Attachment_015_SEMA_Appendix_K_PWS

W58RGZ-15-R-0045 Appendix K TO SEMA PWS

C-12/MC-12/RC-12/EO-5/TO-5/RO-6A

Strip and Paint with Corrosion Inspection

Revision: 2nd 4 Aug 15 1

1. Background

This document establishes requirements to be performed during the strip & paint on the C-12, MC-12, RC-12 , EO/TO-5 and RO-6A aircraft. The primary focus is to ensure continued service life and structural integrity of aircraft. The strip & paint process will also enable the Fixed Wing Project Office (FW PO) to evaluate the condition of the aircraft based on contractual and aircraft manual requirements.

During the aircraft strip and paint process, there must be a methodology that focuses on in-depth corrosion inspections in order to identify, treat, and prevent further corrosion. For clarity of intent, there are tasks/items listed in this document that are basic to the strip and paint process.

These items will be identified and should not be considered as duplicate request(s).

The corrosion inspection is an integral supplement to the maintenance program covered by the base contract for Army aircraft; therefore discrepancies found during this process that should have been discovered during normal site maintenance, scheduled maintenance, and/or inspections, will be considered basic to the contract and covered by basic contract actions and funding, unless otherwise stated in this document. Discrepancies that should have been identified and corrected at the Beddown base are the responsibility of the contractor and shall be listed in the 2408-13-1 and will be deferred back to the BB after delivery or repaired at the expense of the contractor. These discrepancies may be returned to the home Beddown base upon approval of the USG provided the discrepancy does not affect airworthiness or paint.

If the discrepancy could not have been discovered during normal site maintenance, scheduled maintenance, and/or inspections, but was discovered during the performance of the corrosion inspection as required in Section 9, it will be classified as an Over and Above (O&A) repair(s).

2. Maintenance References

The following specifications, drawings, directives, and publications are to be used in support of the paint & strip with corrosion inspection as applicable.

2.1 OEM Specifications

a) Beechcraft Interactive Maintenance Library (IML) ATA Chapter 20, Standard Practices – Airframe

b) SA227 Series, M7 Aerospace LP, Structural Repair Manual, (P/N 27-10054-127), ATA Chapter 51-30-00 Standard Practices.

c) Continued Airworthiness Instruction from all previous and future modifications

2.2 Publications

a) FAR Part 43 - Maintenance, Preventive Maintenance, Rebuilding and Alterations

b) FAR Part 65 - Subpart E Mechanics

c) FAR Part 91 – Subpart E Maintenance, Preventive Maintenance, Rebuilding and Alterations

d) AC 43.9C Maintenance Records, General Aviation Aircraft

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e) AC 43.13-1B/2B Acceptable Methods, Techniques and Practices: Aircraft Inspection and Repair.

f) DA PAM 738-751 the Army Aviation Maintenance Management System

g) AR 750-59 Army Corrosion Prevention and Control Program

h) AR 750-1 Army Material Maintenance Policy

i) TM 1-1500-345-23 Painting and Marking of Army Aircraft, 7 Jul 15

j) TM 1-1500-344-23-2, Cleaning and Corrosion Control, Volume II Aircraft, Change 1

k) TM 55-1500-342-23 Weight and Balance

l) MIL-DTL-64159B Detail Specification Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Single Component, Chemical Agent Resistant

m) MIL-STD-7179, Military Standard: Finishes, Coatings, and Sealants, For the Protection of Aerospace Weapons Systems

n) MIL-PRF-85285, Coating: Polyurethane, Aircraft and Support Equipment

o) MIL-DTL-53072, Detail Specifications: Chemical Agent Resistant Coating (CARC) System Application Procedures And Quality Control Inspection

3. General

The inspection criteria prescribed in this process shall be the minimum requirements necessary to ensure the timely discovery and correction of actual and/or anticipated defects. Compliance with the inspection requirements found in Section 9 shall be mandatory.

The contractor shall prepare aircraft surfaces for painting IAW the guidance found in references, para 2.1 items a, b, c and para 2.2 item i.

All paint types shall be applied to a dry film thickness as recommended by the respective paint manufacturer. A mil measurement of primer thickness and one for paint thickness will be recorded in the DA Form 2408-15.

When applying CARC Paint, the contractor shall apply paint to surfaces IAW the guidance found in reference 2.1 item a, b, c and reference 2.2 item i, l and o. All other paints shall be applied IAW the paint manufacturers requirements.

The contractor shall perform a paint adhesion test IAW 2.2 reference 4-16 item i. The contractor shall pay special attention to areas where paint terminates around panels and deicer boots.

The contractor shall ensure that the paint is free from irregularities as described in reference i, para 2-4 Paint Evaluation, Tables 2-1 and 2-2.

Take adequate precautions during stripping and cleaning operations to prevent ingress of moisture and cleaning compounds into the engine inlet/exhaust openings, static, pitot and vent openings, bearings, bearing surfaces, electrical switches, relays, connectors, wires and all other electrical and electronic components. Protect plastic, glass, and rubber parts during stripping and cleaning. Comply with all applicable safety precautions/procedures when using toxic stripping compounds.

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The contractor shall clean, treat all corrosion and paint aircraft battery compartments with a battery resistant coating equivalent to A-A-1452B.

The contractor shall replace all flight control static bonding straps, static wicks and antenna attachment bonding bases and shall perform an electrical bonding test. The contractor shall ensure all bonding attachment surfaces are free from grease and paint.

The contractor shall lubricate flight controls and gears after paint. All lubricated bearings, bushings and fittings exposed to the high-pressure washing, caustic chemicals, or the painting process shall be lubricated in accordance with maintenance manual procedures or manufacturers' published recommendations. Wheel bearings are to be re-packed.

The inspection criteria prescribed in this process shall be the minimum requirements necessary to ensure the timely discovery and correction of actual and/or anticipated defects. Compliance with the inspection requirements found in Section 9 shall be mandatory. Disturbed Systems: Aircraft Systems, not otherwise assigned a requirement for an operational check/test, that are disturbed during the inspection process to the extent that the systems integrity (i.e., installation and operation) cannot be assured, shall be checked by an operational check/test as necessary to verify proper installation and operation. Controlled substitution of parts between aircraft is not acceptable as a standard practice and must be approved by the FW PO.

Exposed portions of seat frames shall be painted with a like color of paint to match interior.

Painting these portions shall be accomplished in such as way so as to not require the removal of upholstery or disassembly of the seat frames.

Propellers will be dressed and painted prior to the owning unit notification as coordinated with the FW PO (after any required flight or ground operational checks) and ready when flight crew arrives for delivery. Aircraft propellers that are extensive stripped for repaint shall be dynamically balanced.

4. Scope

The intent of this process is to inspect for corrosion and structural integrity in the areas defined by Section 9 of this document. Discrepancies noted while conducting the specified task(s) will be documented and reviewed to determine airworthiness. This process is meant to assess the health and prolong the life of the noted Army aircraft fleet through early detection of issues that could lead to catastrophic conditions or failures. Noted discrepancies that affect airworthiness or paint shall be repaired. Discrepancies that do not affect airworthiness may be returned to a Beddown Base for corrective action with prior approval of the FW PO. Discrepancies returned to the Beddown Base for repair will be recorded in the 2408-13. These items will be provided to the FW PO IAW DI-MISC-80508, CDRL A021prior to application of paint. If the contractor elects to perform field repairs at the Heavy Maintenance facility, the contractor shall be responsible for the cost(s) and impact to the performance period.

The contractor shall provide a Flight Check List of sufficient depth and content to thoroughly evaluate all aircraft systems. The Flight Check list will be approved by FW PO.

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A post paint flight shall be performed. CASS/SWSVT requirements will be complied with/recorded. All faults discovered during the post test flights will be recorded on the DA Form 2408-13-1.

Daily and Turn Around or Pre-Flight Check will be performed prior to presented to the delivery crew for departure

4.1 Definitions

The definitions of common aviation terms found in the Glossary of AC 43.13-1B will be incorporated. If vague or contradicting terminology is discovered, this will be mitigated via contractor and government discussions.

4.2 Period of Performance

The Period of Performance (PoP) for a Strip and Paint shall not exceed thirty (30) calendar days.

If major structural or corrosion repairs requiring Army Engineering Directorate approval must be accomplished prior to returning the aircraft to service, then additional Non-Reportable Time (NRT) may be granted in excess of the 30 calendar day PoP. Other delays caused by the USG may also be used as justification for additional NRT at the discretion of the PCO or ACO.

4.3 Change Recommendations

Recommendations for additions, deletions, or changes to the requirements of this specification are invited and should be submitted to:

PEO Aviation, Fixed Wing Program Office Attn: AMSAM-AC-AR-C (Program Contracting Officer) 650 Discovery Drive Huntsville, AL 35805

5. Corrosion Removal and Surface Treatment

5.1 Corrosion Removal

a) The contractor shall inspect external surfaces normally covered by paint for corrosion IAW the applicable OEM aircraft maintenance manual.

b) The contractor shall protect all parts and components from corrosion during rework.

NOTE

Removal of fasteners at seams and lap joints is not required unless visual examination indicates corrosion of surfaces.

c) Remove all corrosion. Replace corroded parts when the corrosion damage (after corrosion removal) exceeds the limits allowed by applicable overhaul or structural repair manuals.

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d) The removal of corrosion that requires further disassembly past that of the strip and paint(i.e.

rivet/component/fairing removals) will be reported to USG utilizing contractual over and above approval process.

e) Protect parts and components from corrosion during rework.

f) Treat light corrosion IAW with references e, g & j listed in Section 2.2 Publications.

g) Severe corrosion will be reported to USG utilizing contractual Over & Above approval process. Following PCO approval, corrosion will be repaired or components replaced as necessary.

5.2 DEGREES OF CORROSION.

Corrosion shall be evaluated after the initial inspection and cleaning to determine the nature and extent of repair or rework needed. It is difficult to draw a distinct and specific dividing line among the degrees of corrosion. Consequently, the first requirement for a reliable evaluation is sound maintenance judgment. Use the following categories in reporting degrees of corrosion.

a) LIGHT to MODERATE CORROSION.

At this degree, the protective coating is scarred or etched and the condition of the metal is characterized by discoloration and pitting to a depth of approximately one mil (0.001 inch) maximum. This type of damage can normally be removed by light hand sanding.

b) MODERATE to SEVERE CORROSION.

This appears similar to light corrosion, with the addition of blistering or evidence of scaling and flaking of the coating or paint system. The pitting depths may be as deep as 10 mils (0.010 inch).

This type of damage is normally removed by extensive hand sanding or light mechanical sanding.

c) SEVERE CORROSION.

Its general appearance is similar to moderate corrosion, with the addition of severe intergranular corrosion, blistering, exfoliation, scaling, or flaking. The pitting depths are deeper than 10 mils (0.010 inch). This damage must be removed by extensive mechanical sanding or grinding.

The contractor shall remove and treat all light corrosion discovered. Removal of fasteners at seems and lap joints is not required unless visual inspections indicate corrosion of those surfaces.

The removal of corrosion that requires further disassembly past that of strip and paint (e.g. rivet, component, fairing removals) will be reported to the US Government. Moderate to severe corrosion shall be reported to the US Government utilizing contractual Over & Above approval processes. Following PCO approval, corrosion will be repaired or components replaced as necessary.

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5.3 Surface Treatment

(1) Reapply surface treatment to all metal surfaces from which previously applied organic coatings have been removed. Use materials IAW the Aircraft Maintenance Manual to treat aluminum and magnesium surfaces. Follow manufacturers’ recommendations for application and removal of chemical agents.

(2) Apply surface coatings to all newly fabricated metal parts to comply with the requirements of the Aircraft Maintenance Manual.

(3) During assembly of components, parts and subassemblies, insulate dissimilar metals as specified in para 2.1 a, b and c and para 2.2 e and j.

5.4 Seam Sealing

(1) Remove all loose or deteriorated sealant and contamination from the seams. Remove corrosion products. Replace sealant in accordance with the applicable repair manual.

CAUTION: Do not use chemical corrosion removers.

(2) Ensure intersecting fuselage and pressure vessel overlap seams are sealed to comply with OEM Maintenance Manual.

Corrosion Types (from TM 1-1500-344-23-1 (Par 3.9)) Uniform Galvanic Pitting Intergranular Exfoliation Crevice Filiform Erosion Stress Corrosion Fatigue Fretting Hot Corrosion

Table 1 Corrosion Types

6. Weight and balance

At the completion of the strip and paint process, the contractor shall weigh the aircraft per the process and procedures defined in the OEM’s weight and balance manual. The W/B will then be calculated and recorded IAW the PWS Weight and Balance section. All weight and balance forms and record shall be completed by qualified technicians.

7. Aircraft Records Maintenance

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The Contractor shall monitor all Scheduled Inspections and/or Time Change items that are due or may become due during the time that the aircraft is at facility for strip and paint process:

Every effort will be made to notify the contractor approximately 30 days prior to induction.

Contractor shall ensure scheduled inspections and/or Time Between Overhaul (TBO) items due within 100 hours, 50 cycles, or 60 days of Contract Delivery Date are completed prior to induction into paint & strip. Schedule inspections and TBOs not completed prior to induction will be completed during the strip & paint process at Prime contractor’s expense.

The contractor shall maintain the power plant and propeller logbooks in accordance with FAA Regulations. The aircraft records shall be maintained IAW DA PAM 738-751 using DA Form 2408 series forms and records.

8. Paint Scheme Text Descriptions

a) Rendering shade reference codes are called out, however, the contractor may use another paint manufacturer’s equivalent color shades that match the rendering call outs.

b) C-l2 aircraft scheduled for a VIP Gloss White paint job will be painted in accordance with (IAW) MIL-PRF-85285F. MIL-PRF-85285F Gloss Insignia White will be used. Markings will be painted MIL-PRF-85285F Gloss Black. “UNITED STATES OF AMERICA” will be painted MIL-PRF-85285F Gull Gray. Markings will be rendered as depicted in TM 1-1500- 345-23, Airworthiness Directive 2003-02-03, and applicable Original Equipment Manufacturer (OEM) Chapter 11 Placards and Markings. Landing gear, wheels, inside of landing gear doors and wheel wells will be painted insignia white paint # G8022 US paint per

TM 1-1500-345-23.

c) C-12 aircraft scheduled for a VIP CARC Grey will be painted IAW MIL-DTL-64159B.

FED-STD-595 color number 36300 Aircraft Gray will be used. Markings will be painted FED-STD-595 color number 37038 Black. “UNITED STATES OF AMERICA” will be painted FED-STD-595 color number 37038 black. Markings will be rendered as depicted in TM 1-1500-345-23, Airworthiness Directive 2003-02-03, and OEM Chapter 11 Placards and Markings. Landing gear, wheels, inside of landing gear doors and wheel wells will be painted insignia white paint # G8022 US paint per TM 1-1500-345-23.

d) RC-12 aircraft scheduled for a Tactical CARC Grey will be painted lAW MIL-DTL-64159B.

FED-STD-595 color number 36300 Aircraft Gray will be used. Markings will be painted FED-STD-595 color number 37038 Black. Emergency Markings will be rendered as depicted in TM 1-1500-345-23 (C-12/RC-12), Airworthiness Directive 2003-02-03, and OEM Chapter 11 Placards and Markings. Landing gear, wheels, inside of landing gear doors and wheel wells will be painted insignia white paint # G8022 US paint per TM 1-1500-345- 23.

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e) EO/TO-5 aircraft. The Government will elect to utilize the elective improvement clause for strip and paint on EO-5/TO-5 aircraft.

f) RO-6A aircraft. The Government will elect to utilize the elective improvement clause for strip and paint on R aircraft.

9. Maintenance/Inspection

This section contains required inspection areas and test requirements to be accomplished by the contractor to complete the Corrosion Inspection of the C-12, MC-12 and RC-12. Each inspection area shall be a mandatory area of inspection unless otherwise specified.

If during the strip & paint process, there is a need for maintenance and structural repairs, they will be accomplished in accordance with the OEM maintenance manuals, Structural Inspection and Repair Manual (SIRM), Structural Repair Manual (SRM), OEM engineering guidance and

AC 43.13 1B/2B.

The contractor shall use Table 1 in this document to classify Corrosion Discrepancy(s).

Corrosion discovered that should have been discovered and corrected during phase and/or corrosion inspections, or other scheduled inspections at the site will be the responsibility of the Prime Contractor to correct regardless of code rating (par 10).

Contractor shall have access to OEM, DER, or equivalent in order to obtain appropriate repair plans and approvals of repair plans if repair is not covered by IML, Cesview and or AC 43-13- 1B. Engineering cost is part of the base contract. Repairs not contained in OEM manuals or AC 43-13 will also be submitted to USG IAW PWS 4.7.8 Aircraft Induction to Heavy Maintenance (Vendor and Non-vendor).

NOTE

Antennas are not to be painted as part of a strip and paint event. The antenna OEM is the only entity authorized to paint antennas.

Remove all antennas and inspect skin and base; 43-13-1B CH 12, & Applicable Sections of Maintenance Manuals Chapters 23 and 34. Antenna not defined by the aircraft OEM maintenance and servicing criteria as a component of the base aircraft and found to be unserviceable IAW the OEM instruction shall be brought to the government's attention immediately for the repair determination. The contractor shall not replace functional antennas at the expense of the US Government to promote aesthetic appearance. Painted exterior markings, placards, and letters shall be applied with silk screen or a similar method using Arial Bold font or a similar block lettering style. Data plate decals on OEM components, e.g. landing gear are allowed to be used.

9.1 Inspection Criteria

9.1.1 C-12/MC-12/RC-12

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• Strip & paint; IAW Contract, Beechcraft IML Chapter 20-08-00, TM 1-1500-345-23, MIL- DTL-64159B, IAW MIL-PRF-85285E and Paint & marking Technical Data Package C-

12/RC-12/C12J/UC-35

• Placards and markings; IAW Contract, Beechcraft IML Chapter 11-00-00 & 11-20-00, TM 1-1500-345-23 and Marking Technical Data Package C-12/RC-12/C12J/UC-35

• Perform corrosion inspection on the C-12 aircraft IAW Beech Maintenance Manual Corrosion control, Beechcraft IML Chapter 05-29-00-20

9.1.2 EO-5/TO-5

• Viking OEM DHC-7 Manual PSM 1-7

9.1.3 RO-6A

• Bombardier DHC-8-315 Maintenance Program Manual PSM 1-83-7