MCLB Albany, GA

Capability

Characteristics: 950 feet long, 100 feet wide. One 75-ton overhead crane, two 30-ton overhead cranes with five-ton auxiliaries, Eight 1-ton jib cranes, three 3-ton jib cranes and numerous service jibs. Equipped with high tech energy efficient metal halide lighting. Processes work load from the Air Force, Army, Coast Guard, and Marine Corps.

Concrete, mile long oval for testing wheeled and tracked vehicles. The vehicle test tract is a one-mile banked oval concrete testing facility. It contains an additional drive run way with spaced humps to test vehicle suspensions and weapons tracking equipment. The track has imbedded steel vehicle neutral steer turning pads. The 1-mile oval dirt track provides the ability to test cross-country performance of vehicles

15 foot deep concrete pool holding 3.75 millions gallons of water. Contains thrust-measurement propulsion system equipment.

Elevated, concrete test ramp with 30 and 60 percent grades.

Automated parts storage or retrieval close to equipment maintenance area. Capacity up to 5,000 NSNs.

Capability to repair radar/radio sets, communication equipment, and mine detectors of the Marine Corps, Army, Navy, Air Force, and foreign allies. Capabilities include test program development, systems integration, shelter systems development and manufacturing, an array of radio systems, missile systems (support), inertial and satellite signals navigation and tactical survey systems, sensor systems, meteorological measurement systems, telecommunications, electrical and utility systems, integrated systems fielding and New Equipment Training Team support.

Used to calibrate Beta/Gamma radiation-measuring instruments.

The 100-meter completely enclosed range contains one state of the art wet snail bullet traps that eliminated employees lead exposure and two targets, one target at 100 meters and one removable target at 30 meters plus test fire fixture for all small arms up to .50 cal. The function fire range located in building 2200 is completely enclosed and complete with test fire fixture and state of the art wet snail bullet trap that eliminated employees lead exposure. Function fire range will accommodate all small arms up to .50 cal. An additional range contains one shotgun / pistol snail trap.

Test Fire Range for Albany

Sixteen machines available utilizing computer numerical control to automatically perform a number of machining operations start-to-finish. Capabilities to manufacture obsolete components, long lead time items, or are not in the Federal Supply System.

The cross-drive dynamometer contains one 1000 HP electric-over-hydrostatic power unit and two 1500 hp eddy current power absorption units. The dynamometer is complete with TDAC (Transmission Data Acquisition and Control) system. The TDAC system provides real time performance information to the operator for the transmission being test and the dynamometer. The TDAC system provides a computer generated transmission test performance form with pass or fail criteria at the end of the transmission testing cycle. This dynamometer will test Allison X1100, XT1410-5A, HS525, X-1100-3B, XTG-411 and CD850 transmissions. The dynamometer cooling system is completely self-contained and recycles all cooling fluids. This facility is providing support not only for the Marine Corps but also for the US Army and Georgia National Guard.

Capability to measure all performance parameters and simulate actual operation in the vehicle. Used to test conventional transmissions in all wheeled vehicles. Two Hicklin HTDE identical units of 150 constant HP / 240 momentary HP and 3600 rpm capable in line transmission dynamometers. One 400 constant HP / 600 momentary HP Electric Vera-drive EDECT 400CD Hicklin in line / cross drive dynamometer. Dynamometers have ability to test HS 400, HS-525, Allison MT/HT transmission, HummerTurbo Hydromatic 4L80 and MTVR 7 ton truck Allison HD4070 electronic controlled transmission. The EDCT 400CD and transmission being tested is controlled by Hicklin TDAC system. The TDAC system provides a computer generated transmission test performance form with pass or fail criteria at the end of the transmission testing cycle.

Unique, one-of-a-kind design for four-axle vehicles like the LAV. Measures HP output at each drive axle. Simulates actual road conditions. The all weather chassis dynamometer facility contains two chassis dynamometers. One Clayton three-axle chassis dynamometer that will test wheeled Vehicles with a wheelbase up to and including 282 inches will absorb 200-road horsepower at speeds up to 90 MPH. One 4 axle Clayton dynamometer for testing the LAV to it's maximum abilities. The 4-axle chassis dynamometer is the only existing dynamometer of this type in the world. The all weather facility is heated and fans cooled. The individual vehicle exhaust systems provide dissipation of all fumes from the facility. The state of the art computer controlled data acquisition system provides real time vehicle performance information to the operator and provides a computer-generated form of the vehicle performance. The dynamometer cooling units are completely self-contained and recycle all cooling fluid.

The engine dynamometer facility contains six engine testing cells with separate air conditioned sound proof control rooms, male and female toilet / shower facilities and office/ storage room. The engine test cells are provided with two 250 HP, two 500 HP, one 750 HP and one 1,200 HP eddy current water in-gap power absorption units. Each test cell contains one fuel control system that supplies the engines with clean and pressurized fuel. The fuel is metered to provide fuel consumption data. Each cell is provided with a smoke meter. The control room contain state of the are computer controls with manual over ride ability. The computer control system exercises complete control over the engine being tested and the power absorption unit during the testing cycle. This computerized data acquisition system provides real time engine and power absorption unit performance information to the operator. At the end of the testing cycle the computer generates an engine performance form. The dynamometer cooling units are completely self-contained and recycle all cooling fluid. Each testing cells engine exhaust and cell ventilation system insures the complete elimination of exhaust gases in the testing area. Located in engine repair/rebuild section is one 1,800 HP (maximum 4,000 RPM) water break dynamometer. This dynamometer is located in a testing cell with self contained and recycling cooling liquid system. These dynamometers support not only the Marine Corps but also the US Air Force, US Army and Georgia National Guard. And have supported the US Cost Guard and the FBI.

Completely enclosed to reduce noise. Can test-fire gun in or out of vehicle. Used for the chain gun, primary LAV-25 weapon. Test fires motor driven M242 using dummy rounds. Provides ability too monitor gun while firing to aid troubleshooting. Potable test set can troubleshoot the M242 while in vehicle. Building 2226 is the M242 live fire facility. The LAV-25 is driven in to the building and the M242 can be tested with live ammunition. Test firing at this facility is conducted by remote control posing no danger to operating personal. The building contains one M242 test-firing fixture for test firing the weapon with live ammunition when removed from the vehicle. The facility contains a sand bullet trap.

The coatings branch provides an environmentally compliant, high-volume, state-of-the-art painting process utilizing five drive thru paint booths capable of utilizing water borne or solvent based paints. Upgrades to the paint facilities include the replacement of three old booths with two new dry filter systems, the conversion and upgrading of two water fall booths to dry filter system to provide a more environmental friendly system, the conversion of vehicle dry thru booths to an automated pleural mixing system which mixes the paint components, track paint usage, eliminate paint wastage, and communicates the to painter when the components need replenishment, the addition of powder paint operations which includes a batch painting operation and a powder paint state of the art automated paint line, and a burn off oven to remove tough coatings such as powder paint or build up CARC materials. Additional stand alone small component paint include a standard paint conveyor and batch painting. In addition some organic batch paint operations are localized in some shops as needed.

Closed-loop system providing containment of hazardous waste by-products produced during chrome plating process. Air scrubbers to prevent water and air pollution. Fully compliant with Federal, State, and local laws governing hazardous waste disposition.

19,600 square foot area with Tumble Blast, Rotoblast, and Bead Blast machines. Four blast booths use sand, steel shot, plastic, a Bicarbonate of Soda System, glass bead, or coal slag. Six high-pressure, hot water and soap steam cleaning station/parts washer; 10 foot diameter turntable with four-ton hoist. Phosphate coating tank with hot and cold water rinse, one-ton bridge crane above tank. Two steam cleaning pits. Boilers for steam generation. Oil-water separator.

The Abrasive blasting shop has tested this process and has budgeted a machine for FY03. The machine utilizes low pressure potable water and shop compressed air to pressurizes the system to 40,000 psi. The system will be used to remove paint from military equipment that might otherwise be damaged by abrasive blasting or other cleaning processes. System will provide a complementary tool to other blast and cleaning processes in the Maintenance Center. System does not require extensive masking procedures.

Provides safe staging of hazardous waste awaiting disposition. Ensures control of hazardous waste, under full compliance with all Federal, State, and local environmental regulations, until properly disposed.

The Industrial Waste Treatment Facility can process over 200,000 gallons of effluent a day. The facility treats industrial waste material before entering the city sewage system, 24-hour, 635 days a year. Maintenance Center Albany is installing point of usage water recycling systems as part of various processes such as dyno testing, air compressor systems, boiler systems, steam cleaning operations, and chrome plating operations as part of the base overall waste reduction plan.

33,000 square foot climate controlled facility with 8,000 square feet of raised access flooring and 1,000 square feet of radar shielding. Calibration and repair of Electrical, Electronic Physical, Dimensional, LASER and Optical and Electroplate TMDE. Design, development and production of Automatic Test Equipment (ATE) and Application Program Sets (APS).

Certified Precision Gage Laboratory and LASER Repair Facility. The Brunson 270 BN and the Leica Technologies T-4 Collimator support calibration of optical survey instruments.

Technical management and operation of the Marine Corps Automatic Test Equipment Program (ATEP).

Provides full range of automatic testing technical expertise in: analysis of automated testing weapon systems maintenance requirements; planning and establishing type of automated testing support; and, development and manufacture of APS and ATE for maintenance support.

Hardware, software, and instruction documentation necessary to perform complete automatic testing and fault isolation of a particular component in a weapon system.

Design, develop, procure, produce, and support the ATE throughout the Marine Corps.

One 75 foot long, traveling, computer controlled, fully automatic, tracked / wheeled vehicle and component wash system which utilizes specially formulated environmentally friendly detergent and is equipped with a 90% waste water recovery system. Nine independent steam-cleaning bays, each of which uses specially formulated environmentally friendly detergent and is equipped with an environmentally friendly automatic steam and water conservation system. Two 3-ton monorails, which service multiple bays. One 3-ton overhead bridge crane. Dual pump fluid and primary residue containment system. Two 100 HP boilers. Steam temperatures to 365 degrees F. Operating pressure capability from 10 to 150 PSI. 39,200 watts of over head lighting. Capable of 24 hour a day, all weather operation. Processes work load from the Air Force, Army, Coast Guard and Marine Corps.

Warehouse Complex and Maintenance Storage Facility of 221,800 sq. ft. and 86,400 sq. ft of fenced outside bulk storage.

Test facility provides testing of various coating processes for metal applications utilizing chrome plating, both zinc and manganese phosphate coatings, and conversion coatings. All processes are tested as required by customer requirements utilizing requested mil specs and standards or commercial specifications. Laboratory also capable or providing complete oil analysis as required by DOD for military vehicles and equipment repair. On-site analysis of wear metals, failure analysis, metallurgical analysis, identification of unknown fluids, gases and hazardous materials, and fluid viscosity measurements. Equipment includes X-Ray Fluorescence Spectrometer, Infrared Spectrometer, Gas Chromatograph and a Computerized Theodolite Measuring System.

Capabilities in Night Vision include support and rebuild of I square or passive night sights to include night vision goggles, crew served night sights, driver night viewers for rolling stock such as the AAV and LAV

Capabilities to troubleshoot and repair all Marine Corps thermal systems. Capable of working both nuclear and battery powered systems used in conjunction with thermal imaging, and laser range finding to complete the weapons system suite.

Large capacity, automatic, self-contained high-pressure 10 ft. rotary table cleaning system for large subassemblies, components, palletized and containerized parts. Cleaner is equipped with 4 ton hoist and monorail. Utilizes environmentally friendly detergent and recycles 100% of water. Four self-contained automatic cleaning systems for engines, transmissions and small arms. Utilize environmentally friendly detergent and recycle 100% of water.

Performs Non-Destructive Testing on trucks, Amphibious Assault Vehicles, M1A1 Tanks, M88 Retrievers, Light Armored Vehicles, tankers and other large components. Portable lead shielding used in a structure housing two ERESCO 65MF2 x-ray machines. One unit is mounted on a positioning gantry and the other unit is mounted in a special lead enclosure for x-ray of small parts and test coupons. Both machines are capable of x-raying composites and penetrating 5 inches of steel and 10 inches of aluminum to inspect materials for fatigue and stress corrosion cracks, and other material defects affecting equipment integrity. This facility is also used for ultrasonic testing, liquid penetrant testing, and magnetic particle inspection of large items.

State-of-art facility to undercoat vehicles and equipment with environmentally friendly undercarriage corrosion prevention coating. Facility has undercoating pit area, 25 ton vehicle lift, and drive bay to tailor the undercoating process to the vehicle and equipment as required. The Drain Rack Facility has storage tanks for the removal of fuel, antifreeze, and lubrication fluids. This facility has state-of-art drain equipment with three oil water separators providing capability to remove fluids 24-hours a day, seven days a week in inclement water. Both tracked and wheel vehicles of various tonnages can utilize the drain system as needed. In addition fluids removed from other equipment is pumped and stored in the tanks for removal as required. The Preservation facility has eight work bays available for the application of preservation materials including the required mil preps. Utilizing attached covered area if needed can provide additional bays.

Undercoating, Fluids Removal, and Preservation for Albany

1 each 12’-0" three axis and 1 each 20’-0" five axis Computer controlled high-pressure high-speed low temperature water jet cutter to multi-cut, multi-task for greater production. Ability to convert and cut at high speeds any two-dimensional drawing, to produce parts, and or components for use to rebuild all types of Marine Corps Technical Vehicles and any other items in the USMC inventory.

Have the capability to send a metal contact team to any location in the free world. This normally consists of a Quality Assurance Inspector and/or Welding Engineer and welders with the ability to do certified welds by qualified welders under the direction of engineering on all types of metals including High Hard Steel used as armor plate on the LAV family of vehicles.

Fuel Systems Rebuild and Calibration 

The welding facility consists of two buildings which provide specialized and certified welding capabilities on various steel and aluminum vehicles and equipment which include both wheeled vehicles and tracked vehicles such as the LAV and AAV. There are eleven bays available in the welding facilities providing 24 hour, 7 day a week, and inclement weather capability. Spray metalizing is also available to provide a corrosive resistant coating process. A large organic bridge crane is presently available to provide lifting capabilities to the track vehicle area. For small welding jobs welding stations are also provided. Additional welding capabilities are provided in the body shop and engineering equipment areas as needed. Also self contained mobile welding vehicles are available to go wherever welding processes are required quickly and efficiently throughout the Maintenance Center. Either plasma torch or water jet cutting as needed to provide armor plating to the required specification provides cutting capability. Our existing facility has ability to accomplish High Velocity Particle Consolation once the process is experimentally proved. New capabilities will include the addition of a rotating positioning equipment, enabling the entire vehicle to be rotated 360 degrees, so welding could be done in the flat position on all vehicles and facilitating friction stir welding on the AAV.

 New Welding Facility (Barstow)

Welding Facility (Albany)

Heavy Mobile Equipment Mechanic, Electronics Mechanic, Electronic Integrated System Mechanic, Electrical Equipment Repairer, Optical Instrument Repairer, Instrument Mechanic, Machinist, Toolmaker, Welder, Electroplater, Metals Inspector, Mobile Equipment, Metal Mechanic, Painter, Sandblaster, Rigger, Crane Operator, Electronics Measurement Equipment Mechanic, Heavy Tire Repairer, Tools & Parts Attendee, Mobile Equipment Dispatcher, Motor Vehicle Operator, Fork Lift Operator, Upholsterer, Computer Specialist, Sheet Metal Mechanic, Small Arms Repairer, Visual Intermation Specialist, Industrial Specialist, Program Managers, Program Assistants, Project Coordinators, ASNT Level II and III Inspectors, AWS Certified Weld Inspector, Welding Engineer, Engineering Technician, Engineering Draftsman, Mechanical Engineer, Electronics Technician, Chemical Engineer, Industrial Engineer, Technical Industrial Engineer, Safety & Occupational Health Specialist, Environmental Protection Specialist, Safety Technician, Hazardous Material Handler, Hazardous Waste Handler, Materials Handler, Materials Examining and Identifier, Industrial Operations Manager, Senior Product Supervisor, Quality Assurance Specialists (Mechanical),    Materials Expediter, Material Planner, Workload Schedulers, Inventory Management Specialists, Supply Systems Specialist, Clerical/Technical Support, Budgetary/Financial Support and Security Guard Support.

Building 2242 is 37,128 sq. ft. and designed to provide support to all types of engineer equipment. The building is divided into two large bays. Each 282-foot bay contains one bridge crane with 35-ton main and 5-ton auxiliary hoist; building doors are 22 feet high providing maximum headroom for the largest item of engineer equipment. Building is provided with a self-contained lubrication system to facilitate oiling and greasing of equipment. Building contains male and female toilet/shower facilities and office space. Unique feature of this building is the eight doors located on the sides at one end. These doors are paired on opposite sides of the building, they allow the longer items of engineering equipment that do not articulate to enter and leave the building expeditiously.

The Hydraulic Testing center is located in an environmentally controlled clean room. Located in the room are two 100 HP and one 25 HP hydraulic test benches test benches. The 100 HP benches rated for 4,500 PSI at 2,400 RPM with a flow rate of 35 GPM. The hydraulic cylinder disassembly machine located adjacent to the clean room provides a mechanical means of dissembling and assembling hydraulic cylinders.