1.0 Spec sheet 5100-503a NFES 0528.pdf

Specification 5100-503a June 2012

Superseding Specification 5100-503 October 2003

UNITED STATES DEPARTMENT OF AGRICULTURE

FOREST SERVICE

SPECIFICATION FOR

3,000 POUND LEADLINES, EXTERNAL, HELICOPTER

1. General.

1.1. Purpose and Scope. The 3,000 pound helicopter leadline covered herein is established as standard in the USDa Forest Service. This device is used to attach external loads to the cargo hook of a helicopter and is used in activities for the suppression of wildland fire. There are three weight classes of helicopters: light, medium, and heavy.

The helicopter accessory covered by this specification is for use with light and medium helicopters only. additionally, the accessory covered in this specification is for cargo use only. Do not use the item from this specification for any person lifting application, i.e., short haul.

2. aPPlicable DOcUmenTS.

2.1. Publications: The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issue of these documents are those in effect on the date of invitation for bids or requested for proposal.

american national Standards institute, inc (anSi)/american Society for Quality (aSQ)

Z 1.4—Sampling Procedures and Tables for inspection by attributes (american Society for Quality control) copies of the anSi publications can be obtained by writing to the following: american national Standards, inc., 25 West 43rd Street, 4th Fl., new York, new York, 10036

Or at their Web site at <www.ansi.org>.

2.2. Order of Precedence. in the event of conflict between the text of this document and the references cited herein, the text of this document takes precedence. nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained.

beneficial comments and suggestions related to this standard should be addressed using the comment sheet at the end of this document. remarks may be sent via electronic mail (mailroom_ wo_sdtdc@fs.fed.us) or U.S. mail to the USDa Forest Service San Dimas Technology and Development center, 444 e. bonita ave., San Dimas, ca 91773.

5100-503a

3. reQUiremenTS.

3.1. acceptance. lot acceptance of like articles shall be performed on product sample(s) in accordance with paragraph 4.4.1.

3.1.1. First article. Unless otherwise specified, first article inspection shall be performed on a product sample(s) in accordance with paragraph 4.4.2. During the term of the contract the contractor shall be required to notify the contracting officer in writing when a component or the component supplier changes in any way, when a major manufacturing process changes in any way, or when a manufacturing location changes. The contracting officer may at any time require the contractor to submit new first article sample(s) when substantive changes occur during the term of the contract.

3.2. Performance. The leadline shall be capable of performing as specified throughout the temperature range of 0 °F to 140 °F. The leadline shall have a working load limit of 3,000 pounds. The leadline assembly and its components shall have an ultimate strength of at least 12,000 pounds, which corresponds to a 4.0 load safety factor.

3.2.1. Proof Testing. Proof testing of the completed item is required for each and every article in the lot that is being offered for acceptance. The proof test load shall be 6,000 pounds and performed after the slip indicator paint (see paragraph 3.10) is applied to every article. The contractor’s quality assurance system shall show compliance with proof testing and the application of the slip indicator paint. The contractor shall mark the item after proof loading in accordance with paragraph 3.5. Testing and marking shall be performed prior to submittal to the government for first article and acceptance.

3.3. Parts and materials.

3.3.1. component parts. all component parts (including metallic and nonmetallic parts) shall be new and not reprocessed or reworked. When modification is required of commercially available or standard parts, evidence of engineering data or laboratory tests shall be supplied to verify that the modified part meets the requirements of this specification. each component shall be appropriate for its intended function considering the nature and adverse conditions involved in helicopter operations, including firefighting (see paragraph 6.1).

3.3.2. materials. all metallic parts used shall be corrosion resistant or treated for corrosion resistance.

3.3.3. leadline material. leadline material shall be a 6 by19 classification flexible wire rope with an independent wire rope core (iWrc). The wire rope shall have a minimum diameter of 5/16 inch, maximum diameter of 7/16 inch, and sufficient strength to meet the ultimate strength requirement of paragraph 3.2. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6, for the leadline material used in this specification.

3.3.3.1. Plastic coating. Unless otherwise stated in the procuring document, the wire rope shall be plastic coated. The coating shall be 1/32-inch minimum thickness, polyvinyl chloride, ultraviolet stabilized plastic. The coating shall be transparent to the extent that inspection of the wire rope under the coating is visually possible. The color of the plastic shall be green or blue, or as specified by the procuring agency.

3.4. construction and Workmanship. The leadline shall consist of a wire rope, with a hook (see paragraph 3.7) on one end, and a link (see paragraph 3.8) on the other end as shown in figure 5. The leadline shall be manufactured by current standard production processes to provide a clean, finished quality product. Workmanship shall be equal to the best commercial practices consistent with the highest engineering standards in the industry and shall be free from any defect that may impair serviceability or detract from the appearance of the product. The leadline shall be free of sharp edges or other defects that could result in injury.

3.5. Product marking. each and every item procured under this specification shall be marked with a tag. The tag shall contain the information as shown in figure 1 (GSa; the GSa contract number; the item’s working load limit (Wll) in pounds; manufacturer name or trademark; manufacturer and proof test date (month and year); and the approximate weight of a single leadline). (note: GSa contract number, company name, and the date in figure 1 are notional.) The text size shall be a minimum 0.12 inches. The text shall be legibly and permanently stamped, embossed, cut, or etched on to metal tag. The tag shall be either stainless steel or brass. The tag shall be attached to the leadline at the hook end using a galvanized steel wire rope. The securing wire rope for the tag shall be 1/16-inch galvanized steel. This wire rope shall be included in the swaging, which attaches the hook. The loop formed shall be between 1 and 1-½ inches in diameter and oriented in the swage in the direction shown in figure 1. The weight of the item shown on the tag shall be within 1 pound of the actual weight to allow for variation during the manufacturing process.

Figure 1. Marking tag.

marking tag

3.6. certificate of conformance. Where certificates of conformance are required, the Government reserves the right to verify by test any such item to determine the validity of the certification.

3.6.1 certification. The contractor shall provide individual certificates of conformance for the component where required in this specification. The contractor shall provide the following information on the certificate:

a. item description, i.e., eyelet hook, pear link, thimble.

b. item manufacturer’s name, address, and telephone number.

c. manufacturer’s item part number.

d. Procuring document for the item (to include the quantity and date ordered).

e. manufacturer’s lot number, if applicable.

f. manufacturer’s statement of working load limit and ultimate strength for the item, or part rating (applicable to thimbles only).

3.7. Hook. The hook used in the leadline shall be an eyelet style hook only. The hook used in the leadline shall have a working load limit of at least 3,000 pounds and a minimum ultimate strength of paragraph 3.2. The style and dimensions of the hook shall be as shown in figure 2. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6, for all the hooks installed on leadlines meeting this specification. The hook shall be swaged onto the leadline.

Figure 2. Eyelet hook.

3.7.1 Gate release. a gate release shall be incorporated in the hook and have a spring return to lock the gate closed. The release lock and hook gate shall have a minimum engagement of 0.130 inches, as shown in figure 3. (note: The dashed lines in figure 3 are hidden lines.)

A

B

C

Dimensions

A = 1.0-inch maximum B = 1.33-inch minimum C = 0.75-inch minimum

Figure 3. Gate lock engagement.

3.8. link. The link used in the leadline shall be a weldless pear-shaped steel link. The link used in the leadline shall have a minimum working load limit of 3,000 pounds and a minimum ultimate strength of paragraph 3.2. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6, for all the links presented on leadlines meeting this specification. The dimensions of the link shall be in accordance with figure 4.

Figure 4. Link dimensions.

3.9. leadline length. The ordering activity may specify the lengths of 12 feet, 25 feet, or 50 feet. The tolerance on all lengths shall be +/- 3 inches. The length as shown in figure 5 shall be measured from center to center of the thimbles, with the leadline taut, in a straight line, and on a flat surface.

0.130-inch minimum engagement

Dimensions

A = 0.625-inch maximum B = 1.5-inch minimum and 3.0-inch maximum C = 3.0-inch minimum to 4.0-inch maximum D = 0.5-inch minimum inner radius

Figure 5. Leadline length.

3.10. Terminations and Splices. each end of the wire rope shall be terminated using a thimble. The thimble shall be rated extra heavy or heavy duty. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6, for all the thimbles presented on leadlines meeting this specification. The terminations shall incorporate a swage. The swage shall be either stainless or carbon steel, or copper.

aluminum swages shall not be used. The wire rope shall be stripped of the plastic coating before swaging. The swaged area shall not incorporate any part of the plastic coating. all swages shall be painted for slip indication as shown in figure 6. The paint color shall be red. The link end swage shall also be similarly painted. Swages shall not be covered. no splices shall be allowed in the wire rope. For turnback swage terminations, both terminated ends of the wire rope shall be fully contained within their swages and the end of the wire rope shall be flush with the swage collar or extend no more than 0.125 inches beyond the swage. in no case shall the end of the wire rope be contained within the swage on turnback terminations. Flemish eye swage terminations shall meet the swage manufacturer’s requirements. The contractor shall obtain and retain the Flemish eye swage termination process and inspection requirements. The contractor shall provide the government copies of the Flemish eye swage manufacture’s documentation.

Figure 6. Slip indicator paint.

Paint

4. SamPlinG, inSPecTiOn, anD TeST PrOceDUreS.

4.1. General inspections and Tests. The contractor shall be responsible for delivering quality products that meet the requirements of this specification. The contractor shall perform all inspection and test requirements prior to submission for Government acceptance and first article inspections. The contractor’s test and inspection results shall be made available to the Government for both acceptance and first article inspection; for first article inspections (see paragraph 4.4.2), the contractor’s results shall be submitted in the first article inspection package, paragraph 4.4.2.1. The contractor may utilize his or her own test facilities or any commercial laboratory acceptable to the Government.

inspection records of the examination and tests shall be kept complete and available to the Government.

4.2. responsibility for compliance. The contractor’s inspection system shall assure that all product submitted to the government shall meet all requirements of sections 3 and 5.

The inspections set forth in this specification shall become a part of the contractor’s overall inspection system and quality program. The absence of any inspection requirements in this specification shall not relieve the contractor of the responsibility of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements. However, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.3. classification of inspection. The inspection requirements specified herein are classified as follows:

a. First article inspection (see paragraph 4.3.2).

b. lot acceptance inspection (see paragraph 4.3.3).

4.3.1. lot. all like items presented together in one delivery will be considered one lot for the purposes of inspections.

4.3.2. First article. The contractor shall make available to the government items from which a first article(s) may be selected. The government may select 1, 2, or 3 articles for inspection based on the number of items in the lot. at least one of the sample articles will be made unserviceable as a result of the testing and will be retained by the government.

The other will be returned at the request of the contractor. The contractor shall provide the address to ship the remaining serviceable units, if they want them returned.

4.3.3. Sample for lot acceptance inspection/Test. Sampling for lot acceptance shall be in accordance with anSi/aSQc Z1.4. The sample size shall be per special inspection level S-3 and have an acceptable quality level (aQl) of 1.5.

4.4. inspection and Tests.

4.4.1 lot acceptance. When selected in accordance with paragraph 4.3.3, each sample item shall be inspected in accordance with table 1, to determine conformance with this specification. if the sample is found to have any major nonconformances, as identified in table 1, the lot shall not be accepted. a nonconformity not listed in table 1 shall be classified as a minor nonconformance. additionally, if the number of minor nonconformances (per table 1) in the sample exceeds an aQl level of 1.5 percent nonconforming, the lot shall not be accepted.

Table 1. lot acceptance inspection

Reference Nonconformance Class of Para. No. Nonconformance

3.2.1. The leadline was not a proof tested. major

3.2.1. The contractor’s quality assurance system does not major show evidence of compliance with proof loading and/or the slip paint indicator marking prior to proof loading.

3.3.2. all exposed metal parts are not corrosion resistant major or treated for corrosion resistance.

3.3.3. The wire rope used in the leadline has a smaller major diameter than 5/16 inches or greater diameter of 7/16 inches.

3.3.3.1. The wire rope is not plastic coated. major

3.3.3.1. The plastic coating is not transparent. major

3.3.3.1. The plastic coating is not either green or blue. major

3.4. The leadline does not consist of a steel wire rope

with a link at one end and a hook at the other. major

3.4. The leadline contains sharp edges, burrs, or other major that could result in injury.

3.4. The workmanship of the leadline is below industry minor

standards.

3.5. marking does not contain all of the required major information (as in figure 1).

3.5. Text is not at least 0.12 inches in height. major

3.5. any lettering is not legible. major

3.5. Text is not embossed, stamped, cut or etched into major

a stainless steel or brass tag.

3.5. The tag is not located at the hook end. major

3.5. The wire rope attaching the tag to the leadline is not

included in the swage of the wire rope termination. major

3.5. The tag is not oriented in the swage as shown in major

figure 1.

3.7. any dimension of the hook is not per figure 2. major

3.7.1. The minimum engagement of the gate and lock major

release is not greater than shown in figure 3.

3.8. The link is not pear shaped. major

3.8. The link is welded. major

Reference Nonconformance Class of Para. No. Nonconformance

3.8. The link does not meet the dimensions shown in major

figure 4.

3.9. The length of the leadline is not as required by the major procuring document, measured as shown in figure 5.

3.10. The leadline termination does not include a thimble, major and the thimble is not heavy duty or extra heavy.

3.10. The swages used are not either stainless or carbon major steel, or copper.

3.10. The swaged area incorporates any part of the major

plastic coating.

3.10. The swages are not painted for slip indication. major

3.10. The leadline includes a splice. major

3.10. For turnback swages, the cut end of the wire rope major for either termination does not extend beyond the swage collar.

3.10. For turnback swages, the cut end of the wire rope major for either termination extends more than 0.125 inches beyond the swage.

3.10. For Flemish eye swages, the contractor did not major

provide swage processing and inspection information from the swage manufacturer.

3.10. For Flemish eye swages, the swage does not meet major

the swage manufacturer’s inspection criteria.

4.4.2. First article inspection. Unless otherwise specified, the first article(s) submitted in accordance with paragraph 3.1.1, shall be inspected as specified in paragraph 4.4.1 and table 2. The sample size shall be in accordance with paragraph 4.3.2. Government inspection of compliance on the first article(s) may stop upon any single failure (regardless of classification), and the sample(s) not accepted. The contractor will be informed of the nature of the failure. additionally, the Government is not obligated to continue with first article compliance inspection, unless it is considered in the best interest of the Government.

Table 2. First article inspections

Reference Nonconformance Class of Para. No. Nonconformance

3.2. The leadline assembly or its components do not major

have an ultimate strength of at least 12,000 pounds.

3.3.1. all of the components are not new, and major engineering/test data have not been provided justifying the use of reworked/modified component(s).

3.3.1. each component is not appropriate when major considering its intended function.

3.3.3. The certificate of conformance for the wire rope major used on leadline was not provided, or the certificate does not contain all of the required data.

3.3.3. The wire rope used is not a 6 by19 class iWrc major

steel wire rope.

3.6.1. any certificate of compliance does not contain all major of the information in this paragraph.

3.7. The certificate of conformance for the hooks used major

on the leadline was not provided, or the certificate does not contain all of the required data.

3.8. The certificate of conformance for the links used major

on the leadline was not provided, or the certificate did not contain all of the required data.

3.10. The certificate of conformance for the thimbles major

used on the leadline was not provided, or the certificate does not contain all of the required data.

4.4.2.1 First article inspection Package. The contractor shall submit to the Government along with the selected first article(s), copies of:

a. engineering analysis or test data for altered commercial products, if applicable, see paragraph 3.3.1.

b. all certificates of conformance, see paragraphs 3.6, 3.7, 3.8, and 3.10.

c. if Flemish eye terminations are used, provide the swage collar manufacturer’s process and inspection requirements/recommendations, see paragraph 3.10.

d. company inspection records, see paragraph 4.1.

e. all test results for the article(s), see paragraph 4.7.

f. Ultimate strength certificate, see paragraph 4.6.

g. calibration/metrology information on test equipment that was used as a media of in-spection, see paragraphs 4.6 and 4.7.

h. all other material necessary to perform the inspections identified in table 2.

4.5. Proof Testing. Proof testing shall place the item under the load specified for the item in paragraph 3.2.1. The applied force shall be a static load applied in the direction the item will encounter in its intended use. The equipment used to apply the loading force shall be calibrated to a recognized State or Federal standard. The calibration of the equipment shall be current (within the last 12 months) at the time of testing.

4.5.1. Proof Testing inspection. all items shall not exhibit any plastic deformation, take a permanent set, or change its dimensional properties as a result of the proof test load.

4.6. Ultimate Strength Testing. The contractor shall perform testing to verify the completed leadline ultimate strength. Testing shall place the item under the load specified for the item in paragraph 3.2 and held for 10 seconds. The applied force shall be a static load applied in the direction the item will encounter in its intended use. The test equipment used to apply the loading force shall be calibrated to a recognized State or Federal standard. The calibration of the test equipment shall be current (within the last 12 months) at the time of testing. The contractor shall provide evidence of the test equipment calibration.

4.6.1. Ultimate Testing inspection. The item shall not fail, break, or release the load.

The item may yield, experience plastic deformation, or change its dimensional properties as a result of the ultimate test load, but shall not fail or break. all items subjected to ultimate testing shall be considered unserviceable by the testing. as such, they shall be conspicuously marked and not delivered to the government for stock or supply.

4.6.2. certification of Ultimate Test result. The contractor shall prepare and provide as part of the first article inspection and upon request of any Government inspector, a certificate of conformance for the ultimate strength test. The certificate shall contain the following:

a. Product description.

b. Description of the test equipment involved and the metrology information.

c. manufacturer’s name, address, and telephone number.

d. manufacturer’s lot number.

e. Product’s date of manufacture.

f. Test company name, address, and telephone number.

g. Testing date.

h. Test technician’s name and title.

i. all characteristic test values (see paragraph 4.7).

4.7. Test results. The contractor shall have available copies of all test results performed to assure the quality or acceptability of the product submitted for acceptance. The test results shall also show the product’s acceptable range or expected test result and the item’s test value. all test equipment, which shall be used as media of inspection, shall be calibrated and current (within the last 12 months) at the time of testing. calibration shall be to a recognized State or Federal standard. The company shall obtain and retain calibration information on all equipment that is used as a media of inspection for items delivered under this specification.

4.8. nonaccepted lots. nonaccepted lots may be offered again for inspection in accordance with paragraph 6.4 of anSi/aSQc Z1.4, except that Table ii-b – Single sampling plans for tightened inspection (master table) shall be used with the parameters of paragraph 4.4.1. The resubmitted lot shall be inspected in accordance with table 1 of this specification.

4.9. Government lot acceptance. The Government will conduct lot acceptance inspections and tests to determine compliance with the specification. The Government’s inspection will be in accordance with the requirements of section 4. if lot acceptance and tests are conducted at locations other than the manufacturing facilities, the contracting officer will specify location and arrangements. in the case of onsite inspections at the contractor facility, the contractor shall furnish the inspector all reasonable facilities for their work. During any inspection, the inspector may take from the lot one or more samples and submit them to an independent test laboratory approved by the Government or to a Government test facility for inspection and tests.

5. PackaGinG, PackinG, anD cOnTainer/SHiPmenT markinG.

5.1. Packaging, Packing, and container/Shipment marking. The packaging, packing, and container/shipment marking shall be as specified in the contract or order.

6. nOTeS.

6.1. intended Use. all items procured under this specification are intended to attach external loads to the cargo hook of a helicopter and used in the suppression of wildland fire or related activities. The wildland fire environment includes, but is not limited to, fire retardants; dust; moisture; pesticides, fuels (aviation, jet, gasoline, kerosene, diesel, etc.);

hydraulic fluid and oils (aviation and automotive); herbicides; pesticides; and lubricants (aviation and automotive).

6.2. acquisition requirements. acquisition documents should specify the following:

a. Title, number, and date of this specification.

b. if a first article sampling and inspection is not required (see paragraphs 3.1.1, 4.4.2, and 6.4).

c. Whether plastic coating is required on leadlines and color (see paragraph 3.3.3.1).

d. The required length of leadlines (see paragraph 3.9).

e. Packaging and packing and marking (see paragraph 5.1).

6.3. metric equivalence. The following table provides the conversion factors to be used in creating metric equivalence for this specification.

Conversion Factors

English System Calculation To Obtain Metric Equivalence

Pounds lbs. * 0.453 kilograms inches in. * 2.54 centimeter inches in. * 25.4 millimeters

Foot ft * 0.305 meter

Fahrenheit (°F-32)*(5/9) centigrade

6.4. First article. When a first article sample(s) is required, it shall be inspected and approved in accordance with the first article clauses set forth in the solicitation. Specific instructions shall be included regarding arrangements for selection, inspection, and approval of the first article sample(s). The first articles shall be subjected to the ultimate strength requirement of 3.2. as such, the first articles will be made unserviceable by the test. Hence, they shall not be delivered to Government stock or supply.

6.5. Superseding Data. This document supersedes 5100-503 October 2003.

6.6. nOTice: When Government drawings, specifications, and standards or other data are used for any purpose other than in connection with a definitely related Government procurement operation, the United States Government thereby incurs no responsibility nor any obligation whatsoever.

6.7. Preparing activity. USDa Forest Service, Technology & Development center, 444 east bonita avenue, San Dimas, ca 91773-3198.

United States Department of Agriculture, Forest Service Standardization Document Improvement Proposal

Instructions: This form is provided to solicit beneficial comments that may improve this document and enhance its use. contractors, government activities, manufacturers, vendors, or other prospective users of this document are invited to submit comments to the USDa Forest Service, San Dimas Technology and Development center, 444 east bonita avenue, San Dimas, california 91773-3103. attach any pertinent data that may be of use in improving this document. if there is additional documentation, attach it to the form and place both in an envelope addressed to the preparing activity. a response will be provided when a name and address are included.

Note: This form shall not be used to submit request for waivers, deviation, or for clarification of requirements on current contracts. comments submitted on this form do not constitute or imply authorization to waive any portion of the referenced document(s) or to amend contractual requirements.

Standard number and Title: Specification 5100-503a, 3,000 Pound Leadline, External, Helicopter name of Organization and address:

___ Vendor _____User _____ manufacturer

1. ____ Has any part of this document created problems or required interpretation in procurement use?

2. ____ is any part of this document too rigid, restrictive, loose, or ambiguous?

Please explain below.

Give paragraph number and wording:

recommended change (s):

reason for recommended change (s):

remarks:

Submitted by: (Print or type name and address - Optional) Telephone number:

(Optional)

Date:

USDa Forest Service San Dimas Technology & Development center attn: Specification and Standards Project leader 444 east bonita avenue San Dimas, california 91773-3103

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