A21 - PWS_Philpott Bulkhead Testing_03 Jan 2025.pdf

Performance Work Statement

Philpott Secondary Bulkhead – Weld and Steel Testing

Engineer Repair Yard, New Hanover County, North Carolina

03 January 2025

1.0 GENERAL:

The bulkhead for the penstock of the secondary hydropower unit at Philpott Dam needs repair. The bulkhead was fabricated and put into use in the 1940’s. The bulkhead has been brought to the USACE

Engineer Repair Yard, blasted to remove its protective coating, and visually inspected for the condition of the steel and welds. The inspection revealed some locations of porosity and inconsistency in the welds, as well as a fractured beam. As part of the plan to rehabilitate and reuse the structure, the damaged beam shall be replaced with new steel and the welds repaired.

The contractor shall perform strength and material testing on the steel from the damaged beam and the welds on the bulkhead. The bulkhead is approximately 5.5ft x 4.5ft. See Figures 1 and 2 for a top and side view, respectively, of the bulkhead in the engineer repair yard with the damaged beam indicated.

The work shall include the following tasks:

1) Before repairs and welding criteria are designed by USACE:

Testing a 1”x1”x beam thickness piece of steel from the original bulkhead beam

a. Perform chemical analysis to determine the carbon equivalency of the material

b. Provide test reports to include an estimate of the closest matching material specification within two weeks of test completion

2) Before repairs, and after welding criteria has been designed by USACE:

Testing a sample weld between original steel [QQ-S-741] and new steel [A709] (Note: the weld sample will be created by USACE)

a. Perform strength tests for the PQR process – 2 tensile and 4 bending tests

b. Provide test reports within two weeks of test completion

3) Before repairs performed by USACE:

Testing ALL fillet weld connections on the bulkhead

a. Perform 100% non-destructive testing (NDT) on the fillet welds, which would be visually inspected (VT) and magnetic particle tested (MT)

b. Provide test reports within two weeks of test completion

4) After repairs performed by USACE:

Testing ALL fillet weld connections on the bulkhead

a. Perform 100% non-destructive testing (NDT) on the fillet welds, which would be visually inspected (VT) and magnetic particle tested (MT)

b. Provide test reports within two weeks of test completion

1.1 PERFORMANCE PERIOD:

Item 1 above shall be completed within 30 Calendar Days of receipt of steel sample from

USACE.

Performance Work Statement, Philpott Secondary Bulkhead Testing, Engineer Repair Yard, New Hanover County, NC

Item 2 above shall be completed within 30 Calendar Days of receipt of sample weld from

USACE.

Item 3 above shall be completed within 60 Calendar Days of receipt of Notice of Award.

Item 4 above shall be completed within 30 Calendar Days of completion of repairs by USACE.

1.2 SAFETY:

Applicable provisions of the U.S. Army Corps of Engineers Safety and Health Requirements

Manual, EM 385-1-1, will govern all work performed under this task order. The safety manual may be found at:

http://www.publications.usace.army.mil/Portals/76/Publications/EngineerManuals/EM_385-1-

1_2008_Consolidated.pdf?ver=2013-09-04-161030-210

Safety while at the project site will be in compliance with the Corps of Engineers Safety Manual

EM 385-1-1. Use of appropriate safety equipment is mandatory and not limited to hard hats and steel-toed shoes

1.3 COORDINATION

The principal Wilmington District technical point of contact for this contract will be specified at contract award. Submittals shall be made to the Technical Point of Contact. The Contractor shall designate a project manager who shall be the principal point of contact for the Wilmington

District in administering this contract. The Contractor's project manager shall be responsible for all coordination to ensure the work is accomplished in a professional manner. Any directions given that are viewed by the Contractor as a change to the scope of work affecting contract fixed price and performance period shall be brought to the immediate attention of the Contracting

Officer.

1.4 AVAILABILITY AND USE OF UTILITY SERVICES

1.4.1 Availability of Utilities

On site utilities can be utilized by the contractor, including, but not limited to, compressed air at

150psi, multiple volts and plugs in the machine shop, multiple standard outlets, water, etc.

1.5 SECURITY:

1.5.1 General security requirements and guidance: The security requirements described below apply to all contract personnel (including employees of the prime Contractor (“Contractor”) and all subcontractor employees) supporting the performance requirements of this contract. The

Contractor is responsible for compliance with these security requirements. Questions regarding security matters shall be addressed to the designated Government representative (e.g., Contracting Officer Representative (COR), Requiring Activity (RA) representative, or

Contracting Officer (if a COR or other RA representative is not appointed)). Contract personnel are critical to the overall security and safety of US Army Corps of Engineers (USACE) installations, facilities and activities, and security awareness training contributes to those efforts.

The Department of Defense (DoD) and Army security training requirements specified below, if applicable, are performance requirements; all applicable contract personnel shall complete initial training within 30 days of contract award or the date new contract personnel begin performance on the contract. Within five business days from the completion of training, the Contractor shall provide written documentation (e.g., email or memorandum) to the Government representative.

The documentation shall include the names of contract personnel trained and which training they completed; the Contractor shall maintain training records as part of their contract files and be prepared to provide copies of training certificates to the Government representative. Contractor personnel and vehicles are subject to search when entering federal installations. Additionally, all contract personnel shall comply with Force Protection Condition (FPCON) measures, Random

Antiterrorism Measures (commonly referred to as “RAMs”), and Health Protection Condition

(HPCON) measures. The Contractor is responsible for meeting performance requirements during elevated FPCON and/or HPCON levels in accordance with applicable RA plans and procedures -

-this includes identifying mission essential and non-mission essential personnel. In addition to the changes otherwise authorized by the changes clause of this contract, should the FPCON or

HPCON levels at any individual facility or installation change, the Government may implement security changes that affect contract personnel. The Contractor shall ensure all contract personnel are aware of their security responsibilities, including any site-specific requirements identified in local policies or procedures.

1.5.2. Antiterrorism (AT) Level I training: All contract personnel requiring routine access to

Army installations, facilities, and controlled access areas, or requiring network access shall complete initial and annual refresher AT Level I awareness training. Online AT Level I awareness training is available at https://jko.jten.mil/ (website subject to change).

1.5.3 Physical security and access control requirements: All contract personnel requiring physical access to a federal installation or facility shall comply with the access control procedures of that location. Contract personnel requiring unescorted access to meet contract performance requirements on a DoD installation in the US shall be vetted by the installation/facility Provost Marshal/Directorate of Emergency Services/Security Office using the

National Crime Information Center-Interstate Identification Index (commonly referred to as

“NCIC-III”) and Terrorist Screening Database (commonly referred to as “TSDB”). Contract personnel shall comply with all personal identity verification requirements specified in installation/facility policies and procedures. Contract personnel who do not meet requirements for unescorted access to USACE facilities shall coordinate escorted access with the Government representative, as needed. Contract personnel who receive keys, access cards, or lock combinations that provide access to government-owned property shall comply with key and lock control procedures of the RA.

1.5.4 Suspicious Activity Reporting training (e.g. iWATCH, CorpsWatch, or See Something, Say Something): All contract personnel shall receive initial and annual refresher training from the RA representative on the local suspicious activity reporting program. This locally developed training provides contract personnel with general information on suspicious behavior, and guidance on reporting suspicious activity to the project manager, security representative or law enforcement entity.

1.5.5 Escorting in classified and/or sensitive areas: In accordance with applicable regulations, all contract personnel who do not possess the appropriate security clearance or access privileges will be escorted in areas where they may be exposed to classified information or operations, sensitive information or activities, or restricted areas.

1.5.6 Pre-screen candidates using E-Verify Program: Contractors shall comply with the requirements set forth in FAR clause 52.222-54 Employment Eligibility Verification and FAR

Subpart 22.18 in using the E-Verify Program at (https://www.e-verify.gov/) (website subject to change) to meet the contract employment eligibility requirements. Contractors are encouraged to cooperate with Federal and State agencies responsible for enforcing labor requirements to include eligibility for employment under United States immigration laws in accordance with

FAR 22.102-1(i). An initial list of verified/ eligible candidates shall be provided to the COR no later than three business days after the initial contract award. When contracts are with individuals, the individuals will be required to complete a Form I-9, Employment Eligibility

Verification, and submit it to the Contracting Officer to become part of the official contract file.

2.0 EXISTING CONDITIONS:

Figure 1 – Overview of Secondary Bulkhead from the Top, Damaged Beam Indicated

Top Beam Damaged

Figure 2 – Overview of Secondary Bulkhead from the Side