USCG_P-630-0301_retro-reflective_film_specifications.pdf

P-630-0301 Nov 2015

REVISION: D REV DATE Nov 15

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

Specification

For

High Intensity Retro-Reflective Films

For Use On

Marine Aids-to-Navigation

SPECIFICATION NUMBER

P-630-0301

(Formerly HQ Specification No. 393A)

ORIGINATED BY: ___________David W. White DATE: Nov 2015

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC)

DEPARTMENT/DIVISION: ALD/CPD/AtoN Hardware-General Stores____

INTERNAL REVIEWER: DATE: _________

SOWRB APPROVAL: DATE: __________

OCEAN ENGINEERING DIVISION

UNITED STATES COAST GUARD

WASHINGTON, D.C.

OFFICE OF CIVIL ENGINEERING

UNITED STATES COAST GUARD

WASHINGTON, D.C.

HIGH INTENSITY

RETRO-REFLECTIVE FILM

For Use On Marine-Aids-To-Navigation

MAY 1996

Formerly

SPECIFICATION G-SEC-393

1.0 SCOPE

1.1 Purpose. This specification describes the requirements for high intensity retro-reflective-elastomeric films used as sign face materials on aids to navigation in the navigable waters of the

United States.

1.2 Deliverables. Products provided under this specification shall be conformable films, with pressure-sensitive adhesive, as described in section 3, below. Items include:

a. 50-yard rolls in widths of 1, 2, 3, 4, 6, and 12 inches, and in white, yellow, orange, red, and green colors; and

b. Letters and numbers of 6, 8, 10, 12, 16, and 24 inches in height, and in white, red, and green colors.

2.0 APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are needed to meet the requirements specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, users of this specification are cautioned that they must meet all specified requirements of the documents cited in sections 3 and

4 of this specification, whether or not the documents are listed.

2.2. Government documents.

2.2.1. Specifications, standards, and handbooks. The following specification forms a part of this document to the extent specified herein.

COAST GUARD

G-ECV-450 Fabrication of Ionomer Foam Buoys.

(Copies of this specification are available from Commandant (G-432), U.S. Coast Guard, 2100

Second Street, SW, Washington, DC 20593-0001).

2.2.2 Other Government documents, drawings, and publications. The following Government document and drawing form a part of this document to the extent specified herein.

FEDERAL HIGHWAY ADMINISTRATION

Standard Alphabets for Traffic Control Devices (for Streets and Highways)

2009 Edition

(Copies of this document are available from the United States Department of Transportation -

Federal Highway Administration, FHWA Office of Safety, 1200 New Jersey Avenue, SE, Washington DC 20590)

COAST GUARD DRAWING

G-ECV-121169 1995 Type, 5CFR and 5NFR, Unlighted Foam Buoys.

(Copies of this drawing are available from Commandant (G-432), U.S. Coast Guard, 2100

Second Street, S. W. Washington, DC 20598-7901).

2.3 Non-Government Publications. The following documents form a part of this document to the extent specified herein.

APA - The ENGINEERED WOOD ASSOCIATION (APA)

L H870 Voluntary Product Standard 1-09;

(JUN 2010) Structural Plywood.

(Application for copies should be addressed to APA - The Engineered Wood Association, 7011

South 19th Street, P.O. Box 11700, Tacoma, WA 98411-0700.)

AMERICAN SOCIETY for QUALITY (ASQ)

ASQ Z1.4 Sampling Procedures and Tables for Inspection by

(JAN 2008) Attributes-T004.

(Application for copies should be addressed to the American Society for Quality, 600 North

Plankinton Avenue, Milwaukee, WI 53203

ASSOCIATION for AUTOMATIC IDENTIFICATION and MOBILITY (AIM)

AIM BC1 Uniform Symbology Specification Code 39

(JAN-1995)

AMERICAN SOCIETY FOR TESTING (ASTM)

ASTM D 4956 Rev A Retro-reflective Sheeting for Traffic Control.

(FEB 2011)

ASTM D 1248 Polyethylene Plastics Molding and Extrusion

(APR 2012) Materials for Wire and Cable.

ASTM D 3951-10 Standard Practice for Commercial Packaging

(Application for copies should be addressed to the American Society for Testing & Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.)

2.4 Order of Precedence. In the event of a conflict between the text of this specification and the references cited herein, the text of this specification takes precedence. Nothing in this specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 General. Rolls of retro-reflective films and retro-reflective characters supplied under this specification shall meet all requirements for Type III or Type V Sheeting with Class 4 adhesive and a protective liner as described in ASTM D 4956, in Supplementary Requirement S.1 of

ASTM D 4956 (Fungus Resistance), and the additional requirements listed herein. The terms

"films" and "sheeting" shall be understood to refer to both roll-type products and characters

(letters and numbers), and may be used interchangeably.

3.2 Application. Films shall be conformable, and shall be suitable for application to dented, weathered, and/or irregular surfaces that have been wiped clean. The films are intended for application to several different surfaces, including:

a. Plywood - A-C Exterior, A-B Marine, or Medium Density Overlay (single-sided)

APA E30 (APA H850);

b. Corrosion resistant aluminum sheet - such as aluminum alloy 6061-T6;

c. Cast elastomeric (vinyl) sheeting;

d. Mild steel painted with aliphatic acrylic urethane;

e. Medium density, rotationally molded polyethylene - Type II, Class A, Category 3

(ASTM D 1248); and

f. Densified-ionomer foam (G-ECV-450).

The use of a separate primer for application to ionomer foam is permitted. The primer, if required, shall be available from the manufacturer of the retro reflective film as a commercially procurable item by the individual U.S. Coast Guard units which have responsibility for ionomer foam buoys. Application to any of the other five materials listed above shall not require the aid of heat, solvent, or other preparation for adhesion to dry, clean surfaces.

3.3 Environment. The films supplied under this specification shall withstand a marine environment as defined by:

a. Temperature range of -40° to +120° F (-40° to +49° C);

b. Humidity range from 0 to 100%;

c. Winds up to 100 knots (185 km/hr);

d. Salinity extremes (salt spray);

e. Sunlight exposure up to 5000 MJ/m2 per year;

f. Guano deposits; and

g. Mold and fungus growth.

Films applied in accordance with the manufacturer's instructions to the surface materials listed in

3.2.a through 3.2.c, above (signage), shall not loosen, lift, peel, or bubble when exposed to a marine environment for five years. Films applied in accordance with the manufacturer's instructions to the surface materials listed in 3.2.d through 3.2.f, above (buoys), shall not loosen, lift, peel, or bubble when exposed to a marine environment for two years.

3.4 Physical properties.

3.4.1 Appearance. The film shall be free of ragged edges, cracks, scales, pits, blisters, and dirt.

The pattern of the retro-reflective material shall appear uniform across the film surface. The backing of the film shall be completely and evenly covered with the adhesive.

3.4.2 Characters. Letters and numbers shall meet the requirements of the Federal Highway

Administration Standard Alphabets for Highway Signs, Series C, with filleted inside corners.

Characters shall be kiss-cut, and covered with a translucent pre-spacing/pre-masking film, as diagramed in figure 1, below:

Figure 1 – Retro-reflective Film Characters

3.4.2.1 Margins. The side margins about the retro-reflective characters (from edge of character to the edge of the backing film) shall be as follows:

Character Size Margin (inches) Character Size Margin (inches)

6 1/2 12 1-1/4

8 3/4 16 1-1/2

10 1 24 1-3/4

Margins above and below the characters shall be no less than 1/2 inches.

3.4.2.1.1 Margin Width Tolerance. Margin width variance shall be within +/- 0.300 inches.

3.4.3 Dimensions.

3.4.3.1 Thickness. The film thickness, without the protective liner, shall not exceed 0.020 inches

(0.508mm).

3.4.3.2 Roll Width and length. Rolls of film shall have widths within 0.125 inches (3.2mm) of the size ordered. The roll length shall equal or exceed the length ordered.

3.4.3.2.1 Character Width. Character width variance shall be within +/- 0.300 inches.

3.5 Environmental Properties.

3.5.1 Resistance to weathering. The film shall be weather resistant. After five years exposure on a south-facing, vertical surface, in the marine environment of South Florida, the film shall retain a minimum coefficient of retro-reflection as specified in Table 11 of ASTM D 4956.

3.5.2 Colorfastness. After five years exposure on a south-facing, vertical surface, in the marine environment of South Florida, the film shall conform to the requirements of Table 10 and either

Table 2 (Type III) or Table 8 (Type V) of ASTM D 4956, with regard to color retention.

3.5.3 Resistance to heat, cold, and humidity. The film shall not crack, peel, chip or delaminate when exposed to the marine environment for five years.

3.5.4 Solvent resistance. Neither the film nor the adhesive shall dissolve, pucker or blister when exposed to turpentine, mineral spirits, or isopropyl alcohol.

3.5.5 Storage Stability. The film shall meet the requirements of this specification after being stored in a warehouse at 50° to 90° F and 30 to 50% relative humidity for twelve months.

4.0 VERIFICATION

4.1 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First article test (section 4.2).

b. Conformance inspection (section 4.3).

4.1.1 Inspection Conditions. Unless otherwise specified, all inspections shall be performed in accordance with the test conditions specified in ASTM D 4956.

4.2 First Article Test. The U. S. Coast Guard will be responsible for the performance of the first article tests. These tests will be performed on each size and color product offered in response to a contract or purchase order based on this specification. First article test requirements are listed in Table I.

Table I

First Article Tests

Inspection Requirement Test method

Coefficient of ASTM D 4956 ASTM D 4956

Retro-reflection

Daytime Color ASTM D 4956 ASTM D 4956

Weather Resistance ASTM D 4956 ASTM D 49561

Colorfastness ASTM D 4956 ASTM D 49562

Shrinkage ASTM D 4956 ASTM D 4956

Flexibility ASTM D 4956 ASTM D 4956

Liner Removal ASTM D 4956 ASTM D 4956

Adhesion ASTM D 4956 ASTM D 4956

Impact Resistance ASTM D 4956 ASTM D 4956

Specular Gloss ASTM D 4956 ASTM D 4956

Fungus Resistance ASTM D 49563 ASTM D 49563

Adhesion4 3.2 & 3.3 4.5

Appearance 3.4.1 4.4

Characters 3.4.2 4.4

Dimensions 3.4.3 4.4

Resistance to heat, 3.5.3 4.6 cold and humidity

Solvent resistance 3.5.4 4.6

Notes: 1&2Use of five-year, natural weathering, on south-facing, vertical surfaces, in the South

Florida marine environment is preferred to artificial weathering.

3 See Supplementary Requirement S.1 to ASTM D 4956.

4 Adhesion to various additional materials used as marine aids to navigation signage or for manufacture of buoys.

4.2.1 Order of Inspections and Tests. First article tests will be completed in the following order:

a. Visual inspection (see 4.4)

b. All inspections and examinations in ASTM D 4956, including Supplementary

Requirement S.1

c. Adhesion tests (see 4.5)

d. Environmental tests (see 4.6)

4.2.1.1 Acceptance/rejection Criteria. Failure of any one sample to meet the requirements of

ASTM D 4956 for daytime color and colorfastness shall constitute a failure of the first article tests for all materials of a given color. Failure of any one sample to meet all other requirements outlined in ASTM D 4956 shall constitute a failure of all materials submitted for acceptance.

The acceptance/rejection criteria for visual inspection, adhesion and environmental tests are outlined in their respective sections of this specification.

4.3 Conformance inspection. Conformance inspection shall consist of the visual inspection detailed in 4.4. Acceptance/rejection criteria shall be as specified in 4.4.1.

4.3.1 Sampling for conformance inspection. The number of units in the sample size for conformance inspection of a given lot shall be in accordance with ASQC Z1.4, Level S-3.

4.3.3.1 Lot/Unit. The term "lot" refers to all retro-reflective materials, rolls and characters, manufactured in one production run from a common source of material. The term "unit" refers refer to a single 50 yard roll, in the width ordered, or a package of characters, in the quantity specified in the contract of order for unit packages.

4.4 Visual inspection. Sample rolls and characters shall be visually inspected for compliance with the requirements outlined in 3.4 through 3.4.3.2. The entire roll of each sample shall be inspected. The thickness and width of rolls, and character dimensions shall be measured to the nearest 0.005 inch. Roll lengths shall be measured to the nearest 1 inch. Table II outlines the acceptance/rejection criteria for the visual inspection.

Table II

Visual Inspection

Acceptance/Rejection Criteria

Examine Defects

Appearance Surface pattern of film is not uniform.

Any tear, cut, hole, crack, blister, dirt, scale, crease, or pits in the film.

More than one spot, stain, or streak of any size on a single character. (See note.)

More than one spot, stain, or streak of any size per

5-yard segment of a 50 yard roll. (See note.)

Ragged or sticky edges.

Any solid lump. (See note.)

Any spot, stain or streak with a maximum dimension greater than 1 inch.

Characters Does not meet dimensional requirements of FHWA

Standard Highway Signs, Series C.

Inside corners are not filleted.

Are not kiss-cut.

Do not have translucent pre-spacing/pre-masking film.

Thickness Film thickness (without liner) exceeds 0.020 inch.

Width Measured width of a roll is not within 0.125 inch of the specified width.

Length Measured length of a roll is less than 50 yards.

Note: Clearly visible at a normal inspection distance of approximately three feet by an individual with normal or corrected 20/20 vision.

4.4.1 Acceptance/Rejection Criteria. One defect, as defined in Table II, shall constitute a failure of the entire inspection for all materials in a given lot.

4.5 Adhesion. Adhesion of retro-reflective films to various materials used as signage substrates for aids to navigation shall be tested to determine conformance to 3.2 and 3.3. Determine the adhesion properties of the films to the various materials listed in 4.5.1 by the procedures described in 4.5.2 and 4.5.3.

4.5.1 Test panels. Test panels shall include each of the materials listed in 3.2, above. Test panels shall be prepared in the following manner:

a. Dry, clean, group 3 AC-exterior-grade-plywood (APA H850). Rough edges produced by cutting may be lightly sanded or filed. Surface sanding is not permitted;

b. Aluminum sheet, prepared in accordance with 8.2 of ASTM D 4956;

c. Cast vinyl sheet, applied in accordance with the manufacturer's instructions to a plywood panel;

d. Mild steel plate painted with aliphatic acrylic urethane;

e. Medium density polyethylene panel, conforming to Type II, Class A, Category 3, in

ASTM D 1248;

f. Cylindrical section of ionomer foam, conforming to item 2 of Drawing 121169, and manufactured in accordance with G-ECV-450.

4.5.2 Standard condition peel test. Apply four each, 1 inch by 9-inch film samples to the six types of test panels (total of 24 samples). Bond 7 inches of one end of each sample to the test panels. Condition in accordance with 8.1 of ASTM D 4956 and then attach a 1-lb (0.45-kg) weight to the free end and allow it to hang free at an angle of 90° to the panel surface for 5 minutes. At the end of the 5 minute period measure the distance of peeling. If the distance of peeling is greater than 2.0 inches (51mm), the sample fails. Repeat this test with the conditioning period increased to 72 hours.

4.5.3 Low temperature peel test. Condition test panels and twenty four 1 inch by 9 inch film samples at +20° F (-7° C) for 4 hours. Apply four 1 inch by 9 inch samples each to the six types of test panels. Bond 7 inches of one end of each sample to the panels. Condition at +20 (+3°/-0)

° F (-7° (+2/-0) °C) and 50 +/- 5% relative humidity for 24 hours. While maintaining these conditions of temperature and humidity, attach a 0.5-lb (0.22-kg) weight to the free end an allow it to hang free at an angle of 90° to the panel surface for 5 minutes. At the end of the 5 minute period measure the distance of peeling. If the distance of peeling is greater than 2.0 inches (51 mm), the sample fails.

4.5.4 Acceptance/rejection criteria. Failure of any one sample to meet all the requirements for adhesion, as defined by a failure of the tests outlined in 4.5.2 and 4.5.3, shall constitute a failure of this test for all materials in a given lot.

4.6 Environmental tests. The environmental tests outlined in this section shall be used to determine the ability of films to withstand conditions encountered during service in a marine environment, as described in 3.3. Successful completion of these tests shall be considered as demonstrating conformance to 3.5.3 and 3.5.4.

4.6.1 Resistance to heat, cold, and humidity. Determine the resistance of the films to heat, cold, and humidity by the procedures described in 4.6.1.1 through 4.6.6.3. Prepare three pairs of test samples; each pair consisting one each 9 inch by 9 inch samples bonded to aluminum and plywood test panels. Prior to conducting the tests, condition the test samples in accordance with

8.1 of ASTM D 4956.

4.6.1.1 Resistance to heat. Place one pair of samples in an oven. Maintain samples at 120 +/- 5°

F (49 +/- 3°C), for 24 hours. Visually inspect the samples, after they have cooled to room temperature.

4.6.1.2 Resistance to cold. Expose one pair of samples to an air temperature of -40 +/- 5° F (-40

+/- 3° C) for 24 hours. Visually inspect the samples after they have warmed to room temperature.

4.6.1.3 Resistance to humidity. Subject one pair of samples to 100% relative humidity for 24 hours; at a temperature of 73 +/- 4° F (23 +/- 2° C). Remove the panels from the humidity chamber. Allow the panels to dry at room temperature. Visually inspect the samples after they have dried.

4.6.2 Solvent Resistance. Determine the resistance of the films to the solvents specified herein by immersing one test sample in a glass container, for each solvent separately, at room temperature. Samples, each 1 by 6 inches, shall be applied to aluminum test panels. Solvents and immersion time shall be as follows:

Solvent* Immersion time

Turpentine 10 minutes

Mineral Spirits 10 minutes

Isopropyl Alcohol 1 minute

*WARNING: These solvents are flammable and toxic. Avoid inhalation and prolonged skin contact. Do not expose to open flame or sparks.

At the end of the immersion period, remove the panels from the exposure containers and allow drying before visual inspection.

4.6.3 Acceptance/Rejection Criteria. A sample exhibiting any evidence of cracking, peeling, chipping, blistering, pitting, delamination, or dissolving of the film or adhesive at the conclusion of the environmental tests shall constitute its failing the entire testing procedure.

5.0 PACKAGING

5.1 Packaging. Each unit shall be individually packaged in a plastic bag. In addition, all packages of one stock number in an order shall be boxed separately from all items of other stock numbers being shipped in the same order. All shall be in accordance with ASTM D 3951, “Standard Practice for Commercial Packaging”. Packaging shall ensure sufficient protection of units during subsequent shipping and storage.

5.1.1 Unit of Issue. For the purposes of this specification, one unit of issue is one package (pkg).

Note: One package for 24 inch and 16 inch size letters and numbers shall contain 2 items.

One package for 12 inch, 10 inch, 8 inch and 6 inch size letters and numbers shall contain

10 items.

5.2 Marking. Unless otherwise specified in the contract or order, marking shall be in accordance with MIL-STD-129. Each unit package label shall show the number of items in it using the following format: “Pkg of 2” or “Pkg of 10” accordingly. In addition, each unit shall be individually marked with the following statement; “Store in cool dry environment; below 85°

F at below 60% humidity”

5.3 Bar Coding. Each unit package shall be bar coded with the item National Stock Number; all in accordance with AIM BC1.

6.0 REMARKS

6.1 Coast Guard verification. The U. S. Coast Guard reserves the right to perform any and all inspections and tests described in this specification, including both first article tests and conformance inspections. In particular, the U. S. Coast Guard reserves the right to test film which has been stored in a warehouse at 50 to 84° F and 30 to 59% relative humidity for twelve months. The U. S. Coast Guard may also evaluate the weather resistance and colorfastness of films which have been exposed to natural weathering either as part of a test or under actual service conditions. Failure of film to meet the requirements of this specification, as outlined in the applicable acceptance/rejection criteria for the first article tests, shall be grounds for termination of a contract or purchase order.

SPECIFICATION FOR

HIGH-INTENSITY RETROREFLECTIVE FILM

FOR USE ON

MARINE AIDS TO NAVIGATION

SPECIFICATION NO. G-SEC-393

MAY 1996

Prepared by: Reviewed by:

Carl K. ANDERSEN Harley R. CLEVELAND

Signal and Power Team

Approved by:

________________________ Date:___________________

L. E. JAEGER, CDR, USCG

Chief, Ocean Engineering Division