Atch 1. SOW rev 12272021 and Appendix A.pdf

Statement of Work for Effects of Delamination on

Blast Resistance of FE/BR and Blast Resistant Layups

Background

The Department’s Bureau of Diplomatic Security, Physical Security Research and Development Section (DS/PSD/RD) has evidence that the adhesive bonds of glass to PVB (polyvinyl butyral), glass to PC (polycarbonate), and PC to PC degrade over time. Degradation in the case of glass to PVB adhesion can be caused by moisture migration in the PVB from the edges. A widely viewed source of the degradation in the adhesive bond glass and PC results from differences in the thermal expansion and contraction during thermal cycles. Additionally, the inherent stresses in the materials resulting from the lamination process may contribute to delamination. DS/PSD/RD needs to determine what effect this loss of adhesion has on the layups’ blast-resistant properties, and the magnitude of this effect depending on the percentage of adhesion degradation.

Testing

Test Structure

All the test articles shall be mounted in a non-responding and elastic to the load reaction structure, in accordance with Section 9.0 of “Blast Testing SOP for DS/PSD/RD” 2021 edition (Appendix B). The reaction structure shall be large enough to reduce clearing effect and generate a 42psi and 300psi-ms load over the face of the glass for each test. Allowable tolerances of load and reaction structure movement are included in “Blast Testing SOP for

DS/PSD/RD”.

The test articles and any filler plates shall be mounted flush to face of the test structure.

The test structure shall not have any protrusion in the face of the test structure within 2’ of a test article or pressure gauge.

Layups

The five layups shown below shall be included in the test plan.

Layup 1 Layup 2 Layup 3

1/4" HS (attack side) 1/2" HS 3/8" Tempered Glass

0.060" PVB 0.180 PVB" 0.060 PVB"

1/4" HS 1/2" HS 3/8" Tempered Glass

3/8" AIR SPACE 0.180 PVB" 1/2" AIR SPACE

3/16" HS 1/2" HS 3/8" Tempered Glass

0.050" Polyurethane Interlayer 0.060 PVB"

1/4" Polycarbonate (PC) Layup 4 3/8" Tempered Glass

0.025" Polyurethane Interlayer 1/2" Tempered Glass

3/16" Polycarbonate 0.150 PVB" Layup 5

0.025" Polyurethane Interlayer 1/2" Tempered Glass 1/2" Tempered Glass

1/4" Polycarbonate 1/2" AIR SPACE 0.24 PVB"

0.050" Polyurethane Interlayer 1/2" Tempered Glass 1/2" Tempered Glass

3/16" HS 0.15 PVB"

0.050" Polyurethane Interlayer 1/2" Tempered Glass

0.093" PC w/ mar-guard

Test Sample Sizes (Actual) Actual sizes for the layups shall be as follow:

• Layup 1 and 2 size shall be 48”x72”

• Layup 3 and 5 size shall be 48”x48”

• Layup 4 size shall be 48”x96”

Test Sample Sizes (DLO) The test frames shall have a bite of 1.5” on all edges so the Day Light Opening (DLO) sizes are:

• Layup 1 and 2 45”x69”

• Layup 3 and 5 45”x45”

• Layup 4 45”x93”

Layup Categories

There will be three categories of test articles: (1) “control”, (2) “partially laminated”, and (3) “delaminated.”

The intent of this effort is to test laminates with regular/standard adhesion, partial adhesion, and no adhesion. This includes the PVB to glass adhesion bond and the TPU to glass and TPU to polycarbonate adhesion bond.

(1) The control test articles will be normal laminates ordered from a laminator of the performer’s choice and shall be fabricated in accordance with industry practices. A common Quality Assurance and Quality Control (QA/QC) measures used by laminators includes a process known as a pummel test. The pummel test is conducted to determine the level of adhesion a PVB has with the glass it is bonded to. For the control article, the target score is a 5 to 7 pummel rating which is consistent with architectural grade PVB and glass adhesion. Pummel test scores were chosen by the Government after consultations with specialists for PVB manufacturers Kuraray and Eastman.

Pummel tests shall be conducted in accordance with procedure similar to that described in Eastman Saflex Architectural Lamination Guide (AI-ARCH-7860). Of particular importance is the cooling sequence, the impact plan and the evaluation standards.

(2) The partially laminated test articles will be specially ordered products that will require coordination and consultation with the laminator’s engineers/specialists. For the partially laminated test samples the pummel test score shall be in the range of 2 to 4.

Tuning of PVB and TPU adhesion can be done in coordination and consultation with laminator’s and PVB/TPU manufacturers engineers/specialists.

(3) The delaminated test samples shall have no adhesion at all. Delaminated test articles will be specially ordered products that require coordination and consultation with the laminator’s engineers/specialists. The delaminated test articles required shall still be subjected to the lamination process to ensure interlayer material properties are consistent with fully laminated windows. The overarching goal is to produce samples that replicate fully laminated glazings that have de-laminated. It is critical for this effort that the delaminated samples do not have incidental adhesion after the lamination process, e.g. during shipping and test preparation.

For layups 1, 3, 4, and 5 there should be no outer ply’s with regards to PVB. For Layup 2, there will be inner and outer ply’s for the two PVB sheets. The pummel test scores requested are not exact but rather a range, e.g., 2-4, if there is more adhesion at the outer ply (4) then what is the expected adhesions at the inner ply (3 or 2)?

Quality Assurance / Quality Control (QA/QC)

The performer shall ensure the test articles received are assembled correctly and have undergone applicable QA/QC processes. Pummel test results (per interlayer manufacturer recommended method) shall be provided for both the control and partially laminated glass samples. Appendix C includes the pummel test and compressive shear procedures from PVB manufacturers Kurraray and Eastman. The vendor’s laminator will identify which procedure they follow in their QA/QC documentation. QA/QC measures shall also validate that there is no adhesion of interlayers in the delaminated samples. Options for compressive shear testing for adhesion shall be included.

Test Frames

All test articles shall be tested in frames designed and supplied by the performer. The pre-built frame design is at the discretion of the performer but shall be designed to accommodate the control, partially laminated, and delaminated test articles, and the chosen design shall be approved by PSD/RD prior to fabrication.

The pre-built frame shall be designed to be mounted in the performer’s test fixturing, ensure the samples remain in the same condition as when fabricated, and limit variables (such as clamping force) for all test articles. The pre-built frames shall provide a 1-1/2″ glass bite on all edges for every test article, in keeping with the guidance above under “Test Sample Sizes (DLO).” An example test frame shown in Figure 1.

Figure 1: Conceptual Test Frame Configuration That Allows for Flush Mounting to Test Structure

Test Setup

Prior to testing, all test articles shall be stored in conditioned space with ample time allowed to acclimate to test range environmental conditions. The test structure’s interior and exterior environmental temperature and the test articles interion and exterior surface temperature shall be recorded. The combination type of layups that will be tested together are shown in Table 1 Test Matrix. It should be noted that the delaminated and potentially the partially laminated samples may not be able to be installed into the test frame in a vertical orientation, they may need to be installed into their test frames then mounted vertically into the test structure. Since two windows will be tested side by side each other, the test structure shall be divided to prevent broken glass from one test article from impacting the witness panel behind the neighboring test article.

Instrumentation

The overarching intent is to ensure movement and response of the test fixture, reaction structure, and test specimens are gathered. Pressure transducers shall be used to record pressure time history for each test. Pressure gauges shall be mounted flush to the test structure surface, a minimum of two between the test specimens, two to the left, two to the right, one below and one above each the test articles as seen in Figure 2. Additional pressure data recorded shall be free field and the interior of the test structure. Deflection gauges shall be used to instrument the test articles, measurements shall be recorded at the centerline and quarter points of each test article (see Figure 2 below). High speed camera(s) shall be used to capture the overall response of each test article as well as capture any edge pull out that may occur during the blast event.

Figure 2: Example Instrumentation Plan

Additionally, the performer shall provide instrumentation for both the reaction structure and test fixturing to comply with Section 9.0 of “Blast Testing SOP for DS/PSD/RD” attached in Appendix B of this document. The overarching intent is to ensure movement and response of the test fixture, reaction structure, and test specimens are gathered.

Calibration Shots

Eight calibration shots shall be conducted to ensure the desired load is dialed in correctly before conducting testing on the test articles. Before proceeding with the test articles the performer shall provide test data from three of the calibration shots, all using the same charge weight and standoff to demonstrate the average is within acceptable limits per the “Blast Testing SOP for DS/PSD/RD”. Figure 3 depicts an instrumentation layout that would allow for determining if the selected charge size and standoff is providing the desired load of 42psi and 300psi-ms. The calibration shots shall be conducted against a rigid face that is nonresponsive and elastic to the load that will allow for accurate measurements of the loads.

Figure 3: Example Instrumentation Plan of Calibration Shots

Test Matrix

The combination type of layups that will be tested together are shown in Table 1 Test Matrix.

Test Description/Adhesion Category Layup Size (Actual) Load

1 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

2 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

3 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

4 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

5 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

6 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

7 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

8 Calibration Shot N/A Flush Front Test Structure 42psi - 300psi-ms

9 Control / Partially Laminated 1 48”x72” 42psi - 300psi-ms

10 Control / Delaminated 1 48”x72” 42psi - 300psi-ms

11 Partially Laminated / Delaminated 1 48”x72” 42psi - 300psi-ms

12” from edge

24” from edge

Equally spaced 24” max spacing edge

12 Control / Partially Laminated 2 48”x72” 42psi - 300psi-ms

13 Control / Delaminated 2 48”x72” 42psi - 300psi-ms

14 Partially Laminated / Delaminated 2 48”x72” 42psi - 300psi-ms

15 Control / Partially Laminated 3 48"x48" 42psi - 300psi-ms

16 Control / Delaminated 3 48"x48" 42psi - 300psi-ms

17 Partially Laminated / Delaminated 3 48"x48" 42psi - 300psi-ms

18 Control / Partially Laminated 5 48"x48" 42psi - 300psi-ms

19 Control / Delaminated 5 48"x48" 42psi - 300psi-ms

20 Partially Laminated / Delaminated 5 48"x48" 42psi - 300psi-ms

21 Control / Partially Laminated 4 48”x96” 42psi - 300psi-ms

22 Control / Delaminated 4 48”x96” 42psi - 300psi-ms

23 Partially Laminated / Delaminated 4 48”x96” 42psi - 300psi-ms

Table 1: Test Matrix

DS/RD personnel need to be present to oversee the testing in order to observe the damage of each test article and assist in post-test observations. DS/RD prefer to have the shortest turnaround time as possible in between test shots but not at the expense of properly documenting pre- and post-test article conditions and ensuring quality data is captured from all the instrumentation.

Open air testing only, no shock tube testing

Test Data Requirements

Pre-Test

• Laminate characteristics o Thickness

▪ Calculated and actual thickness (averaged over no less than 5 discrete points) o Any notable physical traits o Clearly identify and document actual materials used in test articles

▪ Component manufacturer and product specifics

▪ Provide pummel test result for glass / PVB combinations.

• Glazing surface temperature (exterior and interior surfaces) at time of testing

• High resolution still camera o Document pre-test sample appearance o Document pre-test frame appearance

• Record any other notable observations and/or conditions

• Assign each test article a unique test identifier.

o This identifier shall be present in all pictures and videos to clearly identify the test article in pre-test and post-test documentation.

o NOTE: It is suggested that each test identifier have a format that conveys what the test sample is and the testing parameters for that specimen.

• Temperature data shall be recorded in accordance with Test Setup: Temperature / Conditioning section.

Post-Test

• Physical state of the laminate characteristics o The performance hazard rating conductions of the laminate per ASTM F1642 and GSA TS01 o Observations of the state of the layups: i.e., Glass layer cracked, PET ripped, interlayer (PVB/TPU) undamaged or ripped, length of tear, etc.

• Pressure and Impulse data

• Deflection of test article data

• Physical state of the witness panel: Per ASTM F1642 and GSA TS01

• High-speed camera:

o Capture the response of the layup internally and externally o Capture the effects inside the test structure o Capture any interesting results from the test such as pull out form the glass bite.

• High resolution still camera to document all post test results

• Record any other notable observations

• Assign each test article a unique test identifier.

o This identifier shall be present in all pictures and videos to clearly identify the test article in pre-test and post-test documentation.

o NOTE: It is suggested that each test identifier have a format that conveys what the test sample is and the testing parameters for that specimen.

Deliverables

A quick look report will be provided within 14 days of test completion, with full written reports within 45 days. Reports will include test descriptions, raw gauge data, processed gauge data, high-resolution photos and videos, and documented descriptions of layup and witness panel conditions post-test. All final reports, photos, and full testing videos shall be delivered at the completion of all samples’ testing on a DVD mailed via FedEx or UPS to:

DS/PSD/RD

Attention: Alec Williamson 1400 Wilson Blvd 9th Floor Arlington, VA 22209

A monthly status update on progress, scheduling, delays and any other pertinent information shall be provided on the first of the month. Status updates shall be in the format of an email with subject “Program Title – Month”. An example monthly status update template is provided in Appendix A.

Appendix A:

Example Monthly Status Report

DS/C/PSP/PSD/RD – Project Name

Task Manager: TBD

Developer PI: (Fill in name, phone number once contract is awarded)

Contract Number: (fill in)

MONTHLY STATUS REPORT

1) TASK TITLE: ((fill in)

2) DESCRIPTION/REQUIREMENT: (fill in)

3) DEVELOPER(S): (add any significant subcontractors)

4) TECHNICAL APPROACH: (In five or six sentences, summarize the project’s technical approach.)

5) MILESTONES: (fill in relevant milestones)

Milestone Planned Rescheduled Actual

Project Plan

Kickoff Meeting

Preliminary Design Review

Operations and Maintenance Manual

Critical Design Review

Test Plan

Test Report

Etc.

6) FUNDING & COSTS:

Project Funding History

Funding Action Date Amount Comment

Contract Award 7/15/2016 $68,000.00 Contract award, funds through Nov 2016

Mod 1 10/15/2016 $58,000.00 Incremental funding, funds through Dec 2016.

Mod 2 1/15/2017 $65,000.00 Fully funds effort

Funding

Provided to Date

Expenditures

(Current Month)

Accrued

Expenditures (Cumulative)

Remaining

Obligated Funds

Funding $100,000.00 $25,000.00 $100,000.00 $0.00

Total Funding Provided $200,000.00

Contract Value $300,000.00

Insert graph showing planned expenditures, current funding level, and actual expenditures here. The graph must cover from contract start date to end date. If a revised spend plan becomes necessary, be sure to include the original plan as well. (See sample below):

7) TASK STATUS / MONTHLY ACTIVITIES:

a. Report month –

b. Upcoming Month –

8) ISSUES: (Identify any issue that affects the progress of the project, funds requirements, payment of invoices, potential schedule problems. Include requirements for resolution of the issue.)

9) PHOTOS/VIDEO: (Include at least two current digital images of 300 pixel/inch quality or better, in

“.jpg”, “.tif”, or “.bmp” format that show a conceptual application, design, physical prototype, or other meaningful representation of the project progress If applicable, provide video compatible with Windows Media Player.)