Attachment 0007 - PWS 7 Maintenance.docx

RADFORD ARMY AMMUNITION PLANT

PERFORMANCE WORK STATEMENT (PWS)

PWS 7: Maintenance of Active Facilities April 2026

1. General Information

1.1. Scope: The scope of this PWS includes normal and routine maintenance of the following elements:

1.1.1. The Contractor shall be responsible for the maintenance of all Government Furnished Property (GFP) across the entire Radford Army Ammunition Plant (RFAAP), including but not limited to land, buildings, structures, rail, infrastructure, vehicles, and equipment as prescribed by Federal Acquisition Regulation (FAR) 52.245-1 at the Main Plant (Montgomery/Pulaski County) and the New River Unit (Dublin).

1.1.1.1. Land: All grounds contained within and including the perimeter fencing of the Main Plant and New River Unit sites to include personnel walkways, roadways, vegetation, and land. The perimeter fencing shall be maintained in accordance with PWS 6 requirements.

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

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

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

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

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

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

1.1.1.8. Note that all fire equipment systems inspections, test, and maintenance shall be performed IAW the National Fire Protection Association (NFPA) Standards and Codes and PWS 3 requirements.

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

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

1.2. Program Management and Meetings: The Contractor shall hold recurring monthly meetings with the Government to discuss Contract Data Requirements Lists (CDRLs), Key Performance Indicators (KPIs), work order backlogs, and overall maintenance strategy.

1.3. Applicable Documents

1.3.1. The Contractor shall utilize the below Army Regulations (AR) and UFCs for guidance and shall be held accountable to these requirements:

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

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

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

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

1.3.1.5. AR 420-5 Chapter 9: Fire Protection

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

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

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

1.3.2. Compliance Flow-Down: The Contractor is responsible for adhering to all subsidiary regulations, codes, and industry standards (e.g., National Fire Protection Association (NFPA), American Water Works Association (AWWA), American Society of Mechanical Engineers (ASME) cited or referenced within these primary governing documents. If conflicts arise, the most stringent regulatory standard shall apply.

1.4. Definitions

1.4.1. Maintenance Plan: Maintenance Plan (MP): The governing document written by the Contractor to describe how the Contractor shall meet the requirements outlined in this PWS.

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

1.4.3. Normal Maintenance: Inclusive of but not limited to periodic, day-to-day requested care of production and all elements outlined in section 1.1.

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

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

1.4.6. Deferred Maintenance: Any maintenance tasks that are not performed within the defined timeframes for completion.

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

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

1.4.9. Computerized Maintenance Management System (CMMS): Software that centralizes all maintenance information and facilitates maintenance processes. It helps optimize the utilization and availability of physical equipment and other elements

1.4.10. through prioritizing and scheduling maintenance activities.

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

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

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

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

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

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

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

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

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

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

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

1.4.22. Schedule Compliance: Percentage of scheduled WOs completed IAW the schedule. Work that is not completed IAW the schedule will be considered deferred maintenance at the Government’s discretion.

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

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

1.5. Abnormal Maintenance (defined in Section 1.4.5) and Maintenance of Inactive Facilities (MIF) fall outside the scope of this PWS.

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

2. Technical Requirements

2.1. The Contractor shall maintain all facility assets and equipment IAW the approved Facilities Maintenance Plan to minimize planned and unplanned downtime and maximize asset life cycles in support of production and utility operations

2.2. Unless otherwise prescribed herein, maintenance shall be performed IAW chemical industry best practices for a complex industrial environment where equipment reliability and asset integrity play a crucial role in ensuring safety and efficiency. Given the nature of operations, maintaining asset integrity long-term requires robust operational maintenance strategies.

2.3. Maintenance Plan (MP)

2.3.1. The Contractor shall annually develop, administer, and execute a comprehensive MP (CDRL A07-001). Initial submission of the MP shall be provided no later than 90 calendar days prior to operational control and annual submissions thereafter by 30 January of each year.

2.3.2. The MP shall define the strategy and work processes required to maintain 100% of active GFP at RFAAP (land, buildings, structures, rail, infrastructure, bridges, vehicles, and equipment). The plan must define procedures and frequencies based on original equipment manufacturer standards for preventive, predictive, and corrective maintenance to ensure all outages are scheduled to minimize impacts on production manufacturing.

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

2.3.2.2. The MP shall incorporate PdM, PM, and a Mechanical Integrity (MI) Program IAW PWS 9 and OSHA standards to mitigate production equipment failure. The Contractor shall manage all unexpected service requests and maintenance needs through a formal corrective maintenance process.

2.3.2.3. The MP shall describe in detail how 100% of maintenance activities will be captured in the CMMS, to include subcontracted work.

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

2.3.2.4.1. The Spare and Repair Parts Program shall include stock of spare parts for all assets or a contingency plan that mitigates downtime if the assets were to fail.

2.3.2.4.2. The MP shall include a Mission Essential Asset (MEA) List, prioritized by criticality and redundancy. The Contractor must maintain physical stock of spare parts for all MEAs or provide a documented contingency plan that immediately mitigates downtime in the event of failure.

2.3.3. The Contractor shall coordinate with the Army Natural Resources Manager to identify and treat a minimum of 30 acres annually for invasive species control. Mitigation efforts shall include mechanical clearing, debris disposal, and targeted herbicide application to stumps. The Contractor shall perform follow-up treatments as necessary to ensure effective regrowth control.

2.3.4. The Contractor shall maintain all firebreak trails on RFAAP and NRU properties to ensure effective wildfire barriers and continuous emergency vehicle access. Maintenance activities include vegetation clearing, debris and invasive species removal, and erosion repair. Trails must remain clear of fuel loads and accessible to emergency response personnel and equipment at all times.

2.3.5. Computerized Maintenance Management Systems (CMMS)

2.3.5.1. The Contractor shall utilize and maintain a CMMS with the functional capability to plan, track, schedule, manage, and report on 100% of maintenance activities, including subcontracted work. All non-emergency work shall be scheduled in the CMMS, and work included in the CMMS shall be completed as specified in the timeframes defined within the MP. Work that is not completed within these specified timeframes will be considered deferred maintenance at the Government’s discretion.

2.3.5.2. The system must provide searchable and exportable data fields for asset history, work order status, labor hours, material costs, and all reporting requirements necessary to generate the KPIs defined in Section 6. The Government shall be granted continuous, read-only access to all CMMS data.

2.3.5.3. All Corrective Maintenance (CM), Preventive Maintenance (PM), and Predictive Maintenance (PdM) shall be documented in the CMMS. New defects discovered during routine maintenance must be immediately (within 24 hours of discovery) captured as new or updated work orders within the system. Routine and Preventive task lists must be updated within the CMMS within 14 days of equipment installation or removal.

2.4. Life Cycle Cost Analysis (LCCA)

2.4.1. The Contractor shall submit a quarterly LCCA (CDRL A07-002) within fifteen (15) calendar days after the end of each quarter. The data shall be processed as independent quarters of the year (i.e. not the aggregate YTD data).

2.4.2. The LCCA shall analyze the top 50 assets with the highest repair costs. The LCAA must separate direct repair costs (parts, labor, subcontracts) from the estimated financial impact of lost production downtime. The report must provide both the specific quarter's costs and the rolling lifetime cost of the asset since contract award.

2.5. Monthly PM Completion Reports (CDRL A07-003): The Contractor shall submit a monthly report to the PCO on the tenth calendar day of each month, comparing scheduled to actual PM results. The report shall include the following:

2.5.1.1. Completed: Scheduled and unscheduled PMs.

2.5.1.2. Delinquent & Backlog: Monthly delinquencies and the overall backlog (including delinquent PMs with a frequency > one (1) month, maintained until completed or superseded).

2.5.1.3. Changes & Revisions: Generated, revised, or cancelled/inactivated PMs, including justifications.

2.5.1.4. Forecast: Scheduled PMs for the upcoming month.

2.6. Diagnostics and Corrective Action

2.6.1. Root Cause Analysis & Corrective Actions (CDRL A07-004): The Contractor shall analyze equipment failures, determine contributing factors, and implement corrective actions to prevent recurrence.

2.6.1.1. Monthly Failure Analysis Reporting: By the 10th calendar day of each month, the Contractor shall submit at least one analysis for any category met during the reporting period:

2.6.1.1.1. Repeat/High-Frequency Failures: Failures recurring within a one-month window, or assets exhibiting a low MTBR.

2.6.1.1.2. Production Impact: Failures halting or impacting production for more than 24 hours.

2.6.1.1.3. Safety Events: Near missed or safety incidents involving maintenance personnel or processes.

2.6.1.2. Analysis Requirements: Each submission must include:

2.6.1.2.1. Failure description, root cause, and applicable maintenance history data (CM/PM/PdM).

2.6.1.2.2. Short and long term corrective solutions, including cost estimates.

2.6.1.2.3. An execution plan and associated action log.

3. Major Maintenance

3.1. Funding and Thresholds

3.1.1. A single, discrete maintenance, repair, or replacement project with an estimated cost of $150,000 or greater shall be classified as a Major Maintenance project. The Contractor shall not artificially aggregate or split requirements to manipulate this threshold. The PCO holds final determination authority on project classification.

3.1.2. The Contractor shall execute a minimum of $5,000,000 (excluding Contractor profit and G&A) per year for Major Maintenance during Contract Years 1-5, and a minimum of $6,000,000 per year for Contract Year 6 and beyond.

3.1.3. Major Maintenance funds shall be used exclusively for Major Maintenance and cannot be diverted to fulfill base facility infrastructure requirements already funded under standard maintenance sections of this PWS.

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

3.2. Project Approval and Execution

3.2.1. The Contractor shall maintain a prioritized "1-N List" of identified Major Maintenance projects. The Contractor must submit each project, including justification, operational impact, and cost estimates (based on engineering estimates or vendor quotes), to the PCO for approval prior to execution. (CDRL A07-005)

3.2.2. If project execution costs deviate substantially from the approved estimate, the Contractor must immediately notify the PCO.

3.2.3. The Contractor shall lead quarterly Contractor-Government meetings to review the 1-N List and track the expenditures of all ongoing projects. The Contractor shall submit an annual actual cost data report for all executed projects by 31 December. (CDRL A07-006)

3.3. Funding Reconciliation

3.3.1. Annual unused Major Maintenance funding shall be carried forward as a credit to subsequent contract years. Conversely, costs incurred over the annual allotment shall be deducted from the following year's requirement.

3.3.2. At the conclusion of the contract period of performance, the Contractor shall return any unused Major Maintenance funding to the Government. All equipment or infrastructure purchased under this section becomes Government Property upon execution.

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

4. Key Performance Indicators (KPIs)

4.1. KPIs: The Contractor shall track and report performance monthly via the PWS 7 KPI Report. This report must include all mandatory KPIs and at least three Contractor-identified KPIs evaluating the efficiency of RFAAP Maintenance management. The initial report is due 30 calendar days after operational control. (CDRL A02-007) Mandatory KPIs include:

4.1.1. Emergency & Utility Response Time: Response: ≤ 30 mins (24/7); Mitigation/Repair: ≤ 4 hours.

4.1.2. Maintenance Schedule Compliance: ≥ 90% of scheduled PM/CM completed on time monthly.

4.1.3. Proactive Maintenance Ratio: ≥ 70% of all maintenance hours spent on PM/PdM (vs. reactive CM).

4.1.4. Routine Work Order Cycle Time: 100% of routine work orders completed within 15 business days.

4.2. KPI Management: The initial report shall define the calculation methods and establish performance targets (justified by industry standards or baseline data) for Government approval. If any KPI trends negatively or falls below the target for three consecutive months, the Contractor must submit a Corrective Action Plan detailing mitigation steps, timelines, and the personnel responsible for achieving the target.

5. Applicable Documents

The Contractor shall execute all requirements within this PWS in strict accordance with the latest versions of the following primary governing regulations, laws, and criteria.

All guidelines, technical manuals (TMs), sub-chapters, and industry standards (including NFPA, AWWA, ASME, and EPA) referenced or cited within these parent documents are hereby incorporated by reference and hold the same contractual authority.

5.1. Federal Laws & National Codes

5.1.1. 29 CFR Part 1910 – Occupational Safety and Health Administration (OSHA) Standards

5.1.2. 40 CFR (All Parts) – Environmental Protection Agency (EPA) Regulations

5.1.3. The Clean Air Act (CAA) & Clean Water Act (CWA)

5.2. ARs & DA PAMs

5.2.1. AR 420-1 – Army Facilities Management (The primary authority for all Army real property operations, housing, utilities, and maintenance)

5.2.2. AR 200-1 – Environmental Protection and Enhancement (Primary authority for environmental compliance, hazardous materials, and pest management)

5.2.3. AR 58-1 – Management, Acquisition, and Use of Motor Vehicles

5.2.4. AR 190-13 – The Army Physical Security Program

5.2.5. DA PAM 385-64 – Ammunition and Explosives Safety Standards (Critical for any GOCO facility handling energetics/munitions)

5.3. Unified Facilities Criteria (UFC)

5.3.1. UFC 1-200-01 – DoD Building Code (General Building Requirements)

5.3.2. UFC 3-601-02 – Operation and Maintenance: Inspection, Testing, and Maintenance of Fire Protection Systems

5.3.3. UFC 3-575-01 – Lightning and Static Electricity Protection Systems

5.3.4. UFC 4-860-03 – Railroad Track Maintenance Standards