(03)_461_I_Aluminum_Solar_Panel_Frames.pdf

UNITED STATES COAST GUARD

SHORE INFRASTRUCTURE LOGISITICS CENTER

WATERWAYS OPERATIONS PRODUCT LINE

MAY 2018

SPECIFICATION FOR FABRICATION

OF

ALUMINUM SOLAR PANEL FRAMES

SPECIFICATION NO. 461

REVISION I

MJB_05/18

WORK ITEM 1: 6117-01-336-9133, 121103 Frame Solar Panel 1x10 Watt, Purchase

WORK ITEM 2: 6117-01-336-9132, 121103 Frame Solar Panel 1x20 Watt, Purchase

WORK ITEM 3: 6117-01-336-9131, 121103 Frame Solar Panel 1x35 Watt, Purchase

WORK ITEM 4: 6117-01-334-9292, 121133 Frame Solar Panel 3x10 Watt, Purchase

WORK ITEM 5: 6117-01-335-7377, 121134 Frame Solar Panel 3x20 Watt, Purchase

WORK ITEM 6: 6117-01-334-9295, 121135 Frame Solar Panel 3x35 Watt, Purchase

1. SCOPE

1.1 Intent. This specification defines the requirements for the fabrication of aluminum solar panel frames for use on aids to navigation buoys. The items covered by this specification are as follows:

• NSN: 6117-01-336-9133, P/N: 121103 Frame Solar Panel 1x10 Watt

• NSN: 6117-01-336-9132, P/N: 121103 Frame Solar Panel 1x20 Watt

• NSN: 6117-01-336-9131, P/N: 121103 Frame Solar Panel 1x35 Watt

• NSN: 6117-01-334-9292, P/N: 121133 Frame Solar Panel 3x10 Watt

• NSN: 6117-01-335-7377, P/N: 121134 Frame Solar Panel 3x20 Watt

• NSN: 6117-01-334-9295, P/N: 121135 Frame Solar Panel 3x35 Watt

1.2 Government-Furnished Property.

None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 121103 Rev G, Universal Solar Panel Frame Coast Guard Drawing 121133 Rev D, 3x10 Watt Solar Panel Frame Coast Guard Drawing 121134 Rev D, 3x20 Watt Solar Panel Frame Coast Guard Drawing 121135 Rev D, 3x35 Watt Solar Panel Frame

COAST GUARD PUBLICATIONS

None

OTHER REFERENCES

ANSI/ASQ Q9001, 1 Oct 2015 Quality Management Systems – Requirements – T860E ANSI/ASQ Z1.4-2008, R2013 Sampling Procedures and Table for Inspection by Attributes

(Table IIA, based on General Inspection Level II from Table I) ANSI/NCSL Z540-3.2006, 1 Mar 2006 Requirements for the Calibration of Measuring and Test

Equipment ASTM B209-14, 1 Nov 2014 Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate ASTM B221-14, 1 Oct 2014 Standard Specification for Aluminum and Aluminum-Alloy

Extruded Bars, Rods, Wire, Shapes and Tubes AWS D1.2/D1.2M:2014 Structural Welding Code – Aluminum ASTM F1836M 1 Dec 2015, Standard Specification for Stuffing Tubes, Nylon, and Packing

Assemblies (Metric)1 ASTM D5118/D5118M-15, 1 Oct 2015 Standard Practice for Fabrication of Fiberboard Shipping

Boxes1 ASTM D1974/D1974M-16, 22 Dec 2010 Standard Practice for Methods of Closing, Sealing, and

Reinforcing Fiberboard Boxes1 ASTM D5749-17, 1 Apr 2017 Standard Specification for Reinforced and Plain Gummed Tape for

Sealing and Securing1 ASTM D5168-12, 1 May 2012, Standard Practice for Fabrication and Closure of Triple-Wall

Corrugated Fiberboard Containers1 MIL-STD-2073-1E w/Change 1, 7 Jan 2011 Department of Defense Standard Practice for

Military Packaging MIL-STD-129R, 18 Feb 2014 Department of Defense Standard Practice Military Marking for

Shipment and Storage ISO/IEC 16388:2007, 15 May 2007 Information Technology - Automatic identification and data capture techniques - Code 39 bar code symbology specification

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, which are recommended for additional information or used as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements cited in sections 3, 4, and 5 of this specification, whether the referenced documents are listed here. Suffixes denoting the specific issue of each document are omitted from future references to the documents in this specification.

2.2 Specification order of precedence. In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Materials.

3.1.1 Aluminum Sheet and Plate. Aluminum sheet and plate shall meet the requirements of ASTM B209, Alloy 6061 T6.

3.1.2 Aluminum Bar, Rod, Shapes and Tubes. Aluminum bar, rod, shapes and tubes shall meet the requirements of ASTM B221, Alloy 6061 T6.

3.1.3 Nylon Stuffing Tube and Packing Assembly. The nylon stuffing tube (required on the triple mount frames only) shall be in accordance with the requirements of ASTM F1836M. The 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 and rubber packing gland shall be placed in a transparent plastic bag and secured to the mounting plate of the individual triple mount frame via tie wrap to prevent loss during shipment.

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.

3.3 Welding. The plates, bars, rods and other shapes forming the various components of the items shall be fitted and faired prior to being welded in place. All welds shall be performed as indicated on the drawings. Gas Metal Arc Welding (GMAW) or Gas Tungsten Arc Welding (GTAW) shall be used to weld all aluminum parts. All welding procedures and weld quality shall meet the requirements of AWS D1.2/D1.2M. All welders employed for welding under this specification shall be qualified by the Contractor using procedures which meet the requirements of AWS D1.2/D1.1M.

3.4 Marking.

3.4.1 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 be clearly visible. The marking shall be of the form 18-XX. The first two digits are the last two digits of the calendar year built and the last two letters are the Contractor’s designation, which will be furnished by the Contracting Officer (KO) after contract award.

3.4.2 Serial Number. For inspection purposes, the Contractor shall assign each item a unique serial number of two (2), three (3) or four (4) digits depending on the quantities of the production run. 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 be clearly visible.

3.5 Documentation.

3.5.1 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 on every item throughout its fabrication process. The form shall be printed on standard (i.e., 8½x11 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 form shall be made available to the Contracting Officer’s Representative (COR) for review.

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

• Item serial number

• Date of test or inspection

• Test or inspection to be performed (list every test and inspection required by paragraph 4.0)

• Result of test or inspection

• Accept/Reject criteria for each test or inspection

• Corrective action taken (if any)

• Notes

• Initials or signatures of Contractor’s test personnel

3.5.2 Material Certifications. The Contractor shall furnish material certifications to the COR, either from the material manufacturers or an independent testing laboratory, to the effect that all the material described in paragraphs 3.1.1, 3.1.2 and 3.1.3 have been tested and found to meet the requirements of the applicable sections of this specification. The material certifications shall be stored by the Contractor for the life of the contract.

3.5.3 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 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 Contractor’s calibration system. The contractor shall maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this specification.

The system shall include, as a minimum, prescribed calibration intervals and the source of calibration. A monitoring system to this requirement shall be readily available to the Coast Guard Inspector. Calibration shall be traceable to the National Institute of Standards and Technology in accordance with ANSI/NCSL Z540-3.2006. At the time of CG inspection, documentation in support of this requirement shall be made available to the COR.

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

• First article inspection (paragraph 4.3)

• Contractor production inspection (paragraph 4.4)

• Coast Guard production inspection (paragraph 4.5)

4.3 First Article Inspection. When first article samples are required, the Contractor shall perform a first article inspection in accordance with paragraph 4.6. A first article inspection shall be performed by the Contractor and at the Contractor’s facility. The first articles 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 seven (7) business days prior to the scheduled commencement of any 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 the first article. If the first article is rejected, the Contractor will be notified in writing by the Contracting Officer and allowed fourteen (14) calendar days to fix or resubmit a new first article. Repair or replacement of the first article 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.

4.3.6 Production Lot Sampling. A random sample of items shall be selected from each production lot. The minimum sample size shall be specified by ASQ Z1.4-2008, R2013 Table IIA, based on General Inspection Level II from Table I, Normal, Acceptance Quality Limit (AQL) = 0.65. A production lot shall be all the items from an identifiable production period from one manufacturer and one plant and submitted for acceptance at one time. Each lot sample shall be examined to verify conformance to requirements stated in applicable specifications and drawings. Samples that fail to comply with any production test requirements of this specification, have any defects that will interfere with a sample item’s use, or will decrease its reliability shall be rejected. Entire lots shall be rejected when the percent of nonconformance exceeds ASQ Z1.4-2008, R2013, Level II, Normal, AQL = 0.65.

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:

• Visual inspection

• Weld inspection

• Documentation review

4.6.1 Visual Inspection. Each item shall be visually inspected for quality of workmanship and conformance to this specification and the drawings. The inspection shall include checks of dimensional conformance, mechanical fit, alignment of parts, and marking.

4.6.2 Weld Inspection. All welds shall be visually inspected for quality in accordance with section 5 of

AWS D1.2/D1.2M.

4.6.3 Documentation Review. The documentation required by paragraph 3.5 shall be reviewed for conformance with this specification and provided to the COR upon request.

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. PRESERVATION, PACKING, MARKING, AND SHIPPING

5.1 Preservation. Per MIL-SPEC-2073-1E, Method 10.

5.2 Packing. Shall be in accordance with MIL-SPEC-2073-1E Level B, to protect these assemblies and items during moderate worldwide shipment, handling, and storage conditions.

5.2.1 Frame, Solar Panel (1x10 and 1x35 Watt). Shall be individually packaged in a double-walled (DW) corrugated fiberboard (CF) Regular Slotted box (0201), Class Weather Resistant (WR) in accordance with

ASTM D5118/D5118M-15.

5.2.1.1 Closure of regular slotted boxes shall be in accordance with ASTM D1974/D1974M, Closure Method 2C5. The tape shall comply with Specification D5749, Type II, Grade B.

5.2.2 Frame, Solar Panel (3x10, 3x20, and 3x35 Watt). Shall be individually packaged in a triple-wall (TW) corrugated fiberboard weather resistant (CFWR) Style C box in accordance with ASTM D5168-12.

5.2.2.1 Closure shall be with metal staples due to long term storage and reinforced with strapping in accordance with ASTM D5168-12 (paragraph X1.3.7.1 and X1.3.7.2).

5.3 Marking. Each package is to be individually marked in accordance with MIL-STD-129R.

5.3.1 Marking Layout. The following information shall be on the identification label attached to each box.

See 6.2 for label example and placement.

NATIONAL STOCK NUMBER (Of the item)

CAGE CODE (Contractor’s)

PART NUMBER (Of the item)

QUANTITY & UNIT OF ISSUE 1 EA

CONTRACT NUMBER (See Contract Page 1)

DELIVERY ORDER NUMBER (See Contract Page 1)

MANUFACTURED DATE MFD 05/18

SHIPPING WEIGHT (LBS) WT (As Determined by Contractor)

SERIAL NUMBER SER NO (Of item within)

CONDITION CODE CONDITION A

OTHER DATA AS DIRECTED USCG SILC-WOPL MATERIAL

5.4 Bar coding. U.S. Coast Guard requires bar coding of the NSN, IAW ISO/IEC 16388-2007 Code 39 Symbology. See 6.2 for label example and 6.3 for Bar Code examples.

5.4.1 Bar code label. Can be applied separately or as part of the marking required in 5.3.

5.5 Shipping. The Contractor shall deliver the contracted items/delivery order to the Coast Guard address specified in paragraph 5.5.3, unless directed otherwise per the contract.

5.5.1 Shipment Details. The Contractor shall notify the COR and Contracting Officer within three (3) business days of:

• date of shipment the contracted items/delivery order leaves the Contractor's facility

• name of the shipping company

• tracking number(s) of shipment

• expected arrival date and time at the Coast Guard facility

5.5.1.1 Normal delivery hours at the warehouse (Curtis Bay, MD) are Monday through Friday 0730-1300 (excluding Federal Holidays). Deliveries outside this window shall require prior written approval by the Contracting Officer.

5.5.2 All items shall be shipped FOB Destination.

5.5.3 Address. Unless otherwise specified, the Contractor shall ship, and deliver all parts to the following Coast Guard address:

US Coast Guard

Surface Forces Logistics Center

2401 Hawkins Point Road

Receiving Room - Building 88

Curtis Bay, MD 21226

6. NOTES

6.1 Document sources.

6.1.1 Coast Guard documents.

United States Coast Guard Shore Infrastructure Logistics Center

Waterways 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 Industry Publications.

(ANSI/AIM) American National Standards Institute USA

25 West 43rd Street, 4th floor

New York, NY 10036

Office 212-642-4900 Fax 212-398-0023

Customer Service or Document Sales 212-642-4980 0830-1800

(ANSI/ASQ) American Society for Quality Control

310 West Wisconsin Avenue

Milwaukee, Wisconsin 53203 http://asq.org/index.aspx

(ASTM) American Society for Testing & Materials

100 Barr Harbor Drive

P.O. Box C700

West Conshohocken, PA 19428-2959

Office 610-832-9500 Fax 610-832-9555

(AWS) American Welding Society

8669 NW 36 Street, # 130

Miami, Florida 33166-6672

Office 305-443-9353

(ISO) International Organization for Standardization BIBC II

Chemin de Blandonnet 8, CP 401 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/

1214 Vernier, Geneva, Switzerland

Phone +41 22 749 01 11 Fax: +41 22 733 34 30

Email: central@iso.org

6.1.3 Military Standards and Specifications.

Defense Printing Service Detachment Office

Bldg. 4D (NPM-DODSSP)

700 Robbins Avenue

Philadelphia, PA 19111-5094

215-697-2667 or -2179 Fax 215-697-1462

DOD & Navy Publications & Forms (Other Than DODSSP)

Naval Publication and Forms Center

5801 Tabor Avenue

Philadelphia, PA 19120

215-697-2000

6.2 Military Identification Marking Example.

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

6.3 Bar Coding Example.

SPECIFICATION NO. 461 REV I - FABRICATION OF

ALUMINUM SOLAR PANEL FRAMES

Prepared by: Reviewed by:

Mr. M. J. Beimel LT. Rudy Bowis

Equipment Specialist, Waterways Operations Asset Line Manager, Waterways Operations

Product Line Product Line

Approved by: Date:

Mr. Wayne Danzik

Deputy Manager, Waterways Operations

Product Line