Attachment J-1 CFRB Spec 20May20.pdf

CFRB Specification Rev (-) 20 May 2020

MONTENEGRO AND GUATEMALA

COASTAL FAST RESPONSE BOAT (CFRB)

SPECIFICATION

REV (-)

20 May 2020

REVISION HISTORY

Date Summary Of Change Version

05/20/2020 Initial Issue (-)

TABLE OF CONTENTS

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Definitions

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 Mission Description 042-2 General Requirements 042-3 Montenegro and Guatemala Variants 042-3 Inspections 042-4 Referenced Documents 042-5 Alternate Items

045 CARE OF CRAFT

045-1 General 045-2 Machinery and Equipment 045-3 Running Aground 045-4 Mercury Restriction

050 CRAFT PERFORMANCE

050-1 Craft Performance

070 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

070-1 Environmental Conditions 070-2 Load Conditions 070-3 Seakeeping, Dynamic Stability and Maneuverability 070-4 American Boat and Yacht Council (ABYC) Standards 070-5 Alterations 070-6 Workmanship 070-7 Equipment Installation

071 ACCESS

071-1 Accessibility 071-2 Bilge Access

073 NOISE, VIBRATION, AND RESILIENT MOUNTINGS

073-1 Noise Levels 073-2 Sound Attenuating Materials 073-3 Equipment Mounting 073-4 Mechanical Vibration

074 WELDING AND ALLIED PROCESSES

074-1 General Requirements 074-2 Visual Inspections

074-3 CRITICAL WELDED ASSEMBLIES

075 FASTENERS

075-1 Stainless Steel Fasteners

078 MATERIAL

078-1 Structural Material/Aluminum 078-2 Bedding Compounds 078-3 Non-Biodegradable Materials 078-4 Fabric Material 078-5 Interior Materials 078-6 Other 078-7 Corrosion Control

079 STABILITY

079-1 Stability Requirements 079-2 Flotation Foam 079-3 List Limits

084 TRANSPORTATION AND HANDLING

084-1 Trailer

084-2 Road Transport 084-3 Marine Transport 084-4 Boat and Trailer Tie-downs 084-5 Tie-down Straps

085 TECHNICAL DATA PACKAGE

085-1 Technical Design Analyses 085-2 Drawings 085-3 Boat Technical Manual 085-4 Commercial off-the-Shelf Technical Manuals 085-5 OEM Certification Letters 085-6 OEM Warranties Booklet 085-7 Master Data Index (MDI) 085-8 TDP Format 085-9 TDP Submittal 085-10 TDP Acceptance

092 TESTING

092-1 Test Certifications

094 TRIALS

094-1 Builder's Trials (BT) 094-2 Acceptance Trials (AT)

SECTION 1: HULL STRUCTURE

100 GENERAL REQUIREMENTS FOR HULL STRUCTURE

100-1 General Structural Requirements 100-2 Limber Holes

110 SHELL AND SUPPORTING STRUCTURE

110-1 Beaching Plate

130 HULL DECKS

130-1 Deck Drains 130-2 Watertight Decks and Hull 150-1 Pilothouse and Forward Cabin

167 HULL STRUCTURAL CLOSURES

167-1 Doors and Hatches

169 SPECIAL PURPOSE CLOSURES AND STRUCTURES

169-1 Swim Platform 169-2 Arch 169-3 Bow Push Knees

SECTION 2: PROPULSION

233 INBOARD DIESELS

233-1 Inboard Diesel Performance 233-2 Starter 233-3 Alternator

241 PROPULSION REDUCTION GEARS

241-1 Marine Transmission

247 WATERJET PROPULSION

247-1 Waterjet Propulsion

252 PROPULSION CONTROL SYSTEM

252-1 Propulsion Instrument Marine Package

256 CIRCULATING AND COOLING SEAWATER SYSTEMS

256-1 General 256-2 Propulsion Engine Seawater Cooling 256-3 AC Generator Seawater Cooling

259 ENGINE EXHAUST SYSTEMS

259-1 Propulsion Engine Exhaust (wet) 259-2 Propulsion Engine Exhaust Risers

259-3 AC Generator Muffled Exhaust System

262 MAIN PROPULSION LUBE OIL SYSTEM

262-1 Electric Fast Lube Oil Change System (FLOCS)

SECTION 3: ELECTRIC PLANT

300 GENERAL REQUIREMENTS FOR ELECTRIC PLANT

300-1 General Characteristics 300-2 Suitable for Marine Environment 300-3 Panel Covers 300-4 Switches 300-5 Protection of Personnel 300-6 Enclosures

303 PROTECTIVE DEVICES

303-1 Overcurrent Protection

304 ELECTRICAL CABLE, WIRING, AND CONNECTIONS

304-1 Cable and Wire Connections 304-2 Marine Multi-Conductor Cable 304-3 Cable Installation 304-4 Cable Voltage Drop

310 ELECTRICAL PLANT

310-1 Propulsion Engine Driven Alternators

310-2 AC DIESEL GENERATOR

313 BATTERIES

313-1 Batteries 313-2 Battery Charging (24 VDC) 313-3 Battery Voltmeter 313-4 Shore Power Battery Charger (120/220 VAC to 24 VDC) 313-5 AC Inverter

320 POWER DISTRIBUTION SYSTEMS

320-1 DC Power Distribution System 320-2 AC Power Distribution System 320-3 Shore Power System 320-4 DC Outlets 320-5 AC Outlets

324 DISTRIBUTION PANELS

324-1 Electrical Circuit Breaker DC and AC Panels

330 LIGHTING

330-1 Electronics Dimmer 330-2 Interior LED Lighting 330-3 Deck Low-Level Lighting 330-4 Deck Lights 330-5 Electromagnetic Compatibility

SECTION 4: COMMAND AND CONTROL

404 RADIO FREQUENCY TRANSMISSION LINES

404-1 General Requirements

406 GROUNDING AND BONDING

406-1 General Requirements

421 NON-ELECTRICAL/ELECTRONIC NAVIGATION AIDS

421-1 Magnetic Compass 421-2 Storage

422 ELECTRICAL NAVIGATION AIDS

422-1 Navigation Lights 422-2 Integrated Electronic Navigation Package 422-3 Spotlight, Handheld 422-4 Spotlight, Fixed Mount

430 INTERIOR COMMUNICATIONS

430-1 Intercom System

436 ALARM, SAFETY, AND WARNING SYSTEMS

436-1 Emergency Position Indicating Radio Beacon (EPIRB) 436-2 Carbon Monoxide Detection System

441 RADIO SYSTEMS

441-1 Commercial Marine Band Radio 441-2 Broadband Communications 441-3 Direction Finder 441-4 Very High Frequency (VHF) Radio 441-5 Ultra High Frequency (UHF) Radio 441-6 Tactical Radio Accommodation 441-5 Antenna Mounts

443 VISIBLE AND AUDIBLE COMMUNICATION SYSTEMS

443-1 Navigation Horn 443-2 Law Enforcement Hailer/Siren System 443-3 Law Enforcement Light Kit 443-4 Day Shapes and Signal Flags

450 SURVEILLANCE SYSTEMS

450-1 Electro-Optic Infrared (EOIR) System:

470 COUNTERMEASURE SYSTEMS

470-1 Acoustic Hailing Device Provisions

SECTION 5: AUXILIARY SYSTEMS

500 GENERAL REQUIREMENTS FOR AUXILIARY SYSTEMS

500-1 Mechanical Components

505 PIPING SYSTEMS

505-1 Piping and Hose Materials 505-2 Pipe and Hose Installation 505-3 Hose Clamps

512 HEATING, VENTILATION, AND AIR CONDITIONING (HVAC)

512-1 Defogging System 512-2 Pilothouse Fans 512-3 Compartment Ventilation 512-4 Pilothouse and Forward Cabin Heat and Air Conditioning 512-5 Generator Compartment Ventilation

529 BILGE/DRAINAGE SYSTEM

529-1 Emergency Engine Space Dewatering System 529-2 Portable Manual Bilge Pump 529-3 Electric Bilge Pump(s) 529-4 Hull Drains

541 FUEL SYSTEM

541-1 General Requirements 541-2 Fuel Tank 541-3 Fuel Sounding 541-4 Fuel Level Gauge 541-5 Fuel Valves 541-6 Remote Fuel Shutoff 541-7 Fuel/Water Separator and Filter 541-8 Fuel Stripping Pump

555 FIRE FIGHTING

555-1 Engine Compartment Fixed, Clean Agent Fire Extinguishing System 555-2 Portable Fire Extinguishers 555-3 Fire Port

561 STEERING CONTROL SYSTEMS

561-1 Hydraulic Steering

561-2 Emergency Steering

565 TRIM AND HEEL CONTROL SYSTEMS

565-1 Trim and Heel Control

581 ANCHOR HANDLING

581-1 Anchor Fittings 581-2 Fortress Anchor

582 MOORING AND TOWING

582-1 Tow Provisions 582-2 Bow Eye 582-3 Tow Hawser 582-4 Cleats

592 DIVER SUPPORT SYSTEMS

592-1 Dive Ladder 592-2 SCUBA Tank Stowage

593 SEWAGE CONTROL SYSTEMS

593-1 Portable Toilet

SECTION 6: OUTFIT AND FURNISHINGS

600 OUTFIT

600-1 Onboard Spares 600-2 Boat Hook 600-3 Ring Buoy 600-4 National Ensign 600-5 Mooring Lines 600-6 Fenders 600-7 Air Horn 600-8 First Aid Kit

602 LABELING

602-1 Label Plates (General) 602-2 Piping System Label Plates 602-3 Valve Label Plates 602-4 Instruction Label Plates 602-5 Hoisting Label Plates 602-6 Boat Information Label Plate 602-7 Systems Label Plates 602-8 Stowage Label Plates 602-9 Unique Item Identification (UID)

611 HULL FITTINGS

611-1 Deck Cargo Tie-downs 611-2 Foam Collar 611-3 Hoist Fittings 611-4 Hoist Sling 611-5 Hoist Hardware

612 RAILS, STANCHIONS, AND LIFELINES

612-1 Grab Rails 612-2 Life Lines

625 WINDOWS

625-1 General 625-2 Windshield Wiper/Washer System 625-3 Sun Shades

630 PRESERVATIVES AND COVERINGS

630-1 Bottom Paint 630-2 Exterior Non-Skid

633 CATHODIC PROTECTION

633-1 Aluminum Anodes

635 HULL INSULATION

635-1 Thermal Insulation and Acoustical Treatment

662 WORKING SPACES AND SEATING

662-1 Crew Seating 662-2 Console Ergonomics

670 STOWAGE SPACES

670-1 Stowage (General) 670-2 Stowage (Crew Gear) 670-3 Stowage (Misc)

SECTION 7: ARMAMENT

700 ARMAMENT

700-1 Heavy Machine Gun Foundations 700-2 Ready Service Ammunition Storage

763 SMALL ARMS AND PYROTECHNIC STOWAGE

763-1 Small Arms Stowage Locker 763-2 M2HB Barrel Stowage

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Definitions Sprint Speed: Boat speed at 100% throttle setting (maximum engine RPM). 5

Contractor: The Prime Contractor awarded the contract for design and construction of the CFRB

NAVSEA: The Headquarters of the Naval Sea Systems Command. (NAVSEA was formerly NAVSHIPS.

Documents referred to herein as NAVSHIPS or NAVSEA are under the cognizance of NAVSEA)

NSWCCD: The Naval Surface Warfare Center Carderock Division

Government: The United States Government. 10

Government Representative: The Contract Administration Office or other designated representative specified in the contract. Where such terms as “as approved”, “for approval”, “as directed”, and “for review” are used without further qualification, the approval, direction, decision, or review of the Government Representative is intended.

Craft or Boat: Synonymous terms for the CFRB. 15

Deck House: Synonymous term for Pilothouse or Cabin.

Herein: Refers to this Specification (including any attachments), the Statement of Work and the Contract.

(For example, a requirement that includes the qualifying statement “unless otherwise stated herein” refers to these Specifications, the Statement of Work and the Contract)

042 GENERAL ADMINISTRATIVE REQUIREMENTS 20

042-1 Mission Description The primary areas of operation shall consist of seawater and brackish waters. CFRB shall be capable of conducting fresh water operations. The boat shall be capable of full operations in the Full Load condition in up to three (3) foot significant (average of the 1/3 highest) wave height waves and reduced capability in up to five (5) foot significant wave height waves. 25

CFRB will operate in coastal waters. Operation will be day or night and in all-weather.

CFRB shall have a four (4) person crew including a coxswain, navigator, gunner, and an engineer/gunner.

CFRB shall have a 10-hour mission duration and operate up to 1,500 hours a year.

CFRB mission profile is defined as follows:

Speed Mission Profile

Idle/Loiter: 55%

Cruise 35%

Sprint: 10%

042-2 General Requirements This Specification is for an aluminum Coastal Fast Response Boat with an approximate length of forty-two 5

(42) to forty-five (45) feet.

This Specification provides the minimum required general system characteristics and requirements for the selection; installation; onboard performance; onboard inspection of machinery, equipment, and outfit; and pre-installation handling and inspections of materials for construction.

Only new, marine grade materials and components shall be used for construction and outfitting. Materials 10 shall be stored and protected to maintain their like new operation, appearance, and function.

042-3 Montenegro and Guatemala Variants

The following sections contain differing requirements for boats that are designated for Montenegro or Guatemala. The differences are identified in the following sections by Montenegro Variant and Guatemala Variant. 15

Section Title 070-1 Environmental Conditions 300-1 General Characteristics 310-2 AC Diesel Generator 313-5 AC Inverter 320-3 Shore Power System 320-6 AC Outlets 421-1 Magnetic Compass 450-1 Electro-Optic Infrared System

512-4 Pilothouse and Forward Cabin Heat and Air Conditioning

042-3 Inspections

The Contractor shall allow designated Government Representatives to monitor all aspects of construction and in process testing of the boat for the purpose of ensuring compliance with the contract. During the life of the contract, the Government or its representatives shall have access to the boat for inspection during 20 working hours or outside of normal working hours when 24-hour notice is provided, subject to contractually required security and access control provisions.

042-4 Referenced Documents

Where the issue or revision of referenced documents is not specified herein, the issue in effect on the date of issuance of the Request for Proposal (RFP) shall apply. Use of other issues of these documents shall 25 require Government approval.

In the event of a conflict between the text of this Specification and the references cited herein, the text of this Specification takes precedence. In cases where additional requirements in references cited herein constitute additional details or features, which violate the specified performance, then it shall be considered a conflict. Nothing in this Specification, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 5 If there is a conflict between requirements in referenced documents at the same tier, the more stringent requirement shall take precedence.

1) NSWCCD-80-TR-2014/038, “Weight Management Process Guidance for Boats and Craft”

2) NAVSEA TO300-AU-SPN-010A, “Fabrication, Welding and Inspection of Small Boats and Craft, Aluminum Hulls” 10

3) NAVSEA 0900-LP-060-4010, “Fabrication, Welding and Inspection of Metal Boat and Craft Hulls”

4) ABYC, “American Boat and Yacht Council, Standards and Technical Information Reports for Small Craft”

5) ASTM F593, “Standard Specification for Stainless Steel Bolts”

6) ASTM F594, “Standard Specification for Stainless Steel Nuts” 15

7) NAVSEACOMBATSYSENGSTA Report No. 6660-99 Rev. A, “Procedures Manual for Stability

Analysis of U.S. Navy Small Craft”, 1988

8) MIL-STD-1366E, “Department of Defense: Interface Standard for Transportability Criteria”

9) NSWCCD-23-TM-2009/64, “Small Craft Transportability Design and Certification Process Guidance” 20

10) 49 CFR 393.102, “Securement Systems”

11) WSTDA-T-1, Web Sling & Tie Down Association “Recommended Standard Specification for Synthetic Web Tie Downs”

12) 49 CFR 571.121, “Federal Motor Vehicle Safety Standards (FMVSS) Standard Number 121 Air Brake Systems” 25

13) MIL-STD-209, “Department of Defense Interface Standard for Lifting and Tie-down Provisions”

14) SNAME T&R bulletin 4-16, “Recommended Practices for Ship Heating, Ventilation & Air Conditioning”

15) ASME Y14.100, “Engineering Drawing Practices”

16) NSWCCD-23-TM-2009/61 “U.S. Navy Boat Example Data Package” 30

17) ISO 12215-5, “Hull construction - Scantlings - Part 5: Design pressures for monohulls, design stresses, scantlings determination”

18) ISO 12215-6, “Small craft — Hull construction and scantlings — Part 6: Structural arrangements and details”

19) IEEE Standard 45, “Recommended Practices for Electrical Installations on Shipboard” 35

20) NSWCCD-23-TM-2009/58, “U.S. Navy Boat Electrical Practices”

21) MIL-DTL-3950, “Military Specification: Switches, Toggle, Environmentally Sealed, General Specification For”

22) UL 489 “Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit-Breaker Enclosures”

23) MIL-PRF-55629, “Circuit Breakers, Magnetic, Unsealed or Panel Seal, Trip-Free, General Specification for”

24) MIL-STD-202, “Department of Defense Test Method Standard: Electronic and Electrical Component Parts”

25) UL 1077 “Standard for Supplementary Protectors for Use in Electrical Equipment” 5

26) IEEE 1580, “Recommended Practice for Marine Cable for Use on Shipboard and Fixed or Floating Facilities”

27) UL 1426 “Standard for Electrical Cables for Boats”

28) COLREGS 1972, “UL 1500 “Standard for Ignition-Protection Test for Marine Products”

29) UL 1112 “Standard for Marine Electric Motors and Generators” 10

30) Convention on the International Regulations for Preventing Collisions at Sea, 1972 (COLREGs)”

31) 47 CFR 15 Subpart B, “Unintentional Radiators”

32) NSWCCD-23-TM-2011/05, “U.S. Navy Craft Mechanical Practices”

33) SAE J1273, “Recommended Practices for Hydraulic Hose Assemblies”

34) SAE J2006, “Marine Exhaust Hose” 15

35) NSWCCD-23-TM-2011/39, “Anchoring System Design and Verification Process Guidance”

36) NSWCCD-23-TM-2009/65, “Towing Fitting Design and Certification Process Guidance”

37) NSWCCD-23-TM-2011/38, “Mooring Fitting Design and Verification Process Guidance”

38) NSWCCD-23-TM-2009/33, “Hoisting System Design and Certification Process Guidance”

39) RR-C-271, “Chains and Attachments, Carbon and Alloy Steel” 20

40) ISO 12216, “Small Craft - Windows, Portlights, Hatches, Deadlights and Doors - Strength and Watertightness Requirements”

41) MIL-PRF-24647, “Paint System Anti-Corrosive Ship Hull”

42) MIL-PRF-24667, “Coating System, Non-skid, for Roll, Spray, or Self-Adhering Application”

43) MIL-DTL-24779, “Anodes, Sacrificial, Aluminum Alloy” 25

44) DoD HDBK 743, “Anthropometry U.S. Military Personnel”

45) ASTM F1166, “Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities”

46) NSWCCD-23-TM-2009/63, “Small Craft Crew Served Weapons Integration Guidance and Certification Process” 30

47) NAVSEACOMBATSYSENGSTA Report 60-167, July 1986, “Inclining Experiment Procedure”

48) NSWCCD-80-TR-2015/010, Laboratory Test Requirements for Marine Shock Isolation Seats”

042-5 Alternate Items Where boat components and equipment are specified by brand name or manufacturer and model number and followed by “or equal”, such identification is intended to be descriptive, not restrictive, and is intended 35 to indicate the required characteristics of the product. The Builder may propose the use of other products that are equal to the specified make and model products. The following general requirements shall form the http://www.imo.org/Conventions/mainframe.asp?topic_id=257&doc_id=649 basis for determining the equality of alternate products, unless additional specific or alternate requirements are designated within the applicable sections of these Specifications:

a. The major attributes of form, fit, function, interface, and material of an alternate item shall not degrade the performance of the system within which it is used, nor the boat as a whole.

The alternate item shall require no more space or volume than the designated item for 5 installation, operation, or maintenance. The alternate item shall weigh no more than the designated item. The connection fittings required to incorporate the alternate item into a system shall be identical to those necessary to incorporate the specified item. The principles of operation of the alternate item shall be the same as those of the designated item (e.g. hydraulic cylinders shall not be used in lieu of springs, etc.). Input power, 10 capacity, and other operating requirements for the alternate item shall be no greater than those required by the designated item. Output power, capacity, and other performance parameters of the alternate item shall be no less than those required for the designated item and not so much greater than those of the designated item as to require an increased capacity of the system within which the item is installed. 15

b. The materials of construction of the alternate item shall be the same as those of the designated item unless the Builder can demonstrate to the Government that the proposed alternate material will not adversely affect performance or service life of the item, the system within which it is installed, or the boat as a whole.

c. The reliability and maintainability of an alternate item shall be equal to or better than the 20 specified item. The Builder shall provide evidence of the reliability and maintainability of the alternate item. This evidence may include such things as results of testing, service histories, documentation of successful use in similar applications, planned maintenance requirements, etc. Where the reliability and maintainability of the specified item has been established by testing, the Government may require that the alternate item undergo similar 25 testing to demonstrate its reliability and maintainability. Such testing, if required, shall be at the Builder's expense.

d. An alternate item shall conform to the same industry or Government specifications or standards as the specified item. Where a specified item has been approved or certified by a regulatory or testing agency, such as USCG or Underwriters' Laboratories, the alternate 30 item shall also be approved or certified. The cost of demonstrating compliance with specifications or standards, or of obtaining approval or certification, shall be borne by the Builder.

e. If the specified item is one with established logistic support any alternative item shall have equivalent logistic support. If equivalent logistic support has not been established for the 35 alternate item, the Builder shall bear the expense of establishing equivalent support.

Logistic support shall include, as applicable: maintenance planning and analysis; training and training support, including training equipment, curricula, and instruction materials;

supply support; support equipment such as special tools and test equipment; technical documentation including technical manuals, Product Technical Description (PTD), 40 Planned Maintenance System (PMS), Technical Repair Standards (TRS), and software documentation; computer resource support; facilities for maintenance and training; unique packaging, handling, storage, and transportation requirements; and human engineering considerations.

045 CARE OF CRAFT 45

045-1 General

All parts of the craft, including materials, structure, deck coverings, fittings, equipage, outfit, upholstery, insulation, windows, paint work, machinery, auxiliaries, systems, tanks, appliances, and apparatus shall be maintained in a satisfactory condition during the entire period the craft is in the Contractor’s possession.

During construction all debris, refuse, dirt, and water shall be removed frequently. Tanks and voids shall be cleaned before being closed. Rubbish shall be removed from places that are to be permanently closed or which may become inaccessible. Appropriate measures shall be taken to prevent wear and damage incident to construction and to prevent corrosion or other deterioration, especially to unpainted, polished 5 and moving parts. Piping, machinery and equipment subject to freezing shall be kept drained during freezing weather, except during trials and tests. Equipment, prefabricated parts, furnishings and materials shall be kept clean and protected from the environment when stored prior to installation.

045-2 Machinery and Equipment

The Contractor is responsible for the care of all machinery and equipment whether furnished by the 10 Contractor or by the Government. All components or parts, especially those having working surface, passage or piping for lubricating oil shall be kept clean and protected at all times. Electrical and electronic equipment and machinery shall protected at all times against dust, moisture or other foreign matter or contaminates and shall not be subjected to rapid temperature changes or extremes in temperatures.

045-3 Running Aground 15

Precautions shall be taken to prevent the craft from going aground or encountering hazards in the water. In the event the craft is grounded, or incidentally contacts any hazard in the water, the Government shall be notified promptly and a thorough inspection for damaged surfaces, finishes, running gear and appendages shall be conducted. The craft shall be removed from the water for inspection if requested by the Government. 20

045-4 Mercury Restriction

Mercury, either undiluted or in solution in as small a proportion as one part per million, will cause severe corrosion of aluminum. The Contractor shall protect the craft and the materials used in its construction from contamination. Mercury and mercury compounds shall not be stored or carried aboard the craft. The Contractor shall restrict the use of mercury aboard the craft to mercury or mercury compounds contained 25 in components and which are required for the component to operate properly. Components containing mercury that may be used include florescent lights, mercury batteries and permanently installed instruments, sensors and controls specifically required by these Specifications.

050 CRAFT PERFORMANCE

050-1 Craft Performance 30

a. Sprint Speed: Minimum of 35 knots

b. Cruise Speed: Cruise Speed shall be defined by the builder based on the most economical speed for fuel consumption, measured in nautical miles per gallon. Cruise Speed shall not be less than 25 knots.

c. Vessel Range: Range shall be a minimum of 220 NM

d. Speed and Range requirements shall be evaluated in Calm Water, Full Load condition 35

e. Navigable Draft: Less than 5 ft

f. Minimum Payload: Four (4) crew and effects at 285 lb per crew member, crew served weapons (including one (1) LRAD 500X) and ammunition, small arms weapons and ammunition, and a 1000 lb miscellaneous payload

g. For payload items, which do not have a dedicated stowage location, the weight shall be distributed 40 evenly on centerline between forward and aft ends of the pilothouse and forward cabin at the deck level.

070 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

070-1 Environmental Conditions

The boat shall be capable of full operation in the following range of ambient air and water temperatures:

Montenegro Variant

Low High

Air Temperature 32° F Dry Bulb

93.7° F Dry Bulb /

73.7° F Wet Bulb

Water Temperature 32° F 82° F

Guatemala Variant

Low High

Air Temperature 65° F Dry Bulb

98.6° F Dry Bulb /

91.7° F Wet Bulb

Water Temperature 68° F 95° F

070-2 Load Conditions

The following load conditions are provided for reference throughout this Specification. These definitions apply to the engineering design values for weight and moments of the vessel in the described condition.

Weight Management Process Guidance for Boats and Craft, NSWCCD-80-TR-2014/038 shall be used for 10 guidance.

a. Light Ship: The boat complete in all respects including outfit (defined in Section 600), and ready for service with liquids in machinery at operating levels, but no payload, personnel, fuel, or other variable loads.

b. Full Load Condition: Light Ship plus Minimum Payload as defined in Section 050 and full 15 fuel. Fuel weight shall be calculated using a density of 7 lb/gallon.

c. Minimum Operating (Min Op) Condition: Light Ship plus crew as defined in Section 050 and 10% fuel.

d. Boat Over-the-Road (OTR): Light Ship plus full fuel and Minimum Payload (minus 4 crew at 185 lb each), and a 5-10% margin for growth. Note the boat OTR weight is used for sizing 20 of the trailer. The trailer axles and components shall support the boat and trailer including their margins.

e. Trailer Curb Weight: Trailer complete in all respects, including all tools/stowages on trailer, OTR tie-down straps, and misc. material required for OTR transport (e.g. boat covers, tie-down strap chafe protection, etc), and a 5-10% margin for growth. 25

f. Gross Vehicle Weight (GVW): Combined Boat OTR and Trailer Curb Weight.

g. Boat Design Hoisting Condition: Full Load Condition less personnel (minus 4 crew at 185 lb each) and a 10% margin for growth.

h. Trailer Design Hoisting Condition: Trailer Curb Weight using a 10% margin for growth.

070-3 Seakeeping, Dynamic Stability and Maneuverability

The CFRB shall be safe and controllable at all speeds and under the range of loading conditions specified 5 herein. Safe and controllable includes operation where boat orientation, motions, and accelerations do not pose a hazard to the crew or passengers that is not otherwise controllable by good seamanship and boat handling. Throttle or trim management while maneuvering at Sprint Speed to remain in control or command of the vessel is acceptable, but limits and necessary actions must be documented in the Boat Technical Manual and at the helm station. Maneuvering testing in Section 094 is intended to verify known limitations 10 and ensure all limits are defined.

The CFRB shall be dynamically stable (oscillatory and non-oscillatory) at all operational loading conditions and speeds. Trim control devices may be used to correct a dynamic instability. Speed reduction shall not be used as a correction for a dynamic instability.

In Full Load and Min Op Condition and at all speeds defined herein, the CFRB shall be able to maintain a 15 straight course. Without coxswain action for 10 seconds, the boat shall not deviate course by more than 5 degrees in calm, flat conditions.

In turns at all speeds, including up to the maximum required speed, and loading conditions, CFRB shall maintain a steady turn rate without skidding or any other effects of dynamic instability. Inboard heel shall be maintained throughout turns at speeds above fifteen (15) knots. When coming out of a turn, the boat 20 shall respond to the steering command.

The CFRB shall be capable of stopping from maximum speed to under 5 knots in less than 10 seconds without immersing the bow. Spray/splashing in the bow and astern are acceptable provided there is no ingestion of water in the engine air intake.

The astern performance shall be such that the CFRB can be maneuvered in reverse at speeds of at least 3 25 knots in a straight course and perform backing turns to port and starboard.

070-4 American Boat and Yacht Council (ABYC) Standards

Unless otherwise defined, the boat in all respects shall meet ABYC standards and recommended practices.

070-5 Alterations

Alterations to Original Equipment Manufacturer's (OEM) products by the builder or distributer are highly 30 discouraged. If alternations are necessary, documentation of the change shall be provided with the Technical Data Package (TDP).

070-6 Workmanship Plating shall be fair, closely fitted, and shall be free from buckling or uneven edges. Unless otherwise required herein, warpage and distortion shall not exceed limits stated in NAVSEA TO300-AU-SPN-010A. 35 Fairing compounds shall not be used. Filler shall not be used to correct improper fit.

Heat forming and flame straightening shall not be used.

All sharp edges shall be dressed, ground, or radiused to avoid injury to personnel or damage to equipment, and to promote adhesion of coatings.

Pipe, cable and other penetrations through decks and through watertight bulkheads shall be watertight 40 (Roxtec or equal), shall reduce the transmission of heat, and shall prevent the transfer of machinery vibration and noise through the hull structure. Piping, wiring leads and vent ducts shall penetrate the bulkhead as close to the top of the bulkhead as practicable

070-7 Equipment Installation

Unless otherwise approved by the Government, OEM recommendations for design and installation of their products into the boat shall be followed. Systems and components shall be selected for durability, longevity, 5 safety, and ruggedness. Components shall be selected to maximize the use of commercial-off-the-shelf (COTS) products.

All systems shall be free from leaks and safety hazards. Workmanship shall be in accordance with industry best practices.

Galvanically dissimilar metals (copper compounds or stainless steels, aluminum) shall be isolated using 10 insulating materials to prevent any path for electrical current.

Foundations and brackets for equipment shall be configured to provide access for cleaning, painting, preservation, and maintenance, and to prevent accumulation of water, dirt, and foreign material.

Connecting piping and wiring shall be run to minimize exposure to weather. Bulkhead and deck penetrations shall be as close as practicable to the equipment being served, preferably by direct connection 15 through the adjacent deck or bulkhead.

Systems, equipment, and components shall be installed to facilitate accessibility for operating efficiency and for inspection, adjustment, and repair. Permanent fittings and structure shall be kept clear of routes required for the removal of machinery and equipment. The space behind equipment may be inaccessible after installation; this factor shall be considered in providing proper preservation in way of such equipment 20 and in selecting the location of pipes, ducts, wireways, and other permanent fittings behind such equipment.

Nooks, crevices, and openings where water, dirt, dust, or foreign material can accumulate shall be avoided.

Protection of personnel against operating hazards shall be provided. Shafting, couplings, gears, flexible shafts, and similar items shall have adequate guards installed for protection of personnel. Such protective guards shall be removable without dismantling the machinery surrounded. 25 Guards shall be as light as is consistent with required protection and strength. Guards shall be of sufficient strength to be used as steps or hand holds if located where such use may be anticipated.

Protective guards or insulation shall be installed to prevent contact with equipment where surface temperatures exceed 140 °F. Protective guards, insulation, or caution signs shall be installed to prevent contact with equipment where surface temperatures exceed 120 °F, up to 140 °F. 30 Non-conducting protective guards shall also be installed as barriers to prevent personnel from inadvertently contacting energized and exposed electrical circuits, components, and terminals.

Equipment shall be protected against the hazard of personnel brushing against or being thrown against the equipment, particularly under heavy sea conditions, and inadvertently causing damage to exposed components or resulting in maladjustment of exposed functional controls such as push buttons, knobs, and 35 switches. Protection shall be provided by equipment arrangement or design or by installation of enclosures, screens, or guardrails. All sharp edges exposed to personnel shall be dressed, ground or radiused to avoid injury to personnel.

071 ACCESS

071-1 Accessibility 40

Electrical and mechanical components shall be accessible for maintenance and repair. All items requiring operation or maintenance (e.g. switches, valves, filters, strainers, seacocks, etc.) shall be readily accessible while at the dock, on the trailer, or underway. Stowage and securing of arches, antennas, masts or other items shall not prevent access to critical items such as battery switches, fuel shut off valves or other items that need to be checked, secured, or operated for any of the required transport modes.

071-2 Bilge Access

All bilges and voids shall have removable plates or hatches for bilge access/inspection without the use of tools. The access and inspection openings shall be of sufficient size and location to allow personnel visual 5 access to the entire bilge and void areas. Tightness of plates and hatches shall match the required tightness of the surface on which they are installed. As practical, bilge pumps and float switches shall be visible and accessible from these access points.

073 NOISE, VIBRATION, AND RESILIENT MOUNTINGS

073-1 Noise Levels 10

Noise levels in the pilothouse and forward cabin shall not exceed 84 dBA for all operating conditions.

If noise levels on the exterior decks meet or exceed 85 dBA under any operating condition, a warning label shall be provided on the interior of the access door to the exterior notifying the crew of the noise hazard and the associated operating conditions(s).

If noise levels in the machinery space(s) meet or exceed 85 dBA under any operating condition, a label(s) 15 shall be provided on any interior entrance accesses or in the machinery space(s) notifying the crew of the noise hazard and the associated operating condition(s).

073-2 Sound Attenuating Materials

Any installed sound attenuating material shall: (1) permit inspection of the interior hull and hull structure;

(2) be resistant to absorbing liquid or vapors; (3) not cause any corrosion to the hull material; and (4) be 20 noncombustible.

073-3 Equipment Mounting

Mounts for removable components and accessories subject to vibration, including items moved for towing or transport, shall be provided with resilient material as necessary to prevent rattling.

073-4 Mechanical Vibration 25 The craft and all craft components shall be free from excessive vibration. Vibration is excessive when it interferes, or threatens to interfere, with the proper operation of any craft component.

Any unsatisfactory conditions resulting from the excitation of a resonant frequency by any equipment shall be corrected by local stiffening of structure, installation of suitable mountings, modification of components, or other effective means. Means to prevent excessive vibration during normal craft operating conditions 30 shall be incorporated in the construction of the craft.

Means shall be provided to prevent rattling of removable plates, ladders, gratings, and similar items.

074 WELDING AND ALLIED PROCESSES

074-1 General Requirements

Only qualified weld procedures, materials and personnel shall be used in the fabrication of welded 35 components. Welding and qualifications shall be to military or commercial standards (such as American Bureau of Shipping (ABS), American Welding Society (AWS), NAVSEA TO300-AU-SPN-010A and NAVSEA 0900-LP-060-4010) as selected by the builder. The builder is responsible for maintaining appropriate procedures, materials and personnel qualifications and record keeping to show compliance, or if welding is subcontracted, for imposing the same requirements on the supplier. 40

074-2 Visual Inspections

All welds shall be visually inspected.

Welds shall be free of slag, weld splatter, cracks, sharp irregularities and incomplete fusion.

The weld edge shall not form a reentrant angle with the base metal less than 90 degrees due to lack of fusion, undercut or excessive convexity. 5 Fillet welds dimensioned 3/8 inch or less shall not vary below the specified size by more than 1/16 inch for a total distance greater than 25 percent of the joint length. Fillet welds dimensioned 7/16 inch and larger shall not be less than the specified size. Fillet welds in excess of the required dimensions shall be avoided;

however, oversized welds will be acceptable provided they meet the contour requirements and do not interfere with proper operation of the boat or its components. 10

Undercut shall not reduce the base metal thickness by more than 1/32 inch.

Welds shall not exhibit porosity or worm holes in excess of two indications 1/16 inch or larger in any 6-inch length of weld, exclusive of weld crater porosity.

Grinding to correct the weld profile shall not reduce the base metal thickness by more than 1/32 inch.

074-3 Critical Welded Assemblies 15

The forward and aft tow provisions, bow eye, hoisting fittings, and weapon foundations are critical welded assemblies. The following additional requirements shall apply for critical welded assemblies:

Weld procedures and welder qualification, including the associated record keeping requirements, shall be in accordance with the American Society of Mechanical Engineers (ASME), the American Welding Society (AWS), or NAVSEA TO300-AU-SPN-010 A, dated 5 October, 1992 (NAVSEA SPN-10). 20 The Contractor shall select one of these welding codes and adhere to all requirements of the selected document for each welding procedure specification. The Contractor may select different regulating codes for different weld procedures; however, all documentation, welding and welder requirements for each procedure (for example, the Welding Procedure Specifications (WPSs), the Procedure Qualification Records (PQRs) and the welder qualification and testing of the welds) must follow the same code. 25

All documentation pertaining to the welder and weld procedure qualification shall be maintained by the Contractor, available for inspection by the Government.

Critical welded assemblies shall be visually inspected and dye penetrant (PT) tested as follows:

1. Visually inspect completed critical welded assembly per Section 074-1 prior to painting or installation on the boat. If passing, proceed to step 2. 30

2. Before load testing, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch.

If passing, proceed to step 3.

OR

(Optional) If assembly does not require painting, it may be installed on the craft vice a jig and 35 proceed to step 6 then complete step 7.

3. In a jig, pull test to the load per Section 092-1.

4. After load testing, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch. If passing, proceed to step 5.

5. Paint and install fitting on boat. 40

6. Pull test the installed assembly to the load per Section 092-1.

7. If the critical welded assembly did not require paint and was installed on the boat directly after step 2, PT welds and 1/2 inch of base metal on either side of the weld for linear indications greater than 1/16 inch. If passing, proceed to step 8.

8. Visually inspect fittings and boat structure for signs of failure or permanent deformation and document findings. 5

075 FASTENERS

075-1 Stainless Steel Fasteners

Fasteners shall be type 316 Stainless Steel (UNS S31600), except fasteners used for structural applications shall be ASTM F593, type 316 with ASTM F594 nylon insert lock nuts and flat washers. Where required for high strength application (e.g. engine shaft coupling), non-stainless, high strength fasteners with 10 corrosion protection (e.g. paint corrosion inhibitor, etc.) require Government approval.

Self-locking hardware shall be used unless otherwise specified. Component mounting shall be through-bolted with nylon insert lock nuts and flat washers wherever practical to suit fastener reinstallation during maintenance and repair. For composite materials, fender washers shall be used on any bolted connections where backing plates are not provided. Threaded fasteners shall fully engage nuts with 1 – 3 thread 15 protrusion. Excessive thread protrusion (above 3 threads) that poses personnel hazard shall be avoided.

Fasteners may be threaded into structural or non-structural materials only with Government approval.

Any pins used for folding, removable, or stowable features shall be secured with stainless steel lanyards to prevent loss.

078 MATERIAL 20

078-1 Structural Material/Aluminum

Materials referred to in this Specification without further identification shall comply with this section. Other materials, which are acceptable for use in specific applications, will be defined in the relevant Specification section or reference document that requires their use.

No plastic (without explicit Government approval), polyvinyl chloride (PVC), chlorinated polyvinyl 25 chloride (CPVC), or high-density polyethylene (HDPE) shall be used except OEM components (e.g.

electric bilge pump, NEMA Boxes).

Except as otherwise specified or approved by the Government, materials used shall conform to the following specifications:

Aluminum for structure (if used) shall be: 30

a. Sand-cast: 3560 T6

b. Plate and sheet: 5086 H116 or 5086-H117 both ASTM B928; for non-welded applications 6061 T6 or 6061 T651 may be substituted.

c. Extrusions: 5086 H111; for non-welded applications 6061 T6 or 6061 T52 may be substituted.

d. Drawn tube: 5086 H32; for non-welded applications 6061 T6 may be substituted. 35

e. Non-structural components such as small component brackets and wire ways may include extruded 6061 material. Non-structural 6061 components in welded applications shall be approved by the Government prior to fabrication.

Aluminum for piping (if used) shall be:

a. Drawn tube: 5086-H32 (welded piping) ASTM B210 40

Stainless Steel (if used) shall be:

a. Cast for general applications: J92800 or J92500; for non-welded applications UNS J92900 or J92600 may be substituted.

b. Cast for underwater applications: J92800; for non-welded applications UNS J92900 may be substituted. 5

c. Plate/sheet, bars/shapes, tubing, pipe: S31603; for non-welded applications UNS S31600 may be substituted.

d. Valves and Fittings: Grade F 316, UNS S31600 – ASTM A182; or Type 316, UNS S31600 – ASTM A276; or Grade TP316, UNS S31600 – ASTM A312; or Grade CF8M, UNS J92900 –

ASTM A351. 10

Bronze (if used) shall be:

a. Valves, Strainers, and Fittings: UNS C92200 – ASTM B61; or UNS C83600 – ASTM B62; or

UNS C84400 – ASTM B584

Copper-Nickel (CuNi), 90-10 (if used) shall be:

a. Pipe and Tube: ASTM B466, ASTM B467 (Welded Pipe) 15

078-2 Bedding Compounds

Polysulfide and polyurethane sealants may be used above and below the waterline. Where waterproof adhesive bonds are required, a polyurethane compound shall be used.

078-3 Non-Biodegradable Materials

The use of wood and other hygroscopic or biodegradable materials anywhere on the boat is prohibited, 20 except where provided within OEM equipment and approved by the Government.

078-4 Fabric Material

All boat fabric shall be marine grade as well as fade, stain, and mildew resistant. The fabric color shall be as near match as possible to the surface color it is mounted to or covering unless otherwise noted. Fabrics shall be easy to maintain and waterproof and/or breathable where required. All seams, edges, grommets, 25 fastening points and areas of chafe shall be reinforced. Venting is acceptable to ventilate covers, but must minimize or eliminate the intrusion of water. Seats, seat fabric and foam shall be durable, provide comfort and be flame retardant.

078-5 Interior Materials

All interior materials shall be fire retardant. Generally, finishes shall be easy to maintain, easy to clean and 30 shall not have a gloss finish.

078-6 Other

All materials shall be marine grade and resistant to corrosion. All materials normally subjected to sunlight shall be highly resistant to degradation caused by ultraviolet radiation.

Joining surfaces between mechanically fastened metal components and between metals and laminates shall 35 be protected by the use of bedding compound or structural adhesive, as applicable.

078-7 Corrosion Control All parts and fittings required for disassembly of systems shall be of Monel, stainless steel type 316L (or 316 if not welded), or copper alloy containing no more than 10% zinc (except manganese bronze), whichever is compatible with the basic material of the equipment. Stainless steel, if used where it is likely to be submerged in seawater, shall be type 316L.

Boat mechanical components and subcomponents shall be suitable for a marine environment (water/corrosion resistant). Joined components shall be galvanically compatible with each other wherever possible, or shall be isolated to prevent galvanic corrosion. Components not available in a corrosion 5 resistant material shall be protected/coated to reduce/eliminate corrosion (e.g. paint, corrosion inhibitor, etc.).

Where it is necessary to join dissimilar metals, ensure complete isolation of faying surfaces of the galvanically dissimilar metals, including fasteners, using non-water absorbent dielectric barrier or sealant materials. 10 Use U.S. Navy Craft Mechanical Practices NSWCCD-23-TM-2011/05 for guidance.

079 STABILITY

079-1 Stability Requirements

Intact Stability - The CFRB shall meet the intact stability criteria of “Procedures Manual for Stability Analysis of U.S. Navy Small Craft”, NAVSEACOMBATSYSENGSTA Report #6660-99, Rev. A, with 15 the following clarifications and exceptions:

a. Wind heel speed of 60 knots for Coastwise, group (c) craft

b. Roll back angle of 25 degrees

c. Free to trim in analysis

d. Topside icing calculations are not required 20

e. No “Lifting Heavy Weights over the Side” requirements

f. High speed turn calculations are not required

Damage Stability - The CFRB shall meet the damage stability criteria of “Procedures Manual for Stability Analysis of U.S. Navy Small Craft”, NAVSEACOMBATSYSENGSTA Report #6660-99, Rev. A, with the following clarifications and exceptions: 25

a. Capable of withstanding, as a minimum, the flooding of any single main compartment

b. Wind speed of 30 knots

c. Roll back angle of 14 degrees

d. Free to trim in analysis

e. Unless otherwise proven by direct analysis, permeability for hull compartments shall be 0.85 for 30 Machinery Spaces and 0.95 for all other spaces

079-2 Flotation Foam

If flotation foam is used to obtain the required flotation characteristics, foam in place solutions (pour in foam) shall not be used. Flotation foam installed shall meet ABYC H-8.10 Material specification and ABYC H-8.11 Installation requirements. 35

Flotation foam that must be removed to perform maintenance or repair to mechanical or electrical components shall employ reusable means to secure the foam in place and markings to assist in reinstallation.

Aluminum structure in direct contact with flotation foam shall be painted to prevent corrosion.

079-3 List Limits

The CFRB shall not list more than one (1) degree in static condition across the range of loading conditions from Full Load to Min Op conditions. Ballast shall not be used to meet this requirement.

The CFRB shall not list more than one (1) degree across the range of loading conditions from Full Load to Min OP conditions without the use of trim tabs at any speed when running straight in calm wind and water 5 conditions.

084 TRANSPORTATION AND HANDLING

084-1 Trailer

A trailer shall be provided with the following characteristics:

a. The trailer shall be capable of road tranport, maritime transport, and launching and recovering the 10 boat from a boat ramp.

b. Trailer shall be aluminum or hot-dipped galvanized steel construction. No wood allowed.

c. Trailer shall be a triple or tandem axle. Axles shall be galvanized.

d. Trailer shall be capable of transport over high quality paved roads and secondary roads with 15 washboarding, potholes and loose gravel.

e. GVWR shall not be less than designed GVW (with margins per Load Conditions section).

f. Light Truck (LT) series tires, as a minimum. All wheels shall be galvanized steel.

g. Two (2) matching and mounted spare tire and wheel. 20

h. Brake actuation components shall be capable of total submersion in salt water for short periods of time.

i. Surge brakes or electric-over-hydraulic brakes shall be installed on each axle. All brake components shall be suitable for submersion, including stainless steel rotors, stainless steel brake caliper assembly with stainless steel cylinder and guide pins. Brake system shall be designed to 49 25 CFR 571.121, “Federal Motor Vehicle Safety Standards (FMVSS) Standard Number 121 Air Brake Systems.

j. Stainless steel hydraulic brake lines with smooth regular bends (two-inch minimum radius) or hydraulic flex hoses, where necessary, shall be stainless or Kevlar, and have a minimum rating of 3000 psi. 30

k. On-trailer stowage for tools and tie-down straps.

l. Forward ladder or steps with two-sided handrail, providing access to…