MODIFICATION
99 -- LOW VISIBILITY CRAFT MOLD AND HULL
- Notice Date
- 1/23/2002
- Notice Type
- Modification
- Contracting Office
- 53560 Hull Street Bldg A33 Rm 1602W, San Diego CA 92152-5001
- ZIP Code
- 92152-5001
- Solicitation Number
- N66001-02-Q-3259
- Response Due
- 2/7/2002
- Point of Contact
- Point of Contact - Gina D Bennett, Contract Specialist, 619-553-5208
- Small Business Set-Aside
- N/A
- Description
- This is a combined synopsis/solicitation prepared in accordance with FAR Part 13. No RFQ will be prepared or made available for distribution. The Government intends to procure on a competitive basis one each Low Visibility Craft (LVC) Mold, one Low Visibility Craft (LVC) Hull in accordance with the below LVC Construction Sequence and Specifications. Award will be made based on responsive, responsible, and technically acceptable low bids. Competitive awards may be based on evaluation criteria stipulated in the Red, Yellow, Green (RYG) Contractor Evaluation System. While price will be a significant factor in the evaluation of offers, the final contract award will be based on a combination of price and delivery, a determination of responsibility and technically acceptable low bids. No hard copies will be available. No telephone requests will be accepted. Questions may be directed to Gina Goodman via email: gina@spawar.navy.mil. Facsimile quotations may be sent to (619) 553-1062. The applicable North American Industry Classification System Code (NAICS)is 336212. Note: The full text of the Federal Acquisition Regulation (FAR) can be accessed on the Internet at http://farsite.hill.af.mil/. Offerors must complete and submit with their quote, a copy of FAR 52.219-1 Alt I/II, Small Business Program Representation. Central Contractor Registration is required for resulting award. Information may be found at http://www.ccr2000.com/. See attached drawings and LVC Construction Specifications. 1. Describe your shop facilities and any special processing equipment available for this fiberglass boat building work. 2. Describe the backgrounds, training, and pertinent experience levels of all personnel who will be working on this project. 3. Provide the name and telephone number for the lead individual who will be the technical point of contact for Government technical personnel. This individual may be contacted and interviewed by Government technical personnel. 4. Describe other projects that your company has done in the past five years that are similar or pertinent to work of this nature. Include the types of FRP and related materials which your company typically uses, and note separately the types of materials that have been used, but not frequently. 5. Provide a list of at least five recent customers for whom you have produced boat hulls or similar work in the past five years, including names and dates of projects, points of contact and telephone numbers. These points of contact may be called for references by Government technical personnel. LVC Construction Sequence and Specification. The weight, strength and durability of the Low Visibility Craft (LVC) are extremely critical. All laminates should be well fitted, stretched, rolled and blotted, including bonding angles. Voids, air pockets, resin pools and debris in the laminate shall be minimized. Lamination shall occur in a clean, protected area, with temperature and humidity in accordance with the resin manufacturer's recommendations. Grinding, sanding or other similar processes shall not be done in the same area as the lamination until the resin is set. Core sections should be well fitted to minimize the required use of core bedding material without leaving significant gaps. The Contractor shall allow the Government to witness a typical lamination process prior to lamination of the kayak to ensure proper procedures. Dimensional tolerances and construction sequence are critical to the finished craft quality. The Contractor shall read and understand all drawings and this paper prior to construction. Any processes which the Contractor feels can be done more effectively than those listed herein shall be discussed with the Government, and agreed to in writing prior to any deviations. Dimensions shall be +/- ?" in any direction from the values listed on the drawings. Finished side and top exterior surfaces shall be flat to within 1/8" over their entire span. Materials The Contractor shall verify that all materials are compatible and used in accordance with the manufacturer's recommendations. Materials shall not be substituted without prior approval of the Government. Definitions: Laminating Resin - Dow Chemical DERAKANE 8084. Styrene or thixotrope may be added, if required, in accordance with the manufacturer's recommendations. A surface curing additive should be added for laminating the final layer of reinforcement of the main bottom and deck molds. Resin with surface curing additive may be used for small parts. Gel Coat Resin - Gel coat shall be an isopthalic NPG type resin compatible with the laminating resin. Gel coat shall be pigmented to a "haze gray" color. Flotation Foam - 2 pound per cubic foot closed cell foam. A 2-part system is required for most applications. Core Bedding Material - Core manufacturer's recommended core bedding material (e.g., CORE-BOND if ATC CoreCell foam is used). Another core manufacturer's bedding material shall not be substituted without approval from the core manufacturer. Syntactic Foam - Resin mixed with micro-balloon filler material to reduce weight and provide a thicker material. Thickened Resin - Resin mixed with milled glass fibers. Adhesive - Adhesive shall be 3M 5200. Molds. The Contractor shall allow the Government to check the accuracy and finish of the molds prior to lamination. Two molds are required: a bottom mold, and a side and deck mold (referred to as the deck mold). The bottom mold shall be fabricated to extend wider than the chine points to ensure proper laminate thickness and consolidation throughout the chine region, without the excess laminate distorting the finished part. The bottom mold shall include the skegs aft of the transom, and the transom up to the 5" waterline. The deck mold shall be a 2 piece mold to allow for release. The basic deck and sides shall establish the primary mold piece, and a secondary mold piece shall be added to allow for lamination of a chine flat for secondary bonding to the bottom laminate in the chine region. General Lamination. Prior to each laminating shift, the Contractor shall establish resin gel times using the laminating resins and equipment. These gel times shall be in accordance with the resin manufacturer's recommendations. The Contractor shall allow the Government to witness lamination. The Contractor shall establish a point of contact on the Contractor's staff who will be available throughout the lamination process for Government personnel to discuss any concerns noted during lamination. Reinforcements and core materials shall be stored unboxed and unwrapped in a clean area in which relative humidity does not exceed 50% at ambient temperature for a period of not less than 10 days prior to use. Mold and laminating materials shall be maintained at a temperature of not less than 60 degrees Fahrenheit for 8 hours prior to the start of lamination, throughout the laminating process, and after laminating until the Barcol hardness recommended by the manufacturer has been achieved. Lap and joint locations within a ply of laminate shall be minimized. Laps at ends or edges of reinforcement shall be no less than 1-1/2". With the exception of doublers or bonding angles, laps shall not fall within 4" of each other. Ends of doublers or bonding angles shall be staggered a minimum of 1" in each direction in each stack. Core bedding material shall be used on the blind side of all cored parts. Core shall be saturated with resin on the facing side prior to laying in any reinforcing material. Faying surfaces for bonded parts shall be thoroughly sanded and cleaned of dust, wax and foreign matter immediately prior to bonding. Air hoses shall not be used for the purpose of blowing away debris on any surface prior to bonding or laminating. Core Inserts At several places in the deck and transom, the foam coring material is replaced by thickened resin to produce an insert piece for mechanical fasteners. These can be produced in one of two ways: 1. Laminate a sheet of fiberglass using mat to develop the required core thickness. After curing, sand the sheet and cut disks of the required size for each replacement section. While installing the core into the craft, replace the core where required with the fiberglass mat disks, bedding them in place with thickened resin in place of core bedding material. 2. After the section of cored laminate is complete (with foam installed), drill the required hole for the fastener. Remove the drill bit and replace either with a router bit or an ELL shaped piece of sharpened metal (such as an old Allen wrench). Insert the bit into the hole and carefully carve out the required depth of foam. Replace the carved out foam with thickened resin. Use tape if required to cover the hole to prevent the thickened resin from sagging out. Ensure that the catalyst ratio is adjusted to prevent overheating of the resin during cure, and potential damage to the adjacent foam core. Re-drill as required for the fastener or insert. Bottom Lamination. Following inspection of the mold by the Government, the Contractor shall clean and prepare the mold for lamination. Debonding agent(s) shall be installed in accordance with the manufacturers' recommendations. After application of the gel coat, glass fibers or gun rovings shall be added into the bottom of the skegs and the forward part of the keel as required to develop the radius necessary to get subsequent layers of glass cloth to drape properly. Following that, the ? oz mat and first two layer of woven roving shall be installed over the whole length of the bottom mold, including the skegs and transom. The laminate shall extend wider than the molded chine point to ensure adequate consolidation of the laminate at the molded chine point. Dams shall be set up to contain the flotation foam under the pinger tray supports (outboard of the 9" buttock line), and forward where the chine width narrows to provide a bonding surface for the deck. After the flotation foam is poured and set, the foam shall be trimmed flush with the top side of the chine laminate. Radii required on the drawings shall be cut into the foam or added with syntactic foam if not included by the dam forms. Exposed laminate shall be sanded and cleaned immediately prior to adding additional laminate. The remaining bottom plies shall be installed as shown on the drawings. The foam over the skegs aft of the transom, and the foam forward of Station 0 should only be covered with one sealing layer of ? oz mat. Deck Lamination. Following inspection of the mold by the Government, the Contractor shall clean and prepare the mold for lamination. Debonding agent(s) shall be installed in accordance with the manufacturers' recommendations. After application of the gel coat (the chine flat should not get gel coat), glass fibers or gun rovings shall be added into the chine corner area, and bow and stern edge areas as required to develop the radius necessary to get subsequent layers of glass cloth to drape properly. Following that, the remainder of the outer laminate shall be installed. Core panels shall be shaped, fitted, and bedded in place using core bedding material. Core bedding material shall be placed between adjoining sheets of core. Exposed laminate shall be sanded and cleaned immediately prior to adding additional laminate. The remaining plies of inner laminate shall be installed as shown on the drawings. Preparation for Joining Bottom and Deck After reaching the required barcol hardness, the bottom laminate shall be removed from the mold. The holes for the bow towing fitting rod shall be drilled, and the adjacent interior of the laminate shall be sanded. The holes shall be coated in resin, and the adjacent keel area shall be bedded in thickened resin before inserting the towing fitting rod. After the towing fitting rod is inserted, the top of the rod shall be bedded in thickened resin to create a smooth surface for the sealing plies of glass. After the thickened resin starts to kick, the sealing plies of glass shall be installed. The fiberglass and fastener inserts for the sliding tracks for the foot pedals can either be added now, or they can be installed with slightly more difficulty after the hull and deck are joined. After reaching the required barcol hardness, the chine former for the deck mold should be released and removed. The inner edge of the chine should be dressed to achieve the required chine width. The shape and fairness of the deck are critical, so the deck should not be removed from the deck mold at this point. If pre-release has occurred, the Government should be consulted on how best to press the laminate back into the mold while forming the deck-to-bottom joint. The bottom should be carefully indexed and held in place while pilot holes for the lag bolts are drilled on 6" centers as shown on the drawing. The mating faces of the chine flats should be sanded and cleaned immediately prior to bonding. A release material should be carefully applied to the adjacent area of the deck mold to keep the adhesive from bonding the part to the mold. A low adhesive tape might work well since this area will not be part of the finished product. The adhesive should be applied in accordance with the manufacturer's instructions, and the parts lag bolted (ensure washers are utilized as required) together to attain a uniform adhesive thickness, and to ensure that adhesive is being squeezed out along all bond lines. After the adhesive is fully set (this will take several days), the hull should be released from the deck mold and removed. Excess adhesive should be trimmed from the interior of the craft. Excess chine width should be removed from the bottom mold, with final trimming using a trimming router bit or a sander. After removing the lag bolts, the holes should be plugged with thickened resin. The outer portions of the chine and the side above the chine should be sanded down (about 4 to 4-1/2" back from the chine point) until glass fibers are starting to show through. After cleaning, the sealing ply of tape shall be added. After curing, the gel coat shall be replaced and smoothed (you may want to wait on this step until the entire hull is completed, and do all final gel coat repairs at once). The interior of the chine area shall also be sanded and cleaned, and the sealing tapes installed. Exterior Topside Hatches and Openings. The two personnel access openings, the NMS unit access hatch, and the engine access hatch shall be trimmed to size and the adjacent areas of laminate shall be sanded back until glass cloth is starting to show, and cleaned. The required sections of core doubler shall be shaped, fitted, and bonded in place using core bedding material. Thereafter, the sealing layer of cloth shall be installed as shown on the drawings. After curing, any required repairs to the gel coat shall be made. Interior Outfitting. Prior to installing any secondary bonded components below, ensure that the area under any sealing plies or bonding angles is sanded until glass fibers of the material are starting to show through, and that the area is thoroughly cleaned prior to laminating. Sanding shall not be done while any resin in other areas of the hull or surrounding areas is curing. A section of side core material shall be cut and fitted in place forward to provide a dam for the forward flotation foam. Install fiberglass on the outer (aft side) of the foam on a laminating table, as shown on the drawings. After curing and final trimming, a large diameter pressure relief hole shall be cut toward the top side of the dam. The dam shall be bedded in place using core bedding putty, and bonding angles installed. Install 2 part flotation foam. Multiple pours are recommended to ensure that the foam does not damage or distort the hull. After the final pour, trim off excess foam and seal the overflow hole with fiberglass. Lay up the remainder of the transom on a laminating table, including the transom core inserts. After curing, trimming, sanding and cleaning, bond in place as shown on the drawing. After the transom is fully cured, install the aluminum cap plate and drill the outboard mounting bolt holes through the transom core inserts. Turn the craft 90 deg. onto one side, being sure to protect the sides of the craft against damage. Cut a dam for the top of the foamed area above the skegs aft of the transom. Bond it in place using core bedding putty. After it has cured, pour in 2 part flotation foam to slightly over fill the required volume. Cut and shape the excess foam between the skeg and dam. Turn the craft onto its other side and repeat. Turn the craft upright, with adequate room underneath to support the outboard motor in its operating position. Remove flotation foam until the motor can freely swing from side to side without hitting the foam, and with at least one inch of clearance on each side (but trying not to carve out any more foam than necessary). Install the small block of flotation foam onto the transom point. Seal all of the exposed foam with fiberglass as shown on the drawings. Laminate remaining bulkheads, flats, daggerboard trunks, and seat backs, as required. After curing, trimming, sanding and cleaning, bond in place as shown on the drawings. The fiberglass and fastener inserts for NMS mounting should be installed in accordance with the drawings. If not
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Click on this link to access the SPAWAR Solicitation Page
(https://e-commerce.spawar.navy.mil/command/02/acq/navhome.nsf/homepage?readform&db=navbusopor.nsf&whichdoc=DD913DE2D6CBE69688256B4B000546F2&editflag=0)
- Record
- SN20020125/00018103-020123210333 (fbodaily.com)
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