Specification_for_Fabrication.pdf

UNITED STATES COAST GUARD

SHORE INFRASTRUCTURE LOGISTICS CENTER

WATERWAYS OPERATIONS PRODUCT LINE

FEBRUARY 2018

SPECIFICATION FOR FABRICATION OF AIDS TO NAVIGATION

PLASTIC BATTERY BOXES

SPECIFICATION NO. 199

REVISION K

6160-01-029-6715, Battery Box Assembly Large (Top and Bottom half)

6160-01-041-5030, Battery Box Top Large

6160-01-LG1-3227, Battery Box Bottom Large

6160-01-194-5777, Battery Box Assembly Small (Top and Bottom Half)

6160-01-194-5781, Battery Box Top Small

6160-01-LG1-3228, Battery Box Bottom Small

Fabrication of Aids to Navigation Plastic Battery Boxes

1. SCOPE

1.1 Intent. This specification covers the requirements for the fabrication of complete large or small plastic battery boxes and large or small battery box tops used to house and protect batteries on lighted aids to navigation structures. It establishes uniform standards and procedures to be used in the manufacture process, for example, receipt, evaluation and necessary repair of molds, selection and use of material for manufacture, testing, packaging and marking for shipment.

1.2 Government-Furnished Property. The Government will provide aluminum mold sets for the large battery box bottom half, large battery box top half, small battery box bottom half, and small battery box top half (one male mold and one draw-down heater box each). The Government will provide the mold sets to the Contractor as government furnished property (GFP). For information purposes, the applicable Accounting Control Number (ACN) for each mold set is listed below.

ITEM DESCRIPTION ACN

P/N

QTY

(EA.)

ESTIMATED

COST

($/UNIT)

Mold Battery Box Top Large

ACN: 6140-00-G00-3749

PN: 121065 MOLD BATTERY BOX TOP

LARGE

1 $5,355.80

Mold Battery Box Bottom Large ACN: 6160-01-F05-0422

PN: 121065 MOLD BATTERY BOX

BOTTOM LARGE

1 $5,355.37

Mold Battery Box Top Small

ACN: 6140-01-GG0-1032

PN: 121055 MOLD BATTERY BOX TOP

SMALL

1 $4,358.00

Mold Battery Box Bottom

Small

NN: 6160-01-F05-0424

PN: 121055 MOLD BATTERY BOX

BOTTOM SMALL

1 $2,600.00

1.2.1 Maintenance of Molds. The Government will ship GFE molds to the Contractor's facility after award of contract for manufacture of ordered Battery Box assemblies and tops. The Contractor shall be responsible for any necessary maintenance/reconditioning of the GFE molds for the duration of the contract. The Contractor shall make the molds available for inspection by Government personnel for the duration of the contract. Upon completion of the contract, the Contractor shall return the GFE molds in usable condition. The Contractor shall properly package and label the molds for return shipment per the applicable specifications listed within this document. The Contractor will ship the molds from the Contractor's facility back to the Government to: UNITED STATES COAST GUARD (SFLC), 2401

HAWKINS POINT ROAD, RECEIVING ROOM - BLDG. 88, BALTIMORE, MD 21226.

2. REFERENCES

2.1 General. The documents listed in this section are referenced in sections 3, 4, and 5 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 completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3, 4, and 5 of this specification, whether or not they are listed here.

UNITED STATES COAST GUARD DRAWINGS

• 121065 B Large Battery Box

• 121055 D Small Battery Box

MILITARY SPECIFICATIONS AND STANDARDS

2.2 Specifications and standards. The following specifications and standards form a part of this document to the extent specified herein. Suffixes denoting the specific issue of each document are omitted from future references to the documents in this specification. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) cited in the solicitation.

MIL-STD-2073-1E Change 1, 7 Jan 2011, Standard Practice for Military Packaging MIL-STD-129R 18 Feb 2014, Military Marking for Shipment and Storage

INDUSTRY PUBLICATIONS

SAE-AMS-STD-595 14 Feb 2017, Colors Used in Government Procurement ASTM D256A 01 Dec 2006, Standard Test Methods for Determining the Izod Pendulum Impact

Resistance of Plastics ASTM D638 15 May 2010, Standard Test Method for Tensile Properties of Plastics

ASTM D785 08 2015, Standard Test Method for Rockwell Hardness of Plastics and Electrical

Insulating Materials ASTM D790 17 Apr 2010, Standard Test Methods for Flexural Properties of Un-reinforced and

Reinforced Plastics and Electrical Insulating Materials ASTM F1836M 1 Dec 2015, Standard Specification for Stuffing Tubes, Nylon, and Packing

Assemblies (Metric)1 ASQ-Q9001, 1 Oct 2015, Quality Management Systems - Requirements - T860E ANSI/ASQC-C1-1996 Specification of General Requirements For a Quality Program ANSI/ASQ Z1.4-2008 Sampling Procedures and Table for Inspection by Attributes (Table IIA, based on General Inspection Level II from Table I) ANSI/NCSL Z540-3.2006 Requirements for the Calibration of Measuring and Test Equipment

2.1 Precedence. In the event of a 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 has been obtained.

3. REQUIREMENTS

3.1 Material. The boxes shall be molded from a plastic composite consisting of an Acrylonitrile- Butadiene-Styrene (ABS) substrate with a cap layer of Acrylonitrile-Styrene-Acrylate (ASA). The ASA plastic shall make up the external portion of the box. The ABS and ASA plastics shall meet the minimum requirements listed below.

3.1.1 ABS Plastic. The ABS plastic shall have the following minimum property requirements in accordance with the specified ASTM specification:

PROPERTY REQUIREMENT ASTM SPECIFICATION

Tensile Strength, Yield Type I, .125” 5,400 psi D-638

Tensile Modulus, Type I, .125” 310,000 psi D-638

Flexural Strength, yield, .125” 9,600 psi D-790

Flexural Modulus, .125” 300,000 psi D-790

Hardness, Rockwell 99 psi D-785

Izod Impact, Notched, 73°F 8.4 ft-lb/in D-256

Izod Impact, Notched, -40°F 4.5 ft-lb/in D-256

3.1.2 ASA Plastic. Coextruded onto the ABS substrate shall be ASA plastic. The ASA plastic shall be at least 0.010 inches thick measured prior to forming. The ASA plastic shall have the following minimum property requirements in accordance with the specified ASTM specification:

PROPERTY REQUIREMENT ASTM SPECIFICATION

Tensile Strength, yield Type I, .125” 4,600 psi D-638

Tensile Modulus, Type I, .125” 230,000 psi D-638

Flexural Strength, yield, .125” 7,500 psi D-790

Flexural Modulus, .125” 240,000 psi D-790

Hardness, Rockwell 89 psi D-785

Izod Impact, Notched, 73°F 6.5 ft-lb/in D-256

Izod Impact, Notched, -40°F 1.7 ft-lb/in D-256

3.2 Design and Construction.

3.2.1 Design, Dimensions, and Dimensional Tolerances. All items shall conform to the design, dimensions, and tolerances shown in the drawings.

3.2.2 Color. The ASA portion of the box shall be white (Federal Color Number 17875) in accordance with SAE-AMS-STD-595. This white color shall be homogeneous throughout the thickness of the ASA plastic. The ABS substrate shall be either gray or black. The gray or black colors shall be homogeneous throughout the thickness of the ABS plastic substrate.

3.2.3 Finish. The exterior surface of the box shall be smooth and have a gloss luster finish. The finish shall be uniform and shall not exhibit streaks or discoloration from the substrate.

3.2.4 Workmanship. The finished box shall be uniform in color and shall be free from defects such as cracks, wrinkles, ripples, creases, pits, bubbles, sharp edges, and all other imperfections that would adversely affect appearance or serviceability.

3.2.5 Stuffing Tube and Packing Gland. Each battery box bottom section shall have a nylon stuffing tube (Stuffing Tube size 4T, Military Part No. M19622/1-005, NSN: 5975-00-296-5046) and rubber packing gland (Packing Assemblies size 4D, Military Part No. M19622/19-0004, NSN: 5330-00-202-2594). The stuffing tube shall meet the requirements of ASTM F1836M. The stuffing tube and packing gland shall be placed in a small bag and securely taped inside the bottom section to prevent loss during shipment.

3.2.6 Locking Device. Snap action locking bosses shall be located on the battery box top flange as shown on the drawings. These shall snap firmly under the bottom flange.

3.2.7 Ventilation and Drainage. As shown in the drawings, a slot shall be located on each side of the bottom flange to provide for ventilation. Two half-inch diameter drain holes shall be located in the box bottom as shown in the drawings. A plastic coated, fibrous glass insect screen shall cover the ventilation slots and drainage holes. The mesh size and nominal filament diameter size of the screening used shall be one of the sizes listed below. All filament sizes listed below shall have a permissible variation in the average diameter of the filament of ±25%. The screen selected shall be attached to the battery box by a permanent adhesive suitable for use in a marine environment that cures at room temperature. This adhesive shall not contain any solvents which might craze the ABS or ASA plastic.

MESH SIZE

OF SCREENING*

NOMINAL FILAMENT

DIAMETER (inch) 16x16 0.0130 18x16 0.0150 18x18 0.0150 20x20 0.0150

* Openings per linear inch

3.2.8 Assembly. The gap between the inside of the top flange and the outside of the bottom flange of the assembled box shall not be greater than 0.125 (1/8th) inch at any point on the circumference of the box.

Metal flanges, clamps, or other appurtenances shall not be used.

3.2.9 Nesting. The finished box components of each size shall nest together without sticking, wedging, splitting, or cracking.

3.3 Marking.

3.3.1 Identification Marking. For tracking purposes, each item shall be identified by an identification marking. The marking shall be stamped, engraved, or otherwise permanently affixed to each item. The marking shall consist of ½ inch tall block alphanumeric characters and shall be clearly visible. The marking shall be of the form "18-XX." The first two digits shall be the last two digits of the calendar year built and the last two letters shall be the Contractor’s designation, which will be furnished by the Contracting Officer after contract award.

3.3.2 Serial Number. For inspection purposes, the Contractor shall assign each item a unique serial number. The serial number shall be stamped, engraved, or otherwise permanently affixed to each item.

The serial number shall consist of ½ inch tall block alphanumeric characters and shall be clearly visible.

3.4 Documentation.

3.4.1 Quality Assurance Inspection Form. The Contractor shall develop and provide a Quality Assurance Inspection Form (QAIF). The QAIF shall be used to document the inspections and tests performed during the fabrication process. The form shall be printed on standard (i.e., 8½ x 11 inch) white paper. Inspection results may be handwritten on the form. The form shall be prepared in the Contractor's format and shall be legible, in English, and suitable for reproduction. The Contractor shall maintain the QAIF's on file and make them available for review by the Contracting Officer's Representative (COR).

3.4.1.1 QAIF Content. At a minimum the QAIF shall include:

a) Item serial number.

b) Date of test or inspection.

c) Test or inspection to be performed (list every test and inspection required by paragraph 4.6).

d) Result of test or inspection.

e) Accept/Reject criteria for each test or inspection.

f) Corrective action taken (if any).

g) Notes.

h) Initials or signatures of Contractor’s test personnel.

3.4.2 Material Certifications. The Contractor shall furnish material certifications, either from the material manufacturers or an independent testing laboratory, to the effect that all of the material described in paragraphs 3.1.1 and 3.1.2 have been tested and found to meet the requirements of the applicable sections of this specification. The Contractor shall maintain the material certifications on file and make them available for review by the COR.

3.4.3 Material Inspection and Receiving Report (DHS Form 700-21). A form DHS-700-21 shall be used as a certification of product quality assurance, as a packing list, and as a certification of acceptance. The Contractor shall prepare a separate DHS-700-21 for each shipping lot. Prior to shipment, the DHS-700- 21 form must be signed by the COR.

4. QUALITY ASSURANCE

4.1 General. The Contractor's quality assurance program shall meet the requirements of ASQ-Q9001.

However, the Contractor does not have to be Q9001 certified.

4.1.1 Quality Assurance and Control Plan. A quality assurance and control plan shall be provided to the Contracting Officer prior to commencing production of the first articles.

4.1.2 Test Plan and Procedures. The Contractor shall develop and provide a test plan to the Contracting Officer for first article and production items. The plan shall describe how the tests and inspections in paragraph 4.6 shall be performed and documented on the QAIF described in paragraph 3.4.1.

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

a. First article inspection (paragraph 4.3)

b. Contractor production inspection (paragraph 4.4)

c. Coast Guard production inspection (paragraph 4.5)

4.3. First Article Inspection. When first article testing is required, the Contractor shall produce a lot of four items of each deliverable item or assembly for this purpose. First article tests and inspections listed in paragraph 4.6 shall be performed on the entire lot provided. First article inspection shall be performed by the Contractor and at the Contractor’s facility. The first article lot shall meet the requirements of this specification and shall pass all the tests and inspections listed in this section.

4.3.1 First Article Tests and Inspections Notification. The Contractor shall notify the Contracting Officer in writing at least 10 calendar days prior to the scheduled commencement of any first article inspections and tests required by this specification.

4.3.2 Waiver of First Article Requirements. The Contracting Officer reserves the right to waive all or part of the first article requirements specified herein.

4.3.3 Rejection Criteria. The results of the first article inspection will be reviewed by the Contracting Officer to determine compliance with the requirements of this specification. Failure of any of the tests or inspections described herein will be cause for rejection of that specific first article lot. Similar piece parts manufactured during the same production run used in another first article lot of assemblies shall also be rejected. If the first article lot is rejected, the Contractor will be notified in writing by the Contracting Officer and allowed 14 calendar days to fix the defects or resubmit a new first article. Repair or replacement of failed first articles shall be by the Contractor at the Contractor's expense.

4.3.4 Authorization to Proceed. Upon successful completion of the first article inspection, the Contracting Officer will provide the Contractor with written authorization to begin fabricating production quantities.

4.3.5 Standardization. Materials, parts, design, and fabrication methods used in the production quantities shall be identical to those used in the first articles, unless otherwise authorized in writing by the Contracting Officer.

4.4 Contractor Production Inspection. The tests and inspections required by this specification are not intended to supplant any controls, examinations, inspections, or tests normally employed by the Contractor to assure product quality. The Contractor shall perform the tests and inspections specified in paragraph 4.6 to ensure conformance to this specification. The Contractor shall provide space, personnel, and test equipment to conduct all inspection and test requirements.

4.5 Coast Guard Production Inspection. The Coast Guard reserves the right to observe, verify, or perform the tests and inspections outlined in paragraph 4.6.

4.6 Tests and Inspections. The following tests and inspections shall be conducted for each first article unit and subsequent production units.

a. Visual Inspection (paragraph 4.6.1)

b. Nesting Test (paragraph 4.6.2)

c. Material Thickness Inspection (paragraph 4.6.3)

d. Material Composition Inspection (paragraph 4.6.4)

e. Documentation Review (paragraph 4.6.5)

4.6.1 Visual Inspection. Each item shall be visually inspected to verify compliance with paragraphs 3.2.1 through 3.2.8, 3.3.1, and 3.3.2. Items failing this visual inspection shall be rejected.

4.6.2 Nesting. Four each battery box tops and four each battery box bottoms of the same size shall be nested together. When battery box tops only are produced, four tops shall be nested together. Each nested stack shall be turned with the flanges facing up. In this orientation, they shall be lifted at least 5 feet from the floor and dropped. This operation shall be repeated five times. Following the drop, the box halves shall be undamaged and shall un-nest without the use of a prying tool and without sticking to the extent that any item is damaged while un-nesting. At a minimum, this test shall be performed on items pulled at the beginning, middle, and end of production for each delivery order. If any item fails this test, the item shall be rejected. The test shall then be carried out on all items manufactured since the date of the last successful test for the delivery order. All items failing this test shall be rejected.

4.6.3 Material Thickness Inspection. Verification of material thickness shall be by one of two methods:

4.6.3.1 Method 1 (Preferred). The Contractor shall provide a calibrated device capable of measuring the thickness to the tolerances specified without cutting the battery boxes.

4.6.3.2 Method 2. The bottoms and tops shall be cut from side to side or corner to corner at the COR's discretion. Using a micrometer, the thickness of the battery box shall be measured at selected points along the cutting lines. Any battery box(es) destroyed as a result of the testing or inspection procedures shall not be included as deliverables under the contract.

At a minimum, this test shall be performed at the beginning, middle, and end of production for each delivery order. If any item fails this test, the item shall be rejected. The test shall then be carried out on all items manufactured since the date of the last successful test for the delivery order. All items failing this test shall be rejected.

4.6.4 Material Composition Inspection. The material certifications required by paragraph 3.5.2 shall be reviewed for compliance with this specification. All items manufactured with material that fails to comply with the requirements of paragraphs 3.1.1 and 3.1.2 shall be rejected. Rejected items shall not be resubmitted for testing.

4.6.5 Documentation Review. The documentation required by paragraphs 3.4.1, 3.4.2 and 3.4.3 shall be reviewed for conformance with this specification.

4.7 Rejection for Defects. The Coast Guard will reject all items which do not conform to the requirements of this specification. Repair or replacement of the rejected items shall be by the Contractor at the Contractor's expense. All rejected items shall be resubmitted for inspection only when they conform to the requirements of this specification. Resubmitted items shall be identified as such, and shall be kept separate from new items. If defective items are found, no further items will be accepted by the Coast Guard until the Contractor has demonstrated that the defects have been corrected and that the cause of the defects has been eliminated from the production process.

5. PACKING, MARKING, AND SHIPPING

5.1 Military Packing, Marking and Bar Coding. Each unit is to be packaged in accordance with MIL- STD-2073-1E Military Marking for Shipment and Storage to provide the military packaging that a given item requires to ensure that it is not degraded during shipment, handling, indeterminate storage and distribution to consignees worldwide. See 6.2 for label placement and 6.3 Bar Code examples.

5.1.1 Detailed Military Packing. Marking and Bar Coding. All items (that make up one assembly) or piece parts to be packaged in accordance with MIL-STD-2073-1E Method 10. Each item shall be packaged in a fiberboard box conforming to and packed in an appropriately sized ASTM-D5118 Double-wall Fiberboard Box per 5.2.

5.1.2 Marking and Bar Coding. Marking per MIL-STD-129R MILITARY MARKING FOR SHIPMENT AND STORAGE and Bar Coding is required [ISO/IEC 16388:2007, Code 39 Symbology.]

5.2 Unit Packaging. A unit of issue for a complete battery box shall be one box bottom and one box top nested in one fiberboard box with the required stuffing tube and packing gland placed in a small bag and securely taped inside each bottom section to prevent loss during shipment under the following stock numbers: large; NSN: 6160-01-029-6715, small; NSN: 6160-01-194-5777.

5.2.1 Packaging for Piece Parts.

5.2.1.1 Unit of issue for the large box top, NSN: 6160-01-041-5030 and small box top, NSN: 6160-01- 194-5781 shall be six tops nested in one carton.

5.2.1.2 Unit of issue for the large box bottom, NSN: 6160-01-LG1-3227 and small box bottom, NSN:

6160-01-LG1-3228 shall be four bottoms nested in one fiberboard box with the required stuffing tube and packing gland placed in a small bag and securely taped inside each bottom section to prevent loss during shipment.

6. NOTES

6.1 Document Sources.

6.1.1 Coast Guard documents.

United States Coast Guard Shore Infrastructure Logistics CenterWaterways Operations Product Line, 300 East Main Street, Norfolk, VA 23510-9104 http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4- /Logistic-Centers/Waterways-Operation-Product-Line/

6.1.2 Military Standards and Specifications Sources.

Defense Printing Service Detachment Office, Bldg. 4D (NPM-DODSSP), 700 Robbins Avenue, Philadelphia, PA 19111-5094 215-697-2667/2179 Fax 215-697-1462

6.1.3 Industry Publications.

(SAE-AMS) SAE North America Warrendale, PA, USA - Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096 http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/ http://www.dcms.uscg.mil/Our-Organization/Assistant-Commandant-to-Engineering-Logistics-CG-4-/Logistic-Centers/Waterways-Operation-Product-Line/

724-776-4841 Fax 724-776-0790 www.sae.org

(ANSI/AIM) American National Standards Institute USA, 634 Alpha Drive, Pittsburgh, PA 15238-2802

(ASTM) American Society for Testing & Materials, 1916 Race Street, Philadelphia, PA 19103-1187 610-832-9500 Fax 610-832-9555

(ASQC) American Society for Quality Control, 611 East Wisconsin Avenue, Milwaukee, WI 53202 414-272-8575 Fax 414-272-1734

6.2 Military marking example.

Example of unit pack, intermediate and exterior container identification markings (including an example of bar code markings).

6.3 Bar coding example.

FIGURE 1. TYPICAL LINEAR (CODE 39) BAR CODE FIELD EXAMPLE

SPECIFICATION FOR PLASTIC BATTERY BOXES

SPECIFICATION 199 REV K

Prepared by: Reviewed by:

Mr. M. J. Beimel Mr. Sean McEvoy

WOPL-MSAL Equipment Specialist WOPL-Asset Line Engineer

Approved by: Date:

Mr. Wayne Danzik

Deputy Manager, Waterways Operations Product Line