A21._SOW_-_Highline.docx

Salient Characteristic

1. INTRODUCTION

The 7th Air Force (PACAF) requires all equipment and materials necessary to complete manufacturing and delivery of 2 (two) Highline docks for each of the following Combined Operating Base (COB); Daegu, Gimhae, Gwangju, and Suwon.

2.0 SPECIFIC REQUIREMENTS

2.1 General Requirements

The highline dock shall be a free-standing, self-supporting metal frame capable of holding six 463L pallets on a conveyor system. Each 463L pallet is 88 inches by 108 inches and shall be stored in either orientation. The stop-to-stop dimension shall be minimum 48 feet. The 463L pallet has a capacity of 10,000 pounds. The highline dock shall be used to build-up and breakdown pallet trains where multiple 463L pallets are attached together for shipment of long items. The highline dock shall also be used to store, stage, and transfer 463L pallets and pallet trains. The highline dock shall be Lite Cart model 557 or equivalent.

2.2 Specific requirements.

2.2.1. Capacity

The overall capacity shall be 60,000 pounds. Each 463L pallet position shall support 12,500 pounds. The system shall withstand static loads plus loading during build-up operations when loads are lowered by forklift or crane at creep speed with no permanent deformation.

2.2.2. Dimensions

The fixed frame shall consist of four 8-foot long center sections and two 9-foot long end sections connected end to end. The frame shall be approximately 9 feet wide. The end sections shall include a metal support frame near the middle of the section with adjustable legs similar to the support frame between sections. The extra support frame under the end section shall withstand loading at the forklift interface. Frame sections shall be modular and interchangeable.

2.2.3. Conveyor

The conveyor shall consist of four sections of gravity roller conveyor, each minimum 6 inches between frames. Rollers shall be minimum 2.5-inch diameter, light-oiled bearings, spaced a maximum of 6 inches between centers, positioned a minimum of 0.25 inches above the frame, and shall have a minimum capacity of 550 pounds. Bearings shall be shielded or sealed. Heavy-duty rollers with a minimum capacity of 1100 pounds shall be provided on each roller section at the end of each section, including both ends of the highline, between frame sections, and on both sides of the tine cutouts. Roller frames shall be steel and a minimum of 4 inches high. Centerline spacing of the roller sections across the width shall match k-loader roller spacing. Side guides shall be minimum 6-inch x 4-inch x 0.37-inch structural metal angle.

2.2.4. Pallet Stops

Both ends of the conveyor shall have a set of pallet stops consisting of four spring loaded metal stops (one per conveyor section) capable of stopping a fully loaded 463L pallet moving at 30 feet per second. Each set of stops shall be linked together and operated by a handle. Handles shall be located on both sides of the conveyor and a handle extension shall be provided to provide leverage with the basic handle height below the top of the adjacent side guide.

2.2.5. Forklift Interfaces

Forklift interfaces shall be provided at each end of the conveyor and on both sides of both end sections. All types of 10k forklifts (standard and all-terrain by all manufacturers used by the military) shall be able to pick up and set down fully loaded 463L pallets at all forklift interfaces. Roller frames at forklift interfaces shall be guarded to prevent tines from snagging on or lifting the frames. Side guides shall have openings with removable covers to allow fork tine access.

2.2.6. K-loader Interfaces

Both ends of the conveyor shall interface with both types of K-loaders (60K and 25K) for pallet transfer between the highline dock and the k-loader conveyor.

2.2.7. Decking

Open decking shall be provided between roller frames and between roller frames and side guides. Decking shall securely support a 250-pound person. Decking shall be interlocked to provide a minimum of 0.50 inch lip overlap if it shifts to the limits of movement. No exposed sharp edges shall be on the upper side of the decking for safety.

2.2.8. Collapsible Catwalks

Collapsible catwalks shall be installed along both sides of the highline dock.

The catwalks shall raise and lower by frame section (center section, end section, etc.). The catwalk shall be minimum 18 inches wide and shall have decking conforming to the above paragraph. Catwalks and their supports shall be capable of being raised and lowered by one person in a safe manner. The catwalks shall not interfere with forklift access to sides of the highline dock or the forklift interfaces when lowered. When raised, the catwalks shall provide a stable, safe surface for personnel. Handrails shall be detachable to allow forklift access. Handrails shall be a single welded piece, shall secured lock in place when engaged, and shall not create pinch points where adjacent handrails interface.

2.2.9. Ladder

Two ladders shall be provided, one for each side of the highline dock. The ladders shall be capable of being installed on any center section. The ladder handrails shall extend to the top of the catwalk handrails. There shall be a self-closing gate or sliding opening in the catwalk handrail to allow access and also provide a safety handrail.

2.2.10. Adjustable Legs and Base Plates

Base plates shall have a minimum contact surface of 12 inches by 12 inches. Base plates shall be larger than the contact area by a minimum of 1 inch on each edge. The edge shall be bent at a 15 degree angle so the base plate does not catch if scooted across the ground. The legs shall be adjustable to provide a conveyor height over a minimum range of 44 to 48 inches above the ground.

2.2.11. Marking

Each piece required for assembly shall be marked to indicate an item number that matches the assembly instructions. Hardware may be contained in marked containers or bags instead of individually labeled.

2.2.12. Assembly Instructions

The highline dock shall include unambiguous assembly directions. An illustrated parts breakdown and step-by-step instructions shall be provided. The orientation of each piece shall be clear from the instructions.

3.0 APPLICABLE STANDARDS

3.1. Maintainability

The system shall be designed, fabricated, and installed to facilitate maintainability and ensure a minimum service life of 15 years. The design shall provide for modular assembly of components and subassemblies where feasible to permit repair or replacement of parts in a minimum of time. This shall include plug-in electrical connections for major electrical subassemblies.

3.1.2 Environmental conditions

The system shall operate in a temperature range of -40 to 110 degrees Fahrenheit with up to 95 percent relative humidity. The system shall be constructed to operate in an open warehouse environment.

3.1.3 Standard, commercial components

Standard, commercial components which have been for sale and available for purchase to the general public or government agencies for at least one year shall be used to the maximum extent possible. If requested by the COTR (Contracting Officer's Technical Representative), the Contractor shall furnish evidence that equipment of approximately the same design as that proposed to be installed has been tested and successfully operated. Where two or more units of the same type of equipment are required, these units shall be products of the same manufacturer. All equipment and materials shall be new.

3.1.4 Standardization

Mechanical and electrical interchangeability shall exist between like assemblies, subassemblies, and replaceable parts regardless of the manufacturer's supplier. Interchangeability does not necessarily mean complete identity, but requires that a substitution of such like-assemblies and replacement parts be easily effected without physical or electrical modifications, including cabling, wiring, and mounting.

3.1.5 Accessibility

Structural members shall not prevent access to or removal of components for repair or replacement. Equipment shall be designed for rapid and easy removal as well as replacement or repair of malfunctioning units, by one individual where feasible. Mechanical components shall be designed to permit lubrication of components without disassembly.

3.1.6 Safety

The Contractor shall consider the safety of personnel and equipment when designing the system. Safety provisions shall be incorporated to the maximum extent possible. When possible, hazards shall be eliminated through design. When this is not possible, safety devices such as guards, interlocks, and barriers shall be installed. If this does not eliminate the hazard, warning devices such as warning signs, indicator lights, and audio devices shall be installed. Safety requirements shall include, but are not limited to, the following.

3.1.7 Protection against moving parts

Moving parts shall be provided with guards to protect personnel from possible injury.

3.1.8 Protective coatings

All system component surfaces shall be protected from corrosion by painting, plating, or galvanizing.

3.1.9 Painting

Metal surfaces, which are not galvanized or plated, shall be cleaned, treated, and painted to protect against rust, corrosion, and deterioration. The first coat of paint or primer shall be applied to a dry clean surface as soon as practicable after cleaning and treating the metal. The primer shall not interfere with the application and adhesion of subsequent coats. Paint shall last the service life of the equipment. Paint shall be lead and chromate free and meet air pollution requirements for solvent emissions. When several standard colors are available, a color selection chart shall be submitted to the COTR with the shop drawings for selection. The finish coat shall be a smooth, even surface, free from runs, sags, and defects when dry. Welded surfaces shall be cleaned and painted after the welding process is complete. Pre-painted accessories, as well as surfaces not requiring paint, shall be protected from overspray.

3.1.10 Dissimilar metals

Materials used and their locations shall not promote galvanic corrosion. No combination of materials shall be used that form an electrolytic couple of such nature that corrosion is accelerated.

3.1.11 Forklift Impacts

The forklift interface shall not exhibit damage, deformation, or decreased performance from horizontal impacts with 10K forklifts traveling at 3 miles per hour or from vertical impacts occurring when loads are placed on the conveyor by forklifts.

3.1.12 Deformation under impact

All conveyor frames, balls, rollers, bearings, tread plates, and guide rails shall be capable of withstanding repeated impacts from manual pallet transfer, and forklift pallet transfer without suffering damage or permanent deformation. Manual pallet transfer impacts shall occur from the manual transfer of pallets on the conveyor. Forklift pallet transfer impacts shall occur at forklift interfaces when pallets on forklift tines are lowered onto the conveyor.

3.1.13 Spare Parts

A minimum of 10 extra rollers and 3 extra roller shafts shall be provided. A roller shall consist of the roller tube and 2 bearings.

3.2 Acceptance Criteria

Designated squadron representative will determine service acceptability, upon verification of service performed.