(04) Specification 374 Rev F.pdf

UNITED STATES COAST GUARD

SHORE INFRASTRUCTURE LOGISITICS CENTER

WATERWAYS OPERATIONS PRODUCT LINE

MAY 2018

SPECIFICATION FOR FABRICATION

OF

ALUMINUM RADAR REFLECTORS

SPECIFICATION NO. 374

REVISION F

MJB_0518

WORK ITEM 1: 5840-01-043-6233, 121024 Can Shape Radar Reflector, Purchase

WORK ITEM 2: 5840-01-261-9882, 120316 Nun Shape Radar Reflector, Purchase

1. SCOPE

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

• NSN: 5840-01-043-6233, P/N: 121024 Can Shape Radar Reflector

• NSN: 5840-01-261-9882, P/N: 120316 Nun Shape Radar Reflector

1.2 Government-Furnished Property.

None

2. REFERENCES

COAST GUARD DRAWINGS

Coast Guard Drawing 121024 Rev G, Can Shape Aluminum Radar Reflector Coast Guard Drawing 120316 Rev F, Nun Shape Aluminum Radar Reflector

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 B928/B928M-15, 15 Jun 2015 Standard Specification for High Magnesium Aluminum-

Alloy Products for Marine Service and Similar Environments1 ASTM B221-14, 1 Oct 2014 Standard Specification for Aluminum and Aluminum-Alloy

Extruded Bars, Rods, Wire, Shapes and Tubes1 ASTM D5118/D5118M-15 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

AWS D1.2/D1.2M:2014, 11 Jun 2013 Structural Welding Code – Aluminum MIL-PRF-24647E, 9 Apr 2013 Performance Specification Paint System, Anticorrosive and

Antifouling, Ship Hull QPL-24647, 18 Apr 2018 Qualified Products List of Products Qualified Under Performance

Specification MIL-PRF-24647 Paint System, Anticorrosive and Antifouling, Ship Hull 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 SAE-AMS-STD-595, 14 Feb 2017 Colors Used in Government Procurement SSPC-SP 1, 10 Aug 2016 Surface Preparation Standard No. 1, Solvent Cleaning SSPC-SP 6/NACE No. 3, 1 Nov 2004 Joint Surface Preparation Specification, Commercial Blast

Cleaning SSPC-PA 2, 15 Aug 2016 Paint Application Standard No. 2, Procedure for Determining

Conformance to Dry Coating Thickness Requirements 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 or not 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 Plate and Sheet. All aluminum plate and sheet shall meet the requirements of ASTM B928/B928M, Alloy 5086 and Temper H116.

3.1.2 Aluminum Rod. All aluminum rods shall meet the requirements of ASTM B221, Alloy 5086 and Temper H111.

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/D1.2M.

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 after the items have been painted. 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 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 Surface Preparation. All aluminum surfaces shall be cleaned of contaminants such as oil, water, grease, dust, dirt, weld spatter and slag to achieve surface profile of 1.5 to 2.5 mils in accordance with SSPC-SP6 commercial equivalent prior to painting. Either or both of the following methods shall be used.

3.5.1 Solvent Cleaning. All exterior aluminum surfaces shall be cleaned of visible contaminants such as oil, water, grease, dust, dirt in accordance with SSPC-SP1 Solvent Cleaning.

3.5.2 Mechanical Treatments. All weld spatter and slag shall be cleaned in accordance with SSPC-SP 6/NACE No. 3 Commercial Blast Cleaning. The Contractor shall:

• Use non-metallic abrasive such as aluminum oxide or garnet. (Blasting aluminum with steel grit will create galvanic issue.)

• Coat aluminum within 6 hours of blasting; otherwise aluminum oxide formation will begin.

3.6 Painting. The items shall be painted with the coating system outlined below. All painting shall be performed after the items have been cleaned in accordance with paragraph 3.5. All welding, machining, cutting, drilling, forming, or any other operation which would damage the coating system shall be performed prior to painting. The Contractor shall follow the manufacturer’s instructions for correct application of the coating system. In addition, the Contractor shall be responsible for implementing appropriate worker safety procedures for the application of the coating system, and for ensuring that the procedures are strictly followed by the paint applicators.

3.6.1 Epoxy primer. All exterior surfaces shall be coated with an epoxy primer. The epoxy primer shall meet the requirements of MIL-PRF-24647, Type II, Class 2, Grade B, Application 2 & 3, and shall be listed in QPL-24647. Apply by spraying two contrasting color coats, 5 mils minimum dry film thickness each. Sharp corners, edges, and other hard-to-coat areas shall be stripe coated after each full coat is applied.

3.6.2 Polyurethane topcoat. All exterior surfaces shall be coated with a marine grade of acrylic aliphatic.

This paint shall meet the following requirements:

• It shall be a commercial product from the same manufacturer that supplies the epoxy primer

• It shall have a Volatile Organic Compound (VOC) content of no more than 340 g/L (2.8 lb/gal), a lead content of less than 0.06% by weight, and a chromium content of less than 0.06% by weight

• The required colors shall be in accordance with SAE-AMS-STD-595: red (Federal Color 11350), green (Federal Color 14193).

• Unless otherwise specified in the delivery order, the nun shaped radar reflector shall be painted red and the can shaped radar reflector shall be painted green.

3.6.2.1 Application. Apply by spraying one coat, 3 mils minimum dry film thickness. Sharp corners, edges, and other hard-to-coat areas shall be stripe coated after each full coat is applied.

3.6.2.2 Final Dry Film Thickness. Shall be a minimum of 13 mils.

3.7 Documentation.

3.7.1 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.

3.7.1.1 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

3.7.2 Material Certifications. When requested by the COR, 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, 3.1.2, 3.6.1, and 3.6.2 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.

3.7.3 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) = 1.0. A production lot shall be all of 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 = 1.0.

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

• Paint 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 Paint Inspection. The contractor shall provide written proof that each item was cleaned and painted in accordance with paragraphs 3.5 and 3.6. As part of this inspection, the contractor shall check the dry film thickness in accordance with SSPC-PA 2 at a minimum of six different locations on each part.

4.6.4 Documentation Review. The documentation required by paragraph 3.7 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 Reflector, Radar Can and Nun. Shall be individually packaged in a double-walled (DW) corrugated fiberboard (CF) Overlap Slotted box (0202), Class Weather Resistant (WR) in accordance with ASTM D5118/D5118M-15.

5.2.1.1 Closure of overlap slotted boxes shall be in accordance with ASTM D1974/D1974M, Closure Method 3D4 and shall be reinforced with strapping per Closure Method 5D3.

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

5.3.1 Marking Layout. The following information shall be on the 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 placement 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.

5.5.1 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 RD

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 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/

(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

(SAE) Society of Automotive Engineers

Warrendale, PA, USA - Headquarters

400 Commonwealth Drive

Warrendale, PA 15096

Phone: +1-724-776-4841

Fax: +1-724-776-0790 customerservice@sae.org

(AWS) American Welding Society

8669 NW 36 Street, # 130

Miami, Florida 33166-6672

Office 305-443-9353

(SSPC) The Society for Protective Coatings

800 Trumbull Drive

Pittsburgh, PA 15205

412-281-2331 (877-281-7772) Fax 412-444-3591

(ISO) International Organization for Standardization BIBC II

Chemin de Blandonnet 8, CP 401

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 mailto:central@iso.org

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 Marking Example.

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

6.3 Bar coding example.

Examples of typical linear (Code 39) bar code fields.

SPECIFICATION NO. 374 REV F - FABRICATION OF BUOY

ALUMINUM REFLECTOR, RADAR CAN AND NUN

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