ACE_Matting_TDP_29JULY21.pdf

INCH-POUND

DETAILED SPECIFICATION

FIBER-REINFORCED POLYMER (FRP) MAT FOR TEMPORARY ROADS

This specification is approved for use by all Departments and Agencies of the Department of Defense within the distribution limitations noted at the bottom of the page.

1. SCOPE

1.1. Scope. This specification describes the requirements for manufacturing fiber-reinforced polymer (FRP) panels made of layers of glass fiber impregnated with polyester resin. The FRP mats function as expedient road system.

1.2. Size and Quantity. The FRP panels shall be 80 x 80 inches and produced according to dimensions in the drawings in Appendix A.

2. APPLICABLE DOCUMENTS

2.1. General. The documents listed in this section are specified in sections 3 or 4 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or 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 of documents cited in sections 3 or 4 of this standard, whether or not they are listed.

2.2. Government Documents.

2.2.1. Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-M-43248C Mats, Reinforcing, Glass Fiber MIL-Y-1140 Yarn, Cord, Sleeving, Cloth, and Tape-Glass

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129R Military Marking for Shipment and Storage MIL-STD-1916 DoD Preferred Methods for Acceptance of Product

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094)

Distribution limited to US Government agencies and their contractors; critical technology.

2.3. Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DoDISS are the issues of the documents cited in the solicitation.

ASTM INTERNATIONAL

ASTM D123-13a Standard Terminology Relating to Textiles ASTM D696 Standard Test Method for Coefficient of Linear Thermal

Expansion of Plastics between -30°C and 30°C with a Vitreous Silica Dilatometer

ASTM D790 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM C881/M Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM D1929-96 Standard Test Method for Determining Ignition Temperature of Plastics

ASTM D2565 Standard Practice for Xenon-Arc Exposure of Plastics Intended for Outdoor Applications

ASTM D2583 Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor

ASTM D3039/M Standard Test Methods for Tensile Properties for Polymer Matrix Composite Materials

ASTM D3953-15 Standard Specification for Strapping, Flat Steel and Seals

ASTM D4389 Standard Specification for Finished Glass Fabrics Woven from Rovings

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 or obtained at www.astm.org .)

2.4. Order of Precedence. In the event of a conflict between the text of this document and the references cited herein (except for related associated specifications or specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. N/A

3.2. Materials. Materials shall be as specified herein and in applicable specifications and standards, and other reference documents. Materials not specified shall be selected by the contractor and shall be subject to all provisions of this specification. Materials shall be free of defects which adversely affect performance of serviceability of the finished product. Certification that the herein specified materials meet the requirements of this specification shall be made available to the government at any time upon request.

3.2.1. FRP material. The FRP panels shall be fabricated from fiberglass and polyester resin using a closed molding process (i.e., Resin Transfer Molding (RTM) or Vacuum http://www.astm.org/

Resin Transfer Molding (VRTM)). The FRP panels shall be fabricated as shown in the drawings given in Appendix A. All FRP panels shall include UV inhibitors to minimize degradation during outdoor use. Panels shall be colored “Army” green. A compatible pigment shall be introduced to the resin prior to molding to achieve the proper color. A gel coat shall not be used to achieve proper color.

3.2.1.1. Polyester resin. The FRP panels shall be fabricated using a polyester resin. The resin shall be polyester, thermosetting, RTM laminating type. A catalyst should be used to achieve appropriate gel times. The resin and catalyst composition shall be designated by a code number. The code number may include a trade name, if desired. Any changes in the resin components or manufacturing process shall necessitate use of a different code number. The cured resin shall not be corrosive to metals. When used in conjunction with the fiberglass reinforcement specified in 3.2.1.2, the resin shall produce a laminate with the required physical properties listed in Table I. Furthermore, the resin and catalyst combination in conjunction with the fiberglass reinforcement (3.2.1.2) shall produce a laminate which retains a minimum of 90 percent of the required flexural strength and tensile strength (Table I) after being exposed to artificial ultra violet (UV) light for 720 hours, as per ASTM 2565 Table 1, Cycle Number 2 of this specification.

3.2.1.2. Fiberglass reinforcement. The fiberglass reinforcement shall produce a laminate with the required physical properties listed in Table I.

3.2.1.2.1. Fiberglass type. The fiberglass reinforcement used for the mat panels shall be a fiberglass fabric mat reinforcement composite Type V, consisting of a multi-axial woven, stitched, or knitted roving stitched or bonded to a Type III, Class I, Grade A chopped strand backing per MIL-M-43248C. One ply is defined as the combination of the roving bonded to the chopped fiber layer. Definitions of the textile terms used herein are described in ASTM D123. All fiberglass used in the roving, continuous strand, and chopped fiber mat portions of the reinforcement shall be E-type (MIL-M-43248C). The glass shall be white in color.

3.2.1.2.2. Roving. The roving material shall be constructed by weaving, stitching, or knitting individual rovings in multi-axial (2 or more) directions.

3.2.1.2.3. Chopped strand mat. The chopped strand mat shall consist of randomly oriented strands. The strands shall be treated with a silane sizing compatible with the polyester resin in accordance with ASTM D4389 and shall be bonded together with a compatible bonding agent. Additional thin chopped strand layers may be added as required to promote a proper bond between reinforcement layers.

3.2.1.3. Continuous strand mat. The continuous strand mat shall be a continuous filament mat consisting of randomly oriented strands in multiple layers held together with a polyester binder and with a silane coupling agent. Continuous strand mat shall be compatible with the polyester resin (3.2.1.1).

3.2.1.4. Color of panels. All surfaces of the FRP panels shall be colored representative of an “Army” green using pigmented resin. The selected pigment shall be compatible with the polyester resin (3.2.1.1). Excessive flaking, peeling, or scaling of panel coloring shall be grounds for rejection of the product.

3.2.1.5. Non-skid. The top wearing surface of each panel shall be embossed with a .125-inch x .125-inch x .125-inch pyramid shape non-skid texture except for the underlap edges.

3.3. Panel Dimensions and Weights. All panels shall be identical to the extent necessary to ensure interchangeability of component parts, assemblies, accessories, and spare parts.

3.3.1. FRP panels. FRP panels shall be finished to dimensions shown in Appendix A, Drawing G-101. Panel edges shall be recessed to 0.18 - 0/+.125 inch thickness on top edge (overlap) and 0.18 - 0/+.125 inch thickness on the bottom edge (underlap).

Two adjacent edges of a panel shall have the recess at the panel bottom; the other two edges shall be recessed at the panel top. The thickness of the panels in the center shall be 0.36 - 0/+.125 inches. The 2.50-inch diameter hole pattern along the underlap edges and along the overlap edges is shown in Appendix A, Drawing G- 101.

3.3.2. Weight. Approximate weight of the panels shall be approximately 120 lbs.

3.4. Polyester Resin. The panels shall be fabricated using a polyester resin (3.3.1.1) applied at a ratio of fiberglass reinforcement to resin of approximately 55:45 by weight. The exact rate of application shall be adjusted as required to obtain the specified properties and dimensions of the mat. The polyester resin shall thoroughly wet all reinforcement.

3.5. Holes. Holes shall be cut on the panel overlap and underlap edges in accordance with the patterns shown in Appendix A. The holes on the underlap and overlap edges of the panels shall be 2.50 +/- 0.06 inches in diameter.

3.6. Mechanical Properties. The cured resin shall produce a laminate having the mechanical properties shown in Table I

TABLE I. Required properties of FRP panels

Property Requirement Test Method Reference

Tensile Strength, x or y-axis (Min) 32,000 psi ASTM D3039/M

Flexural Strength, x or y-axis (Min) 42,000 psi ASTM D790

Thermal Expansion (Max) 1.8 x 10-5 in/in/°C ASTM D696

Ignition Temperature, Flash (Min) 450° F ASTM D1929

Hardness, Top (Min) 45 ASTM D2583

Hardness, Bottom (Min) 45 ASTM D2583 Note: The x-direction is defined as the direction transverse to the intended direction of trafficking. The y-direction is defined as the direction parallel to the intended direction of trafficking

3.7. Workmanship. Workmanship for the FRP panels shall be of the quality prevailing among manufacturers normally producing similar items to those specified. Quality Control shall be of the quality prevailing among manufacturers normally producing similar items to those specified, and the panels shall be free from the following defects:

a. Insufficient thickness

b. Incorrect hole placement or size

c. Delamination

d. Dry spots

e. Voids

f. Blisters

g. Crazing

h. Cracks or tears

4. PACKAGING

4.1. Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order. When actual packaging of material is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activity within the Military Department or Defense Agency, or within the Military Department’s System Command. Packaging data retrieval is available from the managing Military Department’s or Defense Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

4.1.1. Recommended FRP panel packaging requirements. Twenty stacked panels shall be wrapped in one layer of polyethylene sheeting, 10 mils. The color of the sheeting shall be white, black, or grey. Prior to banding, the exterior of the packaged assembly shall be sealed to help prevent moisture intrusion. The stacked, wrapped, and sealed assemblies shall be banded along the entire approximate 80-inch length of the stacked assembly by flat steel metallic bands conforming to ASTM D3953, Type 1, Regular Duty High-Strength strapping, size 5/8-inch by 0.023-inches thick.

One band shall be placed on the center line of the 80-inchs side of the stack and one band 28 inches on both sided so the center band. A plastic edge protector of 2.5-inch width and 1.75-inch leg length shall be used to protect the FRP panels from the steel banding at each point of corner contact with the stacked panels (four protectors per band). The plastic edge protector shall be PAC Strapping Products CP-122 or equivalent.

APPENDIX A

MAT DETAIL DRAWINGS

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4.000"

8.125"

FRP ROAD PANEL, PLAN VIEW

SCALE:NTS

NOTES:

1. ALL HOLES ON UNDERLAP/OVERLAP EDGES ARE 2.50" ±.06" DIAMETER.

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ABBREVIATIONS

O.E. OVERLAP EDGE

U.E. UNDERLAP EDGE

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SECTION A-A, LOWER JOINT (UNDERLAP)

SCALE: NTS

NOTES:

1. ALL DIMENSIONS ARE IN INCHES.

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SECTION B-B, UPPER JOINT (OVERLAP)

SCALE:NTS

NOTES:

1. ALL DIMENSIONS ARE IN INCHES.

mmm FIBERGLASS REINFORCEMENT

- ~ CONTINUOUSSTRAND

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