C-6_Attach_2_SOW_Transporter_Dock_Installv2.pdf

ATTACHMENT 2 – STATEMENT OF WORK (SOW)v2

TECHNICAL SPECIFICATIONS

FOR

Transporter Dock Conveyors for Building 59

DEFENSE DISTRIBUTION DEPOT

SAN JOAQUIN, CA

December 1, 2016

PREPARED BY:

DEFENSE DISTRIBUTION DEPOT SAN JOAQUIN

FACILITIES & EQUIPMENT ENGINEERING BRANCH

DS-FJIF

TABLE OF CONTENTS

Page i

SECTION 1

1.0 SCOPE

1.1 SITE

1.2 QUANTITY

1.3 SYSTEM LAYOUT AND FUNCTION

1.4 MATERIAL FLOW

1.5 MATERIAL TO BE HANDLED

1.6 GOVERNMENT FURNISHED EQUIPMENT (GFE)

1.7 ALTERNATIVE DESIGNS

1.8 EXPERIENCE OF PERSONNEL

SECTION 2

2.0 APPLICABLE SPECIFICATIONS, STANDARDS AND CODES

2.1 GOVERNMENT DOCUMENTS

2.1.2 U. S. ARMY CORPS OF ENGINEERS

2.2 NON-GOVERNMENT STANDARDS AND CODES

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1.1 GENERAL

3.1.2 QUALITY

3.1.3 STANDARD PRODUCTS

3.1.4 MATERIAL AND OPERATING CONDITIONS

3.1.5 IDENTIFICATION OF MATERIAL AND FINISHES

3.1.6 STANDARDIZATION OF COMPONENTS

3.1.7 STATE-OF-THE-ART COMPONENTS

3.1.8 MAINTAINABILITY

3.1.9 LUBRICATION AND ADJUSTMENT

3.1.10 PAINTING

3.1.11 NOISE LEVELS

3.1.12 FASTENERS

3.1.13 METAL FABRICATIONS

3.1.14 FLOOR MOUNTING OF EQUIPMENT

3.1.15 SEISMIC ZONE

3.1.16 IDENTIFICATION MARKING

3.1.17 SPECIAL PROVISIONS

3.1.18 SAFETY REQUIREMENTS

3.1.19 CONTRACT DATA REQUIREMENTS

3.2 ELECTRICAL REQUIREMENTS

3.2.1 ELECTRICAL INSTALLATION

3.2.2 EXISTING PANEL BOARDS

3.3 TRAVERSING TRANSPORTER DOCK

3.3.1 GENERAL

3.3.2 PALLET CONVEYOR

3.4 WORKSTATIONS

3.4.1 GENERAL DESIGN

3.4.2 LOAD CARRYING SURFACES

3.4.3 CONNECTORS

TABLE OF CONTENTS

Page ii

3.4.4 PAINTING

3.4.5 WORKBENCHES

3.4.6 CARTON SHELVES

3.4.7 DRAWER

3.4.8 SLAT WALL TOOL SUPPORT

3.4.9 ROLL BAR KITS

3.4.10 WORKSTATION POWER CABLING

3.4.11 LIGHTS

3.4.12 FLOOR MATS

3.4.13 CHAIRS

3.5 ANCILLARY EQUIPMENT

3.5.1 PROTECTIVE GUARDRAILS

3.5.2 AUTOMATIC STRETCH WRAP MACHINES

3.5.3 SCALES

3.5.4 AUTOMATIC STRAPPING MACHINES

3.5.5 BATTERY HANDLING EQUIPMENT

3.5.6 POWERED PALLET CONVEYOR SPURS

3.6 TRAINING

3.6.1 OPERATOR TRAINING

3.6.2 MAINTENANCE TRAINING

SECTION 4

4.0 QUALITY ASSURANCE PROVISIONS

4.1 LAYOUT OF WORK

4.2 SYSTEM MAINTENANCE

4.2.1 MAINTENANCE PRIOR TO FINAL ACCEPTANCE

4.2.2 SYSTEM MAINTENANCE WARRANTY PROVISIONS (SUPPLEMENT) ...32

4.2.3 CONTRACTOR TECHNICAL REPRESENTATIVES

4.3 SYSTEM CHECK-OUT

4.4 INSPECTION AND TEST

4.4.1 RESPONSIBILITY FOR INSPECTION AND TESTING

4.4.2 EXAMINATION

4.4.3 IN-PROCESS INSPECTION

4.4.4 PERFORMANCE TESTS

4.4.5 STATIC AND OTHER TEST

4.4.6 TIME LOST

4.4.7 WARRANTY

4.4.8 FINAL ACCEPTANCE

4.4.9 DEFINITIONS

LIST OF TABLES

TABLE 1

TABLE 2

SECTION 1

1.0 SCOPE

This specification covers the necessary services, labor, project management/systems integration, material, equipment and control components required to design, analyze, provide, install, test, document and make operable transporter dock conveyors to be used for receipt and shipment of palletized material in the new warehouse system. The system shall consist of Traversing Pallet Transporter Dock Conveyors, Workstations, Semi-Automatic Stretch Wrap Machines, Pallet Scales, and all necessary fork truck guards (See DDC Drawing B- 59 1-3 Docks). The Contractor will furnish training to DDJC personnel in the operation and maintenance of all equipment furnished.

1.1 SITE

The site for this project is Defense Distribution Depot San Joaquin, California (DDJC), located in Tracy California. The system shall be installed in Building 59.

1.2 QUANTITY

The Contractor shall furnish, install, integrate, and make operational, the following equipment and building systems:

TABLE 1

Item Units Quantity CLIN # Traversing Pallet Transporter Docks (Bays 1, 2 and 3) EA 3 001 10’ Guard rails for Workstations EA 4 002 Automatic Stretch Wrap Machines EA 6 003 Pallet Scales (include 4’ Floor rail) EA 6 004 Semi-Automatic Strapping Machines EA 6 005 Battery Handling Machines (Bay 1 Both Sides) EA 2 006 Powered Pallet Conveyor (Bay 1 Both Sides) FT 60 007

1.3 SYSTEM LAYOUT AND FUNCTION.

The purpose of the project is to provide an efficient stow and pick environment for bulk stock. The system will be located in a newly constructed 360,000 square foot warehouse (Warehouse 59). The warehouse consists of three (3) sections, each measuring 250’ x 480’, with a clear stack height of 26’. Building Sections 1 through 3 will be outfitted with one (1) traversing pallet transporter docks each for a total of three (3) transporter docks. Material will be received in each section from commercial carriers or the in-bound intra-depot transporter trucks which interface with the traversing pallet transporter docks, and movement within the section will be by forklifts. The packing of materials picked will occur in the respective section. The packed material will be staged and loaded onto intra-depot transporter trucks via traversing pallet conveyor docks. Receipts coming into the warehouse for storage will be delivered directly to the various sections by either intra-depot transporter trucks or fully loaded trailers/vans. Receiving personnel perform inspection/receiving activities and update the upper tier material handling system data records, Defense Storage System (DSS). The system assigns storage locations, prints a routing label and the receipts are then routed to the assigned storage location. Issues are generated from DSS. Material Release Orders (MROs) are printed as a pick tickets in batches based on priority, location, etc. The documents are provided to the warehousing personnel for use in the picking operation. Warehouse personnel will pick one or more MROs in a pick cycle and place them on a pallet (depending on the material/product physical characteristics there may be more than one MRO per pallet). Upon completion of the pick cycle, operators will deliver the material to the packing stations.

1.4 MATERIAL FLOW

Palletized material will be brought into the warehouse by one of two methods. The pallet of material might be delivered via commercial carrier or the in-bound intra-depot transporter trucks which interface with the traversing pallet transporter docks. The material will be transported to a receipt staging area where material will be assigned a storage location. The material will be transported to storage in the narrow-aisle, high-rise pallet rack via man-up turret truck. Material will be selected via man-up turret truck either full pallet or hand selected to a pallet and will transported and placed on a pallet packing station. Once the packing process is complete the material will be transported by forklift to the out-bound traversing pallet transporter docks for movement to the freight terminal via intra-depot transporter trucks.

1.5 MATERIAL TO BE HANDLED

Material to be handled consists of palletized stock. The pallets are 40”L x 48”W x 5”H base size, Type II, IV, V or VIII in accordance with Federal Specification NN-P-71C. Pallet plus load dimensions may range from 40”L x 48”W x 10”H to maximum 44”L x 52”W x 54” high (2” overhang on each side) and weight shall range from 100 to 2,500 lbs. per pallet, with an average weight of 1,000 lbs. See attached photograph of pallet.

1.6 GOVERNMENT FURNISHED EQUIPMENT (GFE)

Not used.

1.7 ALTERNATIVE DESIGNS

The design as specified represents the Government's model design; however, the Government also would like to utilize the Contractor's expertise to ensure the best material handling system is purchased to meet the performance requirements as stated in this specification. Therefore, an alternative system may be proposed provided that the system functions and has the same capabilities as the system specified. In addition, all technical data (equipment layout drawings and manufacturer's brochures for equipment) concerning an alternative system must be included with the alternative design to provide all information required for the Government to evaluate said design. No alternative system will be considered after contract award.

1.8 EXPERIENCE OF PERSONNEL

The Contractor shall ensure that personnel to be utilized on the project have the following levels of experience in installing similar material handling systems.

Key personnel including the site superintendent, supervisory/work leaders for the installation (mechanical and electrical) crews and software programmers (s) have a minimum of 5 years experience.

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 Contractor shall be responsible to ensure that all such applicable regulations are satisfied. Special attention shall be given to Federal, State and Local requirements. It shall be the Contractor’s responsibility to obtain the latest revisions of these documents. The issue in effect of the following documents on the date of the solicitation form a part of the specification to the extent specified herein:

2.1 GOVERNMENT DOCUMENTS

2.1.1.1 FEDERAL SPECIFICATIONS

NN-P-71C Pallets, Material Handling, Wood, Stringer Construction, 2-way and 4-way (partial)

UFC 3-310-01 Design: Structural Load Data UFC 3-600-01 Design: Fire Protection Engineering for Facilities

2.1.1.2 OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

STANDARDS

29 CFR 1910 Occupational Safety and Health Standards

2.1.2 U. S. ARMY CORPS OF ENGINEERS

EM 385-1-1 Safety and Health Requirements Manual

2.2 NON-GOVERNMENT STANDARDS AND CODES

Standards of the National Electrical Manufacturer’s Association (NEMA) American Welding Society Standards (AWS) Code of the American Society of Mechanical Engineers (ASME) Standards of the American Institute of Electrical Engineers National Electrical Code (NEC) Underwriters Laboratories (UL), Inc. Publication Standards American Society for Testing Material Standards (ASTM) American National Standards Institute (ANSI) B20.1 Safety Standards for Conveyors and Related Equipment American Iron and Steel Industrial Standards (AISI) Electronics Industry Association Standards (EIA) National Fire Protection Association Publications (NFPA) Steel Door Institute (SDOI)

SECTION 3

3.0 GENERAL REQUIREMENTS

3.1.1 GENERAL

The Contractor shall supply the herein described equipment/systems, which shall include all services, labor, material, equipment, control components, and engineering necessary to provide a completely operational system. System and component design/layout shall minimize operator motions and optimize operator efficiency. All components requiring human interface shall be designed to current state-of-the-art ergonomics with emphasis on reduction of human error, proper biomechanics, adequate work/rest ratios, elimination of bodily discomfort and efficient workplace layout. The systems shall be tested by the Contractor prior to performance testing by the Government and shall be capable of undergoing the tests specified in paragraph 4.4 without deformation, breakdown, and failure of any component, or development of any other defect, and without any deviations from the performance requirements and cited standards of this specification. 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 proceeding 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, the Contractor shall identify any design changes during the two-year period of field experience. These design changes must be minor and insignificant or be demonstrated reliable through commercial application. Bid proposals shall include descriptive literature for all items of equipment offered. It is the Contractor’s responsibility to notify the Contracting Officer of any design deficiencies or site requirements, which affect or compromise the performance or operation of any portion of the system or the entire system. The Contractor shall be responsible for compliance with all regulations applicable to design and testing of equipment and controls supplied under this specification.

3.1.2 QUALITY

The system shall be in strict accordance with the requirements as herein specified and of high quality, free of any defects, which may affect function, appearance, serviceability, maintainability, or durability.

3.1.3 STANDARD PRODUCTS

Unless otherwise specified, the equipment to be furnished under this specification shall be the manufacturer’s current commercial product and shall have been in production, marketed and in use for a minimum of two years proceeding the issuance date of this solicitation. The introduction of product improvement changes in this two-year period shall be acceptable. Prototype or experimental devices or components shall not be furnished or installed. Where two or more units of the same type or kind of equipment are required, these units shall be identical models of a single manufacturer.

3.1.4 MATERIAL AND OPERATING CONDITIONS

Materials shall be as specified herein. Materials not specified shall be selected by the Contractor and shall be subject to all provisions of the specifications. Unless otherwise specifically stated, all materials shall be new and of the most suitable grade for the intended purpose. All parts shall be manufactured to such standards that will permit replacement or adjustment without modification of system components. The system shall be capable of operating in an industrial environment and extremes of temperature from 10 to 110 degrees Fahrenheit and humidity from 10 to 99 percent relative (non-condensing).

3.1.4.1.1 DISSIMILAR METALS.

Dissimilar metals shall not be used in intimate contact with each other unless protected against galvanic corrosion.

3.1.5 IDENTIFICATION OF MATERIAL AND FINISHES

The Contractor shall identify the specific material, material finish or treatment for use with components and sub-components and shall make information available, upon request, to the Contracting Officer or designated representative.

3.1.6 STANDARDIZATION OF COMPONENTS

Corresponding units and replaceable assemblies, subassemblies and parts in contact shall be physically and functionally interchangeable as complete items without modification thereof or of other articles with which the 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.

3.1.7 STATE-OF-THE-ART COMPONENTS

The Contractor shall furnish a system embodying features, which represent the current commercially available state-of-the-art in the development of his product.

Such features as plug-in electrical or electronic modules, trouble detection and condition status indicators, electronic diagnostic systems and applicable programmable logic controllers shall be utilized to the maximum extent where effective and practicable.

3.1.8 MAINTAINABILITY

Provisions shall be made for ready adjustment, servicing and replacement of all system components. All replaceable components shall be designed for ease of removal and ease of installation. All printed circuit boards shall be of the plug in type to the maximum extent practical. All electrical/electronic equipment shall be designed to permit the use of standard electronic test equipment for maintenance thereof. All parts with identical part numbers, such as rotors or printed circuit boards, shall be inter changeable without modification.

3.1.9 LUBRICATION AND ADJUSTMENT

All equipment shall be greased, oiled or lubricated and properly adjusted by the Contractor to ensure satisfactory operation. Lifetime or automatic lubrication shall be utilized wherever effective and practicable.

3.1.10 PAINTING

All surfaces suitable for painting shall be painted with commercially available practices to provide a finished coat which is a smooth, even surface, free of runs, sags, blisters, chips, areas of no film or thin film or other defects. Color of the finish coat, except where specified in OSHA or other standards, shall be the manufacturer’s normal commercial color. The Contractor using paint of the same color, type, and manufacture, as the original shall touch up all factory painted surfaces that are damaged during system installation.

3.1.11 NOISE LEVELS

No single item of equipment shall produce an operating noise level in excess of 80 decibels within 4 ft. 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).

3.1.12 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. Fasteners shall be S.A.E.

Grade No. 5 minimum, and shall be plated with a metallic corrosion resistant metal.

All fasteners for similar applications shall be identical.

3.1.13 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.

3.1.13.1 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 full strength for main members, at least 2/3 strength for secondary members and 1/3 strength for miscellaneous details. Joint details and production methods shall be in accordance with the applicable standards of the American Welding Society.

3.1.13.2 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, and concentric with rivet holes and in full contact with the surface of the member. Excessive upsetting of rivets to fill holes is not acceptable.

3.1.13.3 CASTINGS AND FORGINGS.

Castings and forging shall be of the best quality normally used in commercial practice. They shall be of uniform quality and condition. They shall be free from blowholes, porosity, hard spots, cracks, tears, fins, spurs, flash, shrinkage defects, misplaced coring or other injurious defects. Castings and forging shall be commercially machinable, of such quality to preclude weeping of internal fluids through the body, permit machining leak free sealing at cover and closure points and shall not be repaired, plugged or welded in any manner that adversely affects strength, use or machinability.

3.1.14 FLOOR MOUNTING OF EQUIPMENT

Except for non-load bearing components of the system (such as conduit) that may be clamped to the building support steel or bolted to the masonry walls or wooden support structure, all equipment except those items specifically identified in the contract shall be supported by the floor. Welding, cutting or drilling of any components to the building support steel, walls or other structural members is strictly prohibited.

3.1.15 SEISMIC ZONE

DDJC is in a Seismic Zone 4.See UFC 3-310-01, Design: Structural Load Data, for seismic design data. Base/city is Stockton/San Joaquin. Contractor is responsible for ensuring that all equipment is designed and installed to meet these conditions.

The Contractor shall provide certified drawings and calculations showing the Contractor’s mechanical/structural designs meet all the seismic requirements (CDRL A002). Mechanical/structural certification shall be by a professional engineer registered in the State of California.

3.1.16 IDENTIFICATION MARKING

All drives and transfer cases shall have identification plates permanently attached.

Identification data shall include, as a minimum, contract number, manufacturer, serial number, model number and date of manufacture.

3.1.16.1 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 required by the National Electric Code (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.

3.1.17 SPECIAL PROVISIONS

3.1.17.1 INTERRUPTION OF OPERATIONS. Ongoing warehouse operations shall not be curtailed nor suspended except as absolutely essential during system installation.

Any required curtailment or suspension shall be coordinated with at least 5 days notice to the Government through the Contracting Officer’s Representative.

Operations shall not be curtailed nor suspended except as absolutely essential after the installation period if warranty work is required. 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 3.1.17.2).

3.1.17.2 WORKING HOURS. Normal working hours are 0700 - 1530 Monday through Friday excepting Federal holidays. The Contractor may be allowed 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.

3.1.17.3 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 maintain the work site and premises in a clean and neat condition during the installation.

3.1.17.4 UTILITIES AVAILABLE FOR USE CONTRACTOR. Electricity (230/460 volt /120 volt, 60 Hz receptacles), and nominal amounts of water required by the Contractor will be furnished by the Government from existing sources. Make up and take down of connections and lines shall be Contractor’s responsibility.

3.1.17.5 DIMENSIONS. Where required to design, fit and install equipment for use in existing facilities, dimensions shall not be taken from drawings but shall be taken in the field from measurements at the site location. All dimensions in this specification are given in nominal values; therefore, the Contractor will be required to make on site measurements and will be responsible for accurate interface between all equipment and facilities modifications supplied and performed by the Contractor to assure smooth material flow throughout the system.

3.1.17.6 PROTECTION OF GOVERNMENT PROPERTY. This system is to be installed within an operational Government supply system. The Contractor shall take all actions necessary and as directed by the Contracting Officer to protect Government property, including stock items, during system installation.

3.1.17.7 RESTORATION. Whenever existing finish surfaces are cut, broken or damaged in any way by the Contractor in performance of this contract, the Contractor shall be responsible for restoration of the surface. Such restoration, unless otherwise specified in other sections of the specifications, shall be accomplished using materials of a kind, quality, texture and color to match the original surface.

Restoration will be accomplished by workers skilled in the trades involved and shall be left in as near original condition as possible.

3.1.17.8 UNLOADING OF EQUIPMENT. The Contractor shall furnish the necessary personnel and special equipment (MHE, cranes, etc.) and shall be responsible for unloading of all Contractor furnished equipment/material delivered to the site. The Contractor shall give the Contracting Officer Representative 48 hours advanced notice of all Contractor material and equipment deliveries to work site.

3.1.18 SAFETY REQUIREMENTS

3.1.18.1 GENERAL REQUIREMENTS

3.1.18.1.1 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 Electrical Code, OSHA, National Fire Code or other established safety requirements.

3.1.18.1.2 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.

3.1.18.1.3 The safety and health manager or his designated authority must approve all protective equipment. The Contractor shall notify the COR and get approval before commencing work.

3.1.18.1.4 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, and respiratory protection, monitoring for air contaminants and requirements to convey to workers the hazards associated with the operation.

3.1.18.1.5 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.

3.1.18.1.6 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.

3.1.18.1.7 No torch cutting or welding work of any description shall be permitted within the installation boundaries without a permit issued by the Fire Chief, DDJC. Permits must be obtained on a daily basis by Contractor personnel calling telephone extension (209) 839-4492 or visiting the fire department, and identifying the location and type of work to be done.

3.1.18.1.8 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 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.

3.1.18.1.9 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.

3.1.18.1.10 FIRE STOPPING MATERIALS. Conduit penetrations through fire-rated walls shall be fire stopped. A through-penetration fire stop system shall be installed to match the fire rating of the wall. The UL system no. (from the UL Building Materials directory) shall be submitted for approval.

3.1.18.2 INSTALLATION SAFETY PRACTICES.

3.1.18.2.1 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.

Contractor-furnished signs shall indicate all hardhat areas. Safety and health office personnel may inspect the work site at any time for compliance.

3.1.18.2.2 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. The Contractor will remove scrap material, such as empty cartons, wood crates, etc., at the end of each workday.

3.1.18.2.3 Smoking is prohibited except in designated areas.

3.1.18.2.4 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 ducked to outside the building subject to the safety and health manager’s approval.

3.1.18.2.5 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.

3.1.18.2.6 Safety markings shall be in accordance with 29 CFR 1910.144 & 145.

3.1.18.3 FIRE PREVENTION. The DDJC Fire Department will control the use of all fire hydrants. 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.

3.1.18.4 FLAME CUTTING AND WELDING PROCESSES.

3.1.18.4.1 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 a firewatcher on duty whenever there is welding, cutting or open flame devices being used.

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

3.1.18.5 SAFETY PLAN. The contractor shall submit a safety plan no later than one week prior to the pre-construction meeting. The safety plan will address/explain, at a minimum, the following:

The contractor shall provide safety meetings once a month minimum and shall maintain and provide documentation to the Safety Office.

The contractor shall maintain records for daily equipment checks.

The contractor shall conduct safety tailgate meetings prior to the beginning of daily work which pertain to the operations for that day.

A thorough discussion on all required Personal Protective Equipment

(PPE) and the proper use/application All local emergency contact numbers and the phone number/location of the nearest hospital.

How to protect government employees from job hazards (i.e. noise, welding, MHE hazards, overhead hazards, etc.).

Where/how to get fire permits for all welding/grinding operations.

License and certification requirements for every employee involved with any confined space or abatement (i.e., Asbestos, Lead Based Paint removal, etc.). (Note: if using own company’s confined space documentation, the contractor shall submit the document to the facility’s Safety Office for review prior to work commencing.)

3.1.19 CONTRACT DATA REQUIREMENTS

The Contractor shall furnish contract data as required in DD Form 1423, Contract Data Requirements List (CDRL), 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.

TABLE 2

Sequence Title DID ID.

Number A001 Installation Schedule DI-S-SAT1 A002 Drawings, Engineering, and Associated List, Layout Drawings DI-E-SAT2 A003 Drawings, Engineering, and Associated List, As-Built Drawings DI-E-SAT2 A004 Commercial Manuals, Operating Manual DI-E-SAT1

A005 Commercial Manuals, Maintenance Manual with Recommended Spare Parts List DI-E-SAT1

A006 Technical Representative List TSP-001 A007 Training Manual DI-E-SAT A008 Power Requirements DI-E-SAT1

3.2 ELECTRICAL REQUIREMENTS

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

3.2.1 ELECTRICAL INSTALLATION

It shall be the Contractor’s responsibility to connect all required electrical equipment to the Contractor supplied electrical power distribution panels and/or substation. Contractor to provide and install new draw out type circuit breaker in existing Square D Substation (277/480 Volt, 3 Phase, 4 Wire System) located on the east side of Warehouse 59 to provide power to new mechanization equipment electrical panels. Existing substation has existing empty 4” conduits for providing new conductors from substation to new electrical panels. All required conduits, wire, electrical power distribution equipment including transformers, distribution panels, and other electrical hardware shall be Contractor furnished and installed.

The Contractor shall install surge suppressors/filters as required to prevent voltage spikes, low voltage or any other deleterious conditions that may damage or interfere with and/or preclude normal equipment functions. All electrical work shall be in accordance with the NEC and standards of NEMA. All Contractor installed electrical panels shall be clearly and permanently labeled to identify voltage and equipment serviced.

3.2.2 EXISTING PANEL BOARDS

All existing Panel Boards in which work will be performed shall be provided with new typed circuit directories to reflect any changes made. Standard covers shall be installed over all circuit breaker spaces.

3.3 TRAVERSING TRANSPORTER DOCK

3.3.1 GENERAL.

Traversing transporter docks shall be nominal 22 ft. long by 8 ft. - 8 in. wide. The traversing transporter docks shall consist of two separate conveyors mounted in a common frame that will operate independently of each other as per conveyor operator requirements. Each lane of conveyor shall have the capability of transporting five pallet loads each independently or simultaneously. The conveyors will be loaded or unloaded by intra depot transporter trucks and standard fork trucks from front, back, and both sides. The traversing transporter dock shall move, as a single unit, from a home position - inside the building - approximately forty (40) inches through an open cargo door to a load/unload position – at the edge of the building - to allow pallets of material to be transported to/from intra depot transporter vehicles. IT SHALL BE THE RESPONSIBILITY OF THE

CONTRACTOR TO ENSURE THAT TRAVERSING TRANSPORTER DOCKS

ARE EQUIPPED WITH ALIGNMENT FIXTURES TO ENSURE PALLETS OF

MATERIAL FLOW SMOOTHLY FROM THE TRAVERSING TRANSPORTER

DOCKS TO THE GOVERNMENT FURNISHED INTRA DEPOT TRANSPORTER

VEHICLES AND VICE VERSA.

3.3.1.1 DESIGN AND FUNCTIONAL REQUIREMENTS

3.3.1.1.1 PHYSICAL CHARACTERISTICS.

Each traversing transporter dock shall be made up of two independently controlled and driven roller conveyor lanes. Each lane shall have a nominal 45 inches wide conveying surface and shall carry a live load of maximum 500 pounds per linear foot at 40 ft. per minute constant speed. Traversing transporter dock height, from floor to top of rollers, shall be 22”. All units shall have adequate bracing to provide a rigid and durable construction. Defense Distribution Depot San Joaquin, CA.

(DDJC) is in a Seismic Zone 4. Contractor is responsible for ensuring that all equipment is designed and installed to meet these conditions. Note: the width of the IDT station/dock and the traversing conveyor unit shall match that of the IDT to ensure ease of transfer of material between the IDT and the conveyors. The IDT conveyors have a combined width of 104” frame to frame (each conveyor is 45” wide nominal) with a 9” spacing between conveyors. See attached photos of IDT.

Appropriate drawings and calculations shall show certification of compliance.

Certification of the design to meet the Seismic Zone 4 requirement shall be by a Professional Engineer registered with the State of California.

3.3.1.1.2 FRAME.

Conveying frame shall be constructed of formed steel designed in size and weight to support 500 pounds per linear foot without conveyor flex or span sag. Frames shall be punched for rollers to set high, not less than ¼” or more than ½” above the outside frame rails. The inside conveyor rails may be set higher than the top of roller. Each conveyor lane width (between frame) shall be a nominal 48 inches clear.

3.3.1.1.3 ROLLERS.

All Rollers shall be zinc coated.

3.3.1.1.4 ROLLER AXLES.

Roller axles or shafts shall be one piece, non-rotating of through construction and shall be solid hexagonal shaped steel. Axles shall be shall be spring retained on chain driven live roller units. Axles held in place by snap rings, cotter keys or locking nuts are not acceptable. All Roller axles or shafts shall be zinc coated.

3.3.1.1.5 CHAIN.

Chain driven rollers, if required, shall be sized to handle the rated load. Sprockets, two per roller, shall be welded to roller tube and every roller shall be driven. The top of the conveyor frame shall be removable for roller chain lubrication and inspection. The removable frame top does not have to be a straightly load bearing member, however, it must be rugged and bolted in place and easily removable.

3.3.1.1.6 BEARINGS.

Bearings shall be precision ball or roller bearings, caged rolling element with lip seals and grease zinc fittings. The pulley bearings shall be a replaceable cartridge type design and equipped with zinc fittings. Bearing inner races shall not rotate on roller shafts, and outer races shall not rotate relative to the roller tubes when installed. Bearings shall be greased, packed for life, and shall include shields to prevent lubricant leakage and to prevent entrance of foreign matter from outside.

3.3.1.1.7 DRIVES.

Drive(s) shall be of the gear head, right angle, parallel shaft or cycloidal disc type, right angle, parallel shaft or cycloidal disc, sized to adequately power working loads. Drive hook ups may be accomplished through the use of chains and sprockets or by direct connection, and shall be properly guarded and mounted on a rugged structure of formed steel bases. Drive(s) shall be a constant speed motor capable of moving loads at speed as noted. Drive(s) shall be located under and within the conveyor bed on the traversing chassis. For the purpose of estimating the required horsepower on accumulative conveyor, use the figure of 500 pounds per linear ft. live load. Floor pits are not permitted.

3.3.1.1.7.1 DRIVE MOTORS.

All drive motors shall be 460/230 volts, three-phase, 60 Hz, one directional, single speed, and totally enclosed fan cooled type with sealed, permanently lubricated bearings.

3.3.1.1.7.2 TRAVERSING CHASSIS DRIVE.

Traversing chassis drive shall be a single drive motor and reducer, with direct or chain final drive reduction. The motor shall be 460/230 volt three-phase 60 hertz, totally enclosed fan cooled with the addition of a (liquid) hydraulic coupling between the motor and reducer. The hydraulic coupling shall reduce the shock of starts and stops of the loaded chassis and conveyor load. The hydraulic coupling shall be able to total slip run without overrunning the chassis track stops if the block chassis sops are used on the track ends. The hydraulic coupling shall be sized to operate without overheating or seizing under full load conditions at a 100 percent duty cycle. Other suitable chassis drive configurations such as controlled current AC or DC. drive motor with soft start and soft stop electrical method are acceptable.

The chassis drive shall require one drive motor to drive two track wheels on a common drive shaft. The chassis frame and conveyor frame may be a unitized type of construction designed and fabricated for heavy Industrial use. The traversing speed will be 30 feet per minute.

3.3.1.1.8 PALLET STOP.

Each transporter conveyor lane shall be equipped with motor operated pallet stops (blade stops) located at both feed and discharge ends independently operated. The pallet stops will be 2 inches higher than the conveyor bed. The truck driver will lower and raise the blade stops using the Traversing Transporter Dock Control Panel. Each stop shall be a minimum of 24 inches wide and be able to withstand load impacts without deformation or equipment damage.

3.3.1.1.9 TRAVERSING UNIT CHASSIS.

Each chassis shall carry two conveyor lanes, as described in section 3.3.2.3, and be ruggedly constructed of structural or formed steel adequate to support the required loads. The wheels, driver and idler, shall be easily removable from the axle and shall be taper locked, bushed, and key retained to the axle. The axle wheel bearings shall be externally mounted, flanged, roller or precision ball bearing type bolted to the wheel housing. The bearings shall be cam locked to the axle; setscrews are not acceptable.

3.3.1.1.10 TRAVERSING UNIT TRACKS.

The tracks shall provide a smooth and positive surface to support and guide the travel of the traversing transporter dock. Construction shall be of structural or formed steel sized to support the dock plus its maximum live load weight. Track and associated components shall be supplied. The track shall be designed to be mounted to the floor. Low profile mechanical safety stops shall be provided at the ends of all tracks to prevent over travel of the dock in the event of switch malfunction. The tracks and stops shall not interfere with forklift travel.

3.3.1.1.11 ELECTRIFICATION SYSTEM.

The Contractor will embed the control and power wiring to the traversing transporter dock in the floor. The system shall be designed with no splices in the solid copper conductors. The system shall be designed for the Contractor designed track travel length. The system, when installed, shall not extend above floor level.

The system shall not interfere with forklift travel at any point.

3.3.1.2 CONTROLS

3.3.1.2.1 GENERAL.

Panel and switch construction shall be rated NEMA 4X for exterior and interior locations. Floor mounting of electrical devices and fittings shall be made flush to the floor surface to avoid impeding forklift traffic access and tripping hazards.

Surface mounting of electrical devices and fittings to the floor is not acceptable.

Switches shall be push button types. Stop buttons shall be red for easy identification. Traversing docks shall be equipped with a Contractor designed electrical/electronic stop system, which will stop the transporter when the unload end on the traversing transporter dock is flush with the end of dock wall. Tape switches or any type of limit switch device, which requires contact with the truck to stop the traversing transporter dock is unacceptable. Traversing transporter docks shall also be equipped with a proximity switch system on both ends of the dock, which shall protect personnel from being hit by the transporter while in motion. Utilizing Dead Man controls for the Travel Out and Travel In switches located on the Master Panel for Traversing Transporter Dock (Figure 1) and Traversing Transporter Dock Control Panel for Truck Driver (Figure 2) is acceptable. A tactile bumper or tape switch system is not acceptable for this purpose. All electrical/electronic devices shall be protected from impact by the frame of the traversing transporter dock. The equipment shall conform to the applicable rules of the National Electrical Code (NEC); and materials and equipment shall conform to the applicable standards of Underwriters Laboratories

(UL).

3.3.1.2.2 MASTER CONTROL PANEL.

Each traversing transporter dock shall be supplied with a master control panel, located inside and adjacent to the traversing transporter dock. The panel front shall have an amber pilot light to indicate when electrical power is being supplied to equipment. The panel shall contain switches with identification plates to indicate the function of each control. The panel and all controls and connections to this panel shall be rated NEMA 4X. See (Figure 1) for a typical layout.

3.3.1.2.2.1 DOOR SWITCH.

The door switch shall incorporate a lockout feature, which shall incapacitate the other switches in the panel until the door is in the fully open position. This switch shall be a three-segment switch designated up, stop, and down. The door switch shall be independent of the dock system operation and shall not be connected to the dock system master switch.

3.3.1.2.2.2 MASTER/SYSTEM SWITCH.

This switch shall control electrical power for the complete dock system. Separate on and off push buttons shall be provided. An amber pilot light to indicate that electrical power is on shall be incorporated with this switch.

3.3.1.2.2.3 CONVEYOR SWITCHES.

Two each three segment switches to control the operation of the left and right conveyor lanes shall be provided. Each switch shall control a conveyor lane and shall operate independently of the other. Each switch shall be designated by lane, out or in (depending on transporter dock function and stop). Each switch shall be momentary contact type. See (Figures 2 and 3) for a typical layout.

3.3.1.2.3 TRAVERSING TRANSPORTER DOCK PANELS FOR TRUCK DRIVER.

The panels shall be located outside on the street side retaining wall of the dock or side of the building to provide the transporter truck driver easy access to all controls. This panel may, depending upon site conditions, be suspended from the building structure; pedestal mounted or set flush into a routed niche on the retaining wall. The panel and all controls and connection to this panel shall be weather tight and rated NEMA 4X for Traversing Transporter Docks. All wiring runs to these panels shall be protected from the elements and present no hazard or obstacle to personnel and operating MHE. See (Figure 2) for a typical layout.

3.3.1.2.4 TRAVERSING TRANSPORTER DOCK CONTROL PANELS.

These panels shall be securely attached to the adjacent wall and be readily accessible for operator control. The panel and all controls and connections to this panel shall be rated NEMA 4X for Traversing Transporter Docks. See (Figures 3) for a typical layout.

3.3.1.2.4.1 TRAVERSING TRANSPORTER DOCK TRAVERSE.

This switch shall be a three-segment switch designated Out, Stop, and In. The switch shall control the traversing transporter dock traversing movement. The traverse in and out buttons shall be dead-man type.

Figure 1.

MASTER PANEL FOR TRAVERSING TRANSPORTER DOCK

MASTER PANEL

FOR TRAVERSING

TRANSPORTER DOCK

DOOR

UP-STOP-

DOWN

TRAVEL

OUT

POWER

ON

STOP

POWER

OFF

IN

Figure 2.

TRAVERSING TRANSPORTER DOCK CONTROL PANEL

- FOR TRUCK DRIVER’S USE

TRAVERSING TRANSPORTER DOCK

CONTROL PANEL FOR TRUCK DRIVER

DOOR

UP-STOP-

DOWN

CONV #1

CONV #2

PALLET

STOPS -

FEED END)

STOPS -

FEED END

STOPS -

DISCHARGE

END

STOPS -

DISCHARGE

END

Figure 3.

TRAVERSING TRANSPORTER DOCK CONVEYOR PANEL

(ON SIDE OF CONVEYOR/DOCK)

TRAVERSING

TRANSPORTER DOCK

CONVEYOR PANEL

(ON WALL)

3.3.1.3 TRAVERSING SAFETY SIGNALS.

The traversing transporter dock shall be equipped with visual and audible devices to warn when the unit is in motion. These devices shall activate automatically with pushing of the traverse button and remain operating until the equipment is stopped.

Audible device shall be positioned and oriented to cause minimal operator discomfort while sounding.

3.3.1.4 TRAVERSING TRANSPORTER DOCK DOORWAY.

Controls to raise and lower the door shall be incorporated into the Master Control Panel (Figure 1) located at the dock interior adjacent to the door frame, on inside of the building and the Control Panel for the Truck Driver (Figure 2) located adjacent to the door on the outside of the building.

3.3.1.5 BUMPER.

A rubber bumper will be installed on the building wall at all traversing transporter docks located at Building 59 to match the rear center bumper on the IDT. The bumper will be approximately 10” high and 18” long and 4” deep with the bottom of the bumper being approximately 28” above the ground.

3.3.2 PALLET CONVEYOR

3.3.2.1 GENERAL

The pallet conveyor shall consist of powered chain driven live roller conveyor sized to handle the material, reference paragraph 1.6. The conveyor elevation will be 22” top of roller.

3.3.2.2 DESIGN AND FUNCTIONAL REQUIREMENTS

3.3.2.3 PHYSICAL CHARACTERISTICS. Conveyor shall have the following characteristics.

a. Galvanized 11 gauge rollers.

b. Carrying rollers will be 2 ½” diameter on 5” centers, and the conveyor speed will be 30 feet per minute.

c. Drive chain shall be No. 40 roller-to roller and No. 60 main drive chain.

d. Roller axles shall be spring loaded so that rollers can be removed and replaced without use of tools.

e. Bearings for carrying, accumulation and return rollers shall be ABEC-1 or equivalent with ball bearings securely mounted in a noise suppressing housing, which is swaged into the roller tube.

f. All drive motors shall…