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1. Fire Engine ReplacementKALISPELL FIRE DEPARTMENT Refurbishing apparatus to meet NFPA 1901-1996 standards Also possible needs to due this to apparatus 20 plus years of age Dollar values are "estimates only' These issue are not required unless you are Re -Furbishing the apparatus. But at re -furbish you could have an issue if it doesn't meet the 1. NFPA recommendations 2. UL Listed 3. ISO requirements Fire Pumps 1. Tested this year. The fire pump is 20 plus years old? Hale Fire Pump Company introduced the replacement pump for the pump in your apparatus this last year? Wonder just how long parts for the OS series Hale Pump will be available since the new Q-Flow and Q-Max Pumps introduction? 2. Fire Pumping capacity requirements are increasing as Cities and towns grow the new apparatus capacity is 1500 GPM single stage centrifugal pump which is the largest single suction inlet pump available today to meet this need. New fire pump $25K Master Steamer Suction Inlet[s]. Will need to add one permanently installed 2 1/2" adjustable suction side relief valve. Discharge to terminate away from operator with a 2 1/2" NST fitting and labeled "Do Not Cap". This should cost about $590.00 to add. Gated Suction Inlets, Discharges, & Preconnects Plumbing is sweated copper tubing is evident and required replacement if need will be very labor intensive. $40.00 ft. What condition are the valve and seats after 20 plus years of service? Probably all the valve will need rebuilt at an average cost per valve of $190.00 each One 30 degree sweep elbow shall be provided for each 2 1/2" discharge. Cost each: $110.00 each Booster Tank Valves & Piping Plumbing is sweated copper tubing is evident and required replacement if need will be very labor intensive. $40.00 ft plus you have tank to pump and pump to tank ball valve systems that will need replacing. Booster Tank Booster tank is simply iron with a coating. Rust is evident in the booster tank both inside and out replacement with a Poly Tank would cost $9.500.00. Pump Operator's Control Panel The surface of operator control panel? Additional panel requirements are. All controls shall be clearly marked with permanent type labels and color.coded. Each new control rod, guides, and label system Cost: $79.00 each. Instrument Panel How are the faces of your master intake and discharge gauges they would probably need to be considered for replacement? Gauge $280.00 each. How are the faces of your individual 2 1/2" discharge gauges they would probably need to be considered for replacement? Gauge $120.00 each. Instrument Cluster Engine information center should be updated: electric tachometer, oil pressure and temperature gauges have to have audible and visual warning now. Engine Enfo center Cost $1,230.00 Low voltage alarm with visual warning are required now and must be monitored. Cost $325.00 Pump Pressure relief valve should be upgraded and serviced. $1,290.00. Hose Body Compartment must have 55 cubic feet according to NFPA minimums?. Apparatus Body & Components this apparatus body doesn't have a sub -framing system and this isn't required but rust is prevalent under the body? New undercoating should be installed during disassembly? Cost $395.00 Apparatus Body Compartments are 20 plus years old. We didn't test for rust or corrosion this will need to be examined to give a good recommendation. Please check all compartment bottoms for corner rust. We would recommend a ball peen hammer to test for breakdown a serious rust problems If base body replacement is needed the cost would be prohibitive suggests replacement of the apparatus. Running Boards ? Walkways ? Trim must be install on a rebuilt apparatus you must install a minimum of 4° reflective stripping the cost would be $750.00 As well as lettering preparation and paint cost $7-$10,000.00 Grab Rails Handrails to meet the below step surface requirements Steps Step would need to be added to the apparatus as per the following NFPA 1901-1996. Steps shall be a minimum of 35 square inches your steps don't meet this requirement, as well as maximum stepping height shall not exceed 18" with the exception of the ground to first step. Cost each step: $86.00 Ground Ladders to meet the new NFPA standards for ground ladders requirements. If the ladders are older than say about 10 years there is a new standard. The cost for new ground ladders and mountings $1,750.00 14' roof, 24' 2 section extension, and 10' folding ladder is minimum. NFPA requires either the hard suction hose or the soft suction hose on all engines. Electrical Equipment & Battery System must meet the new electrical code systems that follows. Your apparatus would need a total electrical update: Cost $3,790.00 minimum estimate? Emergency Signal & Lighting Equipment must meet the NFPA 1901-1996 MINIMUM STANDARD LIGHTS WOULD BE: Minimum Electrical Equipment & Battery System Standards A single instrument panel light, on pump panel shall illuminate with pump engagement. One each compartment light and activated by an automatic door switch. A red flashing indicating light on cab electrical module shall illuminate automatically whenever the apparatus's parking brake is not engaged to warn of the following: 1. When any passenger or equipment door is open. 2. A power light tower is extended. The light shall be marked "Do Not Move Apparatus When Light Is On." All electrical equipment to have resetting circuit breakers. mounted in a panel box with each circuit labeled. Wiring shall be high temperature, copper, multi -strand SXL cross link coated wire. Wire shall be function coded every 3 inches for ease of maintenance. Wiring diagram of the apparatus body to be included in the operations and maintenance manuals of the completed fire unit. All wiring to be protected with automotive type loom with a temperature rating of -30 degree to +300 degree Fahrenheit. Grommets shall be used when wiring through body. Master battery disconnect shall be a Cole Herse manually operated. Converted to a Single battery system, Per NFPA. A license plate light to be provided on the rear of the apparatus body. Minimum Emergency Signal & Lighting Equipment To Meet Standards Electronic Speaker has to be mounted forwards. Lighting for upper zones, A, B, C. & D One (1) all lens light bar with red/clear/red lenses. Mounted Two (2) 550F Rotating beacons with 50 watt fast rotator mounted on rear standards. Total Amps: 27.30 Lighting for lower zones, A B C & D Two (2) 35 watt Halogens, with Red lenses must be mounted on front of chassis cab. Two (2) Model 41-35 35 watt 7" x 3" Halogens, with Red lenses, must be mounted on rear of the body. Six (6) model 41-35 35 watt 7" x 3" Halogens, with Red lenses, must be mounted three (3) each side, one (1) front and rear of apparatus and one (1) midship of body. Total Amps: 16.40 If the Superior is longer than 30' there shall be mid intersection turn signal required. Four (4) ground lights must be installed and mounted, two (2) below running boards below pump compartment, and two (2) below the rear step and activated by a switch on the pump operator's control panel. Ground lights to must be installed below the chassis cab doors and activated by a switch whenever the cab doors are opened and supplied by the chassis builder. Work lights to must be installed in walkway, work areas and steps. A Total System Manager for electrical load management must be installed. The TSM must be installed with outputs to supply warning and load switching requirements. Outputs 1-12 shall be independently programmable to activate during the scene mode, the response mode or both. These outputs can also be programmed to activate with the ignition or warning master switch, or to sequence and shed along with the priority. Output 15 is a user configurable output and shall be programmable for activating between 10.5 and 15 volts. The Total System Manager shall be protected against reverse polarity and shorted outputs, and be enclosed in a metal enclosure to enhance EMI/RFI protection. The body builder shall incorporate all DC electrical system into the same TSM control. Certification must show complies with the following NFPA test requirements will be required of the Superior if refurbished NFPA 1901 1996 Edition Low Voltage Electrical Systems: Minimum electrical load consists of the total amperage required to simultaneously operate the following in a stationary mode at the scene. A. The propulsion engine and transmission B. All clearance and marker lights C. The communication radio -a default of 5.0 amps is used D. Illumination of all walking surfaces, the ground at all egress points, controls and instrument panels and 50% of the total compartment lighting load. E. Minimum warning lights required for "Blocking Right of Way" mode. F. The current to simultaneously operate any fire pump, aerial device & hydraulic pumps. G. Anything defined by the purchaser to be critical to the mission of the apparatus. The first test for the electrical system is the Reserve Capacity Test. All the above are operating with the engine shut off. After 10 minutes all electrical loads are shut off and the battery system has to have enough reserve power to start the engine. Test two is the Alternator Performance Test at Idle. All the above are operating with the engine at an idle. There can be no current draw from the batteries of the apparatus. The third test is the Alternator Performance Test at Full Load. All electrical loads shall be activated with the engine running up to the governed rpm for 2 hours. During the test the system voltage can not drop below 11.7 volts or have excessive battery discharge for more then 120 seconds. Any loads not required above in the minimum electrical load can be load managed to pass the test. All of the tests are to be done with the engine compartment at approximately 200 degrees. Superior Rear Crew Seats will not meet the NFPA Enclosures requirements and this is a serious safety requirement. All apparatus riders must be seated, belted, and with a 360 degree enclosure system. Enclosed Crew Cab Extension: To enclosed crew cab extension shall be installed to safely and comfortably house men in a seated position. The crew cab extension shall be constructed of the same material as the chassis cab and welded to the chassis cab. The crew cab extension shall have an original factory appearance. The floor of the crew cab shall be covered with pebble grain rubber mating. Two (2) entry doors shall be installed on the rear of the crew cab. Crew cab extension doors shall be double walled and constructed from aluminum tread plate with stainless steel hinges and a two point rotary automotive type latch. The stainless steel recessed handle shall match the handle style on the apparatus body. A grab handle shall be provided inside each door for ease in closing. Doors shall open to the center in such a manner as allow easy access to walkway. The walkway is to be - constructed from brite aluminum tread plate. Each door shall have one (1) aluminum framed sliding window in the top half for ventilation. There shall be one (1) window installed on each side of the crew cab to follow the appearance of the existing chassis cab rear window shall be removed as to allow communication between crew members and driver. The crew area shall be upholstered with ribbed commercial quality upholstery material. The color of the upholstery will match or coordinate with the chassis cab. Seating for two (2) men shall be provided. The crew seats shall be deep foam padded and.covered with heavy duty vinyl. The color of the seat upholstery will match or coordinate with the chassis cab. Safety belts shall be provided for all crew members. The roof of the enclosed crew cab shall be raised at least 10 inches and full width of the crew seating area to allow for adequate headroom for crew members. Signs: A permanent plate shall be installed in driver's compartment specifying the quantity and type of the following fluid in the vehicle: 1. Engine Oil 2. Engine Coolant 3. Transmission Fluid 4. Pump Transmission Lubrication Fluid 5. Pump Primer Fluid 6. Drive Axle Lubrication Fluid 9. Power steering fluid 10. Cab tilt mechanism fluid 11. Transfer case fluid 12. Air compressor system lubricant 12. Generator system lubricant A permanent plate with pump performance data and serial numbers shall be installed. A permanent plate shall be installed in the driver's compartment specifying the maximum number of personnel the vehicle is designed to carry per NFPA standards. It shall be located in an area visible to the driver. An accident prevention sign stating "DANGER", personnel must be seated and seat belts must be fastened while vehicle is in motion, or "DEATH OR SERIOUS INJURY MAY RESULT' shall be provided. It shall be visible from each seating position. An accident prevention sign stating "DANGER", do not ride on rear step while vehicle is in motion. "DEATH OR SERIOUS INJURY MAY RESULT"shall be provided. It shall be visible from the rear step area of the vehicle. If an inlet located at the pump operator's position is valved it shall be provided with a permanent label that state 'Warning - Serious Injury or Death Could Occur if Inlets is Supplied by a Pressurized Source When the Valve is Closed." This enclosure would cost $9-11 K Section 20 Chassis Modifications & Miscellaneous Automatic tire chains shall be installed on the rear axle and controlled from chassis cab with a protected switch. Make: Rudd 18 strand Roto Grip Chains. Cost of $2,700.00 An engine high idle control device shall be installed to allow an increase in the engine speed when the apparatus is parked. An interlock shall prevent the operation of this engine speed control unless the parking brake is fully engaged and the transmission in neutral or park, or unless the engine speed control is used with the chassis engine driven components, in which case, it shall be properly interlocked with the engagement of those components and to be supplied on the chassis. Cost $900.00 - The following documentation should be supplied upon delivery. - Two (2) copies of Operation/Service manual of apparatus operations and service manuals supplied by components manufacturers. Pump certification including manufactures record of apparatus construction details. UL Test $1, 200.00 Certificate of compliance to Electrical Warning System Low Voltage test. Water tank capacity certificate. Line Voltage Electrical System test certificate (NFPA 19-14.4.1. - 19-14.4.2). Certificate of approval for stationary pumping. Custom Chassis Needs? At the end of this you still have a 20 plus year old apparatus? i in NFPA es. These reach all Tent man - as well as id halon. also is d access idual all- ategories: fVs). and is needed ` receives =f and the gate, the that cor- inker for i incident 7 ckly to air- REFURBISHMENT VS. NEW PURCHASE SMALL community in northern New Jersey started on the road to refurbishment when its 1975 rear -mount aerial truck failed a nondestructive test due to physical damage to the ladder. A local apparatus dealer studied the damage extensively and gave an estimate to replace the entire aerial ladder as well as refurbish the turntable assembly and hydraulic system. When the truck committee investigated replacement apparatus, it found that a new unit would cost at least four times what it would to replace just the ladder. In addition, the fire station where the unit was located had an extremely low apparatus door, which would not accom- modate most new aerials. The engine, transmission. and chassis were in good condition because of the truck's limited use. The body, however, was showing ' signs of rust and needed attention. The committee decided to proceed with a limited refurbishment. The final outcome was that for less than 50% of the cost of a new rig, the life of this unit has been extended for many more years of the relatively light service the unit performs. 78 Fire Apparatus Purchasing Handbook t THE REFURB QUESTION All local governments large and small are feeling the impact of the rough economic times the country has been experiencing in recent years. Each city agency is fighting for its piece of the budget "pie" to maintain daily operations and services at a reasonable level. Needless to say, this is a poor time for many to request funding for a new piece of fire apparatus, even though the need might be completely evident. As the truck committee or fire chief submits the justification and projected cost of the replacement, the question inevitably will be asked, "What is the possibility of refurbishing your old vehicle?" The degree of refurbishment can run the gamut from a fancy paint job and trim work to upgrading the power plant, drivelines. pump, and aerial device to even replacing components such as the cab to bring the -unit into full compliance. Let's explore the subject of refurbishment to see if it is a viable alter- native for you. Some of the reasons you might consider refurbishing an existing unit as opposed to purchasing a new one follow. • Financial. Obviously if money were no object, you could con- sider the outright purchase of a new, custom-built apparatus to fit your needs. Unfortunately, funding is always a major considera- tion. • Size. Older apparatus generally are smaller in overall length and height. Many units, especially aerial apparatus, just barely fit in quarters no,.,,-. Modern apparatus are built larger to accommodate higher aerial tip loads, more equipment, larger tanks. and longer aerial devices and to accomplish more functions such as rescue and haz mat. To comply with the present axle weight regulations and provide a safer weight distribution. tandem rear axles often 1 are required, adding considerably to the overall length of the vehicle. f • Weight. Just as modern apparatus have increased in size, the ; gross vehicle weight also has increased substantially The new F requirement in NFPA 1904 (Standard for Aerial Ladder and t Elevating Platform Fire Apparatus) of a minimum tip load of 250 i pounds for aerials and 750 pounds for platforms has increased the size and weight of many components, including the frame, out- c rigger assemblies, structural components, and the aerial device s itself. Older fire stations with basements under the apparatus h Refurbishment vs. New Purchase 79 floor that are capable of supporting the weight of the present apparatus might require considerable structural renovation and bracing to hold a modern aerial truck. • Special apparatus or features. Special apparatus that are used occasionally, such as tank trucks and light units, but that are nonetheless valuable could be good candidates for refurbishment. Units with special features that cannot be duplicated such as a short wheelbase, tight turning radius, or narrow jack spread ► might be invaluable when restored to their original state. EVALUATION i i Evaluating your current piece of apparatus is the first step in deter- mining if it is more practical to refurbish or replace. Some considera- tions follow. 1. Is the present unit adequate to safely complete the mission now as well as five to 10 years from now? Consider pump size, tank size, l compartmentation, and aerial ladder length. Are they adequate for your present and planned response districts? Do changing demographics require you to address new needs such as paramedic, haz mat, or foam ; capabilities on your basic fire suppression unit? Are special consider- ations, such as air-conditioned cabs in warmer climates, being addressed? Can these upgrades be incorporated into your original vehicle? 2. Are there special requirements for the apparatus that would be difficult or impossible to duplicate on a new unit, such as limited height, weight, length, or jack spread? 3. What is the condition of the drivetrain? Is the engine reliable and up to power? Does the transmission need work? What is the condition of the driveline, differential, axles, and suspension? Has consideration E been given to upgrading a temperamental gasoline engine to a modern diesel? Is the fire department having difficulty attracting qualified driv- ersfor an apparatus that still uses a standard transmission and clutch? E { 4. Are the apparatus' major components up to par? Can the pump easily pass the annual pump test, or is it showing signs of wear? Has the aerial device been inspected, and has it passed nondestructive test- ing recently? Are the water tank and plumbing still in sound condition? f 5. How close to present NFPA compliance will your finished refurb come? Many of the changes in the new standard deal with safety items such as fully enclosed cabs, increased ladder tip load requirements, higher visibility, cab noise abatement, and various interlocks. Are you is 80 Fire Apparatus Purchasing Handbook .Err; One reason to consider refurbish- ment is hard-to-dualicate special ,equirements, such as a narrow, lack ;Dread. shown here. PHOTO BY 4L THOR BELO'V : The condition of the bodv, compartments. and sheet metal is an obvious indicator of the need for refur- bishment. Consider hidden deteriora- tion In pricing the work. PHOTO BY B. BULAY d Refurbishment vs. Nevv Purchase - 81 willing to delay having certain safety features until you purchase a new unit? 6. Will critical parts be available when needed? Many manufactur- ers have gone out of business, making replacement parts scarce. In addition, older apparatus historically have a higher cost of mainte- nance and operation. 7. What is the condition of the body, compartments, and sheet metal work? They probably have been attacked by rust, the biggest "apparatus killer" today. Currently, many manufacturers have addressed this by building with nonrusting aluminum or stainless steel as well as using improved galvannealed sheet steel and rustproofing techniques. (This most obvious sign of a need for upgrade was last on the list, because you must address the reliability and dependability of the power plant — and main operating components before considering upgrading the body and cosmetics.) DEGREE OF REFURBISHMENT If you answered "yes" to most of these questions, you then should decide what degree of refurbishment is required. Refurbishment can fall into several categories; each involves varying degrees of work. EVALUATING THE POWER TRAIN The first consideration when beginning the evaluation process for a refurbishment is the condition of the power train. Repowering is the rehabilitation of the vehicle's engine, transmission, driveline, and dif- ferential. This could involve repair, rebuilding if necessary, or possibly the conversion from a gasoline engine to a diesel or from a clutch and standard transmission to an automatic. These conversions are quite involved and costly. Changing from a gasoline to a diesel engine is not easy. Because of the many differences between diesel and gasoline engines, several related component systems also will require revision. The weight of a diesel engine is considerably more than that of a gasoline engine. The frame, front axle, and suspension all must be capable of handling the additional load placed on them without signif- icantly changing the stability or handling characteristics of the apparatus. The method of mounting the engine in the frame as well as a larger a 8 82 Fire Apparatus Purchasing Handbook radiator and cooling system also must be considered. The dimensions of the engine with all accessories mounted could differ considerably from the previous unit. The new power plant must be physically able to be installed in the area provided in the chassis without making changes that would compromise the structural stability of the frame. All manufacturers warn against drilling or welding on chassis frames, as it alters the assembly's original strength characteristics. The modern, high -compression diesel engine requires larger batter- ies, cables, solenoids, and related components to power the starter. In addition, the alternator and charging system should be upgraded to provide the necessary current to power all the accessories as well as charge the batteries. Air intakes and air filters on diesel engines must be considerably larger, due to the increased quantity of air that must be introduced in the compression and combustion phases of the engine's operation. The exhaust system also must be able to easily remove the exhaust without creating undue backpressure on the engine. Changing the power plant also has an impact on all the components that connect the engine's output to the rear wheels and fire pump. The transmission, driveline. and differential are all matched to the torque and rpm output of the engine. Diesel engines produce higher torque at lower rpm, which will have a direct bearing on the road speed and power characteristics of the apparatus. The axles, driveshafts. univer- sals, and slip joints all must be capable of transmitting the additional torque without failing. The apparatus obviously must have the necessary braking ability to stop safely. Plan a conversion from hydraulic to air brakes as part of the refurbishment process if the vehicle is so equipped. With a diesel, the additional weight and lack of engine backpressure result in more reli- ance on the brakes to stop the vehicle. Exceeding the normal use of the brakes causes overheating, which leads to brake fade and rapid wear of the linings. Modern antilock air brakes add a new element of safety to the operation of the apparatus and, when used in conjunction with an engine brake or retarder, can reduce the frequency of brake lining replacement and brake fade. As you can see, if repowering involves changing major components, the planning, specifications, and work will be extensive. Refurbishment vs. New Purchase 83 RESTORATION Restoration usually involves returning a vehicle to its original con- dition. This includes body work and refinishing as ivell as possibly repairing or rebuilding the pump, x%-ater tank, plumbing. or aerial device and related systems. It also might involve upgrading or replac- ing worn brake and suspension components. wiring, hoses. lines. tires, and batteries. Some manufacturers offer standard rebuilding specifications that will help the customer through the various processes that are available and recommended. Following is a partial list of the areas that the Baker Aerialscope Company addresses when it rebuilds an apparatus. By evaluating this list. you can get some idea of the work that might have to be performed on any piece of apparatus being considered for refurbishment. ,; X Restoring the aerial device and turntable to their original condition was the first phase of this refurbishment. Consider the condition of the operational components first before making cosmetic improvements. PHOTO BY 8. BULAY . t 84 Fire Apparatus Purchasing Handbook Refinishing the cab interior, including new seats, enhances the appearance of the rerurbish- ment job. PHOTO BY B. BLLAY CAB INTERIOR: —Replace steel diamond plate floor in cab and canopy. —Paint inside. —Repair or replace all electrical components as required. —Repair heating and defrosting. —Recondition seats. —Install new wiring harness. —Install new rocker switch panel. CAB EXTERIOR: —Replace front windshield. —Replace canopy- side windows. —Replace sliding window between cab and canopy. —Replace door windows as required. —Repair as required for finish paint. —Replace battery boxes. —Replace aluminum diamond plate engine cover panels. —Replace aluminum diamond plate battery box tops. —Repair all exterior lights. —Install new lightbar. Refurbishment vs. New Purchase 85 BRAKES AND WHEELS: —Repair or replace brakes, bearings. and other components as required. —Replace all tires. ENGINE AND DRIVETRAIN: —Repair drivetrain as required for normal operation. —Install factory remanufactured engine. —Install factory remanufactured automatic transmission. CHASSIS FRAME: —Sandblast, clean, inspect, and paint. SPRINGS: —Inspect all springs and shackles for required load ratings. —Replace or repair as required. UNDER TRUCE: —Service hydraulic pump. —Change and clean filters. —Install new PTO. —Inspect hoses and replace as required. —Secure all hoses and wires from chafing. —Adjust and service all valves. NEW BODY: —Install D-ring-type door locks. —Install new body lighting. —Recondition front and rear of turntable. —Install aluminum diamond plate on top deck of turntable. —Install aluminum diamond plate on top deck of main body. —Install new turn signals, stop lights, and backup lights at rear. —Install strobe lights mounted at rear. —Install six 24-inch-deep compartments in main body. �m FINISH PAINT AND RUSTPROOFI.NG: —Paint exterior with acrylic enamel paint. —Rustproof entire underside of chassis and body. TEST: —Stabilitv test of aerial device. —Static test of watery+gay. 86 Fire Apparatus Purchasing Handbook Again, this is only a partial list; many of the other items are relative to Baker's particular type of apparatus. This extensive work essentially provides a completely remanufac- tured apparatus. with warranty, for considerably less than the price of a new unit. REFURBISHMENT Full refurbishment addresses the power train requirements and all of the elements of restoration and brings the apparatus up to state-of- the-art condition. It includes as manv of the manufacturer's improve- ments as possible, such as a fully enclosed cab, larger pump and tank, additional lighting, steps, and handrails —which all help to bring the unit into compliance with present NFPA standards. Obviously this is the most involved and costly process. Improvements such as wheelvell SCBA compartments can easily be made during the refur- bishment work. PHOTO BY B. BULAr Refurbishment vs. New Purchase 87 UNSEEN CONDITIONS Additional costs over and above the estimate are not unusual when undertaking a refurbishment job. Expect and plan for them. It is the norm rather than the exception to find additional areas that require attention when major components are removed and hidden deteriora- tion is exposed. Obviously when you reach that point it is too late to turn back, and it would be foolish to ignore the new discovery. You have no alternative but to allocate additional funds to complete the repair. Some authorities advocate including a contingency clause in the original contract. This consists of a fixed amount of money —for exam- ple. $5.000—added to the actual bid price of the refurbishment. If addi- tional work is necessary. the contingence fund could be drawn on to accomplish the job. When the work is completed, the unused portion of the contingency fund is deducted from the final price of the refur- bishment contract. One way to reduce the probability of having to draw from the con- tingency fund is to get several estimates from reputable vendors accus- tomed to working on fire apparatus. It is especially helpful if they have undertaken similar work on apparatus of the same make and model. Based on prior experience, they might have additional insight into what to expect when the components are removed. GLIDER KITS If the major components of your apparatus are in sound condition. another option is a glider kit. Offered by most manufacturers. it involves recycling the old unit's engine. transmission. rear axle. and pump (or aerial device) into a new frame. A new custom cab and body then are constructed. The glider kit option is really not a form of refurbishment, as most of the original vehicle is replaced rather than upgraded. It can save thousands of dollars over the cost of a new unit and is especially suit- able for a vehicle that has had limited use and has been properly main- tained. Another candidate for a glider kit would be an apparatus that has been heavily damaged in a motor vehicle accident but has a sound pump and power train. 88 Fire Apparatus Purchasing Handbook Most manufacturers have returDisnMen[ Cenien di turn 1d%111ty, —Ic-c can result In a -near-new" unit_ COURTESY OF E-ONE, INC. Refurbishment v,s. Nety Purchase BIDDERS' QUALIFICATIONS Establishing the qualifications of a bidder on an extensive refur- bishment job is every bit as important as when you purchase a vehicle new. The specifications should clearly state that bids only will be con- sidered from companies with an established reputation in the field of fire apparatus construction and refurbishment. Require that they sub- mit a contact list of other fire departments that have had similar work done at their facility. Check these references for the quality of the work- manship and the bidder's integrity. Most commercial truck body shops are not qualified to deal with all areas of the refurbishment job. Pumps. plumbing. and other apparatus - related items will not receive the proper attention they require. The quality of the finish work and painting that is suitable for commercial customers will not meet the expectations of the fire service. You can save yourself much grief by awarding the bid to a reputable fire appa- ratus repair facility. SUBCONTRACTORS The specifications also should limit the use of subcontractors or at least require the bidder to submit a list of subcontractors it intends to use and for what purpose. Then investigate the subcontractors as to the quality and reliability of their work. Another serious consideration from a liability standpoint is that the refurbishment or repair of an aerial device should be performed or approved by the original manufacturer of the unit. TIME FRAME AND TRANSPORTATION The specifications also should establish a time frame of when the work is to begin and an estimate of when it will be completed. This information is vital to arranging for substitute fire protection by way of mutual aid or adjustment to your present response districts. The particulars outlining the methods of pickup and delivery should be clearly stated. as well as establishing liability for loss, dam- age, or accident while in the care of the vendor. 90 Fire Apparatus Purchasing Handbook SPECIFICATIONS Preparing specifications for the refurbishment of an existing appa- ratus is considerably more difficult than when purchasing a new vehi- cle. Deciding on the precise areas of the apparatus that require attention and the degree of work required are monumental tasks. Soliciting multiple estimates from qualified rebuilders will help the committee draw up specifications for the work. For a more complete picture of the work that needs to be done, have several trained mechan- ics evaluate the job. In addition, various suggestions and recommenda- tions of how the modifications should be undertaken will allow the committee to incorporate the best ideas into the final specs. The specifications should clearly state component brands and the methods of work expected. For example, one vendor might replace compartments by welding the panels together. while another might use rivets or nuts and bolts. The fire department must outline the accept- able method of construction. :anything not in the specifications is assumed to be up to the contractor doing the work. INSPECTIONS The specifications should include inspections of the apparatus at critical points in the refurbishment process. You might consider sched- uling an inspection after the body work is complete and before the final paint is applied. This gives you the opportunity to change anything not up to specifications prior to its completion. A final inspection at the refurbishment facility is essential. Deficiencies in paint or finish work that could be easily corrected at the facility will become a major prob- lem after the apparatus is delivered. It is much more convenient for all parties concerned to have the apparatus inspected before delivery. TESTING Consider third -party testing of the main components of the appara- tus. A_replacement fire pump and all of its auxiliary systems should be tested and recertified by an outside agency. Likewise, testing and recer- tification of an aerial device also should be part of your specifications. If this provision is included in your specifications, the requirement to supply the certification documents also should be stated. Conduct a final inspection of a refurbished apparatus to ensure compliance with the specifications. PHOTO BY RON JEFFERS WARRANTY The bidder should be required to warrant the refurbished areas of the apparatus to be free from defects in material and workmanship under normal use and service. A period of 12 months is reasonable and usually specified. If the replacement of major components —such as the engine. trans- mission, pump, or water tank —is undertaken, the vendor performing the installation should be required to provide the manufacturer's war- rantv and related maintenance documents. COST ANALYSIS A very practical cost analysis formula comparing a refurbishment with a new acquisition is given in A Guide to Repoivering, Rehabilitating and Reconditioning by F. Wesley Dolezal (International Association of Fire Chiefs Foundation). Using the following facts, it is ; as follows: 92 f ire Appurutus Purchasing Handbook Present Unit Purchase Price Estimated Life Cost to Refurb Number of Extended Years Resale Value Step 1 Purchase Price Step 2 Yrs. remaining times per-yr. cap. Step 3 New Total New Unit Estimated Cast Estimated Life PRESENT UNIT (=) Estimated Life (_) Per -Year Capitalization (+) Cost of Refurb (_) Unit Total Worth (=) New Estimated (_) New Per -Year Life Capitalization* *Compare per -year capitalization. NEW UNIT Step 1 Purchase Price (—) Resale Value of (= J Capital Present Unit Investment Step 2 Capital Investment (=) Estimated Life (_) Per -Year Capitalization* *Compare per -year capitalization. EXAMPLE USING FORMULA PRESENT UNIT #1 Purchase Price $140.000 Life Expectancy Capitalization - 20 Yrs. (_) $7,000 per year #2 Years Remaining (2) Cost of Refurb Total Worth 2 x $7,000 = $14.000 (+) $100.000 (_) $114.000 #3 Total Worth Years of Life New Per-Yr. Cap. $114,000 (=) 7 (_) $16.285 * NEW UNIT #1 Purchase Price Resale Value Cap. Investment $350,000 (—) $20.000 (_) $330,000 Cap. Investment New Unit Life Per-Yr. Cap. $330,000 (=) 20 Years (_) $16,500* *Compare per -year capitalization. t �i�, T�Tt Refurbishment i-s. New Purchase 93 Even though the capitalization per rear is nearly the same. you also must realize that any refurbishment undertaken is only delaying the inevitable —the eventual replacement of the vehicle. Delaying the pur- chase could as much as double the price of the replacement in the future, depending on the rate of inflation. The overall cost should not be the only consideration in your deci- sion to replace or refurbish. New standards for safety and reliability may not be satisfied. and difficulty securing replacement parts not only is a nuisance but also relates directly to downtime. If you decide to go ahead with refurbishment. carefully prepare the specifications and choose a reputable fire apparatus rebuilder to com- plete the work. Va