Description_Requirement_W912HZ16R1777.pdf

Description of Requirement

Purchase of AM2 Mattting and AM2 Stake Packages

Geotechnical and Structures Laboratory

BACKGROUND:

The Airfields and Pavements Branch (APB) of the US Army Engineer Research and

Development Center (ERDC), Vicksburg, MS, has been tasked by the US Army to demonstrate

AM2 matting for vertical take-off and landing (VTOL) operations and to develop an optimized kit to support Army logistics. The purchased AM2 matting and stake package will be used to demonstrate requirements to install a 54-ft wide by 50-ft long VTOL pad. This purchase is required to develop the AM2 VTOL kit and to facilitate tech transfer of a prototype kit to the US

Army.

REQUIREMENTS:

Item Name Short Description Quantity Required

F-71 12-ft AM2 sheets 5

F-72 6-ft AM2 sheets 2

F-74 Stakes and Edgeclamps 1

ITEM DESCRIPTIONS:

F-71 12 foot AM2 Package Assembly:

The F-71 is a 12 foot matpack containing eighteen (18) 12-ft by 2-ft sheets of AM2 matting (432 sf), and twenty (20) 2-ft locking bars. Aluminum end frames and banding are used to contain the matting. Each AM2 mat panel is 1.5 in. thick and consists of a one-piece hollow extruded aluminum section with extruded end connectors welded to each end. Each sheet weighs approximately 150 lb. The sheets are painted Marine Corps Green topped with an epoxy non-skid material of the same color and have four interlocking edges. Locking bars are used to secure the sheet ends together. The US Navy part number for the F-71 is 626578-1.

F-72 6 foot AM2 Package Assembly:

The F-72 is a 6 foot matpack containing eighteen (18) 6-ft by 2-ft sheets of AM2 matting (216 sf), and twenty (20) 2-ft locking bars. Aluminum end frames and banding are used to contain the matting. Each AM2 mat panel is 1.5 in. thick and consists of a one-piece hollow extruded aluminum section with extruded end connectors welded to each end. Each sheet weighs approximately 75 lb. The sheets are painted Marine Corps Green topped with an epoxy non-skid material of the same color and have four interlocking edges. Locking bars are used to secure the sheet ends together. The US Navy part number for the F-71 is 626577-1.

F-74 AM2 Stake Package Assembly:

The F-74 is a 6 foot matpack made from 6 ft AM2 sheets and AM2 end frames containing 56 each of the following items: cruciform stakes, stake pins, universal edge clamps, and 1-ft locking bars. The stakes and universal edge clamps are used to secure AM2 mat edges against the horizontal and vertical load effects of aircraft operations. The short locking bar is used to secure the universal edge clamp to the edge of the AM-2 matting. Stake pins and safety wire are used to secure cruciform stakes to the universal edge clamp. The US Navy part number for the F-74 is

627062-1.

Delivery:

Deliver as soon as possible but NLT 120 days after award.

Deliver to CEERD-GM-A, Hangar 2 of the Waterways Experiment Station, 3909 Halls Ferry

Road, Vicksburg, MS 39180.

AM2 Drawings and Certification Requirements:

1. General:

a. Excerpts from NAEC Design Data Report No. 51-2012, 7 Feb 90, were used in creating the specifications for this solicitation. Distribution is authorized to DOD and DOD contractors only; Critical Technology, 23 Jan 1992. Request for the original document shall be referred to the Commanding Officer, Naval Air Warfare Center Aircraft Division, Lakehurst, NJ

0873305090. In addition, these excerpts may contain technical data whose export is restricted by the ARMS Export Control Act (Title 22, U.S.C. Sec 2751 Et Seq.) or Executive

Order 12470. Violations of these export laws are subject to severe criminal penalties.

b. The U.S. Navy Naval Air System Command (NAVAIR), Lakehurst, NJ, holds all rights and drawings of AM-2 Mod 5. The drawings are export-controlled drawings and all interested bidders must submit a DD Form 2345 to Lakehurst Contracts Dept. along with a written request in order to obtain the drawings. Additionally, they must contact the Defense Logistics

Information Center in Michigan to obtain certification to receive export-controlled material.

c. AM-2 Mod 5 Landing Mats will be produced in accordance with NAVAIRENGCEN drawing

621552 using the Gas Metal Arc Welding (GMAC) process.

d. The inspection procedures outlined herein will be divided into separate phases of manufacture:

(1) the Extrusion; (2) the Assembly; (3) the Test for Interchangeability; (4) the Test of Water

Tightness of Mat; (5) Packaging; and (6) Source Material for Quality Control.

e. The Qualification Process outlined herein will be divided into separate phases of testing:

Qualification Test Rolling and Production Verification Roll Testing.

f. Non-Skid Coating will be applied in accordance with NAWCADLKE-MPR-1213, Material and

Process Requirements (MPR) 1213, Coating AM-2 Mat and Accessories Revision K, 9 Mar 12.

g. The contractor shall provide certification from an independent lab that the alloy used in production is 6061-T651.

2. The Extrusion:

a. The extrusion requirements for AM-2 Mod 5 hardware shall be in accordance with individual

NAVAIRENGCEN part numbers. A preproduction sample of each type extrusion will be submitted to NAVAIR for inspection prior to the production run. Inspection will also be required prior to use of a new or modified die for a production run. The sample shall be suitably prepared for etching the cross-section to determine adequacy of welds.

b. The alloy used in the dimensional test specimen must be that used in subsequent production.

c. Hardness tests must be performed on each extruded charge at the contractor's manufacturing facility. The first and last mat of each extruded charge will be selected for testing. The testing is to be performed after aging. The Barcol instrument shall be used for the tests. A minimum hardness number of 80 will be acceptable. If either the first and/or last mat of an extruded charge does not meet minimum hardness, all mats in the charge must be treated. Each mat shall be permanently marked with “push” number. A minimum of three readings shall be taken on each mat tested to establish the average hardness number.

3. The Assembly:

a. AM-2 Mod 5 Landing Mats:

1) The assembly requirements for AM-2 Mod 5 Landing Mats shall be in accordance with

NAVAIRENGCEN Drawing 621552.

2) The fabrication inspection procedures and criteria performed by the contractor will be as follows:

a) Check mat extrusion length and squareness of ends after cutting in accordance with

NAVAIRENGCEN Drawing 621551.

b) Assembled AM-2 Mod 5 Landing Mat dimensions and tolerances shall be inspected in accordance with NAVAIRENGCEN Drawing 621552.

b. Welding Procedure and Production Inspection Acceptance Criteria

1) Welding Procedure and Qualification

a) Welding shall be accomplished in accordance with the requirements of

MIL-W-22248 for class 2 weldments. MIL-W-22248A, MILITARY

SPECIFICATION: WELDMENTS, ALUMINUM AND ALUMINUM ALLOY (29

SEP 1971). This specification covers the general requirements for aluminum and aluminum alloy weldments fabricated by the inert-gas metal-arc and inert-gas tungsten-arc welding processes.

b) Weld rod shall be ER4043 per AWS A5.10.

c) Prior to production welding, a Welding Procedure Specification and Procedure

Qualification Record per AWS B2.1 shall be submitted to the Naval Air Warfare

Center (NAWC), Aircraft Division, for acceptance. Liquid penetrant inspection is required.

d) Approving activity is the Quality Engineering Branch, Code PD4, Naval Air Warfare

Center, Aircraft Division, Lakehurst, NJ 08733-5092, with copy to Code SR46.

e) During production, all welding shall be accomplished within eight (8) hours of removing the oxide from the area to be welded. Oxide removal can be accomplished by mechanical or chemical means.

2) Production Inspection Criteria

a) All finished parts shall be visually and liquid penetrant inspected by the contractor.

b) 100% penetrant inspection shall be performed per Mil-Std-6866, Type 1, Method A, Sensitivity Level 2.

c) Acceptance criteria for visual and liquid penetrant inspection shall be that of

Mil-Std-2035 for Class 3 weld, except that the weld profile shall not project more than one thirty-second (1/32) of an inch above any connector surface.

4. Test of Interchangeability

a. The first nine mat assemblies off the fabrication line will be assembled in three rows, three sections across, in a brickwork pattern with locking bars, to ensure interchangeability. From every day’s production fabricated thereafter, or from every 1000 mats fabricated, whichever comes first, three mats will be selected at random and assembled as follows: Remove the middle mats from each row of the original configuration and install the three randomly selected mats with locking bars. If the three randomly selected mats do not fit, then the day’s production (or the mats produced since the last acceptable test) lot shall be placed in a “hold” status until the causes for the misfit can be determined and a corrective course of action established. The entire lot must then be tested for interchangeability and mats which do not fit must be corrected.

5. Test of Water Tightness of Mat

a. Every two (2) hours during a continuous production run, weigh one (1) mat and record the weight.

b. Place mat horizontally (flat) in a tank of water. The depth of water above the mat shall be six (6) inches minimum.

c. Leave mat immersed for ten (10) minutes.

d. Remove mat from water and weigh mat within one (1) pound.

e. Increase in weight of more than one (1) pound indicates mat requires repair.

f. If test mat requires repair, all mats produced during the preceding two (2) hours shall be tested for water tightness.

g. If one (1) or more mats are not watertight, the welding procedure shall be checked and all mats failing the water tightness test will be repaired and retested.

6. Packaging

a. The packaging requirements for AM-2 landing mats shall be in accordance with

NAVAIRENGCEN drawings. Inspection procure performed by the contractor shall cover the following:

1) Check packaging for complete assembly and proper installation

2) Check compliance with pallet identification requirements including end frame identification.

3) Ensure that the force used to tighten the bands around the pallet is not excessive in accordance with best commercial practice. Excessive force results in bending the female channel bottom lip on the two vertical mats in each pallet.

7. Source of Material for Quality Control

a. The contractor shall supply all materials required for tests to NAVAIR to maintain quality control.

8. Qualification Process

a. Qualification Test Rolling - To qualify as a supplier of mats defined in the specification the supplier must submit test results from an independent laboratory showing that the mat produced by the supplier can withstand 1000 coverages under the following test criteria:

1) CBR 6.00 for a minimum depth of 3 feet

2) 35,200 lbs single wheel load using an F-15E tire

3) 325 PSI Tire

4) Progressive coverages centered over the side edge joint of one of the panels (distributed over

5 lanes spaced 11.75” apart), the outer two lanes receive one coverage for every two coverages of the center three lanes.

5) Coverages are established for the test when the test section deflects 1.25” below the original grade under load or 10% of the mats have developed failures as determined by tire damage assessment. Any crack that allows a differential movement of more than 1/8” differential movement between parts on either side of the crack shall be deemed failed. Any mat with cracks exceeding 4” in length shall be deemed failed.

(6) No end connector weld breaks are allowed during the Roll Test. If any end weld breaks occur, the test will be considered a failure, and the vendor must re-submit and pass a new test array prior to passing qualification.

(7) Additionally, the non-skid and coating must remain intact during the Roll Test. If any of the non-skid or coating is found to be cracked, flaking, or missing at the end of the Roll Test, this material will be considered insufficient for production and the vendor will not be qualified for production until a new array of panels is tested and pass successfully