PWS Inspect Hangar Door Welds Binder.pdf

PERFORMANCE WORK STATEMENT (PWS)

FOR

Hangar Door Inspections

1.0 General:

1.1 Scope: The contractor shall provide all personnel, equipment, tools, materials, supervision, and quality control necessary, except as specified in Paragraph 3.0, to perform weld inspection services as defined in this Performance Work Statement

(PWS).

1.2 Background: The Air National Guard (ANG) has had welds fail on vertical lift fabric door structural members and is requiring an assessment of all welds on door-bottom beams.

1.3 Period of Performance (PoP): Work must be completed within 90 days after notice-of-award.

1.4 General Information: Contractor and all personnel shall comply with the Standard Industry of New York State Codes. Contractor shall work within the time line specified by COR.

• Contractor shall field verify all site conditions, quantities, measurements, and project requirements.

• Contractor shall protect and barricade all work areas at all times to protect workers and the public from injury.

• Contractor shall protect all structures, utilities, vegetation, sidewalks and vehicles from damage at all times. Replace all damaged materials with new materials to the satisfaction of the Government, at no additional cost to the Government.

1.4.1 Recognized Holidays: The following are recognized US holidays. The contractor shall not perform services on these days:

1.4.2.1 New Year’s Day

1.4.2.2 Martin Luther King, Jr.’s Birthday

1.4.2.3 President’s Day

1.4.2.4 Memorial Day

1.4.2.5 Independence Day

1.4.2.6 Labor Day

1.4.2.7 Columbus Day

1.4.2.8 Veterans Day

1.4.2.9 Thanksgiving Day

1.4.2.10 Christmas Day

1.4.3 Place and Performance of Services: Work hours shall be Monday thru Friday 0700-1530 hours, with the exception of Federal holidays or when the Government facility is closed due to local or national emergencies, administrative closings, or similar Government-directed closings. Contractor must have prior approval in writing to work outside these guidelines. Performance shall be at Buildings 138 and 610 at Hancock Field ANG Base and Buildings 20470 and 20471 at Fort Drum Military Reservation (Wheeler-Sack Army Airfield). The contractor shall maintain an adequate work force for the uninterrupted performance of all tasks defined within this PWS when the Government facility/installation is not closed for the above reasons. When hiring personnel, the contractor shall keep in mind that the stability and continuity of the work force are essential. Teleworking and telecommuting is not authorized.

1.4.3.1 Unscheduled gate closures by the Security Forces Police and Military Police may occur at any time causing all personnel entering or exiting a closed installation to experience a delay. This cannot be predicted or prevented. Contractors are not compensated for unexpected closures or delays. Vehicles operated by contractor personnel are subject to search pursuant to applicable regulations. Any moving violation of any applicable motor vehicle regulation may result in the termination of the contractor employee’s installation driving privileges.

1.4.3.2 The contractor’s employees shall become familiar with and obey the regulations of the installation; including fire, traffic, safety and security regulations while on the installation. Contractor employees should only enter restricted areas when required to do so and only upon prior approval. All contractor employees shall carry proper identification with them at all times. The contractor shall ensure compliance with all regulations and orders of the installation which may affect performance.

1.4.4 Security Requirements. The contractor shall comply with all applicable installation/facility access and local security policies and procedures, which may be obtained from the Contracting Officer’s Representative (COR). The contractor shall also provide all information required for background checks to meet installation access requirements to be accomplished by installation Security Office. The contractor shall ensure compliance with all personal identity verification requirements as directed by DOD and/or local policy. Should the Force Protection Condition (FPCON) change, the Government may require changes in contractor security matters or processes.

1.4.4.1 COMSEC/IT Security. All communications with DOD organizations are subject to communications security (COMSEC) review. All telephone communications networks are continually subject to intercept by unfriendly intelligence organizations. DOD has authorized the military departments to conduct COMSEC monitoring and recording of telephone calls originating from, or terminating at, DOD organizations. Therefore, the contractor is advised that any time contractor place or receive a call they are subject to COMSEC procedures. The contractor shall ensure wide and frequent dissemination of the above information to all employees dealing with DOD information. The contractor shall abide by all Government regulations concerning the authorized use of the Government's computer network, including the restriction against using the network to recruit Government personnel or advertise job openings.

1.4.2.2 Protection of Personally Identifiable Information (PII). The contractor shall protect all Personally Identifiable Information (PII) encountered in the performance of services in accordance with DFARS 224.103 and DoDD 5400.11, Department of Defense Privacy Program, and DoD 5400.11-R. If a PII breach results from the contractor’s violation of the aforementioned policies, the contractor shall bear all notification costs, call-center support costs, and credit monitoring service costs for all individuals who’s PII has been compromised.

1.4.5 Post Award Conference/Periodic Progress Meetings: The contractor agrees to attend any post award conference convened by the KO in accordance with Federal Acquisition Regulations Subpart 42.5. The KO, Contracting Officer’s Representative (COR), and other Government personnel, as appropriate, may meet periodically with the contractor to review the contactor’s performance. At these meetings, the Contacting Officer will apprise the contractor of how the Government views the contractor’s performance and the contractor shall apprise the Government of problems, if any, being experienced The contractor shall resolve outstanding issues raised by the Government.

Contractor attendance at these meetings shall be at no additional cost to the Government.

1.4.6 Contract Manager (CM): The contactor shall provide a CM who shall ensure performance under this contract. The name of this person, and an alternate who shall act for the contractor when the CM is absent, shall be designated in writing to the KO.

The CM or alternate shall have full authority to act for the contractor on all contract matters relating to daily operation of this contract. The CM shall work through the COR, (or the KO if a COR is not assigned), to resolve issues, receive directions and ensure adequate performance of services. The CM shall ensure that contractor employees do not perform any services outside the scope of the contract without an official modification issued by the KO. The CM shall ensure contractor employees understand that services performed outside the scope of the contract are performed wholly at the expense of the contractor.

1.4.7 Identification of Contractor Employees: All contractor personnel attending meetings, answering Government telephones and working in other situations where their contractor status is not obvious to third parties are required to identify themselves as such to avoid creating an impression that they are Government employees. The contractor shall ensure that all documents or reports produced by contractor personnel are suitably marked as contractor products or that contractor participation is appropriately disclosed. The contractor’s status as a “contractor” shall be predominantly displayed in all correspondence types (to include signature blocks on e-mail) and dealings with Government or non-Government entities/ Contractor personnel shall wear identification badges distinguishing themselves as such. The badges shall have the company name, employee name and the word “contractor” displayed. The contractor shall retrieve all identification media (including vehicle passes) from their employees who depart employment for any reason. All identification media (i.e., badges and vehicles passes) shall be returned to the KO within 14 days of an employee’s departure.

1.4.8 Combating Trafficking in Persons: The United States Government has adopted a zero tolerance policy regarding trafficking in persons. Contractors and contractor employees shall not engage in severe forms of trafficking in persons during the period of performance of the contract; procure commercial sex acts during the period of performance of the contract; or use forced labor in the performance of the contract. The Contractor shall notify its employees of the United States Government’s zero tolerance policy, the actions that will be taken against employees for violations of this policy. Such actions may include, but are not limited to, removal from the contract, reduction in benefits, or termination of employment. The Contractor shall take appropriate action, up to and including termination, against employees or subcontractors that violate the US Government policy as described at FAR 22.17.

1.4.9 Organizational Conflicts of Interest (OCI): The contractor and subcontractor personnel performing services under this contract may receive, have access to or participate in the development of proprietary or source selection information (e.g., cost or pricing information, budget information or analyses, specifications or work statements, etc.) or perform evaluation services which may create a current or subsequent OCIs, as defined in FAR Subpart 9.5. The contractor shall notify the KO immediately whenever it becomes aware that such access or participation may result in any actual or potential OCI and shall promptly submit a plan to the KO to avoid or mitigate any such OCI. The contractor’s mitigation plan will be determined to be acceptable solely at the discretion of the KO. In the event the KO unilaterally determines that any such OCI cannot be satisfactorily avoided or mitigated, the KO may affect other remedies as he or she deems necessary, including prohibiting the contractor from participation in subsequent contracted requirements that may be affected by the OCI.

1.5 Special Qualifications: Contractor personnel performing inspection service must be an American Welding Society (AWS) Certified Weld Inspector and must provide KO with proof of certification prior to start of work.

2.0 Definitions and Acronyms:

2.1.1 CONTRACTOR. A supplier or vendor awarded a contract to provide specific supplies or service to the government. The term used in this contract refers to the prime.

2.1.2 CONTRACTING OFFICER (KO). A person with authority to enter into, administer, and or terminate contracts, and make related determinations and findings on behalf of the government. Note: The only individual who can legally bind the government.

2.1.3 CONTRACTING OFFICER'S REPRESENTATIVE (COR). An employee of the U.S. Government designated by the KO to monitor contractor performance. Such appointment shall be in writing and shall state the scope of authority and limitations.

This individual has authority to provide technical direction to the Contractor as long as that direction is within the scope of the contract, does not constitute a change, and has no funding implications. This individual does NOT have authority to change the terms and conditions of the contract.

2.1.4 DEFECTIVE SERVICE. A service output that does not meet the standard of performance associated with the Performance Work Statement.

2.1.5 DELIVERABLE. Anything that can be physically delivered and includes non-manufactured things such as meeting minutes or reports.

2.1.6 KEY PERSONNEL. Contractor personnel that are evaluated in a source selection process and that may be required to be used in the performance of a contract by the Key Personnel listed in the PWS. When key personnel are used as an evaluation factor in best value procurement, an offer can be rejected if it does not have a firm commitment from the persons that are listed in the proposal.

2.1.7 PHYSICAL SECURITY. Actions that prevent the loss or damage of Government property.

2.1.8 QUALITY ASSURANCE. The government procedures to verify that services being performed by the Contractor are performed according to acceptable standards.

2.1.9 QUALITY ASSURANCE SURVEILLANCE PLAN (QASP). An organized written document specifying the surveillance methodology to be used for surveillance of contractor performance.

2.1.10 QUALITY CONTROL. All necessary measures taken by the Contractor to assure that the quality of an end product or service shall meet contract requirements.

2.1.11 SUBCONTRACTOR. One that enters into a contract with a prime contractor. The Government does not have privity of contract with the subcontractor.

2.1.12 WORK DAY. The number of hours per day the Contractor provides services in accordance with the contract.

2.1.13 WORK WEEK. Monday through Friday, unless specified otherwise.

2.2 ACRONYMS:

AFARS Army Federal Acquisition Regulation Supplement AR Army Regulation AT/OPSEC Antiterrorism/Operational Security AWS American Welding Society CFR Code of Federal Regulations CONUS Continental United States (excludes Alaska and Hawaii) COR Contracting Officer Representative COTS Commercial-Off-the-Shelf DA Department of the Army DD250 Department of Defense Form 250 (Receiving Report) DD254 Department of Defense Contract Security Requirement List DFARS Defense Federal Acquisition Regulation Supplement DOD Department of Defense FAR Federal Acquisition Regulation GFP/M/E/S Government Furnished Property/Material/Equipment/Services IA Information Assurance IS Information System(s) KO Contracting Officer OCI Organizational Conflict of Interest ODC Other Direct Costs PII Personally Identifiable Information PIPO Phase In/Phase Out POC Point of Contact PRS Performance Requirements Summary PWS Performance Work Statement QA Quality Assurance QAP Quality Assurance Program QASP Quality Assurance Surveillance Plan QC Quality Control QCP Quality Control Program TE Technical Exhibit

3.0 Government Furnished Property, Material, Equipment and Services (GFP/M/E/S):

The Government will provide the property, material, equipment, and/or services listed below solely for the purpose of performance under this contract:

3.1 Property: The Government will not furnish any workspace for the contractor to perform services outlined in this PWS to include desk space, telephones, computers and other items necessary to maintain an office environment.

3.2 Utilities: All utilities in the facility will be available for the contactor’s use in the performance of this contract. The contractor shall instruct employees in utilities conservation practices. The contractor shall operate under conditions that preclude the waste of utilities, which include turning off the water faucets or valves after using the required amount. Any connection to a water supply must be protected by a backflow prevention device approved by the COR.

4.0 Contractor Furnished Property, Materials, and Equipment (CFP/M/E):

4.1 General: Except for those items specifically stated to be Government-Furnished in Paragraph 3.0, the contractor shall furnish everything required to perform these services as indicated in Paragraph 1.1.

5.0 Requirements.

5.1 The contractor shall provide KO with AWS Welding Inspector certifications prior to start of work.

5.2 The contractor shall visually inspect all splice plate welds and all welds along bottom beans of fabric doors.

5.3 The contractor shall provide within 10 days of inspection a Weld Inspection Report documenting inspection results.

5.3.1 Report must include status of welds inspected (structural soundness, deficiencies, degradation, etc.)

5.3.2 Report must include description of repairs required to bring the door back into service.

5.4 The contractor shall remove and reattach door fabric if removal is necessary to complete inspection of welds.

5.5 Contractor Manpower Reporting Application (CMRA):

5.5.1 Contractors must complete the CMRA at the end of each fiscal year. The application may be accessed at https://cmra.army.mil/Login/aspx. For the administrative purposes of this paragraph, “the Army” includes the National Guard Bureau and subsequently the Air National Guard in its contracting procedures.

5.5.2 The CMRA is an online database that automates the Army’s contract management and reporting process for contract management personnel by allowing users to enter their contract information, track contract data, and view reports based on contract data in the application. Its primary function is to support the Contractor Manpower Reporting program that was approved on September 13, 2002 by the https://cmra.army.mil/Login/aspx

Business Initiatives Council to improve the Army’s visibility of contractor services to planners and programmers.

5.5.3 The Contractor Manpower Reporting business process captures information of funding source, contracting vehicle, organization supported, mission and function performed, labor hours, and labor costs for contracted efforts. It enables the Army to:

• Fully understand the total Army workforce

• Provide better oversight of the workforce

• Ensure the Army receives full value from contractor workforce

• Better account for total Army workforce

6.0 Applicable Publications. Publications relevant to this PWS are listed below:

• AWS D1.1 Clause 6. Cyclically Loaded Structures

TECHNICAL EXHIBIT 1

Deliverables Schedule

PWS Paragraph and Title Frequency Number of copies Medium/Format Submit to

1.4.7 Identification of

Contractor Employees

Return within 14 days of employee’s departure from contract performance.

Originals(s) as applicable

Hard copy COR

5.1 Professional Certifications

Provide prior to start of work.

1 per each inspection contractor

Electronic submission COR

5.3 Weld Inspection

Report

Provide within 10 days of inspection.

2 1 Hard copy and 1 compact disc or electronic submission

COR

5.5

CMRA

End of fiscal year (September 30)

N/A Electronic submission at CMRA web site

CMRA web site

TECHNICAL EXHIBIT 2

INSPECTION REPORT EXAMPLE

ACUREN

Mega Door Inspection - Hanger 409

179 t h Civil Engineering Squadron

BC&G

WEITHMAN

CONSTRUCTIO

N

Client: BC&G Weithman Construction

Project: Mega Door Structural Inspection Hanger 409 Location: 179th Civil Engineering Squadron - Mansfield, OH BC&G Purchase Order:

19-01651

Acuren Job Number: 670191

Contact: Roger Kehres (BC&G Weithman Construction)

Inspection Dates: October 8-9, 2019

Acuren Inspection, Inc.

535 Kennedy Rd.

Suite D Akron, OH, USA 44305 Phone: (330) 733-8160

(800) 321-0878 Fax: (330) 733-8644

A Rockwood Company

October 10, 2019

At approximately 0800 on 10/08/19, I met with Roger Kehres, Carl Gilliam and Mark Clinard to discuss scope of work, and preliminary assessment of the bottom support structure for the Hanger 409 Mega Door. The BC&G Weithman crew disassembled the door skin to allow access to internal ''truss" system.

Mega Door consists of (3) individual sections noted as; Door 1, Door 2 and Door 3 (from left to right while standing inside looking out). Trusses for Door's 1 and 3 are also noted as Left or Right from same viewpoint. Structures are coated; Carbon Steel welded box trusses with plates welded to each end. Door's 1 and 3 consist of (2) trusses bolt spliced at mid-point and approximately 63'-10" in length. Door 2 is approximately 34'-0" in length and is located above man-door in center section.

Doors land 3 Left & Right truss sections:

Each truss section consists of (320) welds, (4) plate to tube welds per end with (312) 1" square tubing welded to 3" square tube. 100% Visual and approximately 75% Magnetic Particle Testing (MT) was performed with approximately 30 - 40 % of welds having some type of indication noted. Of that percentage, approximately 25 - 30 % have rejectable indications as interpreted to AWS D1.1 "Cyclically Loaded Structures", 2015 Edition. Photos attached below.

Door 2:

This truss was 100% visually inspected. (4) Missing welds were noted, (3) at right end, bottom side and

(1) on top back-side approximately mid-point. All other existing welds were found to be acceptable to the visual requirements of AWS D1.1 with only minor, but acceptable, random porosity in a few welds. Photos attached below.

Interpretation Key: (as noted in photos)

LOF- Lack of Fusion UC- Undercut

POR- Porosity (gas holes left in surface of weld) PH- Pin Hole (porosity open to the surface).

INCOMP- Incomplete welds terminated before tie-in at comers had been achieved.

Typical Door Section (2 Trusses, Door 3)

Heavy Undercut noted - Doors 1 & 3

3 of13

Lack of Fusion at Toe of Weld as shown by Magnetic Particle Testing (MT)

Lack of Fusion as found by MT

4 of13

Typical noting of defects on 30 to 40 % of structures.

Missing Weld • Door 3, Left Truss

6 ofl3

Missing Weld, Porosity, Undercut - Door 3, Left Truss

7 ofl3

Door 3, Splice Joint - Improperly seated bolt; Washer resting on weld metal and mating surfaces are not in intimate contact.

Another View of Bolted Splice

Lack of Fusion at Toe of Weld - Door 1, Right Truss (Found by M1)

Missing Weld door 1 left truss

8 of l3

Typical Welds (Approx.30-40%) of Door l & Door 3

Typical Welds (Approx. 30-40%) of Door 1 & Door 3

9 of13

End Plate at Hoisting Point, Lack of Fusion - Door 3, Left End, Top Corner (Found by MT)

Door 3 - Left Truss

Missing Weld End Plate Gusset - Door 3, Right-hand Hoisting Point

Door 2 Truss

Typical Weld Profile - Door 2

Missing Weld- Door 2, Top Back Side, Mid-point of Truss

Missing Weld - Door 2, Right End

Typical Weld Profile - Door 2

It is this inspector's opinion that the trusses on Doors 1 and 3 be rebuilt and replaced as soon as possible.

Furthermore, I recommend having the doors assessed by an engineer for stress evaluations during operational use. In my professional opinion, during the manufacturing of these doors there was a blatant disregard for AWS approved welding practices resulting in a complete lack of weld quality and workmanship on these structures. Please note that the photos attached above are just a small sampling of defects noted. I can put no faith in the workmanship and quality on the doors 1 and 3 trusses.

This pictures attached here are just a small sampling of defects noted.

Should you like to discuss these inspections and my findings in further detail, please feel free to contact my directly.

Michael A. Brown

AWS CWI #: 03030591

SNT-TC-la Level II - VT/MT/PT

Michael A Brown CWI 03030591 QC1 EXP. 3/1/202

TECHNICAL EXHIBIT 3

Door Drawings

Attachment 1: Hancock Field ANG Base, Building 138

Attachment 2: Hancock Field ANG Base, Building 610

Attachment 3: Fort Drum Military Reservation, Wheeler-Sack Airfield, Buildings 20470 and 20471.

NOTE: Door designs are identical for both Fort Drum hangars.

Attachment 1

Hancock Field ANG Base, Building 138

Assembly Drawings and Parts List

17113 Load Diagram and Notes

17192 Assembly Drawing, Elevation

17192(P) Parts List Door

17193 Assembly Drawing, Plan View

17194 Assembly Drawing, Sections

17199 Guide Rails

17300 Header Box Assembly Drawing

17300(P) Parts List Header Box

Attachment 2

Hancock Field ANG Base, Building 610

19989 Load Diagram and Notes

20123 Assembly Drawing, Elevation

20123(P) Parts List Guide Rails

20124 Assembly Drawing, Plan View

20125 Assembly Drawing, Sections

20126 Door 1 Header Assembly Box

20126(P) Parts List Door 1 Header Box

20127 Door 2 Assembly Drawing, Header Box

20127(P) Parts List Door 2 Header Box

20128 Door 3 Header Assembly Box

20128(P) Parts List Door 3 Header Box

20136 Mullion #12 Assembly Drawing

20136(P) Parts List Mullion #12 Assembly

20137 Mullion #23 Assembly Drawing

20137(P) Parts List Mullion #23 Assembly

20135 Guide Rails

20140 Mullion #12 & #23 Guide Rails

Attachment 3

Fort Drum Military Reservation, Wheeler-Sack Airfield, Buildings 20470 and 20471.

NOTE: Door designs are identical for both Fort Drum hangars.

45541 Load Diagram and Notes

45672.pdf Parts List, General

45672 Assembly Drawing, Elevation

45673 Assembly Drawing, Plan Views

45674 Assembly Drawing, Sections

45681.pdf Parts List, Door Leaf

45681 Assembly Drawing Door Leaf

45678.pdf Parts List, Bottom Beam

45678 Assembly Drawing, Bottom Beam

45675 Guide Rails

45542 Electrical Layout Drawing