W911KB-17-T-0005.pdf

SEE ADDENDUM

(No Collect Calls)

W911KB-17-T-0005 06-Dec-2016

b. TELEPHONE NUMBER

907-753-2547

8. OFFER DUE DATE/LOCAL TIME

02:00 PM 20 Dec 2016

5. SOLICITATION NUMBER 6. SOLICITATION ISSUE DATE

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

STANDARD FORM 1449 (REV. 2/2012)

Prescribed by GSA – FAR (48 CFR) 53.212

(TYPE OR PRINT)

(SIGNATURE OF CONTRACTING OFFICER)

ADDENDA X ARE

26. TOTAL AWARD AMOUNT (For Gov t. Use Only )

23.

CODE 10. THIS ACQUISITION IS

SUCH ADDRESS IN OFFER

17b. CHECK IF REMITTANCE IS DIFFERENT AND PUT

BELOW IS CHECKED

TELEPHONE NO.

W911KB9. ISSUED BY

18b. SUBMIT INVOICES TO ADDRESS SHOWN IN BLOCK 18a. UNLESS BLOCK

7. FOR SOLICITATION

INFORMATION CALL:

a. NAME

ERNEST L WOODS III

2. CONTRACT NO. 3. AWARD/EFFECTIVE DATE 4. ORDER NUMBER

(TYPE OR PRINT)

30b. NAME AND TITLE OF SIGNER 30c. DATE SIGNED 31b. NAME OF CONTRACTING OFFICER

30a. SIGNATURE OF OFFEROR/CONTRACTOR 31a.UNITED STATES OF AMERICA

1 27a. SOLICITATION INCORPORATES BY REFERENCE FAR 52.212-1. 52.212-4. FAR 52.212-3. 52.212-5 ARE ATTACHED.X

25. ACCOUNTING AND APPROPRIATION DATA

1. REQUISITION NUMBER

20.

ADDITIONAL SHEETS SUBJECT TO THE TERMS AND CONDITIONS SPECIFIED.

OFFEROR TO COMPLETE BLOCKS 12, 17, 23, 24, AND 30

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

ARE NOT ATTACHED

27b. CONTRACT/PURCHASE ORDER INCORPORATES BY REFERENCE FAR 52.212-4. FAR 52.212-5 IS ATTACHED. ADDENDA ARE ARE NOT ATTACHED

(BLOCK 5), INCLUDING ANY ADDITIONS OR CHANGES WHICH ARE

SET FORTH HEREIN, IS ACCEPTED AS TO ITEMS:

. YOUR OFFER ON SOLICITATION

28. CONTRACTOR IS REQUIRED TO SIGN THIS DOCUMENT AND RETURN

% FOR:SET ASIDE:UNRESTRICTED OR X

SMALL BUSINESSX

WOMEN-OWNED SMALL

BUSINESS (WOSB)

17a.CONTRACTOR/ CODE FACILITY

OFFEROR CODE

U.S. ARMY ENGINEER DISTRICT, ALASKA

CEPOA-CT-SP

PO BOX 6898

JBER AK 99506-0898

18a. PAYMENT WILL BE MADE BY CODE

RATED ORDER UNDER

DPAS (15 CFR 700)

13a. THIS CONTRACT IS A

13b. RATING

CODE15. DELIVER TO CODE 16. ADMINISTERED BY

SEE SCHEDULE

12. DISCOUNT TERMS11. DELIVERY FOR FOB DESTINA-

TION UNLESS BLOCK IS

MARKED

SEE SCHEDULE

14. METHOD OF SOLICITATION

RFQ IFB RFPX

FAX:

TEL: SERVICE-DISABLED

VETERAN-OWNED

SMALL BUSINESS

8(A)

HUBZONE SMALL

BUSINESS

ECONOMICALLY DISADVANTAGED

WOMEN-OWNED SMALL BUSINESS

(EDWOSB)

SIZE STANDARD:

$7.5 M

NAICS:

811310

X

OFFER DATED

29. AWARD OF CONTRACT: REF.

DELIVER ALL ITEMS SET FORTH OR OTHERWISE IDENTIFIED ABOVE AND ON ANY

COPIES TO ISSUING OFFICE. CONTRACTOR AGREES TO FURNISH AND

EMAIL:

TEL:

31c. DATE SIGNED

SEE SCHEDULE

SCHEDULE OF SUPPLIES/ SERVICESITEM NO. QUANTITY UNIT UNIT PRICE AMOUNT

24.22.21.19.

32g. E-MAIL OF AUTHORIZED GOVERNMENT REPRESENTATIVE

SOLICITATION/CONTRACT/ORDER FOR COMMERCIAL ITEMS

(CONTINUED)

PAGE 2 OF59

ACCEPTED, AND CONFORMS TO THE CONTRACT, EXCEPT AS NOTED: ______________________________________________________

32a. QUANTITY IN COLUMN 21 HAS BEEN

RECEIVED INSPECTED

32b. SIGNATURE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32c. DATE 32d. PRINTED NAME AND TITLE OF AUTHORIZED GOVERNMENT

REPRESENTATIVE

32e. MAILING ADDRESS OF AUTHORIZED GOVERNMENT REPRESENTATIVE 32f . TELEPHONE NUMBER OF AUTHORIZED GOVERNMENT REPRESENTATIVE

37. CHECK NUMBER

FINALPARTIALCOMPLETE

36. PAYMENT35. AMOUNT VERIFIED

CORRECT FOR

34. VOUCHER NUMBER

FINAL

33. SHIP NUMBER

PARTIAL

38. S/R ACCOUNT NUMBER 39. S/R VOUCHER NUMBER 40. PAID BY

41a. I CERTIFY THIS ACCOUNT IS CORRECT AND PROPER FOR PAYMENT

41b. SIGNATURE AND TITLE OF CERTIFYING OFFICER 41c. DATE

42a. RECEIVED BY (Print)

42b. RECEIVED AT (Location)

42c. DATE REC'D (YY/MM/DD) 42d. TOTAL CONTAINERS

STANDARD FORM 1449 (REV. 2/2012) BACK

Prescribed by GSA – FAR (48 CFR) 53.212

AUTHORIZED FOR LOCAL REPRODUCTION

PREVIOUS EDITION IS NOT USABLE

SEE SCHEDULE

20.

SCHEDULE OF SUPPLIES/ SERVICES

21.

QUANTITY UNIT

22. 23.

UNIT PRICE

24.

AMOUNT

19.

ITEM NO.

W911KB-17-T-0005

Section SF 1449 - CONTINUATION SHEET

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0001 1 Job

CHENA CRANE BOOM INSPECTION AND REPAIR

FFP

Contractor to provide all parts, tools, equipment, supplies, labor, transportation, and all other requirements necessary to perform crane boom repair services in accordance with Proposal Schedule Item 1, the attached Scope of Work and Service Contract Act Wage Determination 05-2017 (Rev 21), also attached.

FOB: Destination

NET AMT

ITEM NO SUPPLIES/SERVICES QUANTITY UNIT UNIT PRICE AMOUNT

0002 1 Job

CHENA CRANE BOOM INSPECTION AND REPAIR

FFP

TIime and Materials line item for repair of crane boom, Proposal Schedule Item 2.

NET AMT

PROPOSAL SCHEDULE

CRANE BOOM REPAIRS

CHENA RIVER LAKES FLOOD CONTROL PROJECT

North Pole, Alaska

NOTES:

1. ITEMS 2A-2C: Hourly labor rates for performing crane boom section repairs are fully burdened to include all labor markups, overhead and profit.

ITEM ITEM

NAME

ITEM

DESCRIPTION

QTY UNIT UNIT

PRICE

TOTAL

PRICE

Crane Boom

Repairs

Transport, Abrasive Blast, Inspect and

Repaint All Crane Boom Sections

1 Job $________ $________

Boom Section

Repairs

Perform Boom Section Repairs and Inspection (Time-and-Materials)

Time & Materials

Not to Exceed $50,000

2A Welder/Fitter Labor Rate for

Welder/Fitter Performing Repairs

Hour $________

2B Helper Labor Rate for Welder

Helper Performing Repairs

Hour $________

2C Inspector Labor Rate for Non-

Destructive Testing of Repairs

Hour $________

Scope of Work

Crane Boom Repairs Chena River Lakes Flood Control Project

December 2016

1. GENERAL INFORMATION

The Government owns a 90-ton P&H 790-TC mobile lattice boom truck crane located at the Chena River Lakes Flood Control Project near North Pole, Alaska. The crane boom sections are tube steel and require inspection for structural defects or excessive wear and repairs for corrosion control. The contractor shall abrasive blast all existing paint and rust off each crane boom section, perform visual and non-destructive testing to ensure the integrity of the boom section and repaint each crane boom section. The crane boom sections consist of the following:

One 25 foot base section One 25 foot tip section Two 50 foot insert sections One 30 foot insert section One 20 foot insert section

The boom sections will be removed from the crane by the Government. The Contractor shall transport the boom sections to/from their repair facility. The Contractor is required to provide all labor, materials, tools and equipment needed to facilitate this repair. This will be a firm fixed price contract with the exception of the boom section repairs which will be time-and-materials.

2. REFERENCES

AMERICAN SOCIETY OF NONDESTRUCTIVE TESTING (ANST)

ANST RECOMMENDED Personnel Qualifications and Certification PRACTICE NO. SNT-TC-1A in Nondestructive Testing

ASTM INTERNATIONAL

ASTM E709 (2015) Standard Guide for Magnetic Particle Testing

ASTM E1444 (2016) Standard Practice for Magnetic Particle Testing

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC SP 10/NACE No. 2 (2007) Near-White Blast Cleaning

3. SUBMITTALS

a. Qualifications and certifications of inspectors performing visual and non-destructive testing examinations.

b. Inspection reports for both visual and non-destructive tests.

c. Welder Qualifications and Certification.

d. Manufacturer Product Data and Instructions for Coating System Products.

4. ABRASIVE BLASTING

All existing paint, rust or other coatings shall be completely removed by abrasive blasting. Abrasive blast steel surfaces to near-white metal in accordance with SSPC 10/NACE No. 2. Ensure compressed air used for abrasive blasting is free of moisture and oil. Remove rust and corrosion from pits and depressions. Following abrasive blasting, remove any remaining dust and debris by vacuum cleaning. Do not attempt to wipe surface clean.

Dispose of used abrasive in accordance with Federal, State, and Local mandated regulations.

5. INSPECTION

The contractor shall perform visual and nondestructive examination of each crane boom section to identify any structural defects or excessive wear in the boom frame or welded connections.

5.1 Visual Inspection

Perform 100% visual inspection of all welded connections and structural steel members of each crane boom section. Clean and carefully examine the main cords and lacings for cracking or other defects such as deformities, dents and abrasions. Identify and document any chords or lacings which exceed tolerances stated in paragraph “EXTENT OF REPAIR” in attached manufacturer’s recommendations, SECTION XIV BOOM SECTION REPAIR (Attachment 1). Inspect all welded connections for cracking or other defects.

5.2 Nondestructive testing

Perform 100% nondestructive testing of all welded connections, main chords and lacings of each crane boom section. Nondestructive testing for detection of cracks and other discontinuities shall be performed utilizing magnetic particle inspection conforming to ASTM E709. The nondestructive testing and the evaluation of the test results as to the acceptability of the boom structure and welds must be performed by a testing agency adequately equipped and competent to perform such services or by the Contractor using suitable equipment and qualified personnel. Personnel performing the inspection shall be qualified and certified by the American Society for Nondestructive Testing (ASNT) Recommended Practice SNT-TC-1A. The qualifications and valid ASNT certification for the personnel performing the examination shall be submitted prior to the start of any nondestructive testing.

5.3 Reporting

All visual and non-destructive test results for each crane boom section shall be documented and written reports submitted to the Contracting Officer’s Representative prior to performing weld repairs or applying the new paint coating.

6. BOOM SECTION REPAIRS

6.1 General

Perform boom section repairs of lacings or welded connections as identified and directed by the Contracting Officer’s Representative. Repair of boom section chord members is not authorized.

6.2 Welding Qualification and Certification

Prior to completing any repairs, submit qualifications for the welder(s) performing the repairs.

Welders shall be certified with the tubular welding certification procedure included as the final page of the manufacturer’s instructions, SECTION XIV BOOM SECTION REPAIR (Attachment 1)

6.3 Weld Repairs

Defective weld metal shall be removed to sound metal. Thoroughly clean surfaces before welding.

Refer to manufacturer’s instructions, SECTION XIV BOOM SECTION REPAIR (Attachment 1) for welding materials and procedures. Retest welds that have been repaired by magnetic particle inspection.

6.4 Repair of Lacing Members

Repair boom lacing members in accordance with manufacturer’s instructions, SECTION XIV BOOM SECTION REPAIR (Attachment 1), to include completion of post-repair inspection and records requirements.

6.5 Payment for Repairs

Payment for repairs will be on a time-and-materials basis with a not-to-exceed amount of $50,000.

Labor shall be tracked by the hour and shall be billed at the labor rates included in the contract.

The Contractor is required to provide all tools needed to facilitate repairs. Parts, materials, travel and costs for required welder certification shall be billed separately. Profit on parts, materials and travel will not be allowed. Contractor shall submit a copy of receipts for all parts and items needed to facilitate repairs.

7. COATING SYSTEM

Submit coating system manufacturer’s product data sheets and application instructions including detailed mixing and application procedures, number and types of coats required, minimum and maximum application temperatures, and curing procedures.

The required coating system consists of an inorganic zinc primer coat, inhibitive polyamide epoxy intermediate coat, and aliphatic polyurethane finish coat.

Select coatings from the following listing. Ensure all coatings, thinners, and cleaners are the product of the same manufacturer. Ensure each successive coating is a contrasting color to provide a visual assurance of complete coverage. Final finish coat color shall be black.

COATING SYSTEMS

INORGANIC ZINC

INHIBITIVE

POLYAMIDE

EPOXY

ALIPHATIC

POLYURETHANE

MANUFACTURER

Dimetcote 302H Amercoat 370 Amercoat 450HS PPG One PPG Place Pittsburgh, PA 15272 412/434-3131

CarboZinc 11 Carboguard 893 Carbothane 134HG Carboline Company 350 Hanley Industrial Court St. Louis, MO 63144 800/848-4645 Ext. 2557

Catha-Coat 304V Devran 201H Devthane 359 ICI-DEVOE 925 Euclid Ave.

Cleveland, OH 44115 216/344-8798

Ganicin 3.4 IOZ Corlar 3.2 PR or Corlar 2.1PR

Imron 3.5 HG DuPont Company DuPont Building Market Street Wilmington, DE

Porter Zinc 3200 Porter Glaze

4400 High Build Porterthane 9000 Gloss Urethane

Porter Paint Company 400 South 13th Street Louisville, KY 40203 800/332-6270

8. APPLICATION OF COATING SYSTEM

8.1 General Requirements

Manufacturer's instructions for thinning, mixing, handling, and applying products are considered a part of this specification. In the event of conflict between the requirements of this specification and the manufacturer's recommendations, this specification takes precedence.

Inspect and degrease surfaces as required prior to subsequent surface preparation and the application of protective coatings. Degrease by solvent cleaning, detergent washing, or steam cleaning.

Ensure compressed air used for spraying coatings remains free of moisture and oil.

Ensure each coat of material applied is free from runs; sags; blisters; bubbles; mud cracking;

variations in color, gloss, and texture; holidays (missed areas); excessive film build; foreign contaminants; and dry overspray.

Do not apply coating when the temperature or humidity is outside the limits recommended by the coating manufacturer.

Ensure the surface temperature is at least 5 degrees F above the dew point and above freezing.

Work coatings thoroughly into all joints, crevices, and open spaces. Pay special attention to welds, cutouts, sharp edges, rivets, crevices, and bolts to ensure proper coverage and thickness.

Protect newly coated surfaces from damage.

Apply coatings by airless or conventional spray. Use airless spraying for uniform large surface areas. Use conventional spraying for small areas of intricate configuration and for touchup. During application of inorganic zinc coating, maintain uniform suspension.

8.1.2 Mixing and Application Procedures

Stir material thoroughly using an instrument that does not induce air into coating.

Provide continuous slow agitation of the material during application of inorganic zinc coating, maintain uniform suspension. Avoid continuous rapid agitation.

Thin material for workability and improved spray characteristics only.

Apply material in even, parallel passes, overlapping 50 percent. Pay special attention to welds, cutouts, sharp edges, rivets, crevices, and bolts to ensure proper coverage and thickness.

8.1.3 Dry-Film Thickness (DFT)

Apply coatings to the following dry-film thicknesses:

8.1.3.1 Inorganic primer zinc: 3 to 6 mils.

8.1.3.2 Inhibitive polyamide epoxy, second coat: 2 to 4 mils.

8.1.3.3 Aliphatic polyurethane, third coat: 2 to 4 mils, but sufficient to hide previous coat.

9. SCHEDULE

The crane boom sections will be available to the contractor upon contract award. The sections shall be transported to the repair facility within ten (10) days of contract award and returned to the Chena project for reassembly and load testing no later 31 March 2017. Reassembly and load testing will be performed by the Government.

10. ACCEPTANCE OF WORK

The Government representative for acceptance of work will be Mr. Tim Feavel, 907-488-2748, tim.a.feavel@usace.army.mil

11. INVOICING

Submit invoices for payment to the following: Ms. Reyna Volsky, 907-488-2748, Reyna.L.Volsky@usace.army.mil

12. BASIS OF AWARD

This contract will be awarded to the offeror with the lowest price technically acceptable proposal.

The Government will evaluate proposals in accordance with the criteria described below, and award a contract to the responsible offeror with the lowest priced technically acceptable proposal.

A. Technical Proposal:

(1) Experience: The offer shall submit two (2) projects which demonstrate experience inspecting and repairing crane boom sections within the past five (5) years. Provide project title and location, a brief description of the project, date the project was completed, dollar amount of the project and work that was self-performed.

The minimum requirement for this evaluation factor has been met when the offeror demonstrates experience on two (2) projects which each meet the below criterion for minimum acceptability:

Experience welding on crane booms.

The minimum requirement may be met by a subcontractor however if the offeror receives award of this contract, the offeror shall utilize the identified subcontractor.

(2) Past Performance: Provide a past performance point of contact, name and current contact information, for each project submitted for Experience. The Government will contact the references provided. The minimum requirement for this evaluation factor has been met when the two (2) projects each meet the below criterion for minimum acceptability:

A positive past performance reference check for the offeror on previous crane boom inspection and repair projects.

The Government will evaluate the two submitted projects against the requirements listed in above.

To be acceptable, both criteria shall be met for each project.

B. Price Proposal: Submit a properly filled out Proposal Schedule.

Price Evaluation: Price will be evaluated for fairness and reasonableness through price analysis.

ATTACHMENTS:

Attachment 1: Manufacturer’s Instructions SECTION XIV BOOM SECTION REPAIR Attachment 2: Photos of boom sections and corrosion.

SECTION XIV

BOOM SECTION REPAIR

General .................................................................................................... 14-1 Boom Materials ............................................................................................. 14-1 Welding Materials .......................................................................................... 14-1 Welder Qualification and Certification ........................................................................ 14-1 Extent of Repair ............................................................................................. 14-1 Obtaining Material .......................................................................................... 14-2 Tubular Boom Lacing Repair Procedure ....................................................................... 14-2 Angle Chord Boom Lacing Repair Procedure .................................................................. 14-4 Inspection .................................................................................................. 14-5 Weld Certification Procedure Chart ........................................................................... 14-6

J4PMEDLH

Typewritten Text

ATTACHMENT 1

GENERAL

Harnischfeger Corporation provides a worldwide boom re pair service using certified Harnischfeger welders. We recommend that Harnischfeger welders do boom repairs whenever possible. Contact your local Harnischfeger Dealer to arrange for the services of a welder.

This procedure is provided as a guide to aid users in the proper repair of Harnischfeger manufactured boom sec tions when our welders are not available.

IMPORTANT

Repairs made by anyone other ·than a certified Harnischfeger welder are the responsibility of the person performing the repair. Harnischfeger Corpora ation assumes no liability for claims resulting from failures traceable to such repairs.

These instructions pertain to repair of laced bases, boom tips, inserts, masts, and tower crane head sections. In structions apply to both tubular and angle chord booms.

BOOM MATERIALS

The materials used in boom construction are as follows:

Main tubular chords, (referred to as P&H 281) are 100,000 psi minimum yield strength, T1 type or Strolloy C. Some main angle chords (referred to as P&H 106 are ASTM A242 material, 50,000 psi minimum yield strength. Other main angle chords (referred to as P&H 151) are 70,000 psi minimum yield strength. Lacing and end frame tubing (referred to as P&H 280) is welded structural tubing with a 55,000 psi minimum yield strength.

Boom base and boom tip plating (referred to as P&H 106A) is low alloy high strength steel with 50,000 psi minimum yield strength.

Boom lacing and plate material should be obtained from Harnischfeger Corporation authorized dealers to insure proper materials, size, and wall thickness for the particular boom part being repaired.

WELDING MATERIALS

The welding electrodes to be used must be high quality dry low-hydrogen. Type AWS-E-9018 is recommended in sizes of 3/32" diameter or 1 /8" diameter. If AWS-E-9018 is not available, AWS-E-7018 can be used.

NOTE

Do not use electrodes larger than 1/8" diameter, as the thin lacing walls make it extremely difficult to pre vent burn through when using larger electrodes.

Electrodes must be purchased in ten pound hermetically sealed containers and maintained in their "as manufac tured" condition until used. Once opened, these electrodes must be kept in a weld rod holding oven above 250°F until used. No more than a two hour supply shall be exposed to the atmosphere at any one time.

All welding shall be done with direct currect (D.C.) reversed polarity. This must be supplied by a D.C. rectifier or gener ator of sufficient capacity to deliver a minimum of 250amps at 40 volts.

WELDER QUALIFICATION AND CERTIFICATION

Boom sections on a mobile crane are constructed from special alloy and heat treated steels requiring exacting fit up and welding skills.

Only an experienced, skilled, and fully qualified welder may repair booms. It is highly recommended that all welders be certified with the tubular boom welding certification proce dure included as the finaJ page of this procedure.

Practice before boom welding is very desirable. Since lac ing material is, for the most part, thin wall, medium strength material, a very delicate touch and a high degree of skill is required to produce the weld joint between the heavier chord member walls and the thin wall lacing material. It is recommended that damaged lacing material removed from the boom section to be repaired be used to practice welding to 1I4" thick plate to obtain "feel" for the welding and prop er welding machine settings. See Figure 14-1.

EXTENT OF REPAIR

To insure the structural integrity of boom sections during repair the main corner structural members (referred to as chords) must remain straight within 1 /8 inch over the en tire length of the section, or 1 /16 inch between two panel points, as measured with a tight-line or straightedge. See Figure 14-2. The lacing members, diagonals, and vertical members (battens) of the crane boom sections must re main straight within 1 /16 inch between the chords. The tolerance must be checked in two directions, 90 degrees apart.

P142

14-1

Step 1 . Weld removed portion of damaged lacing to 1/4" plate.

Step 2. Cut off lacing.

Step 3. Do it again until settings and techniques are correct.

Figure 14-1. Practicing Welding Techniques

NOTE

Repair of main tubular chord members is not author ized. The entire boom section must be replaced when ever a chord has been visibly damaged.

All bent lacings, diagonals, or battens must be replaced, since they pull the main chords out of true alignment and can cause deflections in the chords which contribute to fail ure of the boom section. Smooth sweep bends in lacings may be straightened by jacking back into alignment with ex-

14-2.

BOOM SECTION REPAIR

treme care being taken not to kink or futher damage bent lacings. If a lacing cannot be straightened within 1 /16 of an inch, it must be removed and replaced.

PANEL POINTS

~~rs I

CHORD

Figure 14-2. Panel Points

OBTAINING MATERIAL

Bulk lacing material may be obtained from any Harnisch feger Corporation dealer by giving the part number and se rial number of the boom section to be repaired, along with the machine model and serial number.

Individually coped lacings can be obtained from any Har nischfeger Corporation dealer by giving the part number and serial number of the boom section to be repaired, iden tifying the physical location of the lacings to be replaced on boom drawings available from all Harnischfeger dealers, along with the machine model and serial number.

NOTE

A typical boom identification plate showing the boom part number and serial number is shown in Figure 14-3.

TUBULAR BOOM LACING REPAIR PROCEDURE

Once a full "Ind detailed inspection of the entire boom has been performed, and those lacing members that need to be replaced or straightened have been identified, the lacing re placement procedure for tubular chord booms is as follows:

1 . If at all possible, replace only one lacing at a time and complete the repair before removing another so as to main tain the original chord alignment. If there is extensive dam age, and more than one lacing must be replaced at one time, extreme care must be used to hold the main chord in align ment, both vertically and horizontally, during replacement.

All damaged lacings must be replaced with tubing of equivalent material and properties, size and wall thick ness.

2. Tubular lacings to be replaced should be cut off me chanically, preferably with a hacksaw, directly above the fil let weld attaching it to the main chord, leaving the original weld on the chord member. Grind or file the remaining weld

P143 bead flush with the main chord, using extreme care not to notch the main chord or nick it in anyway. See Figure 14-4.

Lacings may be removed from heavier booms by careful use of the arc torch, slightly above the attaching fillet weld, again using extreme care so as not to damage the main chord member in any way.

BOOM PART

NUMBER

SHOP ORDER

NUMBER

211~207

784704

6-422

8577 8183

SERIAL

NUMBER

OPERATOR

(CLOCK)

IDENTIFICATION

NUMBERS

Figure 14-3. Typical Boom Identification Plate

CARBON ARC, DISC

GRIND OR SAW OFF

DAMAGED LACING

1/4 INCH ABOVE

WELD. GRIND

REMAINING LACING

AND WELD DOWN

TO WITHIN 1 /16

INCH OF CHORD.

Figure 14-4. Cutting Off Damaged Tubular Lacings

SECTION XIV

3. Remove the remaining material. Grind marks should be parallel to the chord to minimize the possibility of damag ing the chord. See Figure 14-5.

NOTE

Due to the location of the lacing being removed in Fig ure 14-4, disc grinding the remaining 1 /16 inch of weld is difficult, if grind marks are to be kept longi tudinal to the chord. Therefore, a large file should be used to remove the remaining 1 /16 inch of weld. If no other member interferes with grinding, a fine grit disc grinder should be used. Note the direction of the grind marks on Figure 14-5.

Figure 14-5. Removing Remaining Material

NOTE

A smooth gouge free surface is required on the chord before a replacement lacing is fitted in place. Use fine emery cloth to polish the chord after grinding or filing the old lacing and weld material away.

4. When using bulk replacement lacings, cut the lacing to the proper length, which will be about 1 /2 inch longer than is actually required so as to leave sufficient material for con tour fitting. See Figure 14-6.

A. Hold a length of bulk lacing in proper alignment with an other undamaged lacing of the same length as the lac ing to be replaced.

B. Cut at the points and at the angle shown in Figure 14-6.

· MARK ANGLE ON LACING

\ \ MATERIAL AND CUT

, 1/4"LONGER

\ ON EACH END

DOTTED LINES INDICATE ' '

UNDAMAGED LACING

Figure 14-6. Cutting Replacement Lacings P144

14-3

5. Cope the lacing as shown in Figure 14-7. Carefully con tour fit the ends of the replacement lacing so that it fits with in 1 /16th (.060 inches) all around the joint and a slight drive fit is required to align the lacing in its proper location. See Figure 14-8. This fitting is very important as excessive openings will result in greater weld metal deposit, exces sive heat build up which can materially weaken the joint and also result in very undesirable distortion and locked up stresses. Weld sizes required to attach the lacings to the main chords can be determined by looking at the previous welds on the other unaffected joints on the boom. These will usually be from 1 /8 to 3/16 in. leg size. It is extremely important that this fit and weld size be maintained so as not to induce an unbalance of weld shrinkage and locked up stresses.

NOTE

It is very important that the centerlines of the copes on each end of the replacement lacing be in the same plane (not twisted), to assure a good fit on both chords.

6. New lacings must be installed in alignment with adja cent lacings. Accomplish this alignment by placing two straightedges on existing lacings, one on each side of the lacing being replaced. Clamp the straightedges firmly against the existing lacings, bring the replacement lacing against the straightedges, and hold in this position while welding is performed. See Figure 14-8.

C-CLAMP LACING

TO FLAT SURFACE

I TOP VIEW l ii.____ -~V((o\) c-CLAMP I COPE LACING w1~

14-4

LACING DISC GRINDER \

DISC

GRINDER

Figure 14-7. Coping Lacing With Disc Grinder

C-CLAMP

Figure 14-8. Aligning Replacement Lacing

BOOM SECTION REPAIR

7. All welding should be done in the flat or down-hand po sition. The boom section must be rolled or turned to allow the welding to be done in this position.

Keep welding heat as low as possible and weld in two dis tinct steps. Complete the other half of the weld after the joint has cooled to room temperature or 70°F.

All welding should be performed within a material temper ature range of 70°F to 400°F. No welding should be done on material under 50°F. Bring the boom section into a build ing where it can be warmed to this temperature, if neces sary.

Material may be preheated to a maximum of 100°F.

No welding should be done in rain, snow or other climatic conditions in which the weld can be chi I led extremely fast. If it is necessary to perform the weld outside a building, a proper wind-break and enclosure must be constructed over the area to be repaired. Heat must be applied to the area very cautiously to bring the material within the recom mended temperature range. Extreme care and skill is re quired for the proper overlap at the start and stop of the weld joints, or weld passes so as not to leave any unfilled craters which are subject to crater cracks and weakening of the joint.

Be sure that all grease, oil, water and other contaminants are removed from the weld area and the welding is per formed in a dry, still atmosphere away from wind, rain, and other adverse elements.

ANGLE CHORD BOOM LACING

REPAIR PROCEDURE

Replacement of a lacing in an angle chord boom section is similar in most respects to the procedure for lacing re placement in tubular chord boom sections. Only the differ ences will be discussed here. Therefore, be sure to read the procedure for replacement of tubular boom lacings as well as this procedure. The major difference in the procedures is that the ends of the lacings must be crimped or flattened to permit proper fit-up with the edge of the angle chords. See Figure 14-9. Proceep in the following sequence.

ANGLE_

CHORD

Figure 14-9. Fit-Up of Lacings to Chords

1. Cut the lacing to be replaced off about 1 /4 inch above the weld, using a hacksaw, carbon arc torch, or disc grinder.

P145

2. Disc grind the remaining lacing and weld material away until the angle is returned to its original shape. See Figure 14-10.

3. Lacing ends must be flattened by pounding into the ap proximate shapes shown in Figure 14-11 .

CUT LACING OFF 1/4"

ABOVE WELD WITH

SAW, CARBON ARC

OR DISC GRINDER

STEP 1

DISC GRIND

REMAINING LACING

~ AND WELD AWAY

UNTIL ANGLE IS

RETURNED TO

ORIGINAL SHAPE

~~~~"'-=~t ~;:=;;;:;:;:;::::==t STEP2

Figure 14-10. Removing Damaged Lacing

SIDE

VIEW

TOP

VIEW

U

I

I I

I I I

I I I

.260 x .083 WALL

P&H 280

I I I I I

SIDE

VIEW

TOP

VIEW

: I I I

.760 STANDARD

PIPE P&H 134

SIDE

VIEW

I I I I I

TOP

VIEW

.500 STANDARD

P&H 134

Figure 14-11. Approximate Shapes of Lacing Ends

4. When forming lacing ends with a hammer, the lacing will have a tendency to move backward. A holding device similar to the one shown in Figure 14-12 should be used to hold the lacing in place. This will make it easier to obtain the desired shape of the lacing end. Be sure that both ends of the lacing are falttened in the same plane (not twisted).

5. Determine the length of replacement lacings and the correct angle at which they should be cut by placing a length of lacing material against a lacing of identical construction in the boom section to be repaired. Mark the correct length and angle of cut needed and cut the lacing approximately 1 /8 inch longer than required. Saw cut the lacing to the length required.

SECTION XIV

TABLE OR FLAT SURFACE

Figure 14-12. Shaping Lacing Ends

6. Flatten the lacing ends as previously described, and check for correct fit in the position it will occupy in the boom section to be repaired. If necessary, grind the lacing end to the correct length and reshape the end which was ground off.

7. Make sure the lacing is placed in the exact position the damaged lacing was removed from. Then tack weld the lac ing to the chord angle on each side.

8. Weld the lacing in place, using the techniques pre viously described. See Figure 14-13.

ENDS OF WELDS

SHOULD BE

COMPLETELY FUSED

WITH WELD ON

OPPOSITE SIDE 7CINGS/

START WELD I START WELD

ANGLE CHORD

J

HERE HERE

PUDDLE OR TIE-IN

AT CENTER OF LACING

Figure 14-13. Welding Lacings to Angle Chord

INSPECTION

After all welding repairs have been completed, the entire repair area and other welded joints must be non-destruc tively inspected by the magnetic particle method. Make a full visual•inspection to ascertain that craters are full, no undercut is around any of the welding, and that proper con tours have been accomplished.

A full detailed record must be made of the repair, its loca tion, the date, the welder and the circumstances under which the repair was made.

Magnetic particle inspection should be performed accord ing to the ASTM-E109 procedure to detect any surface or underbead weld cracks. Any cracked weld must be re moved and rewelded.

P146

14-5

SECTION XIV BOOM SECTION REPAIR

HARNISCHFEGER CORPORATION

TUBULAR BOOM WELDING CERTIFICATION PROCEDURE

SOCIAL SECURITY NO.-------------------------------

MATERIALS:

Main Chords - P&H 281 - (U.S.S.T. or B&W Strolloy C) 2-112" 0.D. 1 /4" Wall Lacings - P&H 280 - (Welded, low carbon, high yield structural tubing) 1-1 /4 O.D. 0.083" Wall

WELDING DATA:

Filler Metal-----------------------------------

SMAW - AWS E9018 - Preferred AWS E7018 - Alternate

Electrode Size-----------------------------------

1/8", 3/32"

AmP-------------------------------------~

Voltage ____________________________________ _

Tubing Wall

Power Source:--------------- Main Chord1 /4" Lacing 0.083"

Position: Horizontal t

MIN. LENGTH 12"

5/32"

1/4 PULL BAR

NOTE: Weld Items No. 1 & 2 and Pull Bars before making Test Weld.

Weld Size

5/32"

Physical values obtained from test pieces must meet the minimum values required to P&H 280 tubing (55,000 psi minimum yield strength). Fractures must be at least 1I4" away from welds in parent metal.

Test welds must be free of all undercut and within 1 /16" of specified size.

Date: ___________ Approval:------------------------

14-6 P147

Photo 1: Crane Boom comprised of 25 foot base, 50 foot insert section and 25 foot tip.

Photo 2: 20 foot Insert Section

Photo 3: 30 foot Insert Section

Photo 4: Second 50 foot Insert Section

Photos 5 and 6: Boom Section Corrosion

QUALITY ASSURANCE SURVEILLANCE PLAN

FOR

CHENA RIVER LAKES FLOOD CONTROL PROJECT

CRANE BOOM REPAIRS

NORTH POLE, ALASKA

Table of Contents

Subject para

1. Overview 1

2. Description of Services 2

3. Roles and Responsibilities 3

4. Performance Assessment Approach 4

5. Performance Assessment Documentation 5

6. Surveillance Standard 6

1. OVERVIEW

1.1 Purpose. The purpose of this plan is to identify the methods and procedures the Government will use to ensure it receives the services under contract as identified in the Statement of Work (SOW). This plan will focus on the level of performance required by the SOW, not the methodology or process.

1.2 Intent. The intent of this plan is to rely on the Contractor’s quality control, thus changing the Government’s role from “oversight” to “insight”. Performance Objectives (PO) will be periodically monitored and the quality program evaluated but the Contractor is left as free as possible to develop the most efficient methodology to meet and exceed the required thresholds of service.

2. DESCRIPTION OF SERVICES

2.1 Scope of Work. Non-Personal Services: The Government owns a 90-ton P&H 790-TC mobile lattice boom truck crane located at the Chena River Lakes Flood Control Project near North Pole, Alaska.

The crane boom sections are tube steel and require inspection for structural defects or excessive wear and repairs for corrosion control. The contractor shall abrasive blast all existing paint and rust off each crane boom section, perform visual and non-destructive testing to ensure the integrity of the boom section and repaint each crane boom section. The crane boom sections consist of the following:

One 25 foot base section One 25 foot tip section Two 50 foot insert sections One 30 foot insert section One 20 foot insert section

The boom sections will be removed from the crane by the Government. The Contractor shall transport the boom sections to/from their repair facility. The Contractor is required to provide all labor, materials, tools and equipment needed to facilitate this repair.

All services requested under the SOW are non-personal in nature.

2.2 Contract. This contract is a Firm-Fixed-Price (FFP) contract for the abrasive testing, inspection and reapplication of protective paint coating. Any needed repairs to the crane boom sections will be performed as time-and-materials.

3. ROLES AND RESPONSIBILITIES

Contracting Officer (KO) - A person duly appointed with the authority to enter into, administer and terminate contracts on behalf of the Government. The KO is the only person who can legally commit the Government and only the KO, as the Government’s agent, can modify the contract/order. The KO is the final authority for determining the adequacy of the Contractor’s performance. KO decisions arising under or relating to the contact are final.

Contracting Officer’s Representative (COR) – An individual designated in writing by the KO to perform specific technical and administrative functions within the scope and limitations of their written appointment (e.g., surveillance of Contractor’s performance, accept services). The COR is not empowered to make any contractual commitments or authorize any changes to the order/contract or in any way obligate additional funds by the Government; such authority rests solely with the KO.

Quality Assurance Evaluator (QAE) – An individual designated by the requiring activity to assist the COR and provide technical oversight of the Contractor’s performance. The QAE’s primary duty is to monitor the Contractor’s performance by physically checking to see that tasks are completed, reports are submitted, and desired outcomes are achieved. When a surveillance observation results in an unacceptable evaluation, the QAE will report the unacceptable performance to the COR. The QAE is not authorized to direct work, offer advice on how the work should be performed, change the contract, or in any way obligate payment of funds by the Government.

4. PERFORMANCE ASSESSMENT APPROACH

4.1 Purpose. This section details the method(s) used to verify Contractor compliance with SOW requirements. The key elements of this process are the Government identified Surveillance Standard in Paragraph 6 of this QASP.

4.2 Method of Surveillance. Surveillance performed by the Government is to provide objective quality evidence that there is a reasonable level of confidence the services provided by the Contractor have met all the requirements of the contract before authorizing payment. The primary method of surveillance are periodic inspections and customer/user feedback.

Periodic Inspection: Inspections will be performed at the completion of each phase of work. Periodic inspections may be performed more frequently if the COR/QAE discovers the quality or safety of the Contractor’s performance is less than acceptable.

4.3 Annual Review. The COR/QAE must review QASP Surveillance Standard with the contractor annually.

4.4 Special Audits. The COR/QAE must be alert to conditions that would warrant a special quality or safety audit. Any time the COR/QAE observes that a functional area is out of acceptable performance or that the technical expertise is not available, a request for a quality audit should be addressed to the Contracting Officer.

4.5 Deficiency Identification. Effective contract performance assessment relies on two methods for identification of unacceptable performance – Contractor Identified Discrepancies and Government Identified Discrepancies.

4.5.1 Contractor Identified Discrepancies (CIDs). Generated when contractor employees detect discrepancies during performance of services. When reviewed by the applicable representative, follow procedures below.

4.5.2 Government Identified Discrepancies. Generated as a result of Government inspection of contractor performance that identifies noncompliance with contractual requirements. The Contractor will be given the opportunity to show whether the discrepancy has already been identified and in the process of being resolved.

4.5.3 Procedures

4.5.3.1 Review corrective actions taken by the contractor to resolve a discrepancy.

4.5.3.2 Determine whether the discrepancy has been corrected. If the discrepancy has been resolved, review the corrective action taken and any applicable procedures the contractor has established to preclude recurrence of the problem.

4.5.3.3 If not been resolved and the Contractor has established an estimated completion date for resolution of the discrepancy, the representative will monitor the Contractor’s efforts in resolving the discrepancy. If it is determined the estimated completion date for resolution of the discrepancy is excessive based on the nature of the discrepancy, the Contracting Officer (CO) will be notified. The Government can then evaluate the recommendation to determine the appropriate course of action.

4.5.3.4 If not resolved and the COR determines that the Contractor has not established a resolution of the discrepancy or has failed to perform a follow-up action for resolution of a discrepancy, the COR will issue a report. The Contractor will be given a suspense date to provide corrective action to the Government’s findings and describe the Contractor’s plan to preclude repeat deficiencies.

5. PERFORMANCE ASSESSMENT DOCUMENTATION

5.1 Corrective Action Report (CAR). Used by COR/QAE to document contract requirement findings and subsequent corrective actions to be taken. A computer-generated CAR may be used provided the information on the CAR remains the same. See attached CAR and instructions for filling it out.

5.1.1 The individual identifying the discrepancy is responsible for completing the CAR utilizing the instructions attached. If there are other questions as to how the CAR is completed, that individual should consult the COR.

5.1.2 The COR will elevate any CARs that cannot be resolved with the contractor to the Government Contracting Officer for resolution.

5.2 COR Monthly Reports. COR/QAE shall document contractor performance assessments in the COR monthly reports.

6. SURVEILLANCE STANDARD

Generally, under commercial services Contracts, the Government is relying on the Contractor’s assurances that the services conform to Contract requirements. Consistent with FAR 52.212-4, Contract Terms and Conditions, (a) Inspection and Acceptance, the Contractor shall only tender for acceptance those services that conform to the requirements of the Contract. The Government may require re-performance of nonconforming services at no increase in Contract price. The Government reserves the right to refuse acceptance of nonconforming services. In no case shall the Government’s right to inspect services under the inspection provisions of the Contract be prejudiced.

CORRECTIVE ACTION REPORT

(If More Space is Needed Use Reverse and Identify By Number)

1. CONTRACTOR

2. CONTRACT NUMBER

3. TYPE OF SERVICES

4. FUNCTIONAL AREA

5. SUSPENSE

DATE

6. CONTROL

NUMBER

7. MAJOR MINOR

FINDING:

FINDING IMPACT:

Please respond with a written corrective action plan that details the corrective action of the cited deficiency, the cause of the deficiency, and actions taken to prevent recurrence by Suspense Date in Block 5. If date was not entered in Block 5, the contractor is not required to provide a response.

8. QUALITY ASSURANCE PERSONNEL (QAP)

TYPED NAME AND GRADE

SIGNATURE AND DATE

9. ISSUING AUTHORITY

TYPED NAME AND GRADE

SIGNATURE AND DATE

10. QAP RESPONSE TO CONTRACTOR CORRECTIVE ACTION AND ACTION TAKEN

TO PREVENT RECURRENCE

11. CONTRACTOR RESPONSE

ACCEPTED REJECTED

12. CLOSE DATE

CAR Instructions

Block 1. Enter Contractor Name

Block 2. Enter Contract Number

Block 3. Enter Contract Name or Type of Service

Block 4. Enter Functional Area of the Contract

Block 5. a. Enter the assigned suspense date given the contractor to provide a response to the CAR.

b. A date must be entered for a Major finding. A date is optional for a Minor finding.

Block 6. a. All CARs will be tracked with a Control Number.

b. The FD or designee is the Issuing Authority for QAE-initiated CARs.

c. The control number will be made up of the first two letters of the name of the site or contract, the last two digits of the calendar year and a three digit number starting with 001 and progressing upward throughout the calendar year.

d. The QAE is the Issuing Authority for a CAR initiated during a performance assessment audit. The control number will be provided by the QAE and the finding will be tracked to conclusion.

e. The QAE will attach all CARs to their performance assessment audit report.

Block 7. a. Check the block that indicates whether the identified deficiency is a Major or Minor finding. See QASP for the definitions of Major and Minor Findings.

b. Clearly state the details of the finding followed by a reference to the stated contractual requirement. The reference must state the portion of the contract, part, section, paragraph and subparagraph and must make a brief but complete quotation of the contract reference.

c. State the impact that the finding has or could have on mission accomplishment.

d. Normal suspense time for contractor response is ten working days.

Block 8. a. For QAE-initiated CARs, the QAE initiating a CAR signs and dates the report.

b. For CARs initiated during a performance assessment audit, the Contracting Officer signs and dates the report.

Block 9. a. For QAE-initiated CARs, the FD or designee signs and dates the report.

b. For CARs initiated during a performance assessment audit, the Contacting Officer signs and dates the report.

Block 10. Upon review of the Contractor’s reply, the initiator of the CAR will enter comments regarding acceptance or rejection of the contractor’s response. This block may also contain any comments regarding follow-on inspections conducted or needed at a later date to validate that the finding has not reoccurred.

Block 11. The initiator of the CAR accepts or rejects the contractor’s response.

Block 12. a. The initiator of the CAR enters a close out date after acceptance of the Contractor’s response.

b. For QAE-initiated CARs, the report is forwarded to the FD or designee and a copy is provided to the Contacting Officer. The FD or designee will forward the CAR to the contractor and record results of the report in the COS. Copies of completed CARs will be maintained in the FD and QAE performance assessment folders.

c. For CARs initiated during a performance assessment audit, the Contracting Officer will forward the report to the Contractor and provide a copy to the FD or designee.

The FD or designee and QAE responsible for performance assessment will file the CAR in his/her Performance Assessment folder and track to conclusion.

d. If a CAR is not deemed closeable due to incomplete or unacceptable Contractor response, the CAR will be returned to the Contractor for additional information.

INSPECTION AND ACCEPTANCE TERMS

Supplies/services will be inspected/accepted at:

CLIN INSPECT AT INSPECT BY ACCEPT AT ACCEPT BY

0001 N/A N/A N/A Government 0002 N/A N/A N/A Government

DELIVERY INFORMATION

CLIN DELIVERY DATE QUANTITY SHIP TO ADDRESS UIC

0001 POP 30-DEC-2016 TO

31-MAR-2017

N/A N/A

0002 POP 30-DEC-2016 TO

31-MAR-2017

N/A N/A

CLAUSES INCORPORATED BY REFERENCE

52.204-7 System for Award Management JUL 2013 52.212-1 Instructions to Offerors--Commercial Items OCT 2016 52.212-4 Contract Terms and Conditions--Commercial Items MAY 2015 252.203-7000 Requirements Relating to Compensation of Former DoD

Officials

SEP 2011

252.204-7004 Alt A System for Award Management Alternate A FEB 2014 252.232-7003 Electronic Submission of Payment Requests and Receiving

Reports

JUN 2012

252.232-7010 Levies on Contract Payments DEC 2006

CLAUSES INCORPORATED BY FULL TEXT

52.212-2 EVALUATION--COMMERCIAL ITEMS (OCT 2014)

(a) The Government will award a contract resulting from this solicitation to the responsible offeror whose offer conforming to the solicitation will be most advantageous to the Government, price and other factors considered. The following factors shall be used to evaluate offers:

Offers will be technically evaluated in accordance with the requirements set forth in the Performance Work Statement. Award will be made to the lowest-priced technically acceptable offeror. The Government reserves the right to make award on the initial offer received without discussions.

(b) Options. The Government will evaluate offers for award purposes by adding the total price for all options to the total price for the basic requirement. The Government may determine that an offer is unacceptable if the option prices are significantly unbalanced. Evaluation of options shall not obligate the Government to exercise the option(s).

(c) A written notice of award or acceptance of an offer, mailed or otherwise furnished to the successful offeror within the time for acceptance specified in the offer, shall result in a binding contract without further action by either party. Before the offer's specified expiration time, the Government may accept an offer (or part of an offer), whether or not there are negotiations after its receipt, unless a written notice of withdrawal is received before award.

(End of provision)

52.2…