A01 - 1 General Spec SAWS General Ammunition 1 January 2019.pdf

Distribution Statement A. Approved for public release; distribution is unlimited.

Project Manager Maneuver Ammunition Systems

Product Director Special Ammunition and Weapon Systems

GENERAL SPECIFICATION FOR

SPECIAL AMMUNITION and WEAPON SYSTEMS

1 January 2019

1. SCOPE

1.1 Scope. This general specification describes the requirements and verification procedures for

Special Ammunition and Weapon Systems excluding Small Caliber ammunition, Mortar ammunition, Mortar Weapon Systems, and Rocket Propelled & Spin Stabilized Grenade ammunition (see family specifications for these items).

2. APPLICABLE DOCUMENTS

2.1 General. In addition to documents listed in this section, there are documents specified in section 5 of this specification.

2.2 Government documents. Not Applicable.

2.3 Non-Government publications.

a) United Nations Recommendations on the Transport of Dangerous Goods Model

Regulations, 13th Edition, 2003.

b) International Civil Aviation Organization (ICAO) Technical Instructions for the Safe

Transport of Dangerous Goods by Air, 2015-2016 Edition.

c) International Maritime Organization (IMO) International Maritime Dangerous Goods

Code (IMDG), Amendment 34-08.

2.4 Acquisition requirements. Acquisition documents must specify the following:

a. Title and date of this specification.

b. Requirements for certificates of conformance for each lot or shipment of product.

c. Requirements for age of ammunition.

d. Requirements and provisions for submission of data as required.

e. Requirements for acceptance criteria if different than those stated in specification.

f. Requirements for reduction or elimination of verification procedures.

g. Requirements and provisions for contractor and Government verification.

h. Requirements and provisions for packaging of ammunition.

i. Requirements and provisions for transportation of ammunition.

General Specification for PdD SAWS Special Ammunition and Weapon Systems – 1 January 2019

2.5 Order of 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. Requirements specified in the contract or delivery order precede the text of this document. Nothing in this document or the contract, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Technical requirements. Ammunition and non-energetic items shall meet the requirements and verifications of this specification for the ammunition/items listed in ANNEX A. All ammunition/items shall be accompanied with technical data (see APPENDIX) that meets or exceeds the requirements of this specification.

3.1.1 Compliance to technical requirements and storage history records. A Technical Data

Package (TDP) as well as Lot history reports shall be provided to ensure ammunition/items are in compliance with this specification. Additionally, documented storage history of the ammunition/items shall be provided.

3.2 Conformance Testing and Inspection. A sample of the ammunition/items from each lot presented shall be subjected to conformance testing and inspection in accordance with TABLE I.

3.2.1 Stock ammunition. All ammunition/items must be less than 5 years old and meet the verification procedures in TABLE I of this specification. Any lot that has not been adequately tested to comply with all requirements of TABLE I shall be subjected to conformance testing and inspection in accordance with this specification.

3.3. Serviceability. Ammunition/items shall be serviceable and issuable, in good condition and without visible signs of degradation. All parts and assemblies shall be fabricated and finished in a thorough matter and shall be free of burrs, chips, dirt, grease, rust, corrosion and other foreign material that adversely affect fit or function. Coatings and protective finishes shall be uniform and shall provide complete coverage of designated surfaces. The painting and marking shall be restored by the assembling facility on any components that have been marred or obliterated.

3.3.1 Identification of defects. Visual defects shall be identified within the TDP and include a defined method for acceptance/rejection of the ammunition/items. Visual inspections listed in ANNEX

B shall be the minimum requirement.

3.4 Weapon interface and interoperability. The ammunition/items shall be functionally compatible with the weapons identified in ANNEX A or as otherwise specified in the contract or delivery order.

3.5 Operating requirements. The ammunition/items shall provide their functional, operational, and performance capabilities when fired regardless of weather related conditions (i.e. rain, snow, mud, wind, fog).

3.5.1 Operating temperatures. The ammunition/items shall demonstrate safety and reliability throughout exposure to ambient and extreme temperatures (i.e. +50°C to -40°C).

3.5.2 Muzzle velocity. The average velocity of the ammunition obtained at ambient temperature shall meet the requirement listed in the TDP.

3.5.3 Chamber pressure. The individual maximum and average pressure of the ammunition obtained at ambient shall meet the requirements specified in the TDP.

3.5.4 Maximum effective range. Each lot of ammunition shall be tested at ambient to determine maximum range as listed in the TDP.

3.5.5 Dispersion. The ammunition shall demonstrate dispersion characteristics at ambient as specified in the TDP.

3.5.6 Function and casualty. The ammunition/items shall function without casualty or cause damage to the weapon, and shall exhibit a ballistic performance free of misfires, duds, premature bursts, short rounds, and metal parts separation. The ammunition/items shall cause no hazard or unsafe condition to the gunner during storage, transportation or use.

3.5.7 Performance. The ammunition/items shall function according to its specific purpose and as defined in the TDP. Specific performance requirements may include but are not limited to fragmentation, illumination, penetration, smoke and flare.

3.6 Fuze identification and description. When applicable, the fuze shall be identified within each

TDP with a drawing/figure of the internal fuze design with components categorized and a functional description of the fuze that includes, at a minimum, a detailed description of the fuze arming sequence, operating temperatures, in-process tests (i.e. jolt/jumble, sensitivity, safe arming/non-arming etc.), and safe separation distances. Test records shall be available to the US Government for verification.

3.7 Environmental Requirements.

3.7.1 Sequential rough handling. Ammunition/items shall be capable of withstanding the rigors of the sequential rough handling and transportation throughout extreme temperature ranges and meet all performance and safety requirements.

3.7.2 Shelf life. The ammunition/items shall meet all requirements of this specification within its operating temperature range at a minimum of ten (10) years of storage.

4. VERIFICATION

4.1 Technical verification. The ammunition/items shall be subjected to verification of all requirements cited in section 3 in this specification, in accordance with the TABLE I. Noncompliance to any requirements shall be cause to withhold acceptance of the lot or batch in which the noncompliance was found.

TABLE I – Requirements/Verification Cross-Reference Matrix

4.1.1 Lot formation. The ammunition/items shall be assembled into identifiable lots, sublots, or batches, or in such other manner as may be prescribed. Each lot or batch shall, as far as practicable, consist of units of product of a single type, grade, class, size, and composition, manufactured under essentially the same conditions, and at essentially the same time. Lot quantities shall be determined by the total quantity for shipment and include the additional rounds from the same lot to be consumed during lot acceptance testing along with contingency rounds for potential retesting. The lots or batches shall be identified by the contractor and shall be kept intact in adequate and suitable storage space. All ammunition in a given lot must be manufactured prior to lot acceptance testing.

4.1.2 Conformance verification. The ammunition/items shall be subjected to verification in accordance with TABLE I of this specification.

4.1.3 Conformance acceptance. Acceptance of ammunition/items shall be based on compliance with the requirements in TABLE I of this specification. Failure to meet requirements of TABLE I shall be cause to withhold acceptance of the lot or batch for which verification was performed. A Request for

Variance (RFV) may be submitted for special consideration of a lot that does not comply with all requirements of the TDP. The US Government may approve or disapprove RFVs on a case by case basis.

4.1.4 Retest criteria. A ballistic retest is authorized upon initial failure of ammunition/items to meet test requirements as long as the failure is not considered critical. Retest procedures must be clearly defined in the TDP and results must be combined with data from the first test unless a failure analysis confirms that the failure was caused by something other than the ammunition/items being tested (i.e.

weapon failure or faulty test set up).

Section 3

Requirements Requirement

Section 4

Verification

Procedures

Sample Size

3.1 Technical requirements 4.1 -

3.3 Serviceability 4.3 Note 1

3.3.1 Identification of defects 4.3 ANNEX B

3.4 Weapon interface and

interoperability

4.4 ANNEX A

3.5.1 Operating temperatures 4.5.1 ANNEX A

3.5.2 Muzzle velocity 4.5.2 ANNEX A, Note 2

3.5.3 Chamber Pressure 4.5.3 ANNEX A, Note 2

3.5.4 Maximum effective range 4.5.4 ANNEX A, Note 2

3.5.5 Dispersion 4.5.5 ANNEX A, Note 2

3.5.6 Function and casualty 4.5.6 ANNEX A

3.5.7 Performance 4.5.7 ANNEX A

5.1 Packaging - ANNEX B

5.3 Packing - ANNEX B

5.5 Marking - ANNEX B

Note 1) To be performed using a defined sampling procedure for inspection determined by the lot sizes.

Note 2) Not applicable for non-energetic items.

4.2 Verification of evidence of compliance. Evidence shall include, but is not limited to, the following;

a. Identification of technical requirements to which the ammunition/items is/was produced.

b. Producer, date of manufacture and original acceptance documentation.

c. Initial acceptance reports, including type, lot or batch identification, quantity and method of acceptance (e.g. sample size, verification method, acceptance criteria, results…).

d. Surveillance reports, including lot or batch identification, quantity and method of surveillance (e.g. sample size, verification method, criteria for action to be taken on lot or batch, results).

e. Storage history, including duration and storage condition (e.g. controlled, uncontrolled).

4.3 Serviceability and identification of defects. A random sample shall be selected from each lot of ammunition/items using a defined sampling procedure for inspection. The ammunition/items shall be visually inspected for signs of degradation and the identification of defects in accordance to ANNEX

B of this specification. Re-inspection of a lot that fails for non-ballistic reasons is authorized as long as the criteria for re-inspection is clearly outlined in the TDP per ANNEX B.

4.4 Weapon interface and interoperability. A random sample shall be selected from each lot of ammunition/items to be delivered and inserted into a weapon chamber or chamber gage that conforms to the identified weapon system to check for profile and alignment. Inability to interface properly with weapon system shall be considered a failure to show compliance and constitute a single reliability failure.

4.5 Operating verification. The same cartridge of ammunition can be used for multiple tests provided the test equipment is capable of capturing all necessary test data. For example; Muzzle

Velocity, Maximum Effective Range and Function & Causality testing can be done at the same time using the same cartridges. Called warmers and spotters are allowed and encouraged. "Called" means that before the cartridge is loaded into the weapon, the US Government representative must be informed that the next cartridge to be fired is a warmer or spotter. Should a cartridge not be "Called" it shall be counted toward whichever test is being conducted, potentially resulting in a LAT failure. Safety failures apply to all cartridges fired during LAT, regardless of which test is being performed. The following safety failures shall result in the immediate rejection of the lot; there shall be no retest:

a. Detonation of an HE, Practice or Smoke cartridge within the weapon or before impact with the ground.

b. Any in-bore or early functions of the fuze (Illumination cartridges)

c. Metal parts separation.

d. Short rounds; a cartridge impacts the ground at a range 80% or less of the range average or its respective temperature/charge/group; excluding the cartridge(s) in question.

e. A cartridge that either causes injury to user, damages the weapon or renders it inoperable (without the use of special tools).

4.5.1 Operating temperatures. Ammunition shall operate reliably and safely when conditioned and fired throughout reasonable extreme operating temperature range as provided by the manufacturer.

With the exception of hand grenades, temperature testing may be conducted on a skip-lot basis (see

APPENDIX) during LAT. A single safety failure will result in lot rejection and there shall be no retest.

Functional testing parameters must be defined in the TDP and meet manufacturer requirements. The entire cartridge, including all components necessary to fire and function (i.e. fuze, warhead, propellant, etc.) shall be temperature conditioned based on the maximum cartridge body diameter. Additionally the cartridges shall be fired within the following times after being removed from the conditioning chamber or thermally insulated bag.

a. Ammunition less than 85mm in diameter shall be conditioned for not less than six (6) hours and fired within five (5) minutes of removal from conditioning box or thermally insulated bag.

b. Ammunition between 85mm and 120mm in diameter shall be conditioned for not less than nine (9) hours and fired within six (6) minutes of removal from conditioning box or thermally insulated bag.

c. Ammunition greater than 120mm in diameter shall be conditioned for not less than twelve (12) hours and fired within eight (8) minutes of removal from conditioning box or thermally insulated bag.

4.5.2 Muzzle velocity. Velocity tests shall be conducted in accordance with the manufacturers test procedures to verify that a sample representative of the lot meets the minimum velocity requirements specified in the TDP. If the lot fails to meet the Velocity requirements a retest of the same sample size

(10 cartridges minimum) is permitted. The cumulative average of all cartridges tested (20 cartridges minimum) shall be used to determine if the lot passes.

4.5.3 Chamber pressure. Pressure tests shall be conducted in accordance with the manufacturers test procedures to verify samples from the lot do not exceed the average or individual pressure requirements listed in the TDP. Pressure testing shall be conducted during the LAT, regardless of in-process testing. If the lot fails to meet the Pressure requirements a retest of the same sample size (10 cartridges minimum) is permitted. The cumulative average of all cartridges tested (20 cartridges minimum) shall be used to determine if the lot passes. Any single round that exceeds the maximum individual pressure requirement will result in lot rejection, there shall be no retest.

4.5.4 Maximum Effective Range. Maximum effective range shall be verified during lot acceptance testing to ensure compliance with the TDP (does not apply to medium caliber ammunition).

4.5.5 Dispersion. Dispersion tests shall be conducted to verify that each lot of ammunition meets the specified requirements in the TDP. If the lot fails to meet the Dispersion requirements a retest of the same sample size (10 cartridges minimum) is permitted. The cumulative average of all cartridges tested (20 cartridges minimum) shall be used to determine if the lot passes.

4.5.6 Function and casualty. A random sample shall be selected from the ammunition/items lot in accordance with ANNEX A to be delivered and functioned from the identified weapon system to check for function, casualty and metal parts security. The ammunition/items shall function across the entire operating temperature range without casualty or damage to the weapon, and shall exhibit a ballistic performance free of misfires, duds, premature bursts, short rounds and metal parts separation. The ammunition shall cause no hazard or unsafe condition to the gunner during storage, transportation or use. Any round which detonates prior to impact of intended target, or which detonates in the weapon is considered a safety critical failure and will result in immediate lot rejection. Multi-option fuzes shall be set to Point Detonating for LAT testing.

4.5.7 Performance. Proper functioning for each ammunition/items type is defined below. Any round which does not function properly according to the below definitions and the requirements in the

TDP is considered a function failure:

a. Fragmentation: The ammunition shall produce a high-order detonation of the warhead upon initial impact with the target (terrain or man-made structure) as specified in the TDP.

b. Illumination: The ammunition shall provide candlepower illumination and the parachute suspended burn time as specified in the TDP.

c. Smoke: The ammunition shall produce a volume of smoke upon impact with the target as specified by the manufacturer in the TDP.

d. Penetration: The ammunition shall meet the armor penetration characteristics as specified in the TDP.

e. Flare: The ammunition shall deploy from the launcher and produce its intended effect for a minimum amount of time as specified in the TDP.

f. Links and Linked Belts: Link and belt requirements shall include applicable testing for cartridge extraction forces, fanning, folding, twisting, loading, extension, etc. as specified in the TDP.

g. Linking Machines: Linking machines shall include all applicable testing for verification of failure free functioning as specified in the TDP.

5. PACKAGING

5.1 Preservation, packaging, packing, unitization, and marking shall provide protection for multiple handling, redistribution, and shipment by any transportation mode and meet or exceed the following requirements.

5.1.1 Packaging containers for hazardous materials, ammunition and explosives shall meet or exceed the requirements found in part 6 of the "United Nations Recommendations on the Transport of

Dangerous Goods Model Regulations" and in a manner acceptable to the competent authority of the nation of origin and in accordance with the regulations of all applicable carriers.

5.1.2 Cleanliness - Items and packaging shall be free of dirt and other contaminants which would contribute to the deterioration of the item or which would require cleaning by the customer prior to use.

Coatings and preservatives applied to the item for protection are not considered contaminants.

5.1.3 Preservation - Items susceptible to corrosion or deterioration shall be provided protection against external environmental effects.

5.1.4 Cushioning - Items requiring protection from physical and mechanical damage (e.g. fragile, sensitive, critical material) or which could cause physical damage to other items, shall be protected by wrapping, cushioning, pack compartmentalization, or other means to mitigate shock and vibration and prevent damage during handling and shipment.

5.1.5 Wood Packing Material - All natural wood packing material shall be constructed from heat treated lumber and certified by an accredited recognized agency in accordance with International

Standards for Phytosanitary Measures (ISPM-15) regardless of origin or destination. All natural wood packing materials must include certification markings that are readily visible to inspectors and on at least two sides of every container when palletized.

5.1.6 Firing Tables – A copy of the firing tables shall be included in each wooden box for all ammunition such as Artillery and Tank which utilize them. A copy shall also be included with the TDP.

5.2. Unit Package

5.2.1 Unit package shall be so designed and constructed that it will contain the contents with no damage to the item(s), and with minimal damage to the unit pack during shipment and storage in the shipping container, and will allow subsequent handling. The outermost component of the unit package shall be a container such as a sealed bag, carton, or box.

5.3. Packing

5.3.1 Unit packages must be packed in shipping containers. All shipping containers shall be the most cost effective and shall be of the minimum cube to contain and protect the items.

5.3.2 Shipping Containers - the shipping container (including any necessary blocking, bracing, cushioning, or waterproofing) shall comply with the regulations of the carrier used and shall provide safe delivery to the destination at the lowest tariff cost. The shipping container shall be capable of multiple handling, stacking at least ten feet high, and storage under favorable conditions and meet the requirements of the “United Nations Recommendations on the Transport of Dangerous Goods”.

5.4. Unitization

5.4.1 Shipments of identical items going to the same destination shall be palletized if they have a total cubic displacement of 20 cubic feet or more unless skids or other forklift handling features are included on the containers. Pallet loads must be stable, and to the greatest extent possible, provide a level top for ease of stacking. The weight capacity of the pallet must be adequate for the load. A pallet load shall not exceed 4,000 pounds and should not exceed 52 inches in length or width, or 54 inches in height. The load shall be contained in a manner that will permit safe handling during shipment and storage.

5.4.2 Banding - metal banding shall be used to secure load. Straps shall be applied to each column or layer of boxes. Tie down straps shall be applied to each column of boxes at 90 degrees to the load straps. Edge protectors shall be used when securing fiberboard boxes.

5.5. Marking

5.5.1 Packaging marking shall be visible, clear, and remain legible during normal life cycle handling.

5.5.2 All unit packages, intermediate packs, exterior shipping containers, and, as applicable, unitized loads shall be marked with item description, quantity, lot number, or serial number. The outer shipping container and unitized load shall indicate load weight, UN dangerous goods proper shipping name, UN number and UN POP marking.

5.5.3 Each package shipping container shall show the United Nations packaging symbol and applicable codes in accordance with the construction requirements and testing of packaging as expressed in part 6 of the "United Nations Recommendations on the Transport of Dangerous Goods Model

Regulations, 13th Edition, 2003".

5.6. Additional Requirements for Hazardous Materials

5.6.1 The shipment shall be prepared in accordance with the "United Nations Recommendations on the Transport of Dangerous Goods Model Regulations, 13th Edition, 2003" and other applicable regulations effective at the time of shipment in a manner acceptable to the competent authority of the nation of origin and in accordance with the regulations of all applicable carriers.

5.6.2 Packaging and marking for hazardous material shall comply with the requirements for the mode of transport and the applicable performance packaging contained in the following documents:

a. International air transport: International Civil Aviation Organization (ICAO)

Technical Instructions for the Safe Transport of Dangerous Goods by Air, 2015-

2016 Edition.

b. International vessel transport: International Maritime Organization (IMO)

International Maritime Dangerous Goods Code (IMDG), Amendment 34-08.

Frank Altamura Product Director Special Ammunition and Weapon Systems

Picatinny Arsenal, NJ

Annex A: Weapon Interface and Sample Size Requirements

Annex B: Visual Inspection Requirements

APPENDIX - Definitions

ANNEX A - Weapon Interface and Sample Size Requirements

Medium Caliber

Item1,8,9 Weapon Interface

(or similar)

Function and Casualty/Safety

Order size greater than 1000 cartridges

Sample Size2-Accept-Reject & Retest

(cumulative)

Function and Casualty/Safety

Order size 100-1000 cartridges10

Sample Size2-Accept-Reject &

Retest (cumulative)

14.5 x 114mm (All Types)3,4,5,6,7

KPV Machine Gun

Ambient Hot Cold Ambient Only

32-0-1

Retest 60-1-2

(Cumulative)

32-1-2

Retest 60-2-3

32-1-2

Retest 60-2-3

Retest 60-1-2

23 x 115mm (All Types)3,4,5,6,7 GSh-23

23 x 152mm (All Types)3,4,5,6,7 ZU-23

30 x 165mm HEI5,6,7

2A42 or Gsh-30

30 x 165mm HE-T3,5,6,7

30 x 165mm APT3,4,7

Note 1: Any medium caliber ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show function and casualty at ambient temperature. 32 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: Not less than 80% of the Tracer cartridges (10 shot minimum) shall ignite and remain lit for a minimum time or distance as per the manufacturers

TDP. All tracers within the lot shall be of the same color.

Note 4: Not less than 80% of the Armor piercing cartridges (10 shot minimum) shall have full penetration of armor with a thickness as per the manufacturers TDP.

Note 5: Not less than 80% of the Incendiary cartridges (10 shot minimum) shall, upon impact, develop an incandescent flash sufficiently hot, intense and sustained to ignite explosive vapors or initiate combustion in readily ignitable materials.

Note 6: Not less than 80% of High Explosive cartridges (10 shot minimum) shall completely detonate upon initial impact with their target. Self-destruct detonation or fuze function only shall be scored as a function failure, if shot as part of a function test.

Note 7: If the lot fails to meet the Tracer, Incendiary, Armor Piercing, and/or HE requirements, a retest of the same sample size (10 cartridges minimum) is permitted. The cumulative average of all cartridges tested (20 cartridges minimum) shall be used to determine if the lot passes.

Note 8: A function failure shall be defined as:

a) A cartridge that will not load into the weapon

b) A misfire

c) A cartridge that does not completely detonate upon initial impact with their target (HE and Practice cartridges only). Self-destruct detonation or fuze function only shall be scored as a function failure, if shot as part of a function test.

Note 9: Safety failures are listed in section 4.5 of this specification.

Note 10: For orders less than 100 cartridges function and casualty tests are not required. The Government reserves the right to increase these requirements in their proposals.

ANNEX A - Weapon Interface and Sample Size Requirements (continued)

Artillery Ammunition

Item1,4,5,6 Weapon Interface

(or similar)

Function and Casualty/Safety

Order size greater than 250 cartridges

Sample Size2-Accept-Reject & Retest

(cumulative)

Function and Casualty/Safety

Order size 100-250 cartridges3

Sample Size2-Accept-Reject &

Retest (cumulative)

122mm HE Frag Full Charge

D-30 Towed

Howitzer

Ambient Hot Cold Ambient Only

122mm HE Frag Partial

Charge

15-0-1

Retest 29-1-2

15-1-2

Retest 29-2-3

122mm HEAT

122mm WP Smoke

122mm Illumination

152mm Frag-HE D-20 Towed Howitzer

122mm Artillery Rockets BM-21 Grad Multiple

Rocket System (MRS) Note 1: Any artillery ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: For orders less than 100 cartridges function and casualty tests are not required. The Government reserves the right to increase these requirements in their proposals.

Note 4: The average corrected range of all cartridges when discharged during ambient testing shall be within 95% to 105% of their respective firing tables.

Note 5: A function failure shall be defined as:

a) A cartridge that will not load into the weapon

b) A misfire

c) A cartridge that does not produce smoke (Smoke cartridges only)

d) A cartridge that does not have a parachute suspended burn time as identified in the TDP. (Illumination cartridges only)

e) A cartridge that does not completely detonate upon initial impact with their target (HE and Practice cartridges only). Self-destruct detonation or fuze function only shall be scored as a function failure, if shot as part of a function test.

Note 6: Safety failures are listed in section 4.5 of this specification.

Aircraft Ammunition - Rockets

Item1,4,5

Weapon

Interface

(or similar)

Function and Casualty/Safety

Order size greater than 250 cartridges

Sample Size2-Accept-Reject & Retest (cumulative)

Function and Casualty/Safety

Order size 100-250 cartridges3

Sample Size2-Accept-Reject &

Retest (cumulative)

57mm S-5KO

Aviation Rocket

UB-16-57UM

/UB-32

Rocket Pod

57mm S-5KO

Practice

Aviation Rocket

57mm S-5KP

Aviation Rocket

80mm S-8

Aviation Rocket

B-8M1/B8V20

Rocket Pod

Note 1: Any aviation ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: For orders less than 100 cartridges function and casualty tests are not required. The Government reserves the right to increase these requirements in their proposals.

Note 4: A function failure shall be defined as:

a) A cartridge that will not load into the weapon

b) A misfire

c) A cartridge that does not completely detonate upon initial impact with their target (HE and Practice cartridges only). Self-destruct detonation or fuze function only shall be scored as a function failure, if shot as part of a function test.

Note 5: Safety failures are listed in section 4.5 of this specification.

Aircraft Ammunition - Pyro

Item1,4,5

Weapon

Interface

(or similar)

Function and Casualty/Safety

Order size greater than 100 cartridges

Sample Size2-Accept-Reject & Retest (cumulative)

Function and Casualty/Safety

Order size 1-100 cartridges3

Sample Size2-Accept-Reject &

Retest (cumulative)

PP3

Ambient Hot Cold Cold5

PP9

PPL YaKB

EKSR-46 Flare Mi-17/35

PPI-26 Flare

ASO-2/

ASO-2V

Note 1: Any Pyro cartridges not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: Due to the intended use of these pyro devices testing shall be conducted at cold for order quantities of less than 100.

Note 4: All cartridges shall function per the manufacturer’s specification. A function failure shall be defined as:

a) A cartridge that will not load into the firing device or weapon

b) A misfire or failure to ignite

c) A cartridge that does not meet manufacturers minimum requirements (i.e. light intensity, pressure, velocity, duration…)

Note 5: Safety failures are listed in section 4.5 of this specification.

Tank, Gun and ATGM Ammunition

Item1,4,5,6,7 Weapon

(or similar)

Function and Casualty/Safety

Order size greater than 250 cartridges

Sample Size2-Accept-Reject & Retest (cumulative)

Function and Casualty/Safety

Order size 100 – 250 cartridges3

Sample Size2-Accept-Reject & Retest

(cumulative)

100mm HEAT &

HE-Frag T-55 Tank Ambient Hot Cold

Ambient Only

Ambient only:

15-0-1 or 29-1-2

115mm APFSDS, HEAT & HE Frag T-62 Tank

15-0-1

Retest 29-1-2

(Cumulative)

15-1-2

Retest 29-2-3

(Cumulative)

15-1-2

Retest 29-2-3

(Cumulative)

15-0-1

Retest 29-1-2

(Cumulative)

125mm APFSDS, HEAT & HE-Frag T-64/T-72 Tank

73mm HEAT &

HE-Frag 2A28 Grom

AT-3 ATGM HE,

(Sagger)

BMP-1, launcher 9P111, BRDM Vehicle

AT-5 ATGM HE

(Spandrel)

BMP-2/BRDM-2

Note 1: Any tank, gun and ATGM ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: For orders less than 100 cartridges function and casualty tests are not required. The Government reserves the right to increase these requirements

Note 4: Not less than 80% of cartridges containing tracers (10 shot minimum) shall ignite and remain lit for a minimum time or distance as per the manufacturer’s requirements. All tracers within the lot shall be of the same color. If the lot fails to meet the Tracer requirements, a retest of the same sample size (10 cartridges minimum) is permitted. The cumulative average of all cartridges tested (20 cartridges minimum) shall be used to determine if the lot passes.

Note 5: The average corrected range of all cartridges when discharged during ambient testing shall be within 95% to 105% of their respective firing tables.

Note 6: A function failure shall be defined as

a) A cartridge that will not load into the weapon

b) A misfire

c) A cartridge that does not completely detonate upon initial impact with their target (HE cartridges only). Self-destruct detonation or fuze function only shall be scored as a function failure, if shot as part of a function test.

d) A cartridge that does not have complete penetration of armor per manufacturer’s requirements (AP cartridges only).

Note 7: Safety failures are listed in section 4.5 of this specification.

Hand Grenades

Item / Requirement1,8 Function and Casualty/Safety

Order size greater than 250

Sample Size2-Accept-Reject & Retest (cumulative)

Function and Casualty/Safety

Order size 100 – 250 cartridges7

Sample Size2-Accept-Reject &

Retest (cumulative)

RKG-3 / Armor penetration >=150mm5

Grenade, Rubber Buckshot3

Grenade, Flash & Bang4

Grenade, HE, HE Frag. or Thermobaric3

Retest 60-1-2

(Cumulative)

32-0-1

Retest 60-1-2

(Cumulative)

32-0-1

Retest 60-1-2

(Cumulative)

32-0-1

Retest 60-1-2

(Cumulative)

Grenade, Smoke

Grenade, Tear Gas

Note 1: Hand grenades not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 32/15 rounds shall be tested for function and safety at the operating temperature extremes. A single safety failure will result in lot rejection and there shall be no retest.

Note 3: These grenades must be tested at hot/cold/ambient for each lot (skip lot testing does not apply). Any lot that exhibits a delay of less than 3 seconds shall be rejected, there shall be no retest.

Note 4: These grenades must be tested at hot/cold/ambient for each lot (skip lot testing does not apply). Any lot that exhibits a delay of less than 1 second shall be rejected, there shall be no retest.

Note 5: These grenades must be tested at hot/cold/ambient for each lot (skip lot testing does not apply). Detonation prior to impact shall result in lot rejection, no retest.

Note 6: All applicable grenades shall completely detonate. Fuze function only shall be scored as a function failure.

Note 7: For orders less than 100 cartridges function and casualty tests are not required. The Government reserves the right to increase these requirements in their proposals

Note 8: Safety failures are listed in section 4.5 of this specification.

Links, Linked Belts, and linking Machines

Item1 Caliber Weapon Interface

(or similar)

Function and Casualty/Safety at Ambient

Sample Size-Accept-Reject & Retest (cumulative)

Ambient

Links 20mm and larger GSh-23, ZU-23, 2A42, Gsh-30

50-1-2

Retest 100-2-3

(Cumulative)2,3

Linked Belts 14.5mm and smaller

RPD, KPV, PKM,

PKT, YaKB, DshKM

200-1-2

Retest 400-2-3

(Cumulative)2,3

Linking Machines All calibers of links and belts

5-0-1

Retest 10-1-2

(Cumulative)4,5

Note 1: Any size/caliber link, belt, or linking machine not listed in this table is still required to meet sample size-accept-reject criteria listed in this table.

Note 2: For orders less than 10,000 links or 200 belts function and casualty tests are not required. The Government reserves the right to increase these requirements in their proposals.

Note 3: These samples sizes shall be used to show performance and function and casualty at ambient temperature. Live cartridges shall be fired. The number of belts used for function and casualty will be determined by the number of rounds they hold (i.e. for 50 round belts, a total of 4 belts shall be fired to meet a requirement of 200 rounds). For individual links, the contractor can determine how many cartridges will be linked together to form a belt, however, a belt shall contain not less than 10 cartridges.

a) Any type of weapon stoppage that cannot be attributed to the ammunition or weapon shall be counted as a single link/belt failure.

b) Links/belts that damage the weapon or cause weapon stoppages which cannot be cleared without use of special tools, rendering it inoperable, are critical. The lot shall be rejected. No retest allowed.

Note 4: For orders of 25 or greater linking machines a minimum of 5 linking machines shall be tested for failure free operation. For orders less than 25 linking machines a minimum of 3 machines shall be tested. The Government reserves the right to increase these requirements in their proposals.

Note 5: A total of 100 cartridges shall be cycled through the linking machine regardless of caliber and belt length. Inert/Dummy cartridges are allowed.

a) Any stoppages or jams due to design or manufacturing defect of the linking machine shall be counted as a single failure. Any damage to the links or ammunition caused by the linking machine shall be counted as a single failure.

b) Linking machines that severely damage links/belts/ammunition rendering them unable to be fired in a weapon are critical. The lot shall be rejected. No retest allowed.

ANNEX B – Visual Inspection Requirements for Ammunition

Critical: 24-0-12 Major: 24-1-22

Re-inspection: 72-3-4 (cumulative)1

Minor: 24-3-42

Re-inspection: 72-9-10 (cumulative)1

Missing, cracked, loose or bent parts Cases with moving cartridges; loose pack Discolored, oily, dirty, or smeared

Gross Corrosion / Pitting

Incorrect quantity of cartridges in packaging (light boxes shall have their corners painted) each cartridge missing shall constitute one failure

Minor surface corrosion

Spillage/leakage of energetic materials Wire Security Seal missing Dents, chips or burrs

Incorrect Marking of cartridge type:

HE cartridge marked as Practice, Smoke or Illumination

Mixed ammunition types: Training cartridge mixed with Combat cartridge lot Scratches on cartridge

Gross deformation Missing, illegible or incorrect marking Excessive grease on cartridge

Splits in the case around primer area, case groove or case rim (14.5, 23 and

30mm cartridges only)

Incorrect Marking of cartridge type:

Practice, Smoke or Illumination cartridges marked incorrectly

Irregular disposition of cartridges in case

Mixed ammunition types: Combat cartridge mixed with training cartridge lot

Paint damaged, wet or incomplete

Note 1: If the number of allowable defects is exceeded a double sample quantity of 48 cartridges shall be re-inspected. The accept/reject criteria is based on the cumulative number of defects for all three samples.

Note 2: If a critical is found or the number of allowable majors or minors, after re-inspection, is exceeded the lot fails.

General Specification for PdD SAWS Small Caliber Ammunition – 1 January 2019

ANNEX B – Visual Inspection Requirements for Links, Linked Belts and Linking Machines

Belts and Linking Machines1

Critical: 5-0-14

Belts and Linking Machines1

Major: 5-1-23

Re-inspection: 15-3-4 (cumulative)3,4

Belts and Linking Machines1

Minor: 5-3-43

Re-inspection: 15-9-10 (cumulative)3,4

Links2

Critical: 24-0-14

Links2

Major: 24-1-23

Re-inspection: 72-3-4 (cumulative)3,4

Links2

Minor: 24-3-43

Re-inspection: 72-9-10 (cumulative)3,4

Gross corrosion or pitting Minor surface corrosion Discolored, excessive oil, dirty, or smeared

Gross deformation Missing wire security seal Dents, folds, or wrinkles

Missing, cracked, or loose parts Missing, illegible, or incomplete markings Scaly, scratched, or chipped metal

Incorrect quantity of links in belt (belts only) Sharp edges

Incorrect quantity of items in packaging Surface coating wet, damaged, or incomplete

Mixed or incorrect caliber type

Note 1: A minimum of 5 belts/linking machines shall be visually inspected per lot.

Note 2: A minimum of 24 links shall be visually inspected per lot.

Note 3: If the number of allowable defects is exceeded a double sample quantity shall be re-inspected. The accept/reject criteria is based on the cumulative number of defects for all three samples.

Note 4: If a critical is found or the number of allowable majors or minors, after re-inspection, is exceeded the lot fails.

General Specification for PdD SAWS Small Caliber Ammunition – 1 January 2019

APPENDIX

1. DEFINITIONS

1.1 PdD SAWS Special Ammunition and Weapon Systems. PdD SAWS Special Ammunition and Weapon Systems are those munitions that have not been safety tested and type classified for Army use, and cannot be procured through the Army supply. Munitions and explosives that are not managed by National Inventory Control Points, have not been safety tested nor type classified for Army use, do not have a national stock number (NSN) and cannot be procured or requisitioned through the Army or other Department of Defense supply system.

1.2 Technical data. Technical data, otherwise known as the technical data package (TDP) is the product specific technical drawings and Quality Assurance (QA) requirements to which ammunition and associated packaging is produced and accepted for each applicable Contract Line Item Number (CLIN).

For the purpose of this specification, the TDP, as a minimum, must contain the following: Government contract number and delivery order; top assembly, fuze and key component drawings with revision number, revision date, document control signature, key interface dimensions, and a list of component assemblies with drawing numbers and revision dates; packaging and marking drawings with revision number, revision date, document control signature and markings; and product specification with final assembly, fuze and key component in-process acceptance test methods with sample size, and accept/reject criteria, and retest criteria. Within the TDP there shall also be a clear cut-away and/or exploded drawing(s) to show all of the inner parts and workings of the fuze. Additionally, there shall be paragraphs which describe the fuze arming sequence and events leading to function. A copy of the manufacturers firing tables shall be included in the TDP for all ammunition such as artillery and tank which require them.

1.3 Non-Energetic Items. Items such as links, belts, and linking machines which are associated with ammunition and weapon systems but do not fire a projectile or contain pyrotechnics or other energetic materials.

1.4 Degradation. Ammunition with gross nonconformance to identified technical requirements, corrosion, cracks, deformation, and spillage

1.5 Deterioration. Packaging ripped, broken, perforated, with water damage, crushed.

1.6 Skip-Lot Temperature Testing. Except for the hand grenades identified in ANNEX A which require temperature testing on all lots, testing at the operational temperature limits shall be conducted on the first lot of every delivery order and every 5th lot thereafter (1, 5, 10, 15...). The ammunition must pass the requirements defined in ANNEX A. If a lot is rejected for any reason, the following two lots must pass temperature testing before resuming the skip lot procedures.