor as necessary to equipment furnished by the contractor.

c. Hands-on training in the repair, adjustment, disassembly, inspection, overhaul, and reassembly of system components to circuit board component level.

d. Preventative maintenance.

3.4 ELECTRICAL REQUIREMENTS

All electrical construction, controls and equipment shall be manufactured and installed in accordance with NFPA 70 (National Electrical Code).

3.4.1 ELECTRICAL INSTALLATION

It shall be the contractor’s responsibility to connect all required electrical equipment to the existing or contractor supplied electrical power distribution panels. Unless otherwise specifically stated, electrical power sources shall be 480 volt, 3 phase, 60 Hz and 120 volt, single phase, 60 Hz. The power source shall be from the 480 volt, 1200 amp main distribution panel located on the south side wall in Bay 3 of Building 1331. All required conduits, wires, electrical power distribution equipment, breakers, transformers, distribution panels, and other electrical hardware shall be contractor furnished and installed. All electrical work shall be in accordance with the NEC and the standards of NEMA. Contractor installed distribution system shall have an isolated ground and surge protection adequate to protect electronic equipment and computer terminals. All contractor installed electrical panels shall be clearly and permanently labeled to identify voltage and equipment serviced.

3.4.2 EXISTING PANEL BOARDS

All existing PANEL BOARDS in which work will be performed shall be provided with new typed circuit directories and standard covers shall be installed over all circuit breaker spaces.

3.4.3 SWITCHES AND CONTROLS

Each operating system shall be furnished with a master-operating console. All stop start buttons, switches, selection buttons, and other control devices shall be marked with a permanent identifying label. All wires used in control circuits shall be identified at each junction or end with a wire number which corresponds to the number used in the contractor’s electrical control drawings specified in the Contract Data Requirements List (DD 1423), Sequence A002, of this document.

SECTION 4

4.0 QUALITY ASSURANCE PROVISIONS

4.1 LAYOUT OF WORK

The contractor shall accurately lay out his work according to approved drawings. The contractor shall give general supervision to the work using his best skill and shall designate a superintendent in charge of installation who will remain on the premises during working hours until the installation is complete. The superintendent’s name shall be provided to the Contracting Officer, the Contracting Officer’s Representative, and the site supervisor.

4.2 SYSTEM MAINTENANCE

4.2.1 MAINTENANCE PRIOR TO FINAL ACCEPTANCE

The contractor shall insure that competent maintenance personnel are on site once the equipment becomes operable. Maintenance of the entire system supplied by the contractor shall be the responsibility of the contractor until final system acceptance.

4.2.2 SYSTEM MAINTENANCE WARRANTY PROVISIONS (SUPPLEMENT)

If CLIN 0005 is awarded, the contractor shall also be responsible for all manufacturers’ recommended preventative maintenance (minimum quarterly maintenance on the entire system) and shall provide corrective maintenance support for all system breakdowns for the equipment supplied and this contract. The contractor shall be required to maintain 98% up time throughout the period of operation which is 6:00 am through 6:00 pm Monday through Friday. The contractor shall provide a 2 hour response time for any corrective maintenance action required throughout the normal hours of operation.

4.2.2.1 SPECIAL TECHNICAL ASSISTANCE/MAINTENANCE

During the warranty period, the contractor shall provide technical assistance and remedial maintenance when necessary to keep the system operational in accordance with the specification performance requirements. Upon notification by the Government of system/equipment malfunction or failure to operate, the contractor shall promptly provide technical assistance via telephone consultation within two hours after contact to enable trouble shooting and correction by the Government, or arrive at the installation site within 24 hours after notification for continued consultation and performance of remedial maintenance action necessary for correction, if correction cannot be attained by the Government. All contractor parts, labor, and transportation to provide special technical assistance/ maintenance as specified shall be furnished at no increase in the contract price, unless or except as otherwise provided by the warranty clause provisions specified in this contract.

4.2.2.2 CONTRACTOR TECHNICAL REPRESENTATIVES

The contractor’s technical representative(s) list requirement (CDRL A006), shall identify the representative(s) for contact and notification who shall provide technical assistance and/or to arrive at the installation site within 24 hours. Identification shall include primary and alternate individual’s names, the firm’s name and address if other than the contractor’s and phone numbers where the individual representatives can be contacted. If multiple contact sources apply due to the various subsystems required by this specification, the contract data shall clearly identify the specific subsystems and their appropriate responsible technical representative(s).

4.3 SYSTEM CHECK OUT

Upon completion of each phase of the installation, the system shall be checked out by the contractor using test procedures designed to evaluate system performance at maximum rated capacity. The system will be under the contractor’s control until modifications and/or adjustments are considered complete by the contractor.