Attachment 3 5100-505B_6000 lb Leadline Technical Specifications.pdf

Specification 5100-505B

6,000 POUND LEADLINES,

EXTERNAL, HELICOPTER

Issue Date: July 2026

Supersedes: 5100-505A

June 2012

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

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Beneficial comments and suggestions related to this standard may be sent via electronic mail (SM.USDA-FS.NTDP.FAM@usda.gov) or U.S. mail to the USDA Forest Service National Technology and Development Center, 5785 Hwy 10 West, Missoula, MT 59808.

Record of revisions: This is a record of changes made to this revision only.

Date Revision summary

July 2026 Updated formatting for 508 compliance Product marking criteria (paragraph 3.5) Updated plastic coating requirement for wire cable (paragraph 3.3.3.1) Dimension of link in figure 4 changed to 5/8” nominal dimension

[Future revisions] Capture changes that will be incorporated in a future revision (working drafts).

1. SCOPE

1.1. Purpose and applicability

1.2. Interpretations and definitions

2. APPLICABLE DOCUMENTS

2.1. Non-Government publications

2.2. Order of precedence

3. REQUIREMENTS

3.1. Acceptance

3.2. Performance

3.3. Parts and materials

3.4. Construction and workmanship

3.5. Product marking

3.6. Certificate of conformance

3.7. Hook

3.8. Link

3.9. Leadline length

3.10. Terminations and splices

4. SAMPLING, INSPECTION, AND TEST PROCEDURES

4.1. General inspections and tests

4.2. Responsibility for compliance

4.3. Classification of inspection

4.4. Inspection and tests

4.5. Proof testing

4.6. Ultimate strength testing

4.7. Test results

4.8. Nonaccepted lots

4.9. Government lot acceptance

5. PACKAGING, PACKING, AND CONTAINER/SHIPMENT MARKING

5.1. Packaging, packing, and container/shipment marking

6. NOTES

6.1. Acquisition requirements

6.2. Metric equivalence

6.3. First article

6.4. Superseding data

6.5. Notice

6.6. Preparing activity

1. SCOPE

1.1. Purpose and applicability.

The 6,000 pound helicopter leadlines covered herein are established as standard in the USDA Forest Service. These devices are used to attach external loads to the cargo hook of a helicopter and are used in activities for the suppression of wildland fire. Additionally, the accessory covered in this specification is for cargo use only. Do not use items from this specification for any person lifting application, i.e., short haul.

1.1.1. Intended use.

All items procured under this specification are intended to attach external loads to the cargo hook of a helicopter and used in the suppression of wildland fire or related activities. The wildland fire environment includes, but is not limited to, fire retardants; dust; moisture; pesticides, fuels (aviation, jet, gasoline, kerosene, diesel, etc.); hydraulic fluid and oils (aviation and automotive);

herbicides; pesticides; and lubricants (aviation and automotive).

1.2. Interpretations and definitions.

1.2.1. Interpretations.

To carry out the provisions of this document, the word “shall” is understood to be mandatory.

1.2.2. Definitions.

Nonconformity—A departure of a quality characteristic from its intended level or state that occurs with severity sufficient to cause an associated product or service not to meet a specification requirement (per ANSI/ASQ Z1.4).

2. APPLICABLE DOCUMENTS

2.1. 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 in effect on the date of the solicitation or agreement. Non-Government standards and other publications normally are available from the organizations that prepare and distribute the documents. These documents also may be available in or through libraries or other informational services.

2.1.1. American Society for Quality (ASQ).

Copies are available from the American Society for Quality, PO Box 3005, Milwaukee, WI 53201- 3005, website www.asq.org.

Z1.4 - Sampling Procedures and Tables for Inspection by Attributes http://www.asq.org/

2.2. Order of precedence.

In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. Acceptance.

Lot acceptance of like articles shall be performed on product sample(s) in accordance with paragraph 4.4.1.

3.1.1. First article.

Unless otherwise specified, first article inspection shall be performed on a product sample(s) in accordance with paragraph 4.4.2. During the term of the contract the contractor shall be required to notify the contracting officer in writing when a component or the component supplier changes in any way, when a major manufacturing process changes in any way, or when a manufacturing location changes. The contracting officer may at any time require the contractor to submit new first article sample(s) when substantive changes occur during the term of the contract.

3.2. Performance.

The leadline shall be capable of performing as specified throughout the temperature range of 0 °F to 140 °F. The leadline shall have a working load limit of 6,000 pounds. The leadline assembly and its components shall have an ultimate strength of at least 24,000 pounds, which corresponds to a

4.0 load safety factor.

3.2.1. Proof testing.

Proof testing of the completed item is required for each and every article in the lot that is being offered for acceptance. The proof test load shall be 12,000 pounds and performed after the slip indicator paint (see paragraph 3.10) is applied to every article. The contractor’s quality assurance system shall show compliance with proof testing and the application of the slip indicator paint. The contractor shall tag the item after proof loading in accordance with paragraph 3.5. Testing and tagging shall be performed prior to submittal to the government for first article testing and acceptance.

3.3. Parts and materials.

3.3.1. Component parts.

All component parts (including metallic and nonmetallic parts) shall be new and not reprocessed or reworked. When modification is required of commercially available or standard parts, evidence of engineering data or laboratory tests shall be supplied to verify that the modified part meets the requirements of this specification. Each component shall be appropriate for its intended function considering the nature and adverse conditions involved in helicopter operations, including firefighting (see paragraph 1.1.1).

3.3.2. Materials.

All metallic parts used shall be corrosion resistant or treated for corrosion resistance.

3.3.3. Leadline material.

Leadline material shall be a 6 x 19 classification flexible wire rope with an independent wire rope core (IWRC). The wire rope shall have a minimum diameter of 1/2 inch, maximum diameter of 9/16 inch, and sufficient strength to meet the ultimate strength requirement of paragraph 3.2. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6, for the leadline material used in this specification. A certificate of conformance shall be provided with the first article documentation package.

3.3.3.1. Plastic coating.

Unless otherwise stated in the procuring document, the wire rope shall be plastic coated. The coating shall be 1/32-inch minimum thickness, polyvinyl chloride, ultraviolet stabilized plastic. The coating shall be transparent to the extent that inspection of the wire rope under the coating is visually possible. The color of the plastic shall be green or as specified by the procuring agency.

The coating shall have a Durometer Shore OO hardness between 85 and 90. The coating shall meet the requirements of MIL-I-631 Type F, Form U, Grade A, Lass 2. The Contractor shall submit Certificate of Conformance regarding the vinal coating.

3.4. Construction and workmanship.

The leadline shall consist of a wire rope, with a hook (see paragraph 3.7) on one end, a link (see paragraph 3.8) on the other end, and two thimbles (see paragraph 3.10) and swages (see paragraph 3.10) as shown in figure 5. The leadline shall be manufactured by current standard production processes to provide a clean, finished quality product. Workmanship shall be equal to the best commercial practices consistent with the highest engineering standards in the industry and shall be free from any defect that may impair serviceability or detract from the appearance of the product. The leadline shall be free of sharp edges, points, and other defects that could result in injury.

3.5. Product marking.

Each and every item procured under this specification shall be marked with a tag. The tag shall contain the following information (see figure 1); NFES 0380; SWL 6000 LBS; Contract number;

Manufacturer name (not the vendor); Proof Date (format example 01/2025); Item WT XX LBS. The text size shall be a minimum 0.12 inches in height. The text shall be legible and permanently stamped, embossed, cut, or etched on to metal tag. The tag shall be either stainless steel or brass.

The tag shall be attached to the leadline at the hook end using a galvanized steel wire rope. The securing wire rope for the tag shall be 1/16 inch galvanized steel. This wire rope shall be included in the swaging which attaches the hook. The loop formed shall be between 1 and 1½ inches in diameter and oriented in the swage in the direction shown in figure 1. The punched hole in that tag should be in the upper left corner and be inset at least one hole diameter from the edge of the tag.

The weight of the item shown on the tag shall be within 1 pound of the actual weight to allow for variation during the manufacturing process.

Figure 1 - Making tag

3.6. Certificate of conformance.

Where certificates of conformance are required, the Government reserves the right to verify by test any such item to determine the validity of the certification.

3.6.1. Certification.

The contractor shall provide individual certificates of conformance for the component where required in this specification. The contractor shall provide the following information on the certificate:

a. Item description, i.e., eyelet hook, pear link, thimble.

b. Item manufacturer’s name, address, and telephone number.

c. Manufacturer’s item part number.

d. Procuring document for the item (to include the quantity and date ordered).

e. Manufacturer’s lot number, if applicable.

f. Manufacturer’s statement of working load limit and ultimate strength for the item, or part rating (applicable to thimbles only).

3.7. Hook.

The hook used in the leadline shall be an eyelet style hook only. The hook used in the leadline shall have a working load limit of at least 6,000 pounds and a minimum ultimate strength specified in 3.2. The style and dimensions of the hook shall be as shown in figure 2. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6.1, for all the hooks installed on leadlines meeting this specification. The hook shall be swaged onto the leadline.

Figure 2 - Eyelet hook

3.7.1. Gate release.

A gate release shall be incorporated in the hook and have a spring return to lock the gate closed.

The release lock and hook gate shall have a minimum engagement of 0.2 inches, as shown in figure 3. (Note: The dashed lines in figure 3 are hidden lines.)

Figure 3 - Gate lock engagement

3.8. Link.

The link used in the leadline shall be a weldless alloy steel and be pear shaped. The link used in the leadline shall have a minimum working load limit of 6,000 pounds and a minimum ultimate strength of paragraph 3.2. The contractor shall obtain and retain a certificate(s) of conformance, meeting the requirements of paragraph 3.6.1, for all the links presented on leadlines meeting this specification. The dimensions of the link shall be in accordance with figure 4. A

Figure 4 - Link dimensions

3.9. Leadline length.

The standard length is 12 feet, but ordering activity may specify other lengths. The tolerance on all lengths shall be +/- 3 inches. The length (as shown in figure 5) shall be measured from center to center of the thimbles, with the leadline taut, in a straight line, and on a flat surface.

Figure 5 - Leadline length

3.10. Terminations and splices.

Each end of the wire rope shall be terminated using a thimble. The thimble shall be rated extra heavy or heavy duty. The contractor shall provide a certificate(s) of conformance, meeting the requirements of paragraph 3.6.1, for all the thimbles presented on leadlines meeting this specification. The terminations shall incorporate a swage. The swage shall be either stainless or carbon steel or copper. Aluminum swages shall not be used. The wire rope shall be stripped of the plastic coating before swaging. The swaged area shall not incorporate any part of the plastic coating. All swages shall be painted for slip indications shown in figure 6. The paint color shall be red. The link end swage shall also be similarly painted. Swages shall not be covered. No splices shall be allowed in the wire rope. For turnback swage terminations, both terminated ends of the wire rope shall be fully contained within their swages, and the end of the wire rope shall be flush with the swage collar or extend no more than 0.25 inches beyond the swage. in no case shall the end of the wire rope be contained within the swage on turnback terminations. Flemish eye swage terminations, if used, shall meet the manufacturer’s requirements. The contractor shall obtain and retain the Flemish eye swage termination process and inspection requirements. The contractor shall provide the government copies of the Flemish eye swage manufacturer’s documentation.

Figure 6 - Slip indicator paint

4. SAMPLING, INSPECTION, AND TEST PROCEDURES

4.1. General inspections and tests.

The contractor shall be responsible for delivering quality products that meet the requirements of this specification. The contractor shall perform all inspection and test requirements prior to submission for Government acceptance and first article inspections. The contractor’s test and inspection results shall be made available to the Government for both acceptance and first article inspection; for first article inspections (see paragraph 4.4.2), the contractor’s results shall be submitted in the first article inspection package, see paragraph 4.4.2.1. The contractor may utilize their own test facilities or any commercial laboratory acceptable to the Government. Inspection records of the examination and tests shall be kept complete and available to the Government.

4.2. Responsibility for compliance.

The contractor’s inspection system shall ensure that all products submitted to the government shall meet all requirements of sections 3 and 5. The inspections set forth in this specification shall become a part of the contractor’s overall inspection system and quality program. The absence of any inspection requirements in this specification shall not relieve the contractor of the responsibility of the contract. 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.

4.3. Classification of inspection.

The inspection requirements specified herein are classified as follows:

a. First article inspection (see paragraph 4.3.2).

b. Lot acceptance inspection (see paragraph 4.3.3).

4.3.1. Lot.

All like items presented together in one delivery will be considered one lot for the purposes of inspections.

4.3.2. First article.

The contractor shall make available to the government items from which a first article(s) may be selected. The government may select 1, 2, or 3 articles for inspection based on the number of items in the lot. The sample articles will be made unserviceable as a result of the testing and will be retained by the government.

4.3.3. Sample for lot acceptance inspection/test.

Sampling for lot acceptance shall be in accordance with ANSI/ASQC Z1.4. The sample size shall be per special inspection level S-3 and have an acceptable quality level (AQL) of 1.5.

4.4. Inspection and tests.

4.4.1. Lot acceptance.

When selected in accordance with paragraph 4.3.3, each sample item shall be inspected in accordance with table 1, to determine conformance with this specification. If the sample is found to have any major nonconformances, as identified in table 1, the lot shall not be accepted.

Additionally, if the number of minor nonconformances (per table 1) in the sample exceeds an AQL level of 1.5 percent nonconforming, the lot shall not be accepted.

Table 1 - Lot acceptance inspection Reference paragraph number

Nonconformance Class of nonconformance

3.2.1. The leadline was not a proof tested. Major

3.2.1. The contractor’s quality assurance system does not show evidence of compliance with proof loading and/or the slip paint indicator marking prior to proof loading.

Major

3.3.2. All exposed metal parts are not corrosion resistant or treated for corrosion resistance.

Major

3.3.3. The wire rope used in the leadline has a smaller diameter than ½ inches or greater diameter of 9/16 inches

Major

3.3.3.1. The wire rope is not plastic coated. Major

3.3.3.1. The plastic coating is not transparent.

Major

3.3.3.1. The plastic coating is not either green or as otherwise specifed. Major

3.4. The leadline does not consist of a steel wire rope with a link at one end and a hook at the other.

Major

3.4. The leadline contains sharp edges, burrs, or other that could result in injury.

Major

3.4. The workmanship of the leadline is below industry standards. Major

3.5. Marking does not contain all of the required information (as in figure 1).

Major

3.5. Text is not at least 0.12 inches in height. Major

3.5. Any lettering is not legible Major

3.5. Test is not embossed, stamped, cut or etched into a stainless steel or brass tag.

Major

3.5. The tag is not located at the hook end. Major

3.5. The wire rope attaching the tag to the leadline is not included in the swage of the wire rope termination.

Major

3.5. The tag is not oriented in the swage as shown in figure 1. Major

3.7. Any dimensions of the hook is not per figure 2. Major

3.7.1. The minimum engagement of the gate and lock release is not greater than shown in figure 3.

Major

3.8. The link is not pear shaped. Major

3.8. The link does not meet the dimensions shown in figure 4. Major

3.9. The length of the leadline is not as required by the procuring document, measured as shown in figure 5.

Major

3.10. The leadline termination does not include a thimble, and the thimble is not heavy duty or extra heavy.

Major

3.10. The swages used are not either stainless or carbon steel; or copper.

Major

3.10. The swaged area incorporates any part of the plastic coating. Major

3.10. The swages are not painted for slip indication. Major

3.10. The leadline includes a splice. Major

3.10. The turnback swages, the cut end of the wire rope for either termination does not extend beyond the swage collar.

Major

3.10. The turnback swages, the cut end of the wire rope for either termination extends more than 0.25 inches beyond the swage.

Major

3.10. For Flemish eye swages, the contractor did not provide swage processing and inspection information from the swage manufacturer.

Major

3.10. For Flemish eye swages, the swage does not meet the swage manufacturer’s inspection criteria.

Major

4.4.2. First article inspection.

Unless otherwise specified, the first article(s) submitted in accordance with paragraph 3.1.1, shall be inspected as specified in paragraph 4.4.1 and table 2. The sample size shall be in accordance with paragraph 4.3.2. Government inspection of compliance on the first article(s) may stop upon any single failure (regardless of classification), and the sample(s) not accepted. The contractor will be informed of the nature of the failure. Additionally, the Government is not obligated to continue with first article compliance inspection, unless it is considered in the best interest of the Government.

Table 2 - First article inspections Reference paragraph number

Nonconformance Class of nonconformance

3.2. The leadline assembly or its components do not have an ultimate strength of at least 24,000 pounds

Major

3.3.1. All of the components are not new, and engineering/test data have not been provided justifying the use of reworked/modified component(s).

Major

3.3.1. Each component is not appropriate when considering its intended function.

Major

3.3.3. The certificate of conformance for the wire rope used on leadline was not provided, or the certificate does not contain all of the required data.

Major

3.3.3. The wire rope used is not a 6 by 19 class IWRC steel wire rope. Major

3.3.3.1 The durometer reading for the plastic coating is not between 85 and 90, inclusive.

Major

3.3.3.1 The certificate of conformance for the plastic coating was not provided, or the certificate does not contain all of the required data.

Major

3.6.1. Any certificate of conformance does not contain all the information in this paragraph.

Major

3.7. The certificate of conformance for the hooks used on the leadline was not provided, or the certificate does not contain all of the required data.

Major

3.8. The certificate of conformance for the links used on the leadline was not provided, or the certificate did not contain all of the required data.

Major

3.10. The certificate of conformance for the thimbles used on the leadline was not provided, or the certificate does not contain all the required data.

Major

4.4.2.1. First article inspection package.

The contractor shall submit to the Government along with the selected first article(s), copies of:

a. Engineering analysis or test data for altered commercial products, if applicable, see paragraph 3.3.1.

b. All certificates of conformance, see paragraphs 3.3.3, 3.3.3.1, 3.7, 3.8, and 3.10.

c. If Flemish eye terminations are used, provide the swage collar manufacturer’s process and inspection requirements/recommendations, see paragraph 3.10.

d. Company inspection records, see paragraph 4.1.

e. All test results for the article(s), see paragraph 4.7.

f. Ultimate strength certificate, see paragraph 4.6.

g. Calibration/metrology information on test equipment that was used as a media of inspection, see paragraphs 4.6 and 4.7.

h. All other material necessary to perform the inspections identified in table 2.

4.5. Proof testing.

Proof testing shall place the item under the load specified for the item in paragraph 3.2.1. The applied force shall be a static load applied in the direction the item will encounter in its intended use. The equipment used to apply the loading force shall be calibrated to a recognized State or Federal standard. The calibration of the equipment shall be current (within the last 12 months) at the time of testing.

4.5.1. Proof testing inspection.

All items shall not exhibit any plastic deformation, take a permanent set, or change dimensional properties as a result of the proof test load.

4.6. Ultimate strength testing.

The contractor shall perform testing to verify the completed leadline ultimate strength. Testing shall place the item under the load specified for the item in paragraph 3.2 and held for 10 seconds. The applied force shall be a static load applied in the direction the item will encounter in its intended use. The test equipment used to apply the loading force shall be calibrated to a recognized State or Federal standard. The calibration of the test equipment shall be current (within the last 12 months) at the time of testing. The contractor shall provide evidence of the test equipment calibration.

4.6.1. Ultimate testing inspection.

The item shall not fail, break, or release the load. The item may yield, experience plastic deformation, or change its dimensional properties as a result of the ultimate test load, but shall not fail or break. All items subjected to ultimate testing shall be considered unserviceable by the testing. As such, they shall be conspicuously marked and not delivered to the government for stock or supply.

4.6.2. Certification of ultimate test results.

The contractor shall prepare and provide as part of the first article inspection and upon request of any Government inspector, a certificate of conformance for the ultimate strength test. The certificate shall contain the following:

a. Product description.

b. Description of the test equipment involved and the metrology information.

c. Manufacturer’s name, address, and telephone number.

d. Manufacturer’s lot number.

e. Product’s date of manufacture.

f. Test company name, address, and telephone number.

g. Testing date.

h. Test technician’s name and title.

i. All characteristic test values (see paragraph 4.7).

4.7. Test results.

The contractor shall have available copies of all test results performed to assure the quality or acceptability of the product submitted for acceptance. The test results shall also show the product’s acceptable range or expected test result and the item’s test value. All test equipment, which shall be used as media of inspection, shall be calibrated and current (within the last 12 months) at the time of testing. Calibration shall be to a recognized State or Federal standard. The company shall obtain and retain calibration information on all equipment that is used as a media of inspection for items delivered under this specification.

4.8. Nonaccepted lots.

Nonaccepted lots may be offered again for inspection in accordance with paragraph 6.4 of ANSI/ASQC Z1.4, except that Table II-B – Single sampling plans for tightened inspection (master table) shall be used with the parameters of paragraph 4.4.1. The resubmitted lot shall be inspected in accordance with table 1 of this specification.

4.9. Government lot acceptance.

The Government will conduct lot acceptance inspections and tests to determine compliance with the specification. The Government’s inspection will be in accordance with the requirements of section 4. If lot acceptance and tests are conducted at locations other than the manufacturing facilities, the contracting officer will specify location and arrangements. In the case of onsite inspections at the contractor facility, the contractor shall furnish the inspector all reasonable facilities for their work. During any inspection, the inspector may take from the lot one or more samples and submit them to an independent test laboratory approved by the Government or to a Government test facility for inspection and tests.

5. PACKAGING, PACKING, AND CONTAINER/SHIPMENT MARKING

5.1. Packaging, packing, and container/shipment marking.

The packaging, packing, and container/shipment marking shall be as specified in the contract or order.

6. NOTES

6.1. Acquisition requirements.

Acquisition documents should specify the following:

a. Title, number, and date of this specification.

b. If a first article sampling and inspection is not required.

c. The required length of leadlines (see paragraph 3.9).

d. Packaging and packing and marking (see paragraph 5.1).

6.2. Metric equivalence.

The following table provides the conversion factors to be used in creating metric equivalence for this specification.

Table 3 - Metric conversion table English system Calculation To obtain metric equivalence Pounds 𝑙𝑙𝑙𝑙𝑙𝑙.× 0.453 Kilograms Inches 𝑖𝑖𝑖𝑖.× 2.54 Centimeters Inches 𝑖𝑖𝑖𝑖. × 25.4 Millimeters Foot 𝑓𝑓𝑓𝑓. × 0.305 Meters

Fahrenheit (℉− 32) × (5 ÷ 9) ℃entigrade

6.3. First article.

When a first article sample(s) is required, it shall be inspected and approved in accordance with the first article clauses set forth in the solicitation. Specific instructions shall be included regarding arrangements for selection, inspection, and approval of the first article sample(s). The first articles shall be subjected to the ultimate strength requirement of 3.2. As such, the first articles will be made unserviceable by the test and will not be delivered to Government stock or supply.

6.4. Superseding data.

This document supersedes 5100-505A, June 2012.

6.5. Notice.

When Government drawings, specifications, and standards or other data are used for any purpose other than in connection with a definitely related Government procurement operation, the United States Government thereby incurs no responsibility nor any obligation whatsoever.

6.6. Preparing activity.

USDA Forest Service, National Technology & Development Program, 5785 Hwy 10 West, Missoula, MT 59808.

2.2. Order of precedence.