Attachment 0001 MIL-PRF-32233D.pdf

Comments, recommendations, additions, deletions, clarifications etc. and any data that may improve this document should be sent to U.S. Army Ground Vehicle System Center, ATTN:

FCDD-GVS-SAT, MS #267, 6501 E. 11 Mile Road, Detroit Arsenal, MI 48397-5000 or emailed to usarmy.detroit.ccdc-gvsc.mbx.standardization@mail.mil. 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/.

AMSC N/A FSC 5430

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

INCH-POUND

MIL-PRF-32233D

07 March 2022

SUPERSEDING

MIL-PRF-32233C

04 January 2021

PERFORMANCE SPECIFICATION

TANKS, COLLAPSIBLE,

3,000, 10,000, 20,000, 50,000, AND 210,000 U.S. GALLONS,

FUEL

This specification is approved for use by all Departments and Agencies of the Department of Defense.

1. SCOPE

1.1 Scope. This performance specification covers 3,000, 10,000, 20,000, 50,000, and 210,000 U.S. gallon capacity, collapsible fuel storage tank assemblies.

1.2 Classification. Tanks will be of the following sizes as specified (see 6.2).

Size I: 3,000 U.S. gallons Size II: 10,000 U.S. gallons Size III: 20,000 U.S. gallons Size IV & IV-A: 50,000 U.S. gallons Size V: 210,000 U.S. gallons

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2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification 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 documents cited in sections 3 and 4 of this specification, 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 cited in the solicitation or contract.

INTERNATIONAL STANDARDIZATION AGREEMENT

STANAG-3747 Guide Specifications (Minimum Quality Standards) for Aviation Turbine Fuels (F-24, F-27, F-34, F-35, F-37, F-40 and F-44), AFLP-3747

COMMERCIAL ITEM DESCRIPTION

A-A-52022 - Repair Outfits, Collapsible Tanks, and Drums (ROCTAD) A-A-59326 - Coupling Halves, Quick-Disconnect, Cam-Locking Type, General Specification For

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5624 - Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-DTL-83133 - Turbine Fuel, Aviation, Kerosene Type, JP-8 (NATO F-34), NATO F-35 and JP-8+100 (NATO F-37) MIL-DTL-25524 Turbine Fuel, Aviation, Thermally Stable (JPTS) MIL-PRF-370 - Hose and Hose Assemblies, Nonmetallic: Elastomeric, Liquid Fuel

(Copies of these documents are available online at https://quicksearch.dla.mil.)

ATPD-2262 - Berm Liner Assemblies ATPD-2263 - Repair Kit and Repair Kit Components for Collapsible

Fabric Tanks and Drums

(Copies of these documents are available from U.S. Army RDECOM, Tank Automotive Research, Development and Engineering Center, ATTN: RDTA-EN/STND/TRANS MS #268, 6501 E. 11 Mile Road, Warren, MI 48397-5000 or can be requested by sending an email to usarmy.detroit.rdecom.mbx.tardec-standardization@mail.mil.)

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https://quicksearch.dla.mil/ mailto:usarmy.detroit.rdecom.mbx.tardecstandardization@mail.mil

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 - Identification Marking of U.S. Military Property MIL-STD-810 - Environmental Engineering Considerations and Laboratory

Tests

(Copies of these documents are available online at https://quicksearch.dla.mil.)

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 these documents are those cited in the solicitation or contract.

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

AATCC 111 - Weather Resistance of Textiles: Exposure to Daylight and Weather

(Copy of this document is available online at http://www.aatcc.org/testing/methods/topical.htm.)

ASTM INTERNATIONAL

ASTM D 381 - Fuels by Jet Evaporation, Gum Content In ASTM D 413 - Rubber Property - Adhesion to Flexible Substrate ASTM D 471 - Rubber Property - Effect of Liquids ASTM D 750 - Rubber Deterioration Using Artificial Weathering

Apparatus, Standard Practice for ASTM D 751 - Fabrics, Coated ASTM D 975 - Oils, Diesel Fuel ASTM D 1149 - Rubber Deterioration – Surface Ozone Cracking in a

Chamber ASTM D 1655 - Standard Specification for Aviation Turbine Fuels ASTM D 3776 - Fabric, Mass per Unit Area (Weight) of ASTM G 155 - Operating Xenon Arc Light Apparatus for Exposure of

Non-Metallic Materials

(Copies of these documents are available online at http://www.astm.org.)

SAE INTERNATIONAL

SAE AMS-STD 595 - Colors Used in Government Procurement

(Copies of these documents are available online at www.sae.org.)

2.4 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, the text of this

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https://quicksearch.dla.mil/ http://www.aatcc.org/testing/methods/topical.htm http://www.astm.org/ document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Description. The tank assembly shall consist of a collapsible tank with attached handles and fittings, accessories, berm liner, emergency and long-term repair kits, hose support pads, and tank chest, unless otherwise specified (see 6.2). The tank assembly shall be for storage of military specification fuels in accordance with 3.3.3.

3.2 First Article. When specified (see 6.2), a tank assembly (or assemblies) shall be subjected to first article inspection in accordance with 4.2.

3.3 Materials. The manufacturer shall verify that the materials used meet all of the operational and environmental requirements specified. The contractor shall verify that properties of all fabrics used during manufacturing of first articles and tank assembly lots meet the requirements of this specification and any property changes are subject to a re-verification and/or an Engineering Change Proposal (ECP). The tank assembly shall be newly fabricated from recovered materials to the maximum extent practicable, provided the components meet all other requirements of this specification. The materials shall be of sufficient durability to meet all the requirements as specified herein. No material shall have an adverse effect on the health of personnel when used for its intended purposes.

3.3.1 Deterioration Prevention and Control. The tank assembly shall be fabricated from compatible materials, inherently corrosion resistant, or treated to provide protection against various forms of corrosion or deterioration to which they are susceptible.

3.3.2 Recycled, Recovered, or Environmentally Preferable Materials. Recycled, recovered, environmentally preferable, or biobased materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. Used, rebuilt, or remanufactured components shall not be permitted.

3.3.3 Fuel Compatibility. The contractor shall certify that each tank assembly is compatible for service with all of the fuels listed below. In this context, compatibility means that the tank assemblies shall meet the requirements of 3.5, 3.6 and 3.7. In addition, tank base fabric samples and seam samples shall meet the requirements of Tables I & II, respectively, for all fuels listed unless otherwise noted in verification sections.

JP-8, IAW MIL-DTL-83133

JP-5, IAW MIL-DTL-5624

Jet A/A-1, IAW ASTM D 1655

F-24, IAW STANAG AFLP-3747

Diesel Fuel, IAW ASTM D 975

JPTS, IAW MIL-DTL-25524

3.3.4 Additional Material Tests. The tank material shall meet the requirements of Table I and tank seams shall meet the requirements of Table II.

TABLE I. Characteristics of Tank Materials.

* Pounds per linear inch

Test Property/Application Requirements Test Reference Specification

Paragraph ASTM AATCC

Ozone Resistance No cracks under 7X lens D1149 4.5.2.3

Fuel contamination:

Existent/unwashed gum (mg/100 ml) Solvent washed gum (mg/100 ml)

20 (max)

5 (max)

D381 4.5.2.4

Diffusion rate (fl oz/sq ft/24 hr)/tank material After low temperature crease resistance

0.035 (max)

0.05 (max) 4.5.2.5

4.5.2.7

Puncture resistance (lb)/tank material 225 (min) D751 4.5.2.6

Low temperature crease resistance/tank material

No cracking, peeling, or delamination under 7X lens

4.5.2.7

Material Breaking Strength (warp & fill) before and after fuel extraction and followed by accelerated weathering at 5% ultimate elongation at break

Meet or exceed 4.0 Safety Factor (minimum allowable 400 pli *

D750, G155, & D751 Procedure

B

Option

A

4.5.2.1, 4.5.2.2, 4.5.2.10

Material Breaking Strength Retention (warp & fill) before and after fuel extraction and followed by accelerated weathering at 5% ultimate elongation at break

85% Retention

D750, G155, & D751 Procedure

B

Option

A

4.5.2.1, 4.5.2.2, 4.5.2.10

Fungus

Rating 0

None

4.5.2.14

TABLE II. Characteristics of Panel Seams and Seam Materials.

* Pounds per linear inch

3.4 Tank Construction.

3.4.1 Seams and Joining of Materials. All seams and any other areas of the tank where two materials are joined shall meet or exceed all the strength properties of the tank material.

3.4.2 Weight. The weight of the packaged tank assembly shall not exceed the

Test Property/Application Requirements Test Reference Specification

Paragraph ASTM AATCC

Dead load shear resistance for each type of panel seam and manufacturing process utilized in the fabrication of the tank

No visual seam separation or delamination

4.5.2.9

Panel seam breaking strength after fuel extraction and accelerated weathering at 5% elongation

Meet or exceed 4.0 Safety Factor (minimum allowable 400 pli *

D750, G155, & D751 Procedure

B

Option

A

4.5.2.1, 4.5.2.2, 4.5.2.11

Panel seam breaking strength retention after fuel extraction and accelerated weathering at 5% elongation

85% Retention

D750, G155, & D751 Procedure

B

Option

A

4.5.2.1, 4.5.2.2, 4.5.2.11

Seam Peel Adhesion after fuel extraction

50 pli * (min) D413 4.5.2.12

Seam Peel Adhesion after fuel extraction and water immersion

40 pli (min).

The surfaces of specimens shall not display any cracking when examined with 7X lens.

D413 4.5.2.13 following:

Size I, II, III, IV, and IV-A: 5,000 lbs.

Size V: 10,000 lbs.

3.4.3 Fittings. Each tank shall be furnished with fittings. The quantity required and location for the filler/discharge fitting, vent fitting, and drain fittings shall be as shown in FIGURES A-1, A-2, and A-3. The bond between fittings and tank shall meet or exceed all the properties of the un-seamed tank material. All fittings as well as the interface between the tank material and the fittings shall be capable of withstanding 150 psig of fuel pressure without leaking and while maintaining a leak free configuration for the life of the tank.

3.4.3.1 Filler/Discharge Fitting. The male coupling halves (terminating ends) and coupling half caps shall be in accordance with A-A-59326 and compatible with the corresponding filler/discharge elbows and filler/discharge hose assembly accessories noted in

3.7. All fittings shall include a respective size coupling half and dust cap with chain in accordance with A-A-59326 and shall be installed with the chain tethered to the fitting and the cap. The fitting size and quantities shall be as specified below:

Size I: One 2-inch and one 4-inch male coupling half Size II: Two 4-inch male coupling halves Size III: Two 4-inch male coupling halves Size IV: Two 4-inch male coupling halves Size IV-A: Two 6-inch male coupling halves Size V: Four 6-inch male coupling halves

3.4.3.1.1 Filler/Discharge Fitting Flow Rates. Each filler/discharge fitting shall be designed for a flow rate as specified without excessive restriction or damage to the tank. The 2-inch fittings shall be rated at 200 gallons per minute (GPM); 4-inch fittings shall be rated at 600 GPM; and 6-inch fittings shall be rated at 1200 GPM.

3.4.3.2 Drain fittings. For Sizes II through V, the tank shall be provided with a means to drain sediment, water and residual fuel. The quantity required and location for the drain fittings shall be as shown in FIGURES A-1, A-2, and A-3. The draining capability shall interface with the drain hose accessory noted in 3.7. The drain fittings shall have a minimum 2-inch ID. The drain assembly shall not be a threaded type fitting. Each drain shall come with an installed blind flange on the drain for quick deployment where drains are not required or desired.

Each collapsible tank shall be equipped with spare drain gaskets.

3.4.3.3 Vent Fitting. The tank vent shall be of a passive type design and ensure complete venting of fuel vapor in the tank and located in accordance with FIGURES A-1, A-2, and A-3. The weight of the vent shall minimize the accumulation of water on top of the tank.

The vent shall provide vapor pressure relief, be fitted with a flame arrestor, and provide protection against water or airborne contamination of the stored fuel.

3.4.4 Maximum Tank Dimensions. The new, untested, empty tank shall not exceed the following dimensions:

Size I: 14 feet x 14 feet Size II: 22 feet x 22 feet Size III: 30 feet x 30 feet Size IV & IV-A: 30 feet x 75 feet Size V: 75 feet x 75 feet

3.4.5 Handles: The tank shall include handles on all sides. Handles shall be evenly spaced 6 feet ±1 foot from each other. Attachment points of handles to tank shall be designed to keep the stress from concentrating on any point of the attaching surface to minimize the risk of the tank leaking at that point.

3.5 Performance.

3.5.1 Safety Factor. The tank shall have a rated capacity as specified below with a minimum safety factor of 4.0 times the maximum in-plane principal stress (manufacturer calculated design stress) that is dependent upon the material used and the materials’ rate of degradation. This calculated safety factor shall apply throughout the minimum three year service life with exposure to all other environmental conditions contained in this specification.

3.5.2 Cycling. The tank assembly shall be capable of withstanding cycling throughout the service life.

3.5.3 Environmental. The tank assembly shall be suitable for service (operation) in ambient temperatures ranging from –25 to 140°F with continuous exposure to direct sunlight, rain, hail, sleet, snow, wind, blowing sand, and any combination thereof. The tank material and all fabricated seams shall be suitable for solar loads under ambient temperatures which may cause tank surface temperatures to be elevated higher than ambient. The tank assembly shall be fabricated from materials resistant to microbiological growth for the duration of the required storage and service life and will not be damaged when exposed to microbial growth or relative humidity of up to 100%.

3.5.4 Service life. The tank assembly shall have a service life of a minimum of 3 continuous years in environmental conditions as specified. Tank assembly shall be capable of being drained, folded and relocated a minimum of 3 times during its service life.

3.5.5 Storage life. The tank assembly shall withstand a manufacturer determined storage configuration at ambient temperatures from -50 to 160°F (reference MIL-STD-810) for a minimum of 12 years, without damage or leakage when subsequently filled with fuel. The tank assembly shall not require any cleaning or maintenance when taken out of storage prior to being placed in service.

3.5.6 Tank Overload. The tank shall be designed to accept a 10% overfill condition without leaking or failure.

3.5.7 Pressurization. The tank shall be capable of withstanding an internal air pressure of 0.5 pounds per square inch gauge (psig) without evidence of leakage.

3.5.8 Fungus. All materials used in the bladder shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The bladder shall be suitable for operation and storage in conditions encountered in a tropical environment. The bladder shall show no ability to support spore growth when tested in accordance with 4.5.2.14.

3.6 Capacity. For design purposes the tank assembly shall be capable of storing the volumes listed below without leaking.

Size I: 3,000 U.S. gallons Size II: 10,000 U.S. gallons Size III: 20,000 U.S. gallons Size IV & IV-A: 50,000 U.S. gallons Size V: 210,000 U.S. gallons

3.7 Accessories. Unless otherwise specified (see 6.2), each tank shall be provided with the accessories in the quantities shown in TABLE III. Each accessory in TABLE III shall be suitable for use in continuous contact with the fuels referenced in 3.3.3. Each assembly in TABLE III shall be provided fully assembled complete with coupling halves, dust caps and plugs conforming to A-A-59326. Plugs and caps shall be tethered. Accessories such as valves, fittings, plugs, caps, etc., shall be rated for minimum working pressure of 150 psig. Valves shall not be capable of opening or closing during flow without human operation. Hose assemblies shall be IAW MIL-PRF-370, and a Certification of Conformance (CoC) shall accompany or be attached to each hose assembly.

TABLE III. Tank Accessories.

Item Conformance Size / Number

I II III IV IV-A V

Drain Hose Assembly

2-inch ID non-collapsible.

Length of hose shall be sufficient to extend 5 feet past the footprint of the tank (empty). One end shall have a matching bolted flange for connection to the collapsible tank and the other end shall be a 2-inch male coupling half.

0 1 1 1 1 1

2-inch ID non-collapsible hose, 10-feet in length with male-female coupling half ends.

0 1 1 1 1 1

Drain Valve Assembly

2-inch valve with male-female coupling half ends. 0 1 1 1 1 1

Filler/Discharge Hose Assembly

4-inch ID non-collapsible hose, 12-feet in length with male-female coupling half ends.

0 2 2 2 0 0

6-inch ID non-collapsible hose, 12-feet in length with male-female coupling half ends.

0 0 0 0 2 4

Filler/Discharge Valve Assembly

4-inch valve with male-female coupling half ends. 0 2 2 2 0 0

6-inch valve with male-female coupling half ends. 0 0 0 0 2 4

Filler/Discharge Elbow (female to female)

4-inch 1 1 1 1 0 0

6-inch 0 0 0 0 1 2

Filler/Discharge Elbow (female to male)

2-inch 1 0 0 0 0 0

TABLE III. Tank Accessories - Continued.

Item Conformance Size / Number

I II III IV IV-A V

Filler/Discharge Elbow (female to male)

2-inch 1 0 0 0 0 0

4-inch 0 1 1 1 0 0

6-inch 0 0 0 0 1 2

Consumable Items/Overpack Kit

Each tank shall contain spare/overpack consumable item(s) as required for service life. (e.g., gaskets, o-rings, nuts, bolts, etc.)

1 1 1 1 1 1

3.8 Markings. Unless otherwise specified (see 6.2), each tank assembly shall be provided with the below markings. Additionally it shall be marked with an Item Unique Identification (IUID) in accordance with MIL-STD-130.

3.8.1 Identification. The tank shall be permanently marked in at least two opposing locations and visible at any level of fill. Identification may be stenciled directly on the tank material, but must last and be legible for the life of the tank. The following information shall be provided using 1.00 inch high (minimum) letters:

COLLAPSIBLE FUEL TANK

(Specify) U.S. GALLONS, FUEL NSN: (Specify) MANUFACTURER: (Specify) DATE MANUFACTURED: (Specify month (3 letters) and year (4 numbers)) CONTRACT NO: (Specify) LOT & SERIAL NO: (Specify) WEIGHT EMPTY: (Specify approximate weight in pounds)

3.8.2 Warning labels. The tank shall be permanently marked with warning labels visible throughout the perimeter of the tank at any level of fill. Each label shall contain the following information using 1.00 inch high (minimum) letters, except for the word “WARNING” that shall be 2.00 inch high (minimum) letters. One label shall be placed on each side of the tank making a total of 4 labels per tank.

WARNING

DO NOT OVERFILL

OVERFILLING MAY RESULT IN PERMANENT

DAMAGE AND FAILURE OF THE TANK

MAXIMUM CAPACITY: (Specify) U.S. GALLONS MAXIMUM TANK HEIGHT: (Specify) FEET (Specify) INCHES

3.8.3 Valve Labeling. Valves shall be permanently marked to indicate status (i.e., “OPEN” for the opened position and “CLOSED” for the closed position) as well as direction of operation for each status.

3.9 Color. Unless otherwise specified (see 6.2), the color of the exposed surfaces of the tank assembly shall be in accordance with SAE AMS-STD-595, color chip 33446 (Yellow, Flat or Lusterless), general match or lighter.

3.10 Rework and Repair. Reworked and repaired tank assemblies are subject to the limits provided below in 3.10.1, 3.10.2, and 3.10.3. All rework and repair shall be identified, documented, and provided to the government in electronic format.

3.10.1 Rework. Rework is defined as any process or procedure repeated to correct a defect during the manufacturing process prior to submittal for first article or conformance testing. Limited rework shall be permitted. Rework of seams shall not be greater than 1% of each continuous seam length in the tank or as limited by the accumulated totals from rework and repair as stated in 3.10.3. Individual rework areas of fabric panels shall be limited to 6.00 inches in diameter, length, or width as applicable. Rework of interfaces between fittings and tank shall be permitted, e.g., gasket, plate.

3.10.2 Repair. Repair is defined as any process or procedure performed to correct a defect during first article or conformance testing. Limited repair shall be permitted. Repair of seams shall not be greater than 1% of each continuous seam length in the tank or as limited by the accumulated totals from rework and repair as stated in 3.10.3. Individual repairs of fabric panels shall be limited to 6.00 inches in diameter, length, or width as applicable. Repair of interfaces between fittings and tank shall be permitted, e.g., gasket, plate. Any tank that is repaired due to a leak identified during the air leakage test as specified in 3.5.7 and defined in

4.5.1.1 shall be subjected to the overload test as specified in 3.5.6 and defined in 4.5.1.7 followed by the air leakage test as defined in 4.5.1.1. A defect (i.e., leak) shall not be repaired more than one time. No repairs of rework areas or previous repairs are permitted.

3.10.3 Limits of Rework and Repair. Accumulated totals from rework and repair of seams shall not exceed 1% of each continuous seam length. Accumulated totals from rework and repair of individual fabric panel defects shall not exceed the maximum numbers indicated below. These numbers apply to the combined internal and exterior surface areas of the tanks.

Size I: 4 Size II: 9 Size III: 14 Size IV & IV-A: 24 Size V: 38

3.11 Deployability. The Size I through IV (including IV-A) tank assembly shall be deployable (not including berm construction and berm liner deployment) by a maximum of 6 personnel in 20 minutes once the tank assembly is positioned inside the berm. For the Size V tank assembly, 15 personnel are permitted and the time extended to 60 minutes. Only common hand tools shall be required. Deployment of the tank assembly shall not cause it to leak.

3.12 Workmanship. The fabric-reinforced flange-type fittings shall contain no gum voids, cracks or tears that could adversely affect the strength of the assembly. All metal parts shall be clean and free of sand, dirt, scale, flux, burrs, sharp edges, and corrosion, and shall not be broken or malformed. Metal surfaces shall be smooth with edges rounded or beveled. The inside and outside of the tank shall be clean and free of foreign materials (excluding talc). Any necessary rework and repair shall meet all applicable requirements of this specification. The cemented surfaces of all spliced areas, fitting flanges, and patch-type repairs shall affect a bond that will result in strength of the cemented area not less than the strength of adjacent tank fabric.

Fabric components shall be free of holes, cuts, or tears, thin, or weak areas, caused by abrasion, exposed fabric, blisters, holidays, tunnels, unadhered pockets, loose edges, or any delamination of coating.

3.13 Berm Liner. Unless otherwise specified (see 6.2), a berm liner in accordance with ATPD-2262, and of matching size, shall be furnished with each tank assembly.

3.14 Emergency Field Repair Kit. Unless otherwise specified (see 6.2), each tank assembly shall include an emergency field repair kit IAW ATPD-2263 that contains items necessary to perform on site repairs such as punctures, tears and leaks in emergency situations.

The kit shall include all necessary tools to complete field repairs.

3.15 Long-Term Field Repair Kit. The contractor shall develop and make available to the government a repair kit IAW A-A-52022 that can be used to perform repairs on a tank already deployed for service without the need for special tools. The kit shall include all items necessary to perform long-term repairs of punctures, tears, and leaks at seam locations and material panel areas. The repair kit shall be capable of performing long-term repairs and shall be capable of withstanding all environmental conditions as documented in this specification for the original tank material and seams. The duration of the repair for stoppage of leaks shall be for a minimum of one year after application of the repair.

3.16 Hose Support Pads. Each tank assembly shall include hose support pads to support each Fill/Discharge hose size (i.e., 2 inch, 4 inch, and 6 inch) that are compatible with all fuels listed in 3.3.3 to reduce the stress on the interface between the fill/discharge fittings and the tank material.

3.17 Tank Chest. If specified (see 6.2), an aluminum lightweight tank chest shall be furnished for storage of each tank and components. The tank chest shall have provisions for handling by Material Handling Equipment (10,000-lbs forklift), personnel (when tank chest is empty), and sling lifts. The tank chest shall be capable of storing the tank, emergency repair kit, and all ancillary components (not including the berm liner). The tank chest shall have a lid that can be removed and secured without the use of tools. Tank chest shall be compatible with a standard cargo International Standard Organization (ISO) 8 feet x 8 feet x 20 feet container.

4. VERIFICATION

4.1 Classification of Inspections. Inspections are classified as follows:

First article inspection (see 4.2) Conformance inspection (see 4.3)

4.1.1 Fabricated Samples for Inspection. Fabricated Samples (FS) shall be produced using materials from the same lot as that used in fabrication of the tank assembly. Laboratory samples (i.e., samples produced in a testing facility or by test or quality control personnel using production equipment) shall not be acceptable. Each tank shall include a sufficient number of fabricated samples to conduct inspection tests IAW 4.5.2. The contractor shall ensure that the fabricated samples are representative of the corresponding production tank or first article tank

4.2 First Article Inspection.

4.2.1 Tank Assembly Fabric Baseline. The contractor shall establish and report baseline properties for the fabric used to manufacture the first article tank assembly in the First Article Test Report. Additionally, the contractor shall report and maintain a record of fabric properties used post first article for comparison during conformance testing addressed in 4.3.4 and TABLE IV. Any proprietary data will be certified with a CoC.

4.2.2 Examinations. Each first article tank assembly (see 6.3) shall be examined as specified in TABLE V. Presence of any defects shall be cause for rejection.

4.2.3 Tests. Each first article tank assembly shall be tested as specified in TABLE VI.

The number in the ‘First Article Sequence’ column specifies the order in which the corresponding test shall be performed. An ‘X’ indicates the corresponding test can be performed in any order. ‘FS’ indicates Fabricated Samples as specified in 4.1.1. The actual test to be performed is listed in the ‘Test’ and ‘Test Paragraph’ columns. Failure of any test shall be cause for rejection.

4.2.4 Safety Factor. The manufacturer shall provide a finite element analysis to determine the highest stress point(s) on the tank and the safety factor shall be based on this analysis IAW 3.5.1.

4.3 Conformance Inspection.

4.3.1 Inspection Lot. The lot size shall be a government determined quantity of tank assemblies (per tank size) manufactured successively. The assigned Government representative will randomly select a tank assembly for conformance inspection. The following maximum lot sizes are designated for each size tank assembly:

Size I: 25 tank assemblies Size II: 25 tank assemblies Size III: 25 tank assemblies Size IV & IV-A: 15 tank assemblies Size V: 10 tank assemblies

4.3.2 Examination. Each tank assembly selected IAW 4.3.1 shall be examined as specified in TABLE V. Any nonconformance revealed by the examination shall be cause for rejection of the entire lot.

4.3.3 Tests. All production tanks shall be subjected to the air leakage test. The tank assembly selected IAW 4.3.1 shall be tested as specified in TABLE VI. An overload test IAW

4.5.1.7 (Step 1 only, using water up to 100% capacity) shall be required when the randomly selected tank in the lot acceptance/conformance test process fails the air leakage test. The number in the ‘Conformance Inspection Sequence’ column of TABLE VI specifies the order in which the corresponding test shall be performed. An ‘X’ indicates the corresponding test can be performed in any order while an ‘NR’ indicates the corresponding test need not be performed.

‘FS’ indicates Fabricated Samples as specified in 4.1.1. The actual test to be performed is listed in the ‘Test’ and ‘Test Paragraph’ columns. Failure of the overload test or final air leakage test following a successful overload test shall constitute rejection of that tank. Additionally, rejection of the conformance test tank shall require testing of additional tanks and may be cause for rejection of the entire lot at the discretion of the government contracting officer. See FIGURE A-5 for a conformance testing flow chart for tank assemblies.

4.3.4 Tank Assembly Fabric. Properties for the fabric used to manufacture production tank assemblies shall be documented IAW TABLE IV and provided to the government in electronic format for each material lot. A comparison of these properties with the baseline of fabric properties in 4.2.1 shall be made by the government. If a variance is noted with any of these properties during production an ECP may be required.

TABLE IV. Base Fabric Properties Quality Assurance.

Test ASTM Guidance/Reference Paragraph

Weight of fabric D3776

Peel adhesion (coating) D751

Breaking Strength D751 – Procedure B

Tear strength D751

Elongation at Break D751

Coating compound composition n/a

Diffusion rate 4.5.2.5

4.4 Examination Schedule.

TABLE V. Examination Schedule.

Number Examination Description Requirement Paragraph

101 Certification of tank assembly components not as specified.

3.3, 3.4, 3.5

102 Dimensions of the tank not as specified.

3.4

103 Drain fitting assembly not as specified.

3.4

104 Vent fitting assembly not as specified.

3.4

105 Berm liner not as specified.

3.13

106 Repair kit not as specified. 3.14, 3.15

107 Quantity of accessories not as specified. 3.7

108 Drain hose assembly(s) not as specified and/or not completely assembled. 3.7

109 Drain valve assembly(s) not as specified and/or not completely assembled. 3.4, 3.7

Filler/discharge hose assembly not as specified and/or not completely assembled.

3.7

Filler/discharge valve assembly not as specified and/or not completely assembled.

3.4, 3.7

112 Identification markings not as specified. 3.8

113 Warning labels not as specified. 3.8

114 Valves not labeled as specified. 3.8

115 Color not as specified. 3.9

116 Repair and Rework not as specified. 3.10

4.5 Testing.

4.5.1 Tank Assembly Tests.

4.5.1.1 Air Leakage. Pressurize the tank to a minimum of 0.5 pound per square inch gauge (psig) internal air pressure without restricting volumetric growth. Thirty (30) minutes after initial pressurization, adjust the internal air pressure, as required, to maintain a minimum of

0.5 psig. Conduct the test indoors to control conditions, use a soap and water solution, and examine the entire tank, including all seams and fittings for air leakage. Any evidence of air leakage shall constitute failure of this test.

4.5.1.2 Low Temperature. The tank shall be folded exactly the same way as for placement in the shipping container and then placed, unshielded, in a low temperature environment for a period of 72 hours where the temperature may not be warmer than -25ºF. At the end of this period, the tank shall be completely unfolded within 30 minutes. Any flaking, cracking, delamination, or separation of the coated fabric, shall constitute failure of this test.

4.5.1.3 High Temperature. The tank shall be folded exactly the same way as for placement in the shipping container and then placed, unshielded, in a high temperature environment at a minimum of 160ºF for a period of 48 hours and cooled to a minimum of 100ºF for an additional 24 hours. At the end of the test time, while still at final test temperature, the tank shall be completely unfolded within 30 minutes. Any flaking, cracking, delamination, or separation of the coated fabric shall constitute failure of this test.

4.5.1.4 Tank Assembly Deployment. The tank assembly shall be deployed in a berm in accordance with 3.11. Failure to meet the requirements stated in 3.11 constitutes failure of this test.

4.5.1.5 Test Fuel. Prior to filling tank(s) assemblies during fuel storage (4.5.1.6), two one-gallon samples shall be obtained in approved sample cans from the source fuel used for Tank Overload in paragraph 4.5.1.7. Samples shall be tested by an approved DoD/DLA laboratory or commercial equivalent capable of testing all Aviation Turbine Fuel IAW fuels specifications listed in paragraph 3.3.3.

4.5.1.6 Fuel Storage. Place the tank outdoors, without environmental protective covering, in a berm lined with a berm liner. Unless otherwise specified, fill the tank to a minimum of 100% of rated capacity (by volume) with JP-8 and allow to stand for a minimum of 30 days. During the test, examine the tank twice daily as well as at the end of the test period for signs of leakage, including wetness. Any examination shall be postponed if weather conditions, such as rain or high humidity, inhibit inspection and will resume under favorable examination conditions. Any evidence of leakage shall constitute failure of this test.

4.5.1.7 Tank Overload. At the end of the 30 day storage test, the first article sample tank shall be subjected to a tank overload test according to the procedures as outlined below.

The tank shall be filled with JP-8. The test shall be conducted in a dry location and the tank placed on a non-absorbent berm liner during this test. The tank shall be monitored throughout each step of the test. Immediately after the tank is emptied, the tank bottom and berm liner shall be examined for leakage, i.e., wetness or discoloration of fabric shall constitute failure of this test. All times listed are minimum times.

1) Fill bladder to full capacity +10%; allow to stand for 8 hours.

a) Recirculate unfiltered fuel for twenty minutes.

b) To ensure good representative samples are obtained; under flow conditions, trying to capture initial, midpoint and end of fuel flow collect a composite two one-gallon sample into approved sample cans for Post Tank Overload Testing.

c) Samples shall be tested by an approved DoD/DLA laboratory or commercial equivalent capable of testing all Aviation Turbine Fuel IAW fuels specifications listed in paragraph 3.3.3.

d) Results will be compared to results from 4.5.1.5. Existent Gum content shall be tested IAW ASTM D381 and not exceed 3mg/100ml over the max limit as required in all Aviation Turbine Fuel specifications listed in paragraph 3.3.3 herein.

2) Drain bladder to 40% capacity; allow to stand for 1 hour

3) Fill bladder to full capacity +10%; allow to stand for 8 hours

4) Drain bladder to 40% capacity; allow to stand for 1 hour

5) Fill bladder to full capacity +10%; allow to stand for 8 hours

6) Drain completely; fold to original configuration; allow to sit for 48 hours

7) Unfold completely; fill bladder to full capacity +10%; allow to stand for 8 hours

8) Drain bladder to 40% capacity; allow to stand for 1 hour

9) Fill bladder to full capacity +10%; allow to stand for 8 hours

10) Drain completely

4.5.2 Tank Base Fabric Sample and Seam Sample Tests.

4.5.2.1 Fuel Extraction. Fabric samples shall be prepared using the following procedures:

1) Immerse separate samples in JP-8 for 7 days at 160ºF

2) Remove the specimens from the fuel, blot with paper towels, and allow drying in an air circulating hood for at least 24 hours

3) Place samples in a vacuum oven and dry for 16 ± 2 hours at 120ºF at 20 inches of mercury

4.5.2.2 Accelerated Weathering. Fabric samples shall be prepared IAW ASTM D750, ASTM G155, and AATCC 111 using a Xenon light type weatherometer after fuel extraction (IAW 4.5.2.1). Expose the dried samples (exterior surface facing the light source) in the weatherometer in accordance with ASTM D750 for 1500 hours.

4.5.2.3 Ozone Resistance. Ozone resistance after fuel extraction (IAW 4.5.2.1) and drying shall be tested as specified in ASTM D1149, Test Method A, Procedure A1. The samples shall be conditioned for 14 days at a temperature of 104 ± 4ºF in air having a partial pressure of ozone of 50 millipascals. Nonconformance to TABLE I requirements shall constitute failure of the test.

4.5.2.4 Gum Content. Cut a 0.2-ounce specimen of each tank material into approximately 0.0625-inch squares, place in a flask containing 8.5 fluid ounces of Reference Fuel D of ASTM D471, and allow to stand for 48 hours at 73±5°F. A sample of the fuel shall be retained for later use. Decant and filter the contaminated fluid through Whatman 41H filter paper or equal. Determine the existent/unwashed gum content of the filtrate in accordance with ASTM D381 using the air jet or steam jet vaporizing medium (which is appropriate for the fuel) and an evaporation time of 45 minutes. Using the same samples after completing the existent/unwashed gum content test above, determine the solvent washed gum IAW ASTM D381. A minimum of three specimens shall be used. The retained fuel sample shall be tested with the same methods. The existent/unwashed gum content from the original fuel sample shall be subtracted from the existent/unwashed gum obtained from the fuel used in the soak test. The solvent washed gum from the original fuel sample shall be subtracted from the solvent washed gum obtained from the fuel used in the soak test. Nonconformance to TABLE I shall constitute failure of the test.

4.5.2.5 Diffusion. The test apparatus shall consist of a diffusion cup and ring, using FIGURE A-4 as a guide. Other cup designs are acceptable as long as the inside diameter of the cup and ring is maintained at 2.00 ± 0.02 inches and the cup is 1.00 ± 0.06 inches deep. Cut a circular test disk of coated fabric to conform to the outside diameter of the cup flange. Punch holes in the disk to correspond to the flange bolt dimensions as needed. The cup shall be filled with approximately 1.4 fluid ounces of JP-8. A suitable solution shall be used to seal the exposed fabric around the outer edge of the test disk and to seal the test disk to the diffusion cup flange. The test disk shall be placed over the cup with the tank "interior" side toward the fuel.

The bolts shall be tightened securely. Place the diffusion cup in a suitable rack in a constant temperature of 73.3 ± 2ºF, and a relative humidity of 65 ± 2 percent. Allow 1 hour for the assembly to reach equilibrium, and then weigh the cup to the nearest 0.005 gram and place in the rack face upward. Keep the cup at the above constant temperature and humidity for 24 hours and then weigh and check for vapor loss. Re-torque the bolts if necessary. Invert the cup (test disk down) in a rack that permits free access of air to the test disk. Weigh the cup daily.

Defective films or leaks caused by faulty assembly are usually found when the cup is weighed on the third day. Continue to weigh the cup daily until the weight loss is constant to within 0.010 grams per day after two 24-hour periods. Then record daily weight loss for a continuous interval of 72 hours. The diffusion rate (D) in fluid ounces per square foot per 24 hours shall be the average of not less than three samples when calculated from the following expression:

D = 144 (average daily loss in grams) (Sp. Gr.) (29.573)(3.142)(R²)

Where Sp. Gr. is the specific gravity of the test medium and R is the inside radius of the test cup.

Nonconformance to the requirement in TABLE I with JP-8 as the test fluid shall constitute a failure of this test.

4.5.2.6 Puncture Resistance. Puncture resistance testing shall be in accordance with

ASTM D 751 (Puncture Resistance, Section 22-25), except the ring clamp mechanism shall have an internal diameter of 3 inches. Nonconformance to TABLE I requirements shall constitute failure of this test.

4.5.2.7 Low Temperature Crease Resistance. Condition and dry three, 8 inch coated fabric samples as stated in 4.5.2.1. Fold the samples in half in each direction so that a folded corner occurs in the center of each sample. Place each folded sample under a 4-pound load and condition at -25 ± 2ºF for 46 hours. At the end of the conditioning period, unfold the samples while still at a temperature of -25ºF and examine visually. Cracking, peeling, or delamination of any coating material shall constitute failure of this test. If samples do not fail, then subject them to the diffusion test specified in 4.5.2.5 except position the sample in the diffusion cup in such a manner that the center of the previous fold coincides with the center of the cup and use JP-8 as the test fluid. Nonconformance to TABLE I requirements with JP-8 as the test fluid shall

4.5.2.8 Blocking. Place three coated fabric samples 6.00 inches by 1.00 inch on a smooth surface in such a manner that the ends are overlapped 1.00 inch. Place a 4-pound weight (± 1 ounce) directly on the overlapped areas. Place prepared samples in an oven. After conditioning at a temperature of 158 ± 2ºF for 4 hours, take the samples from the oven; remove the weight, and condition for 1 hour at 73 ± 5ºF and 65 ± 2 percent humidity. Retain one end of the sample in a suitable clamping device, allowing the other end to hang, and suspend a 4-ounce load from the free end of the samples. Inability of the strips to separate within 5 seconds under the 4-ounce load shall constitute failure of this test.

4.5.2.9 Seam Dead Load Shear Resistance. The test samples shall be 1.00 ± 0.02 inch wide (parallel to the seam) with coated fabric extending a minimum of 3.00 inches (perpendicular to the seam) on each side of the seam for holding and attaching the weight. One index mark shall be scribed on each side of the seam to facilitate observation and measurement of slippage. Each sample shall be subjected to a constant (dead load) tension force equivalent to the 4.0 safety factor ± 0.50 pounds while immersed in JP-8 at 160 ±5ºF for 96 ± 2 hours. The container holding the sample and fuel shall be leak proof and capable of withstanding the JP-8 vapor pressure at the test temperature. After 96 hours examine each sample while under tension for signs of slippage or seam delamination. Three samples shall be tested for each determination. Slippage or delamination, by any sample, greater than specified in TABLE II shall constitute failure of this test with JP-8 as the test fluid.

4.5.2.10 Breaking Strength and Breaking Strength Retention - Material. Material breaking strength retention is defined as the ratio of the breaking strength of the conditioned fabric to the breaking strength of the unconditioned fabric.

1) Original Material Breaking Strength – Determine breaking strength as received according to ASTM D751, Procedure B (Cut Strip Test Method). Cut three 1 inch x 6 inch coated fabric specimens in the warp (machine direction) and the fill (cross) directions. Test and report each specimen separately in pli.

Nonconformance to TABLE I requirements shall constitute failure of the test.

2) Breaking strength after Fuel Extraction and Accelerated Weathering. Determine breaking strength according to ASTM D751, Procedure B (Cut Strip Test Method). Cut three 1 inch x 6 inch coated fabric specimens in the warp (machine direction) and the fill (cross) directions, and prepare according to the Fuel Extraction procedures contained in 4.5.2.1 and the Accelerated Weathering procedures contained in 4.5.2.2. Test and report each specimen separately in pli.

Nonconformance to TABLE I requirements shall constitute failure of the test.

4.5.2.11 Breaking Strength and Breaking Strength Retention - Panel Seam. Panel seam breaking strength retention is defined as the ratio of the breaking strength of the conditioned seamed fabric to the breaking strength of the unconditioned seamed fabric.

1) Original Panel Seam Breaking Strength– Three panel seam breaking strength specimens 1.00 inches wide (parallel to the seam) and extending (perpendicular to the seam) 3.00 inches beyond both edges of the seam are used and tested at room temperature in accordance with ASTM D751. Express reported values in pli.

Failure within the seam on any specimen constitutes failure of the test.

2) Breaking strength after Fuel Extraction and Accelerated Weathering. Three panel seam breaking strength specimens 1.00 inches wide (parallel to the seam) and extending (perpendicular to the seam) 3.00 inches beyond both edges of the seam are prepared according to the Fuel Extraction procedures contained in

4.5.2.1 and the Accelerated Weathering procedures contained in 4.5.2.2. Test each sample at room temperature in accordance with ASTM D751 and express reported values in pli. Nonconformance to TABLE II requirements shall

4.5.2.12 Peel Adhesion After Fuel Extraction - Panel Seam. Three specimens of panel seam at least 1 inch wide by at least 6 inches long shall be prepared according to the Fuel Extraction procedures contained in 4.5.2.1 and the Accelerated Weathering procedures contained in 4.5.2.2. Peel adhesion of the specimens shall be in accordance with ASTM D413, Machine Method. Nonconformance to TABLE II requirements shall constitute failure of the test.

4.5.2.13 Peel Adhesion After Fuel Extraction and Water Immersion - Panel Seam.

Three specimens of panel seam at least 1 inch wide by at least 6 inches long shall be prepared according to the Fuel Extraction procedures contained in 4.5.2.1 and the Accelerated Weathering procedures contained in 4.5.2.2. Immerse the dried specimens in distilled or deionized water for 28 days at 180ºF. At the end of the 28 day immersion period, remove the specimens and condition in fresh distilled or deionized water at room temperature for at least one hour prior to testing. Peel adhesion of the specimens shall be in accordance with ASTM D413, Machine Method. Nonconformance to TABLE II requirements shall constitute failure of the test.

4.5.2.14 Fungus test. Three fabric samples adequately representing applicable portions of the bladder that might be damaged by exposure to fungus attack shall be subjected to a fungus test in accordance with MIL-STD-810 Method 508.8 using test duration of 28 days to demonstrate compliance with the requirements of 3.3.4. The test shall be interrupted at seven (7) day intervals, during a total of 28 days, to ascertain spore growth on control samples.

4.5.3 Test Schedule.

TABLE VI. Test Schedule.

NOTE 1: Overload test using 4.5.1.7 (Step 1 only, using water up to 100% capacity) shall be required when the randomly selected tank in the lot acceptance/conformance test process fails the air leakage test.

First Article

Sequence

Conformance Inspection Sequence

Test Test Paragraph Requirement Paragraph

(All production tanks)

Air leakage 4.5.1.1 3.5

2 NR Low temperature 4.5.1.2 3.5

3 NR High temperature 4.5.1.3 3.5

4 NR Deployment 4.5.1.4 3.11

5 NR Fuel storage 4.5.1.6 3.5

6 (See Note 1) Tank overload 4.5.1.7 3.5

X (FS) NR Weather resistance 4.5.2.2 3.3.4 & TABLE I

X (FS) NR Ozone resistance 4.5.2.3 3.3.4 & TABLE

II

X (FS) NR Solvent washed gum 4.5.2.4 3.3.4 & TABLE I

X (FS) X (FS) Diffusion rate 4.5.2.5 3.3.4 & TABLE I

X (FS) X (FS) Puncture resistance 4.5.2.6 3.3.4 & TABLE I

X (FS) NR Low temperature crease resistance 4.5.2.7 3.3.4 & TABLE I

X (FS) X (FS) Blocking 4.5.2.8 3.3.4 & TABLE I

X (FS) X (FS) Seam dead load shear resistance 4.5.2.9 3.3.4 & TABLE

II

X (FS) NR Breaking strength retention

4.5.2.10 (material)

4.5.2.11 (seam)

3.3.4 & TABLES

I and II

X (FS) NR Seam peel adhesion 4.5.2.12 & 4.5.2.13

3.3.4 & TABLE

II

X (FS) NR Fungus resistance 4.5.2.14 3.3.4 &

TABLE I

5. PACKAGING

5.1 Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When actual packaging of materiel is to be performed by DoD or in-house contractor personnel, these personnel need to contact the responsible packaging activity to ascertain packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activities within the Military Service or Defense Agency, or within the military service’s system command.