SOW Maintenance Bonding Layout Room B1295 22 Jan 10.doc

147 Reconnaissance Wing, Ellington JRB, Tx FWJH092456 Pre-Fabricated Bonding/Layout Room B1295

STATEMENT OF WORK:

The project shall consist of a turnkey design, purchase and installation of a pre-fabricated bonding/layout room for building 1295. The structure shall be located within an existing maintenance bay located in building 1295. All utility support shall be provided and drawn from building 1295, i.e., electrical, fire suppression wet pipe system, water, etc.The Contractor shall be required to purchase the pre-fabricated structure, provide engineered drawings and specifications that are coordinated and approved by a registered engineer (PE) within each discipline and then construct and install in order for a complete and usable system to be provided.

A. The projects shall be accomplished in 5 parts They are as follows:

a. Field verification and analysis,

b. Coordination meetings to discuss findings and recommendations

c. Engineered (PE) design and specifications, and cost proposal

d. Government review of submission,

e. Installation of all design elements upon approval of the reviewed submission.

B. The field verification and analysis shall consist of but not limited to identification of existing individual equipment, utility support, etc.. The informal report shall identify any changes that are required and any impediments.

C. Meetings with Base Engineering shall be conducted at this point to discuss the recommendations to be included as part of the design.

D. Upon completion of the analysis meetings, data will be forwarded to the licensed professional engineer to design for the application.

E. Engineering drawings and specifications shall be accomplished. The designer shall also provide a material submittal in accordance with the technical specifications being created. The design and specifications shall be submitted to the Base Civil Engineer for review and approval.

F. Upon approval of the design by the Base Civil Engineer for work to be performed, the Contractor shall be instructed by the Contracting Officer to move forward with installation of the complete and usable system.

PART 1

GENERAL:

All work performed under this contract must be in accordance with the general conditions and technical specifications provided.

A. The Contractor shall abide by the General Condition which is a part of this Scope of Work and the templates can be provided by the Base Civil Engineer.

SECTION

DISCRIPTION

01001 Ellington Field General Requirements

01019 Contract Considerations

01039 Coordination and Meetings 01105 Hazardous Material Procedures

01300 Submittals

01400 Quality Control

01420 Environmental Protection

01430 Operation and Maintenance Data

01600 Material and Equipment

01640 Manufacturer’s Services 01650 Start of Systems 01700 Contract Closeout

AF 3000

Material Submittal Form

AF 3052

Construction Cost Estimate Policy Letter Contractor/Visitor Access Procedures

SF 1413

Statement and Acknowledgment

Texas ANG Transmittal of Shop Drawing, Equipment Data Material Samples, or Material

Certificate of Compliance

1.2 DESIGN STANDARDS, CODES AND CRITERIA: As Required, but not limited to The design shall comply with the base specific General Design Guidelines and the Architectural Compatibility Guidelines of that base.

In addition to the specific codes, standards and criteria referenced throughout this RFP, the Contractor shall prepare design and construction documents for all elements of the project in accordance with UFC 4-740-14 and the following codes using the most current editions. Where there is a conflict between the RFP and building codes, the most stringent shall apply. When codes are in conflict, the most stringent shall apply. This list is not intended to be a complete list. All work shall be designed and constructed to meet all state and federal codes, standards and laws. Reference other sections of this RFP and the UFGS specifications referenced for use for other standards and references not listed below.

ABA

Architectural Barriers Act

AFDS

Air Force Design Guide, current edition

ANSI

American National Standards Institute Standards

ASCE

American Society of Civil Engineers, Minimum Design Loads for Buildings and Other Structures, Latest edition.

ASHRAE

American Society of Heating, Refrigeration and Air Conditioning Engineers

ASTM

American Society for Testing and Materials

DCID

Director of Central Intelligence Directive 6/9, Physical Security Standards for Sensitive Compartmented Information Facilities

EIA

Electronic Industries Association

ETL

Engineering Technical Letters

IBC

International Building Code

IEEE

Institute of Electrical and Electronics Engineers

IES

Illuminating Engineering Society Lighting Handbook

IFC

International Fire Code

IMC

International Mechanical Code

IPC

International Plumbing Code

MILHDBK

Military Handbooks

NEC

National Electrical Code, current edition

NEMA

National Electrical Manufacturer's Association

NESC

National Electrical Safety Code

NFPA

National Fire Protection Association Codes and Standards, most current edition

SMACNA

Sheetmetal & Air Conditioning Contractors National Association

TI’s Technical Instructions

TM’s Technical manuals

UL

Underwriter's Laboratories

The Contractor shall also follow all current national and state codes, regulations and specifications involving civil, architectural, interior design, structural, mechanical, electrical, and environmental disciplines which are applicable to the engineering design and construction industry, including OSHA Safety and Health Standards.

Use of the most current versions of the National Fire Codes and Life Safety Codes, published by the National Fire Protection Association (NFPA), the International Building Code (IBC), and the Architectural Barriers Act (ABA) is mandatory. In case of conflict between code requirements, the most stringent criteria shall apply.

A. NEC

National Electrical Code

B. ANG ETL 01-1-1

Air National Guard Design Policy March 2004, Section 10 and 16 C. ASHRAE Handbooks – Latest Edition

D. ASHRAE Standard 62.1-2004 – Ventilation for Acceptable Indoor Air Quality

E. ASHRAE Standard 90.1-2004 – Energy Standard

F. ETL 83-1 Design of Control Systems for HVAC

G. FC 3-600-01: Fire Protection Engineering for Facilities

H. SMACNA Guidelines – Sheet Metal and Air-conditioning Contractors' National Association

I. SMACNA HVAC Duct Const Stds, HVAC Duct Construction Standards - Metal and Flexible

J. 147 RW, Base Architectural and Mechancal Standards K. Standard for Wet Chemical Extinguishing Systems, 2009 Edition L. R-102 Fire Suppression System Specifications

1.3 EXISTING:

1 Not Used

1.4 GENERAL: Provide a bid proposal to analyze, design and install a pre-fabricated aircraft bonding/layout room and all associated utility support that will be located in building 1295.

1.5 OBJECTIVE: The pre-fabricated bonding layout room shall be complete and usable and pass all operational requirements in support of its aircraft related mission. The facility shall pass all facility and environmental code compliant laws for Federal, State, and Local criteria.

1.6

LICENSING AND CERTIFICATION

A. The contractor and fire protection engineer shall be licensed and will provide their credentials to Base Civil Engineer at the pre-construction conference. The design of the wet pipe sprinkler system shall be approved and signed by a licensed fire protection engineer.

1.7

QUALITY ASSURANCE

A. Contractor shall thoroughly check and test all parts and pieces to insure they are operating correctly and the complete system is working and meets the objective of a complete and usable system.

B. See Section 01400 of the General Conditions

1.8

SUBMITTALS:

Contractor will submit:

A. Product Data: Provide manufacturer’s data on system.

B. Provide manufacturer installation instructions, wiring diagrams and all other publications that are required for a complete and fully functional system.

C. Contractor shall not order or begin any construction until the submittal has been approved by the Contracting Officer D. See section 01300 Submittal of the General Conditions.

E. In additions to the number of copies under section 01300, provide one electronic copy to the BCE of all submittals.

1.9

WARRANTY:

A. System including all equipment and devices shall have a minimum of a 1 year full Materials and Labor Warranty.

PART 2

PRODUCTS:

2.1

EQUIPMENT:

Not Used

PART 3 EXECUTION

3.1

INSTALLATION

A. Equipment and materials shall be installed in an approved manner and in accordance with equipment manufacturers’ installation requirements.

3.2

FIELD QUALITY CONTROL

A. See section 01400 Quality Control of the General Conditions.

B. Provide all necessary testing of the fire protection system to insure the system meets the manufacturer’s written instructions and that the system performs to the objective.

3.3 TRAINING

Not Used 3.4

PRE-FABRICATED FACILITY GUIDANCE

The bonding/layout room shall be comprised of the following detailed guidlines:

24' x 40' x 12' High Integra 400 Interior Modular Class 300,000 Cleanroom Operational Class 300,000 cleanroom (As Built Class 100,000 cleanroom ISO 8@ 36 air changes per hour with10' ID ceiling) Ceiling System. The facility shall be constructed with a clear span interior space.

HVAC Controls

A 5 ton DX Split HVAC, 15 seer, 20 fin unit with heresite protective coating and a MERV 11 pre filter system with humidification controls will be stand alone system and will be floor mounted with with Ductwork, Registers, Fittings, Therm, Low Volt Wiring.

Temperature Requirement. At the absolute minimum, the facility must be designed to maintain the temperatures 68 to 80 degrees Fahrenheit plus or minus 5 degrees.

Humidity Requirement. The facilities must be designed to maintain the range in human comfort level of 47% to 70% RH from a wall mounted thermostate. The facility shall incorporate fiberglass reinforced plastic wall facings to combat moisture exposure and provide a vapor barrier. The entire facility shall be caulked and sealed at all connection seams, points, connections, and joints.

Ductwork. Shall be galvanized steel ductwork with inner liner on main trunk line and a single wall snap lock with exterior insulation wrap.

Air Filtration Requirement for Bonding/Layup Room. ISO Class 8.5 clean room (or Class 300,000, as built class 100,000 @ 36 air changes per hour) with an operational occupancy state (when in use), HEPA System with mortarized fan filter units.

Positive Pressure. This is a flexible requirement for the layup room. Only a slight positive pressure (0.05” water) is needed. A layup room shall NEVER be designed with a negative pressure.

Fresh Air Intake. Ten percent fresh air taken into the HVAC system with a damper control with an off on switch prior to the filters is the norm for composite repair areas. The fresh air intake shall be located away from sources of contamination.

Return Air Intake. The bottom of the return air intake should be located approximately 6 inches above the floor.

Forced Air Supply Vents. The facility shall use a open plenum recirculation system.

Fire Protection/Sprinkler System. An automatic sprinkler system is required and shall be drawn from the existing facility. The requirements are as follow:

Preparation of shop drawings for submittal.

Tie onto existing wet system, run new main over new modular cleanroom building inside hanger, and drop sprinkler heads through ceiling.

Heads to be sealed at ceiling by fire caulking only.

Ordinary hazard group2 protection only.

Drawings to be stamped by a fire protection professional engineer.

Materials and equipment approved by NFPA #13. Pendent sprinklers are to be standard semi-recessed type with white escutcheons. Pipe to be galvanized schedule 40

Windows. Windows shall be installed in panels per customer drawing. Windows shall be the picture-window type per customer drawing. The window glass shall be a minimum 3/16-inch thick amber lexan (non film) or polycarbonate pre-mounted in an white powder coated aluminum frame. A 3-1/2" air gap shall separate the two pieces of polycarbonate or lexan for optimum sound and temperature control. Windows shall be a nominal 40 inches in height and extend across the full width of its supporting panel. The windowsill height shall be 41 inches from the floor.

Doors. The room shall have both a personnel door and a 16’x10’ large door (such as a roll-up door) large enough for the largest part (and dolly) expected to be repaired in the room. If the door is motorized, the motor, greased gears, etc should be placed on the outside of the layup room; this will help prevent contamination. All doors shall be pre-hung at the factory and assembled into panels to ensure easy installation and proper fit. Doors shall be a nominal 36 inches wide by 84 inches high and have thickness of 1-3/4 inches. The interior and exterior finish of the doors shall be white powder coated. All doors shall have the same finish on both sides. Door types are as follows:

a. (1) 3070 Steel door with standard hinges and knob. Powder coated white to match wall color.

Doors shall be fitted with sweeps, gaskets thresholds, commercial doors closers and ADA complaint lever handles.

Floor Surfacing. The floor shall have a white epoxy flooring - No Urethane.

Walls. The walls, to the greatest extent practical, shall be free of overhangs, ledges, protrusions and other dust traps. They shall be a smooth, easy to clean surface. Wall system shall be 4" min. actual thickness overall. The entire wall system shall be approved by UL (Underwriters Laboratory).

Panels shall be modular and interchangeable with a minimum thickness of 3-1/2" overall. The standard panel shall consist of an insulated rigid polystyrene core permanently laminated between two sheets of white embossed fiberglass reinforced sandwich panel facing wit. Heavy-duty vinyl laminated facing shall be permanently applied at the factory and shall be easily cleanable. The panels shall be fully fabricated at the factory for easy installation. No splicing shall be necessary for any panels under 10' total height. All panels will be UL Classified and meet a class "C" fire rating.

Base Channel. The base channel shall be white powder coated anodized aluminum with a minimum thickness of .080. The base channel shall be anchored at 48" O.C. with 1/2" x 3-1/2" minimum embedded wedge anchor or per engineers specifications. Anchors shall be included with materials.

Posts and Framing. Posts shall be white powder coated anodized aluminum framing channels with minimum temper strength of 6063-T5. The posts will allow for a load up to 3,500 lbs., but not to exceed 4,000 lbs. each and shall be an intricate part of the structure. The connecting posts shall serve as electrical raceways accommodating electrical, data and phone. The raceway shall bear a UL approved sticker and conform to all UL reports

Ceiling. A suspended ceiling with sound absorbing tiles is preferred as long as the room is not subject to intense vibrations that will cause the tiles to release particles which will contaminate the room. The ceiling shall be suspended from the roof deck and supported by the wall perimeter or in accordance with the manufacturer's standard installation procedures. The suspended ceiling shall consist of 1 ½” PVC faced pregasketed co-extruded aluminum T-bar ceiling grid hung from 12 gauge hanger tabs and wires, white vinyl-faced gypsum with easily cleanable finish. The ceiling panels shall be 2 feet wide by 4 feet long by minimum 1/2-inch thick lay-in Class 100 Vinyl Clad gypsum. The ceiling structure shall meet UL Class A Fire Rating with 0-25 flame spread. The T-bar ceiling grid shall provide support for the light fixtures and shall be supported at each corner of each light fixture.

Hardware. Coordinate with the COR, Hardware must accept a 7-pin figure 8 Best Core.

Size. The room shall be sized 24’x40’x12’

Color Scheme. Light reflection and glare may become a hazard because of the need for smooth, hard finishes in the layup room. Floors should be light colored to aid in reflectivity. Walls within the field of vision should be the same color; paint should be semi-gloss for ease of cleaning.

Electrical Requirements Existing Facility Electrical Capabilities provide:

120/208 / 440 / 460

Should a step down transformer be required to support the proposed facility, The contractor shall be responsible for purchasing this piece of equipment as part of this proposal.

Pre-wire. Please provide electrical wiring of all outlets and switches. All concealed electrical shall be encased in flexible aluminum or steel conduit. All exposed conduit shall be encased in steel conduit. All components shall be wired to a load center /sub panel or one location within the proposed structure. All wiring to the load center / sub panel shall be wired to breakers that are also provided. All wiring must be field-tested. All wiring shall consist of 12 GA. minimum THHN type and shall comply with all N.E.C. requirements. All circuits shall be 20 amp single pole or 20 amp 2-pole breakers. A ground wire shall be pulled to all lights, outlets, and any other electrical component. This does not include main electrical hookup or phone and data jacks to the main board.

HVAC System. HVAC Unit shall be capable to accepting 460 3 phase electrical to power the unit provided by the government.

Cleanroom Building Subpanel. Shall have 120/208 Max 3 Phase power. Shall include all breakers necessary for powering all integral cleanroom electrical devices (lights, switches, motorized hepa filters, duplex outlets).

HEPA System. Voltage shall be 115v

High Speed Roll Up Door. Door control panel electrical shall be hook up by the government. Door shall be able to accept either Single phase 208-230 or Three phase 208-230, 460 VAC Outlets. This is a hard requirement for the layup room and recommended for the damage removal area. The facility shall function on a three phase 120/208 volts system. 5-110v and 4-208 volt, 30 amp circuits will be provided. No more than two sets of outlets should be placed on a circuit. The freezer and refrigerator must be placed on their own circuit.

Lighting. Light fixtures shall be recessed in the ceiling. The lay-in light fixtures shall be 2 feet wide by 4 feet long and incorporate T8 4100K lamps with electronic ballasts. Light fixtures shall have a minimum 128-watt capacity and be equipped with amber diffuser lens. The appropriate quantity of light fixtures shall be located in the ceiling such that a minimum of 100-foot candles lighting at a height of 30” from the floor is evenly maintained throughout the modular cleanroom. Tubes are not included. Double Gasketed Cleanroom Lights must be suitable for Class 10000 environments.

Light Switches. A light switch shall be provided at each doorway. (1) Light switch shall be located on the interior wall and opposite the door hinges. Light switches shall be conveniently placed for easy access. Light switches shall be located 42 inches in height from the floor. Light switches shall be provided with white cover plates. Light switches shall conform to the National Electric Code.

Compressed Air Filtration. This is a hard requirement for the compressed air supply in the layup room. Filter Efficiency. Multiple stage filters will be required. For composite work, the final filter must remove extremely fine particulate and be virtually oil free. Filters designed to provide instrument quality air such as the Wilkerson Grade C filter and the Balston grade BX filter are acceptable and information is shown in appendix K. Filter Location. Whenever possible, the filters should be located outside of the rooms, but as close as practical to the point of use; this is so that they do not contaminate the room when they are drained. If filters are located in the rooms, they shall NOT have automatic drains.

3.5 PRE-FABRICATED FACILITY SPECIFICATIONS REQUIRED:

This quote should include but not limited the following items listed below:

152 Linear Ft Wall Sections 12' High -4" Wall System

3,648 Sq. Ft. Wall Make-Up: Exterior White Textured FRP/Foam/Interior White Textured FRP

152 Linear Ft. Upgrade to Powder Coat Aluminum (White Color) - Includes Floor

Track, Top Cap, Corner Posts, Raceways, Window Frames and Door Frames

1 White Power Coated Steel Frame for Roll-Up Door (16’ wide x 10’ high)

1 Dynaco Power M2, Ultra Safe High Speed Roll Up Door(s).

Designed to control interior or exterior environments while operating under pressures of up to 63.5 mph. The self reinserting door curtain incorporates a soft bottom edge.

Door Size: 16'-0" wide x 10'-0" high.

STANDARD DOOR FEATURES INCLUDE:

Push Pull Drive System: Direct drive system eliminates dangerous and maintenance prone tensioning systems, wind bars, wind ribs and rigid bottom bars.

Crash Curtain is free of rigid components that bend and break. In the event of an impact, the curtain is designed to disengage from the side frame without damage.

Self Reinserting: After an impact, the curtain is reset automatically by opening the door.

Curtain:

Reinforced PVC suitable for applications from -22F to +158. Patented continuous end lock design provides a tight seal and allows the door to reinsert automatically. Colors: yellow, gray, blue, red, green, orange, white, brown or black. (Selection made by COR) Tight Seal: Mobile top seal, soft bottom edge and continuous break away end locks in the side guide, provide a virtually perfect seal. Drive Unit: 1 HP or 2 HP

Variable Speed, direct drive NEMA 4 motor incorporates Soft Start/Stop technology and dynamic braking. Absolute encoder maintains door position at all times.

Door Speed: 48" per second open and close. Optional: 96" per second open.

Control Panel: Self diagnostic Dynalogix II controller includes variable frequency controller, multifunction command center with multi line LCD screen for easy troubleshooting and diagnosis. Side Guides: Galvanized Steel 3-1/8" x 1-5/8" x 1/8", UHMW inner guides. Additional Safety: Wireless bottom detector opens the door upon contacting an obstacle during the close cycle. One set of infrared photocells are located in the side frame and constantly monitor the door opening.

Vision Banner, Transparent PVC, 15" x full width, centered 5'3" above the floor.

PRICE SHALL INCLUDES: Freight, Mechanical Installation (Open shop, No union or prevailing wage) Electrical Hookup, from the door components & activators to the door control panel (EMT and Sealtite). Power to the control panel by customer.

1 3070 x 1-3/4 White Powder Coated 18ga Steel Door With Standard Hardware and Painted Steel Frame

1 Locking Lever Hardware (ADA Compliant) Grade 2

1 Commercial Door Closer

1 Door Sweep, Gasket and Threshold

1 20 x 24 Vision Lite Frame W/3/16 Dual Pane Temp. Safety Glass (Door Window)

2 48 x 40 Solid Dual Pane Window Frame with (2) 3/16 Clear Tempered Glass

1 12'-UL Classified 4" Raceway- Includes Switch White

5 12'-UL Classified 4" Raceway- Includes 110v 20amp Duplex White

4 12'-UL Classified 4" Raceway- Includes 240v 30amp Duplex White

14 2' x 4' Inlay Cleanroom Class 10,000 Troffer Double Gasketed T-8 Light Fixture 4-Tube Capacity (Tubes Not Included). 100ft Candles of Light

960 Sq. Ft. Of 2' x 4' x 1-1/2" Pregasketed PVC Faced Extruded Aluminum Clean

Room Grid with 1/2" Vinyl Faced Tiles

960 Sq. Ft. Galvanized Dust Cover .20 Gauge

80 Ln. Ft. Neoprene End Closers 3W & B-36 Deck

40 Linear Ft Beams up to 8" Powder Coated White

1 12' High Support Column With Foot Plate (foot plate size to be determined)

Powder Coated White

128 Linear Ft. Roof Fascia

1 3 Phase Load Center 120/240 Max with 20 Amp Breakers 150 Amp Capacity Main Lug

12 Fan Powered HEPA Filter, 99/99% @ 0.3 Micron CL100 RSR Media, Downstream (room side replaceable hepa filters) and 3 speed switch Air Flow

12 18" x 18" Return Air Grill w/1" Prefilter Installed in Panel.

1 Magnahelic Gauge

Projected hours for installation

Hours: (Area must be Free and Clear of all Obstacles and Debris)

152 Installation of 12' wall by factory trained installers

960 Installation of Grid by factory trained installers

960 Installation of Dust Cover by factory trained installers

40 Installation of Beams by factory trained installers

1 Installation of Column(s) by factory trained installers

37 Pre-Wire Electrical To Our Provided Load Center Or One Location Within The

Proposed Building - (Includes Material and Labor, Does Not Include Electrical

Permit)

1 Labor to Caulk & Seal all Seams

1 Estimated Equipment Rental

1 Round Trip Travel And/Or Lodging Expenses (Prices Subject To Change Due To Airfare)

1 Architectural Drawings & Structural Calcs with Wet Stamps for the State of Texas

960 Sq. Ft. Epoxy Flooring - No Urethane. Includes Installation and Light Patch Work (Pricing Subject To Change Due To Floor Conditions)

1 Estimated Prepaid (Flatbed) Freight To: Houston, TX (Excludes Fork-Lift) Actual Cost to be Billed.