The Regional Commander certifies that this project has been considered for joint use potential. Unilateral Construction is recommended. Mission requirements, operational considerations, and location are incompatible with use by other components. Activity POC: Willian H. Livingston Phone No: 252-464-9520 DD (45983) EQUIPMENT FROM OTHER APPROPRIATIONS (NON ADD) 10. Description of Proposed Construction 1) Construct a new 2,159 square meter (23,239 square feet) Gearbox Repair and Test Facility consisting of a single story, high bay addition to the existing Power Plant Facility, Bldg 133. Built-in equipment shall include Telecommunication heating, ventilation and air conditioning (HVAC) system, two three-ton overhead bridge crane railing subsystem, three ten-ton overhead bridge crane railing subsystem, and one thirty-ton overhead bridge crane railing subsystem. (2) Construction of a new 277 square meter (2,982 square feet) single story, high bay Hydraulic Testing Facility addition to the existing Power Plant Facility, Bldg. 133. (3) Construction of a separate 655 square meter (7,050 square feet) single story, high bay facility to replace the existing Jet Engine Disassembly Facility, Bldg. 421. Builtin equipment shall include two bridge crane railing subsystems, each with capacity for two three ton hoists and Telecommunication HVAC system. (4) Construction of a separate 103 square meter (1,109 square feet) single story facility to replace an existing Air Compressor Facility, (Bldg. 4057). (5) Construction of a separate 93 square meter (1,000 square feet) single story preengineered metal shed to replace an existing canopy to be demolished at the V-22 Gearbox Repair & Test Facility site. This shed is used for the storage of low-level radioactive waste. Built-in equipment will include Two overhead bridge crane railing subsystems, with the capacity of two (2) three (3) ton overhead bridge cranes each. All facilities shall include anti-terriorism/force protection measures. Supporting facilities include the following: (a) demolition of a 514 square meter (5,533 square feet) Jet Engine Disassembly Facility Building 421 (Built in 1944), demolition of a 103 square meter (1,109 square feet) Compressed Air Facility, demolition of a 54 square meter (580 square feet) old Demountable F-402 Test Cell (Built in 1968), demolition of a 279 square meter (3,000 square feet) shelter, Bldg. 4528, and removal of their utilities/ foundations and the sites cleared, relocation truck scales, replacement of JP-5 test fuel supply tank/lines, replacement of a supply tank with sheltered berm and replacement of associated oil-water separator, to facilitate vehicular access and movement of large components into Building 133's engine test cells. In accordance with Executive Order 13123 and 13101, this facility will be designed using sustainable development principles. 11. Requirement: PROJECT: DD 3315m2 Adequate: 0m2 Substandard: 0m2 This project constructs a V-22 Gearbox Repair and Testing Facility addition and a 5,000 PSI Hydraulic Testing Facility addition to Power Plant Facility for support of the new V-22 Osprey. Construction of the new V-22 Gearbox Repair And Testing Facility addition is required to be finished by October 2008 so that the gearbox test stand equipment can be installed and made operational by January 2009. Cherry Point has been designated as the Depot Repair Point (DRP) for the V-22's unique tilt-rotor gearboxes and 5,000-PSI hydraulic components. NAVAIRDEPOT will begin receiving hydraulic test equipment in July 2005 to test various hydraulic components on the V-22 with no facilities to support these requirements. At least six months is necessary to install three massive, 50-ft high gearbox test stands, and ensure they work properly (est. July 2008-Jan 2009). Another year will be required for the NAVAIRDEPOT to begin and successfully complete the capability establishment process (train artisans, develop work procedures and processes; and produce prototype gearboxes) lest. Jan 2009 Jan 2010). Although V-22 Bell Helicopter is currently providing for repairs on V-22 gearboxes, their capacity will be saturated by the start of FY2010. The NAVAIRSYSCOM Program Manager Aircraft (PMA) has budgeted $44 MILLION of V-22 support equipment in FY04 and FY05 specifically for these requirements. New facilities must be constructed to accommodate this new equipment and to establish the unique testing capabilities required in performing depot level maintenance and repairs by the Government Support Date of January 2010. CURRENT SITUATION: There are a total of five gearboxes for the V-22 Osprey, costing roughly $3M combined. NAVAIRDEPOT does not currently have the organic capability to test/repair V-22 gearboxes and hydraulic components, nor does any other government agency. Bell Helicopter is the only company that has the unique testing capabilities for the V-22 gearboxes, and their existing test stands were constructed in support of manufacturing requirements. Therefore, Bell Helicopter is projecting by FY2010, that their existing test stands will be required solely to support production schedules, and that additional testing capacity will be required prior to the Government Support Date (GSD) of January 2010. The host Marine Corps Air Station (MCAS) Cherry Point is also unable to provide adequate space in support of these requirements, necessitating new construction. IMPACT IF NOT PROVIDED: Without these additional facilities, the Naval Aviation Depot Cherry Point will not be able to perform the required depot level maintenance and repairs on V-22 gearboxes and hydraulic components. Without new facilities, the $44 MIL of peculiar support equipment can not be accommodated. Because there is a known gearbox capacity shortfall at the V-22 OEM (Bell-Boeing), failure to build these required facilities on schedule will leave the Navy with no |