A02_Purchase Description_Shoot Packs.docx

AR/PD 11-01 Rev C INCH-POUND AR/PD 11-01C 22 January 2021

SUPERSEDING AR/PD 11-01B

23 July 2020

PURCHASE DESCRIPTION

MSV-B-100 AND PATHFINDER-S

BALLISTIC SHOOT PACKS FOR HARD ARMOR TEST

The Army has approved this purchase description for use by the Army and it is available for use by all Departments and Agencies of the Department of Defense within the distribution limitations noted at the bottom of this page.

RECORD OF REVISIONS

Revision Number

Date

1.0 Scope. The contractor shall provide ballistic shoot packs in accordance with all terms listed herein. The contractor shall provide all program and production management necessary to meet the quality standards, reporting systems, and supportability required for testing, inspection, and delivery of the items as defined in the Contract and this Purchase Description (PD). The Government encourages the Contractor to use commercial or industrial processes and practices that will reduce production and operational support costs while meeting the requirements of this Contract. The Contractor shall meet the requirements set forth in this PD.

1.1 Purpose. The Government designed the shoot pack to be a simulant or surrogate of the ballistic resistant soft armor material systems to enable consistent hard armor testing. The Improved Outer Tactical Vest (IOTV) soft armor system provides protection from conventional fragmenting munitions and multiple hits from 9 mm handgun rounds. The Modular Scalable Vest (MSV) soft armor system meets the requirements of IOTV and adds protection from .357 MAG and .357 SIG handgun rounds as well as an expanded series of environmental conditions for fragmentation protection. The Pathfinder-S shoot pack is a simulant of the IOTV system, and the MSV-B-100 shoot pack is a simulant of the MSV system. The material system description of the Pathfinder-S is located in Table B-I and the material system description of the MSV-B-100 is located in Table A-I.

2.0 Applicable Documents. The following documents form a part of this PD to the extent specified herein.

2.1 Government Documents.

AR/PF 15-03 F Amend 1 Body Armor, Torso and Extremity Protection Modular Scalable Vest, Generation II And Body Armor, Multiple Threat / Interceptor Improved Outer Tactical Vest, Generation V

FQ/PD 07-05 Body Armor, Multiple Threat / Interceptor Improved Outer Tactical Vest

2.2 Non-Government Standards.

ISO 9001:2015 Quality Management Systems-Requirements

ANSI/ISO/ASQ Q10012-2003 Measurement Management Systems-Requirements for Measurement Processes and Measuring Equipment

MIL-DTL-32439A Cloth, Duck, Textured Nylon

MIL-STD-810H Environmental Engineering Considerations and Laboratory Tests

A-A-55126C Fastener Tape, Hook and Pile, Synthetic

A-A-59826A Thread, nylon, bonded

ASTM D-6193 Standard Practice for Stitching Seams

ASTM D-3776 Standard Test methods for Mass Per Unit Area (Weight) of Fabric

ASTM D-1777 Standard Test for Thickness of Textile Materials

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

DRAWINGS

2.3 Order of Precedence. Unless otherwise noted herein or in the Contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless the Contractor has obtained a specific exemption from the Government.

3.0 Requirements. The Contractor shall fabricate, test, and deliver ballistic shoot packs in accordance with this PD, Contract-specific delivery orders, and delivery schedules. The Contractor shall ensure that the delivered ballistic shoot packs comply with all of the requirements of the Production Process Package (PPP), Technical Design Package (TDP), Contract, and this PD. Product Manager Soldier Protective Equipment (PM SPE) designates both the MSV and IOTV shoot pack a Critical Safety Items (CSI) so First Article Test (FAT) and Lot Acceptance Test (LAT) are required.

Table I. Requirements

CHARACTERISTIC

REQUIREMENT

/ VERIFICATION PARAGRAPH

FAT

LAT

GOVERNMENT CONFORMANCE INSPECTION*

4.1.1

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6

4.2

4.2.1

4.2.2

4.2.3

4.2.3.1

4.3

4.3.1

4.4

4.4.2

CHARACTERISTIC

REQUIREMENT

/ VERIFICATION PARAGRAPH

FAT

LAT

GOVERNMENT CONFORMANCE INSPECTION*

4.4.3

4.5.1

4.6

4.6.1

4.6.2

4.6.3

4.6.4

4.6.5

4.7.2

4.7.3

LEGEND:

3.1 Materials. The materials and components shall conform to applicable specifications, standards, and patterns required herein (see Table I). The shoot pack system will be pre-assembled, consisting of an approved ballistic inserts and the shoot pack carrier.

3.1.1 Cloth, Ballistic Insert. The ballistic material system will meet the Approved TDP provided in Appendix A or B when be tested as specified in 4.1.1.

3.1.2 Cloth, Ballistic Panel Cover.

3.1.2.1 MSV-B-100. The ballistic panel cover shall be a lightweight, polyurethane coated nylon that does not exceed 210 denier and shall be heat sealed around the ballistic insert with a minimum heat seal width of 0.2 inches. The ballistic cover shall conform to the physical requirements listed in Table IIA, when tested as specified in 4.1.2.1.

3.1.2.2 Pathfinder-S. The ballistic cover shall be a lightweight, nylon ripstop that does not exceed 70 denier 1.9 oz. The ballistic cover shall be sewn around the ballistic insert with a minimum seam edge of 1/4 inches. The ballistic cover shall conform to the physical requirements listed in Table IIA, when tested as specified in 4.1.2.2.

3.1.3 Cloth, Shoot pack carrier. The cloth utilized to fabricate the material shall be textured nylon duck conforming to MIL-DTL-32439 Type III Class 3 meeting the characteristics outlined in Table IIA, when tested as specified in 4.1.3.

TABLE IIA. CLOTH MATERIAL REQUIREMENTS

Break Strength (minimum):

Warp Fill Test Method: ASTM D-5034 lbs.

Tearing Strength (minimum):

Warp Fill

2.5 2.0 2.5 2.0 Test Method:

ASTM D-2261

lbs.

1/ Rated using the AATCC Evaluation Procedure 1, Gray Scale for Color Change and AATCC Evaluation Procedure 2, Gray Scale for Staining.

2/ Evaluated using ASTM D3884 Abrasion Resistance of Textile Fabrics, (Rotary Platform, Double Head Method). H-18 abrasive wheel with 1,000-gram load shall be used.

3.1.4 Fasteners, hook and loop high profile. High profile hook and loop fasteners located throughout the system shall conform to A-A-55126 Type II Class 1 or compatible equivalent and conform to the physical requirements listed in Table IIB, when tested as specified in 4.1. Warp knit loop shall come 1/2 inch width. The extruded hook fastener tape shall be continuous extrusion in 1/2 inch widths. The hook and loop high profile fastener shall meet these requirements when tested as specified in 4.1.4.

TABLE IIB. HOOK AND LOOP FASTENER REQUIREMENTS

Class 1 Unit of Measure and Method of Evaluation

1/ Rated using the AATCC Evaluation Procedure 1, Gray Scale for Color Change and AATCC Evaluation Procedure 2, Gray Scale for Staining.

3.1.5 Thread, non-ballistic. The non-ballistic thread shall be nylon, bonded, Size E (Tex 70-76) or Size F (Tex 90-112), A-A-59826, Type II or compatible equivalent, Tan 499, conforming to the physical requirements listed in Table IIC. The non-ballistic thread shall meet these requirements when tested as specified in 4.1.5.

TABLE IIC. NON-BALLISTIC THREAD REQUIREMENTS

3.1.6 Thread, ballistic. The TDP shall specify the ballistic thread if used for this system. The thread type and break strength shall be verified as specified in the applicable Commercial Item Description as the ballistic thread specified in the Contractor’s ballistic panel build sheet and as specified in 4.1.6.

3.2 Construction. The following requirements apply to all components and subcomponents of the shoot pack system. All shoot pack systems shall consist of (1) a ballistic insert and (2) a shoot pack carrier with insert pockets. End item shoot pack carrier assemblies shall conform to the drawings referenced in the Contract. Unless otherwise noted, a tolerance of +/- 1/8 inch shall be used.

3.2.1 Ballistic Insert Construction. The Government will furnish a TDP for the baseline shoot pack carrier and ballistic insert (see Appendices and drawings). The ballistic material shall meet these requirements when tested as specified in Appendix A and Appendix B. The ballistic insert construction shall meet these requirements when tested as specified in 4.2.1.

3.2.2 Shoot Pack Carrier Construction. Shoot pack carrier construction is detailed in A.1.1 and B.1.1. The ballistic carrier construction shall meet these requirements when tested as specified in 4.2.

3.2.3 Stitching. Stitching shall conform to ASTM D-6193, 8-15 stitches per inch. End of seams and stitches (stitch type 301) that are not caught in other seams or stitching shall be secured through backtacking or backstitching. The Contractor shall secure thread breaks or bobbin run-outs occurring during sewing by stitching back of the break a minimum of ½ inch. Thread shall maintain tension so that there shall be no loose stitching resulting in loose bobbin or top thread, or excessively high stitching resulting in puckering of the materials sewn. The Contractor shall trim thread ends to a length of not more than ¼ inch. Stitching through the composite laminate material, low profile hook, or Laminated Circular Engagement (LCE) shall conform to ASTM D-6193, 6-10 stitches per inch (stitch type 301), and shall avoid needle cutting by sewing multiple stitches along the same stitch line of the material. The stitching shall meet requirements as specified in 4.2.3. All edge stitching shall be 1/8 ± 1/16 inch unless otherwise specified. Fabric edges shall not unravel.

3.2.3.1 Automatic stitching. Automatic stitching machines may be used to perform any of the stitching patterns provided the requirements for the stitch pattern, stitches per inch, size, and type of thread are met and at least three or more tying, overlapping, or back stitches are used to secure the ends of the stitching. The TDP specifies stitching requirements when tested as specified in 4.2.3.1.

3.3 End Item Visual Inspection. As specified in Section 4, the Government will test component and end items in accordance with all the requirements of referenced documents unless otherwise excluded, amended, modified, or qualified in this document or other applicable procurement documents. The Government reserves the right to test and inspect all components and end items to determine conformance to requirements. The end items shall be inspected for the defects listed in Table VI.

3.3.1 End Item Dimensional Inspection. At a minimum, the shoot pack and components shall be inspected for finished measurements as follows and per Table I. All end items shall conform to the drawings.

3.3.1.1 Linear Measurements. Shoot pack end item measurements are taken along the horizontal and vertical center line by holding the material flat and measurements taken to the nearest 1/16 inch. Horizontal and vertical measurements shall be taken for the ballistic insert.

3.4 Identification and traceability. The Contractor shall comply with ISO 9001:2015 Clause 8.5.2 – Identification and Traceability as required by the Contract. Lot numbering is applicable. The Contractor shall maintain traceability records for all component parts used to manufacture the end item product. All component and parts lot identification shall be traceable via each shoot pack’s serial number and Contract number. Subcontractor’s component lot information shall enable traceability to the raw materials used in the component part. The Contractor can make a shoot pack lot from multiple lots of ballistic material, where the Government defines a lot of ballistic material as an individual roll of ballistic material. In the case where there is remaining ballistic material left over from the production-run of a shoot pack lot, the Contractor shall only use that material in the next consecutive lot. Records shall be maintained and made readily available for Government inspection and audit. For end item products identified with individual serial numbers, the traceability requirements listed above shall be traceable via the individual serial number and Contract number. This would mean that if there is a ballistic lot failure, there would be no additional end item lots contaminated.

3.4.1 Certificate of Compliance (CoC). When a CoC is required, the CoC shall certify, by signature of the authorized representative, that the material, component, or service meets the required specifications. Verification of compliance shall be by test, inspection, demonstration, or analysis, on the end item assembly or lower level as appropriate to verify compliance. The Contractor shall maintain a file of every CoC for each FAT and LAT in order to maintain traceability to raw materials and shall submit the complete file attached to a DD 1222 to the Government at final inspection. CoC files shall contain CoCs for all materials and components used in the lot, including test data required, and shall begin with a Summary Table. The CoC Summary Table shall be organized according to the Bill of Materials, include a column to identify for the specific CoC representing material in the current lot, and an indicator of any CoCs represent new lots of material introduced during each production lot. The CoC Summary Table shall have, at a minimum, the information in Table IIIB. For each LAT, the Contractor shall submit a CoC Summary Table along with a DD1222 to the Government and to the approved test lab. The Government will periodically request CoC files and reserves the right to test such items to verify conformance to requirements. The Government will randomly select lots to conduct a full CoC file inspection. The Contractor shall provide all CoC files to the Government at the end of each Delivery Order.

(1) Component CoCs (CoC-C). Component CoCs shall address Workmanship, Safety, Hazardous materials, and Toxicity as applicable. Component CoCs shall have, at a minimum, the information in Table IIIA.

(2) Test CoCs (CoC-T). In addition to Table IIIA, Test CoCs shall provide Test Performance Data, Evaluation Factors, Test Method, Pass or Fail Criteria, Test Quantity, Results per Serial Number(s), and the Pass or Fail Decision.

TABLE IIIA. CERTIFICATE OF COMPLIANCE

3.4.2 Labels. The label shall be of sufficient strength to withstand repeated abrasion during production, storage, and testing. The ballistic insert and shoot pack carrier will be labeled with, at a minimum, the following information:

a) Manufacturer identification

b) Design identification

c) Date of manufacture

d) Lot identification

e) Serial number

f) Contract number

3.4.3 Marking. Both the ballistic insert as well as the shoot pack carrier will be marked per SPE-BAT-20345-6350-001 (MSV-B-100) or SPE-LST-20324-6350-001 (Pathfinder-S). All markings will be indelible under normal environmental conditions.

3.5 Responsibility of compliance. The overall evaluation of the shoot pack shall consider all aspects of the design, including mission capability, operational safety, readiness, reliability, producibility, serviceability, testability, and manufacturing costs respectively. The Contractor shall provide evidence of conformance through CoCs to include test verification, workmanship, hazardous material, toxicity safety, and Berry Amendment guidelines for all components that make up the end item.

3.5.1 Workmanship. The finished shoot pack shall conform to the quality of product established by this PD. The Contractor shall verify and validate that all fabrication procedures yield quality workmanship to meet product specifications and Contract requirements. All materials used in the construction shall consist of quality levels that assure conformance to all requirements unless otherwise authorized. All workmanship shall eliminate and avoid human-induced defects. Manufacturing practices shall consistently yield product that conforms to all requirements in this PD, including implied specifications for the shoot pack and its components. Materials shall produce and integrate to provide consistency of appearance throughout the life of the shoot pack. The Contractor shall ensure all components are free from production debris, stains, and other foreign matter prior to assembly. Material layers shall be free of contaminants such as, but not limited to, any foreign media not associated with the TDP, loose fragments of component materials, or operator elements not part of component materials. Material interfaces shall be compatible and ensure ease of use. This paragraph is applicable to all materials and components of the product whether furnished by the Prime Contractor or by any of their suppliers or subcontractors. The Contractor shall obtain the written consent of the Government prior to making any changes to the material, process, or equipment used in production of the shoot pack. The shoot pack workmanship shall meet these requirements when tested as specified in 4.5.1.

3.6 Performance Requirements.

3.6.1 Areal Density (AD). AD of the shoot pack shall be measured to confirm uniformity of the ballistic material. The ballistic insert (without stitching and the ballistic insert cover) shall not exceed the requirements listed in Table IV, when tested as specified in 4.5. Except for ancillary materials, such as thread, the ballistic insert shall be made entirely of ballistic materials. The ballistic insert design shall be a uniform areal density.

TABLE IV. MAXIMUM AREAL DENSITY (lb/ft2)

3.6.2 Functional Integration. All ESAPI and XSAPI hard armor sizes shall integrate into the shoot pack and function as required when tested in accordance with (IAW) 4.6.2. Insertion of the hard armor will be plate bottom edge first into the hook and loop accessed side of the shoot pack. No rotating of the hard armor will be required to securely seal the hook and loop.

3.6.3 Weight. The ballistic inserts will be measured for weight IAW 4.7.3. Weight notation is for Government reference only.

3.6.4 Ballistic Protection Levels. Testing requirements for the MSV-B-100 are located in Appendix A. Testing requirements for the Pathfinder-S are located in Appendix B.

3.6.5 Operating Environment. Conditioning requirements for the MSV-B-100 are detailed in A.2. Conditioning requirements for the Pathfinder-S are detailed in B.2.

3.7 Testing. The Government reserves the right to perform inspections and verifications, and to witness testing set forth in this document as deemed necessary to ensure that materials and components conform to the prescribed requirements. Table VI delineates requirements for FAT and LAT. The shoot pack shall meet testing requirements when verified as specified in 4.7. The Government may elect to perform testing at their discretion at any time during production for all or selected requirements. FAT and LAT testing shall consist of the following:

a. Sampling. The absence of any inspection requirement shall not relieve the Contractor of the responsibility of ensuring that all items submitted to the Government for acceptance comply with all requirements of the Contract, including this PD. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material. If there is a conflict between the stated requirements in this PD and the ANSI/ASQ Z1.4 standard, the more restrictive standard shall apply. When specified, the Government will subject sample(s) to FAT as specified in the requirements and verification methods within this PD. Test personnel shall randomly select finished shoot packs used for FAT. Test personnel shall perform the sampling selection for LAT (production lot testing) in accordance with ANSI/ASQ Z1.4, as defined by the Contract, except where otherwise indicated. The lot size shall be expressed in units of individual end items. The sample unit shall be one completely fabricated shoot pack. The Government shall select samples randomly from within the finished lot.

b. End item inspection. As specified in Section 4, the Government will test components and end items in accordance with all the requirements of referenced documents unless otherwise excluded, amended, modified, or qualified in this document or other applicable procurement documents. The Government reserves the right to test and inspect all components and end items to determine conformance to requirements.

3.7.1 First Article Test (FAT). FAT inspection and approval under the appropriate provisions of FAR 52.209.3 shall precede all authorized production of CSI Personal Protective Equipment (PPE) such as the shoot pack. In some cases, the Government will perform verification on a test item that has been previously subjected to another verification test. The Government will subject FAT samples, representing full production quality, to first article inspection as specified in this PD (see 4.7.2).

a. All FAT samples shall be accompanied by a DD1222 signed by the Government. In addition, the Contractor shall submit a binder containing final test reports for all materials and components called out in 3.1 of this PD. All test reports shall be no older than 180 days at the time of submission. If testing is not complete on any components called out in 3.1, then testing personnel shall evaluate components during FAT.

b. FAT approval only applies to the specific TDP submitted as specified in 3.7.1.a. Any changes to the PPP such as, but not limited to, production processes, work instructions, or material providers, must be tested with a separate FAT as specified by the Government in 3.7.1 and 4.7.1.

c. After original FAT approval, any material or process changes to any item potentially affecting the performance of critical safety features shall undergo FAT to ensure delivered items continue to meet the requirements of this PD.

3.7.2 Lot Acceptance Test (LAT). The Government will subject all lots to LAT. The Contractor shall submit LAT samples representing full production quality with evidence of CoCs (see 3.4.1). The Government subjects these samples to LAT verification as specified in 4.7.3. The Government has stated the acceptance criteria for each inspection herein. Unless noted otherwise, the Government will conduct all LAT under ambient conditions.

4.0 VERIFICATION

4.1 Materials verification. The materials and components shall conform to applicable specifications, standards, and patterns required herein as stated in 3.1. The Government has sole authority to determine whether called out manufacturer part numbers are equivalent. During determination of equivalency, the Government reserves the right to perform any of the inspections or testing set forth in this document where the Government deems such inspections are necessary to ensure the supplies conform to the prescribed requirements. Such verification methods include but are not limited to, CoC process surveillance, audits, tests, or visual examinations. The materials shall conform to applicable specifications, standards, and patterns required herein. When part or component manufacturers are referenced herein, it will be according to alphabetical order, not by preference.

4.1.1 Cloth, Ballistic Insert. The Contractor shall verify the ballistic material conforms to the physical requirements in the requirements document for the specific material selected and identified on the TDP. Ballistic materials shall meet requirements as specified in 3.1.1.

4.1.2 Cloth, Ballistic Panel Cover.

4.1.2.1 MSV-B-100. The Contractor shall verify the ballistic panel cover meets requirements detailed in TABLE-IIA at FAT and through visual inspection and CoC-T at LAT. The ballistic panel cover shall meet requirements as specified in 3.1.2.1.

4.1.2.2 Pathfinder-S. The Contractor shall verify the ballistic panel cover meets requirements detailed in TABLE-IIA at FAT and through visual inspection and CoC-T at LAT. The ballistic panel cover shall meet requirements as specified in 3.1.2.2.

4.1.3 Cloth, Shoot pack carrier. The Contractor shall verify the ballistic panel cover meets requirements detailed in TABLE-IIA at FAT and through visual inspection and CoC-T at LAT. Cloth shall meet requirements as specified in 3.1. 3.

4.1.4 Hook and Loop Fastener. The Contractor shall verify hook and loop fasteners conform to A-A-55126 Type II Class 1 through visual inspection and CoC-T. Fasteners shall meet requirements as specified in 3.1.4.

4.1.5 Thread, Non-Ballistic. The Contractor shall verify non-ballistic thread conforms to requirements in 3.1.14 through visual inspection and CoC-T. Non-ballistic thread shall meet requirements as specified in 3.1.5.

4.1.6 Thread, Ballistic. The Contractor shall verify the ballistic thread conforms to the physical requirements in the requirements document for the specific thread selected and identified on the Build Sheet. Ballistic thread shall meet requirements as specified in 3.1.6.

4.2 Construction. The cut parts for the shoot pack carrier and ballistic materials shall be 100% inspected by the Contractor during the cutting process to identify parts containing defects such as a hole or cut. Whenever a nonconformance is noted, the Contractor shall remove the item from production. The Contractor shall not re-work the nonconforming item but may produce a new item following only the procedures, work instructions, and processes contained in the FAT-approved PPP and design build. Construction verification shall meet requirements as specified in 3.4.

a. Visual examination. Testing personnel shall examine the shoot pack for defects and shall classify all defects as shown in Table VI according to MIL-STD-961.

b. Patterns, Drawings, and Design. End item shoot packs shall conform to the drawings referenced in the Contract. Unless otherwise noted, a tolerance of +/- 1/8 inch shall be used.

4.2.1 Construction Verification of the Ballistic Insert Material System. The ballistic material system shall meet the Approved FAT design and shall conform to the system descriptions in Appendix A and Appendix B. Ballistic inserts shall be 100% inspected by the Contractor during the assembly of the individual groups. The Contractor shall ensure ballistic inserts contain the correct number of plies; that no individual ply is pieced; that the quality of each individual ply is free from defect holes, cuts, tears, smash floats, slubs, thin places, mend patches, creases, wrinkles, excessively soiled or stained);and that all plies are marked correctly as to the size and number of plies. Ballistic material verification shall meet requirements as specified in Table A-I and Table B-I.

a. In-process visual examination of ballistic material system for size. Table VI provides visual examination criteria for the ballistic material system.

4.2.2 Shoot pack carrier construction. The cut parts for the carrier materials shall be 100% inspected by the Contractor during the cutting process to determine that parts containing defects such as a hole or cut, are removed from production.

4.2.3 Stitching. Testing personnel shall inspect the end items for the defects listed in Table VI. The sample unit shall be one completely fabricated shoot pack carrier assembly with ballistic insert.

4.2.3.1 Automatic Stitching. Testing personnel shall inspect the end items for the defects listed in Table VI. The sample unit shall be one completely fabricated carrier assembly or individual component.

4.3 End Item Visual Inspection. Testing personnel shall inspect the shoot pack for the defects listed in Table VI.

4.3.1 End Item Dimensions. Testing personnel shall inspect the end items for finished measurements as specified in 3.3.1.

4.3.1.1 Linear Measurements. The Government will measure shoot pack end items along the horizontal and vertical center lines of each by holding the material flat and by measuring to the nearest 1/16 inch. The Government will take horizontal and vertical measurements for the ballistic insert.

4.4 Identification and traceability. The Government will verify materials, components, and finished shoot pack inspection and assessment results as specified in 3.4.

4.4.1 Certificate of Compliance (CoC). CoCs shall verify the Contract number, purchase order number, part number or serial number, lot or batch number, quantity, Berry Amendment compliance, facility name, address and phone number of testing or purchase, MIL STD and DTL Compliance, and signature of quality verification. Conformance shall be verified by test, inspection, demonstration, or analysis on the end item assembly or lower level (i.e., materials, end item, construction, testing) as appropriate. The Government reserves the right to test such items to verify conformance to requirements. The Prime Contractor shall attach the CoC to a DD1222 when providing samples for LAT. The Contractor shall present all component CoCs for each LAT to the Government for verification during LAT presentation, and shall maintain records as appropriate. CoC verification shall meet requirement as specified in 3.4.1.

4.4.2 Labels. Test personnel shall verify labels meet the minimum requirements set forth in 3.4.2.

4.4.3 Marking. Test personnel shall verify markings meet the minimum requirements set forth in 3.4.3.

4.5 Responsibility of Compliance Verification. Testing personnel shall verify that the finished shoot pack meets the quality of product established by this PD. This is applicable to all components whether finished by the Prime Contractor or the Prime’s subcontractors. The Contractor shall use the utmost care during fabrication to verify and ensure quality workmanship and the safety of the service person using the item. The Prime Contractor shall immediately report any deviations in acceptable manufacturing procedures or the quality of materials to the Contracting Officer or his/her designee. Except as otherwise specified herein, the Government does not allow repairs to the shoot pack. Compliance verification shall meet requirements as specified in 3.5.

4.5.1 Workmanship. Testing personnel shall verify that the finished shoot pack meets the quality of product established by this PD. This is applicable to all components whether finished by the Prime Contractor or the Prime’s subcontractors. The Contractor shall use the utmost care during fabrication to verify and ensure quality workmanship and the safety of the service person using the item. The Prime Contractor shall immediately report any deviations in acceptable manufacturing procedures or the quality of materials to the Contracting Officer or his/her designee. Except as otherwise specified herein, the Government does not allow repairs to the shoot pack. Workmanship verification shall meet requirements as specified in 3.5.1

4.6 Performance Requirement Verification.

4.6.1 Areal density. Testing personnel shall calculate areal density on unstitched ballistic material (no ballistic cover) for the base as specified in ASTM D-3776, Standards Test Methods for Mass per Unit Area of Fabric, Option C, with exceptions.

4.6.1.1 Areal density shoot pack. The Contractor shall build shoot packs used for the areal density calculation as specified in 3.6.1. Each 15 inch by 15 inch ply of ballistic material (no ballistic cover) shall have two (2) 100 centimeter squared (cm2) die cut samples cut out and weighed independently to the 0.001 lbs. The weight percent difference between the first sample and the second sample shall be within 2%. The areal density for a single ply shall be the total mass of the two pieces divided by the total area of the two pieces. Testing personnel shall calculate the actual areal density for the entire ballistic material by adding each ply’s areal density together. Testing shall conduct areal density calculations on two (2) shoot packs. The average of the areal densities measurements is determined and compared against the requirement in the associated TDP in the Appendices.

4.6.2 Functional integration verification. One barehanded person shall demonstrate insertion of the hard and soft armor ballistic inserts into the shoot pack carrier pouches without tools or special aids. Insertion of hard and soft armor ballistic inserts shall require a maximum of 30 seconds for each item. Body armor and carrier interoperability shall meet the requirements as specified in 3.4.7.

4.6.3 Weight. The shoot pack ballistic inserts will be measured for weight. Weights are taken on a tared scale and measured to the nearest 0.01 pound. Weight notation is for Government reference only.

4.6.4 Ballistic Protection Testing. All ballistic testing for FAT and LAT shall be conducted at Aberdeen Test Center (ATC) test facility. ATC will submit all ballistic reports to PM SPE for acceptance purposes.

4.7 Test and Inspection.

4.7.1 Test Reporting. The tester shall report test data as required by 4.7.3.6 (ballistic test criteria) below.

4.7.1.1 Classification of Test and Inspections. The test and inspection requirements specified herein are classified as outlined below. Unless otherwise specified, the Contractor is responsible for the performance of all test and inspection requirements specified herein. The Government reserves the right to perform any of the test and inspections set forth where such tests and inspections are deemed necessary to ensure the supplies conform to prescribed requirements.

a) First Article Test (see 4.7.2)

b) Lot Acceptance Test (see 4.7.3)

4.7.2 First Article Test. A First Article Test shall be performed at ATC for the items listed in Table I under the column marked FAT. An approved FAT will remain in effect until LAT failure rules apply (see 4.7.3) or until the Contractor ceases manufacture of an approved First Article design for a period of 180 consecutive days or more. When multiple designs have been approved over the course of the Contract, each design production time will be self-contained. Non-production under this stipulation will result in automatic revocation of the FAT approval.

4.7.2.1 First Article Testing Protocol. Shoot pack First Article Testing shall be conducted in accordance with paragraph 4.7.2 and the following:

FAT Testing Instruction:

Shot patterns are as specified below for all V50. Starting velocity shall be approximately 100 feet per second (fps) above required minimum V50 and shall follow up and down procedure as specified in MIL- STD-662F.

Diagram I. First Article Test Shot Patterns

3 inches

0 degree obliquity 7 16 shots

45 degree obliquity4.5 inches 3 inches

12 shots

AR/PD 11-01 Rev C

Comments, suggestions, or questions on this document should be addressed to Product Manager – Soldier Protective Equipment, Program Executive Office – Soldier, US Army, 10170 Beach Road, Building 328T, Fort Belvoir, Virginia 22060. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only for Administrative or Operational Use as determined on 18 September 2019. Other requests for this document shall be referred to Product Manager-Soldier Protective Equipment, Program Executive Office Soldier, US Army, 10170 Beach Road, Building 328T, Fort Belvoir, Virginia 22060.

AMSC N/A

FSC 8470

TABLE V. VS/VR STARTING VELOCITY

Velocity

4.7.2.2 Ballistic Qualification. At any point after a First Article Test has been approved, any material or process change to the ballistic package will require the new ballistic package to pass all ballistic First Article Test requirements as specified in 4.7.2.

TABLE VI. END ITEM DEFECTS

Any abrasion marks, broken or missing yarns or multiple floats.

smash.

Not firmly and tightly woven, edges frayed or scalloped.

Seams and Stitching

More than ½ inch NOTE: a seam shall be classified as an open seam when one or more stitches joining a seam are broken or when two or more consecutive skipped or runoff stitches occur.

Seam & Stitch Type Wrong seam or stitch type.

loose bobbin or top thread.

Excessively tight, resulting in puckering of material.

open seams.

Component & Assembly Any area of ballistic insert bunched (i.e., does not lie flat).

Any component part omitted or not as specified (unless otherwise classified herein).

Needle chews.

Any mend, darn, patch, holes, splice or other unauthorized repair.

covered by component part.

Component and Location Dimensions Not within specified tolerance.

(1) 3/16 inch to 3/8 inch at any point around the periphery. 1/ 2/

(2) More than 3/8 inch at any point around the periphery. 1/ 2/

(3) 1/8 inch up to 3/16 inch around entire periphery. 2/

B) larger than cutting pattern by 3/8 inch or more at any Point. 1/ 2/

for a distance of 2 inches or more or in several areas with an accumulated distance of 5 inches or more

(2) By more than 1/4 inch for a distance of 2 inches or more in several areas with an accumulated distance of 5 inches or more

Gaps or bubbles in heat seal around the ballistic insert.

Heat seal width under 0.2 inches.

*The presence of a number designates critical, major or minor. The value of the number is for internal inspection purposes only.

** Critical Items will be for Ballistic Materials only 1/ to be scored when condition exists for a length of more than 2 inches or if condition exists in several areas with an accumulated distance of 4 inches.

2/ the shoot pack carrier individual components, as applicable shall be examined with the applicable cutting pattern

4.7.3 Lot Acceptance Testing Protocol.

4.7.3.1 Requirements and Verifications. Table I delineates performance requirements verified through visual methods, including physical measurements, in order to determine that no deficiencies exist.

4.7.3.2. Functional Integration. An insertion demonstration shall be performed with Mock ESAPI conforming to drawings 2-6-0588, 2-6-0589, 2-6-0590, 2-6-0591 and 2- 6-0592, produced at the maximum thickness dimension, without tools or special aids. The shoot pack hook and loop shall be closed and secured on the same side as the top of the ESAPI or XSAPI. Insertion of the hard armor will be plate bottom edge first into the hook and pile accessed side of the shoot pack. A defect shall be scored if any ESAPI or XSAPI must be forced into or cannot easily be inserted or removed from the shoot pack, or if excessive force is needed to secure the hook and loop. No rotating of the hard armor should be required to securely seal the hook and loop.

4.7.3.3 Ballistic Performance. First Article Testing and Lot Acceptance Testing will be conducted on the complete end item shoot packs. Failure to meet the requirements of any sub-test will constitute failure for the entire First Article Test or Lot Acceptance Test.

4.7.3.4 Shoot Pack Fragmentation Protection. The ballistic material system (Table A-I for MSV-B-100 and Table B-I for Pathfinder-S) shall provide consistent ballistic performance. All shoot packs shall be made from the same approved ballistic package. Tables A-IV and A-V (for MSV-B-100) and Tables B-IV and B-V (for Pathfinder-S) list the required minimum V50 values at specified obliquity when tested with the Fragment Simulating Projectile (FSP) and Right Circular Cylinder (RCC). Testing is specified in section 4.0.

4.7.3.5 Handgun Protection. Tables A-III and A-V (for MSV-B-100), and Tables B-III and B-V (for Pathfinder-S) outline the ballistic material system minimum V50 and Resistance to Penetration (RTP) acceptance for the required threats.

4.7.3.6 Ballistic Test Criteria. For all Protection Ballistic Limits (BL), V50, Vs/Vr, and RTP acceptance tests, the Government will require the following minimum information to validate performance:

a) Description including exact materials and areal density of ballistic insert, and sizes and weights of all components.

b) Conditioning of shoot pack.

c) Test projectile, threat code and the difference between reference weight and test projectile weight (do not include threat weight, only the difference (±) between the test projectile and referenced projectile weight).

d) Temperature and humidity measurements.

e) Yaw angle.

f) Angles of target obliquity.

g) All velocity measurements of each test shot used to test the shoot pack (regardless of whether that particular velocity was used in the V50 or RTP determination). Ensure proper drag table for each threat is used to calculate impact velocity.

h) Velocity loss and corrected striking or residual velocity. Strike velocity shall be used for ballistic requirements.

i) PP (Partial Penetration) and CP (Complete Penetration) next to each shot velocity as determined.

j) Angle of spall or debris ejection if applicable.

k) Type of gun barrel, caliber, propellant type, propellant weight, twist rate, and gun barrel serial number.

l) Range measurements including distances from gun barrel to velocity measurement devices and target.

m) Back Face Deformation measurements in mm with significant digits recorded only to the accuracy of the measurement method.

n) Name of organization or company performing tests.

o) Calculated V50 BL. In a situation where the V50 BL, Vs/Vr, or RTP data sheet would compromise the Security Classified Guide for Armor Materials, the data sheet should exclude the specific projectile used during testing.

p) Shoot pack weight and ply count per ballistic material layer (e.g.,8 Twaron/18 Kevlar/8 Twaron).

q) Clay drop temperatures, locations, depth, and clay box number.

r) Remarks or Notes for all testing anomalies, unfair hits, etc.

s) All shot locations.

t) Revision #/level of all ballistic test software used by test lab (e.g., FARO software including smoothing function, etc.).

4.7.3.7 Projectile Velocity Determination. Projectile velocity and time of flight measurements shall be in accordance with ITOP 4-2-805. Instrumental velocity shall be translated into strike velocity at the target and the strike velocity shall be used for ballistic requirements. Projectile velocity measurement methods shall employ either high velocity lumiline screens or electrical contact screens which either open or close an electric circuit by passage of the projectile through the detector. Contact screens may consist of metallic foils separated by a thin insulating layer, or may consist of a circuit printed on paper with the circuit spacing such that the projectile passing through the screen will break the circuit. An electric counter type chronograph measuring to the nearest microsecond or as a minimum to the nearest 10 microseconds will be used with these measuring devices. As an alternative, radiographic equipment calibrated to capture the projectile at various time intervals of flight can be used. For all projectiles, velocity correction methodology shall be used to calculate the actual striking velocity and, where appropriate, actual residual velocity.

4.7.3.8 Weapon Mounting Configuration. The spacing from the weapon muzzle to the first pair of triggering devices shall be sufficient to prevent damage from muzzle blast and obstruction from smoke in case optical devices are used. Recommended distances can be found in ITOP 4-2-805. Spacing between triggering devices is a function of the expected velocity of the projectile being fired. In many instances, physical restriction, such as short overall distance from muzzle to test sample dictates the spacing of the triggering devices. The last pair of triggering devices shall be placed at least four (4) feet (122 cm) in front of the test sample and should be protected from possible damage resulting from fragments.

4.7.3.9 Environmental Test Conditions. All ballistic tests will be performed at 68 +/- 10 degree F and 50-percent ± 20-percent relative humidity (RH). Temperature and humidity measurements will be recorded at the beginning of each test.

4.7.3.10 Projectile Yaw Determination. Projectile yaw shall be measured for each firing by yaw cards, flash radiograph or photography. Any round for which yaw is determined to be greater than degrees shall be disregarded in the calculation of the ballistic limit. The measurement system employed should be capable of measuring yaw within an accuracy of 1.0 degrees.

4.7.3.11 V50 BL Calculation. V50 will be determined in accordance with MIL-STD-662. For Lot Acceptance Testing, three (3) Partial Penetrations (PPs) and three (3) Complete Penetrations (CPs) within a 125 fps velocity spread, or five (5) Partial Penetrations (PPs) and five (5) Complete Penetrations (CPs) within a 150 fps velocity spread yield the V50 BL determination that will be accepted. First Article Testing will require five (5) Partial Penetrations (PPs) and five (5) Complete Penetrations (CPs) within a 150 fps velocity spread to determine V50 BL.

4.7.3.12 PP and CP Determination for V50. Complete and Partial penetrations (4.7.3.3) will be determined based on the impressions left on an aluminum witness sheet. A 0.020 in. (0.51 mm thick 2024 T3 sheet of aluminum) shall be placed 6 + 1/2 in. (152 + 12.7 mm) behind and parallel to the target.