Rigging_Board_Specs.pdf

PB: RB-5

08 November 2012 Supersedes

PB: RB-4

May 15, 2008

DEPARTMENT OF THE TREASURY

BUREAU OF ENGRAVING AND PRINTING

WASHINGTON, D.C. 20228

BEP SPECIFICATION FOR

PAPERBOARD: RIGGING BOARD (ROTARY CURRENCY PRESS)

1.0 SCOPE AND CLASSIFICATION

1.1 Scope This specification covers performance and acceptance requirements for rigging board material suitable for use as an impression material in high-speed sheet-fed rotary intaglio presses at the Bureau of Engraving and Printing, hereinafter referred to as the BEP. The rigging boards shall be suitable for use as an inner covering on impression cylinders of high-speed, sheet-fed rotary I-10 and Super Orlof intaglio presses. The rigging boards will be used on presses to print United States currency.

1.2 Classification This specification covers one grade and two types of rigging boards for use on the I-10 intaglio presses and three types of rigging board for use on the Super Orlof intaglio presses.

1.2.1 Type ll Type ll rigging board for the I-10 presses for the BEP’s Washington, DC and Fort Worth, Texas facilities shall be identified as BEP stock item number 1L001959.

1.2.2 Type III Type III rigging board for the I-10 presses for the BEP’s Washington, DC and Fort Worth, Texas facilities shall be identified as BEP stock item number 1L002002.

1.2.3 Type IV Type IV rigging board for the Super Orlof Intaglio (SOI) presses shall be identified as BEP stock item number 1L002017.

1.2.4 Type V Type V rigging board for the Super Orlof Intaglio (SOI) presses shall be identified as BEP stock item number 1L002026.

1.2.5 Type VI Type VI rigging board for the Super Orlof Intaglio (SOI) presses shall be identified as BEP stock item number 1L002039.

2.0 APPLICABLE DOCUMENTS

2.1 Government Documents

Supersedes

2.1.1 Specifications, Standards, and Handbooks The following

specifications, standards, or handbook form a part of this specification to the extent specified herein.

Federal Standards

Federal Standard-141 Paint, Varnish, Lacquer, and related Materials: Methods of Inspection, Sampling and Testing

(Federal specification and standards may be obtained from the General Services Administration, Federal Supply Service; Specification Section (3FP-E), 470 East L’Enfant Plaza; SW; Suite 8100, Washington, DC 20407.)

Bureau of Engraving and Printing Specification:

B: ECF-3 BEP Specification for Blanket: Elastomeric-Coated Fabric

L: VAB-1 Specification for Vendor Affixed Barcode Labels for Bureau of Engraving and Printing Materials.

(Single copies of BEP documents are available from the Contracting Officer, BEP, 14th and "C" Streets, S.W.; Washington, D.C. 20228).

2.1.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this solicitation.

Publications

29 CFR 1910, Part 1200 – Hazard Communication Standard (Occupational Safety and Health Administration). See also Federal Register Vol. 48, No. 228, November 24, 1983

40 CFR 261 – Identification and Listing of Hazardous Waste. See also Federal Registrar, Vol.55, No. 61, March 29, 1990

40 CFR Part 707 – Chemical Imports and Exports

40 CFR 720 – Premanufacture Notification; Premanufacture Notice Requirements and Review Procedures

40 CFR 761 – Polychlorinated Biphenyls (PCB's), Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions

Superfund Amendments and Reauthorization Act (SARA) Title III:

Supersedes

40 CFR 355--Requirement for Emergency Planning and Notification Under

CERLA

40 CFR 370—Hazardous Chemical Reporting and Community Right to Know Requirements

40 CFR 372—Toxic Chemical Release Reporting

49 CFR 100-199--Department of Transportation Rules and Regulations

42 UNITED STATES CODE 6901 et seq., and 6962-- See also General Provisions for USC 6901 and Federal Procurement for USC 6962.

Clean Air Act Amendments of 1990, Section 112, Air Toxics

(The Code of Federal Regulations (CFR) and the Federal Register (FR) are for sale on a subscription basis by the Superintendent of Documents; U.S.

Government Printing Office; Washington, D.C. 20402. Reprints of certain regulations may be obtained from the Federal agency responsible for their issuance.)

District of Columbia Municipal Regulations (DCMR), Title 20, Air Quality Control Regulations

District of Columbia Municipal Regulations (DCMR), Title 21, Discharge Standards, Chapter 15, Section 1502.4(c). Discharge to Wastewater Systems.

(Request for copies should be addressed to the District of Columbia, Office of Documents and Administrative Issuance; Room 520, One Judiciary Square; 441 4th Street, NW; Washington, DC 20001.)

California's "Safe Drinking Water and Toxic Enforcement Act" of 1986 (Proposition 65)

(Requests for copies should be addressed to the California Environmental Protection Agency; Office of Environmental Health Hazard Assessment; 301 Capitol Mall, Room 205; Sacramento, California 95814)

2.2 Non-Government Publications The following documents form a part of this specification to the extent specified herein.

Supersedes

Testing Methods and Recommended Practices of the Technical Association of the Pulp and Paper Industry (TAPPI) Methods:

T400 Sampling and Accepting a Single Lot of Paper, Paperboard, Containerboard, or Related Product T402 Standard Conditioning and Testing Atmosphere for Paper, Board

Pulp Handsheets and Related Products T409 Machine Direction of Paper and Paperboard T411 Thickness (caliper) of Paper, Paperboard, and Combined Board

(Request for copies should be addressed to the Technical Association of the

Pulp and Paper Industry; Technology Park Atlanta; P.O. Box 105113; Atlanta, Georgia 30348)

American National Standards Institute (ANSI)/ International Standards Organization (ISO) American Society for Quality (ASQ):

ANSI/ISO/ASQ Q9001: 2008 Quality Management Systems-Requirements

(Request for copies should be addressed to the American National Institute; 25 West 43rd Street, 4th Floor; New York, NY 10036 or by visiting their website at www.ansi.org)

National Motor Freight Classification Rules and Container Specifications

(Request for copies should be addressed to the American Trucking Association, Inc.; 2200 Mill Street; Alexandria, Virginia 22314-4677)

(Non-Government standards and publications are available from the organizations that prepare or distribute the documents. These documents also may be available in, or through, libraries or other information services.)

2.3 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, supersedes applicable laws and regulations unless a specific exemption has been obtained.

2.4 Internal References All paragraph and section references will be to paragraphs and sections of this specification, unless stated otherwise.

3.0 REQUIREMENTS

3.1 Material The rigging board shall be manufactured from either cellulosic fibers, synthetic fibers or a combination of these types of fibers. Other materials

Supersedes such as filler, binder, dye, adhesive, biocide, etc. may be added provided that all requirements of the specification are fully met.

3.1.1 Recovered Materials In accordance with the requirements of 42 United States Code 6901, et. Seq., and 6962, the BEP encourages the use of the highest percentage of recovered materials practicable in the manufacture and delivery of the finished materials as specified herein, as long as all specification requirements are fulfilled.

3.2 Performance The rigging board shall perform as a component of each section of the impression cylinder in the rigging system used in the sheet-fed rotary intaglio currency presses. The press rigging may consist of one to three layers of rigging boards placed under an elastomeric-coated fabric known as a “drawsheet”. The I-10 face and back presses use two rigging boards. The Super Orlof Intaglio (SOI) face and back presses use either one type VI rigging board or the combination of two (2) rigging boards which are: one type IV and one type V rigging boards. Each rigging board shall have mounting holes punched along the edge as shown in Figures 1 and 2 of the specification. The rigging boards shall conform to the curvature of the impression cylinder and drawsheets (see Section 6.1). Using the holes, the board is mounted on the pins.

The minimum service life of Type II and Type III rigging boards shall be 250,000 press impressions. The minimum service life of Type IV, V and VI rigging boards shall be 250,000 press impressions. The rigging boards shall perform under the printing pressures and temperatures (see Section 6.1). The rigging boards shall not contain or develop any one of the following: creases, tears, indentures, holes, lumps, and any other condition that might damage the press and/or printing plate and/or produce an unacceptable print quality. The rigging boards shall not delaminate during use. The print quality of United States currency produced using the rigging boards as a component of the press rigging system shall equal or exceed that of the BEP print quality standards.

3.3 Physical Requirements The rigging board shall comply with the requirements listed in TABLE I of this specification.

Supersedes

TABLE I

Physical Properties

PROPERTY TYPE II TYPE III TYPE IV TYPE V TYPE VI

Grain Direction Short

Dimension Short

Dimension Short

Dimension Short

Dimension Short

Dimension

Press I-10 I-10 SOI SOI SOI

Thickness, mm (thousandths of an inch (mil))

Target 1.27 (50)

1.27 (50)

1.02 (40)

0.50 (20)

1.52 (60)

Minimum 1.21

(47.6) 1.21

(47.6) 0.97

(38.2) 0.48

(18.9) 1.47

(57.9)

Maximum 1.33

(52.3) 1.33

(52.3) 1.07

(42.1) 0.53

(20.9) 1.57

(61.8)

Maximum Thickness Variation within Boards (mm)

0.076 0.076 0.061 0.030 0.061

Width (mm/inches)

Minimum 646 / 25.4 667 / 26.3 835 / 32.8 835 / 32.8 835 / 32.8

Maximum 654 / 25.8 669 / 26.3 839 / 33.0 839 / 33.0 839 / 33.0

Length (mm)

Minimum 612 / 24.1 640 / 25.2 770 / 30.3 770 / 30.3 770 / 30.3

Maximum 625 / 24.6 642 / 25.3 774 / 30.5 774 / 30.5 774 / 30.5

3.3.1 Structure The rigging board shall be resistant to cracking or tearing at the edges. The plies of the rigging board shall be well adhered to each other.

The rigging shall accept a sharp 90o angle bend in either direction of the grain without fracturing, cracking, and/or delaminating.

3.3.2 Defects The rigging board shall have a surface, formation, and texture that will ensure acceptable printing impression. It shall be free from high and low areas, lumps, creases, tears, holes, blisters, irregularities, and the presence of dirt or foreign matter.

3.3.3 Trim The rigging board shall be well trimmed on all four sides with clean and smooth linear edges. The edges of the rigging board shall not cut into the drawsheet. The corners of the rigging boards shall be square. The corner of the rigging board shall be considered square if the edges of the sheet forming that corner, measured at the points on the edges most distant from the corner, are no more than 1.3 millimeters (0.05 inch) from the position that the edges would occupy if the corner had an angle of exactly 90o . Square rigging boards are necessary to ensure proper fit on the impression cylinder.

Supersedes

3.3.4 Mounting Holes Holes for mounting the rigging boards on the press impression cylinder shall be punched as shown in Figures 1 and 2 of the specification. Holes shall be punched cleanly having no frayed edges or hangers.

3.3.5 Grain Direction The rigging board shall have a grain direction in the short dimension.

3.4 Environmental, Health, and Safety Requirements in Manufacture, Handling, Printing, and Processing The contractor shall comply with the requirements of Environmental, Health and Safety for Materials Specifications (See attachment).

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Contractor Quality Assurance Plan The BEP shall rely on the contractor’s existing quality assurance system or plan prior to delivery of the material. However, the BEP reserves the right to perform any inspections and tests that the BEP deems necessary upon receipt of the material to assure conformance to requirements. The BEP may conduct periodic site visits and quality audits of the facilities of the manufacturer or major first tier subcontractor in cases where the contractor is a “broker” or “regular dealer”. Upon the request of the BEP, the contractor shall provide a copy of their current quality assurance system document, e.g., quality assurance plan and its associated quality system documents to the BEP. If the contractor is a “broker” or a “regular dealer” and not the manufacturer of supplies to be delivered under the terms of the contract, the BEP may request that the contractor provide a copy of the current quality assurance system document, i.e., quality assurance plan and its associated quality system documents of its major first-tier subcontractors. The quality assurance system document will be used by the BEP as the basis for conducting the quality audit.

4.2 Control Chart The contractor shall provide a control chart for each of the control variables identified by the BEP. The control variables are characteristics or properties of the rigging boards identified in the BEP specification. The control chart is a plot of the control variable of each lot or batch of materials plotted sequentially by date of manufacture and shall contain the specification limits for the characteristics or properties. The contractor shall furnish a hard copy and a diskette of the control chart of each control variable to the Contracting Officer’s Technical Representative (COTR) for each shipment.

4.2.1 Control Variable The contractor shall provide control charts for the following control variables: thickness, length, width, and thickness variation.

Supersedes

4.3 Inspection and Testing

4.3.1 Responsibility for Inspection and Testing Unless otherwise specified in the contract or in the purchase order, the contractor is responsible for the performance of all inspection and testing specified. Except as otherwise specified, the contractor may utilize its own facilities or other commercial laboratory acceptable to the BEP. The BEP reserves the right to perform any inspection and tests set forth in the specification. This may include site visits and periodic quality audits at the facilities of the contractor and sub-contractor.

4.3.2 Sampling Sampling shall be conducted in accordance with TAPPI method T-400. The lot size shall be determined by the contractor, based on the contractor’s knowledge of the manufacturing process. The lots shall be expressed in units of boards and shall consist of single manufacturer’s batch or run, and must have uniform properties. Sublots shall be established whenever conditions indicate a significant difference in raw materials and/or manufacture.

4.4 Testing Testing shall be conducted in accordance with the following methods. Reference to specific instruments is for information only. Use of a company and/or product name in this document does not imply approval or recommendation of the product in preference to others that may also be suitable.

The BEP will work with the contractor to establish correlations between various instruments when required.

4.4.1 Test Conditions The rigging board samples shall be conditioned and tested under environmental conditions that meet the requirements of TAPPI method T402.

4.4.2 Grain Direction The grain direction of the rigging board shall be determined according to TAPPI method T409.

4.4.3 Thickness The thickness of the rigging board shall be determined according to TAPPI method T411. Report the average, minimum, and maximum thickness for each lot.

4.4.4 Thickness Variation Thickness variation shall be determined by measuring the thickness of each sample board in each corner and the center of the board. The difference between the lowest and the highest thickness measurements shall be the thickness variation of the board.

4.5 Inspection Inspections shall be conducted for the requirements listed in TABLE ll, in accordance with the method given:

Supersedes

TABLE II

INSPECTION

Paragraph/Requirement(s) Inspection Method 3.3.1/Structure Visual evaluation 3.3.2/Defects Visual evaluation 3.3.3/Trim Visual/ measurement 3.3.4/Mounting Holes (see figures) Visual evaluation/measurement 3.3.5/Grain Direction Visual evaluation Section 5/ Preparation for Delivery Visual evaluation

4.6 Certifications and Reports The contractor shall certify in writing that the rigging boards supplied in each delivery are in compliance with all the requirements including health, safety, and environment as set forth in this specification. The signed and dated certification shall include a statement of the recovered material content if applicable. This certification of compliance shall accompany the report of inspections and tests. The contractor shall furnish copies of the result of inspections and tests performed for each batch or lot of rigging boards within the shipment to the COTR in electronic form.

5.0 PREPARATION FOR DELIVERY

5.1 Packaging The packaging shall conform with the Department of Transportation Rules and Regulations and to applicable requirements of the National Motor Freight Classification Rules and Container Specifications.

5.1.1 Packing The rigging board shall be delivered in a corrugated fiberboard container of suitable strength to provide protection during shipping and handling.

Each container shall contain 100 boards. The packing shall keep the boards flat (no curl) and provide protection for the edges of the boards. The packing shall include a waterproof liner to keep the boards from picking up moisture.

5.1.2 Palletization The container shall be delivered on sturdy wooden pallets, which allow four-way entry for forklift truck. The pallets may be slatted, and if slatted, the space between adjacent slats shall not exceed 12.5 centimeters (1/2 inch.) Each pallet shall contain a maximum of 1,000 boards. Pallet loads shall be shrink wrapped and/or strapped with plastic bands to prevent shifting of the containers during shipping and handling. No other packaging arrangements can be made unless a written approval is first obtained from the Contracting Officer.

5.2 Marking

Supersedes

5.2.1 Container Marking Each container shall be plainly marked with the appropriate BEP stock item number: “Rigging Board, Stock Item Number 1L001959,” “Rigging Board, Stock Item Number 1L002002,” “Rigging Board, Stock Item Number 1L002039,” “Rigging Board, Stock Item Number 1L002017,” or “Rigging Board, Stock Item Number 1L002026.” Each container shall be plainly marked with the contractor’s name, the identification number, the batch or lot number, the date of manufacture, the net weight, and the BEP purchase order number.

5.2.2 Marking Size and Color The markings used on each container shall be legible and of a color contrasting to that of the container. The item name and BEP stock number shall be 25 mm (one inch) high.

5.2.3 Hazard Warning Labels Each container shall be labeled in accordance with the provisions of the Hazard Communication Standard, 29 CFR 1910.1200 (f). This label shall include the name and address of the manufacturer, the identity of the hazardous materials, and the appropriate hazard warnings.

5.2.4 Barcode Label Each container shall be marked in accordance with the barcoded information listed in TABLE III of this specification. The Barcode labels shall conform to the “Specification for Vendor Affixed Barcode labels for Bureau of Engraving and Printing Materials” and shall be affixed on the packaging of each container.

Supersedes

TABLE III

BARCODE INFORMATION

Specification Description

RIGGING BOARD (SHEET-FED CURRENCY PRESS)

PO# BEP Purchase Order Number

Part # The applicable BEP Stock Item Number

Quantity Number of boards per box (container)

Batch/ Lot # The Manufacturer’s lot number

Weight Weight of the boards plus weight of the box (container)

6.0 NOTES This section contains information of a general or explanatory nature that may be helpful, but not mandatory.

6.1 Rigging System and Press Conditions The press rigging system consists of rigging boards and drawsheets. For the I-10 and Super Orlof presses, the rigging boards are installed on the impression cylinder using mounting pins. The trailing end of the rigging board is then placed in a clamp and put under tension to bend the rigging board to conform to the curvature of the impression cylinder. The drawsheet is installed to the top rigging board with a strip of double-sided adhesive. TABLE IV provides dimensions of the intaglio press components associated with drawsheet installation.

TABLE IV

INTAGLIO PRESS COMPONENT DIMENSIONS

Press Type

I-10 SOI

Impression Cylinder Radius 480 mm (18.9 in.)

420 mm (16.5 in.)

Tensioning Bar Diameter

50 mm (1.97 in.)

50 mm (1.97 in.)

Note: The Tensioning Bar is the mechanism on the impression cylinder for tensioning the drawsheet.

Supersedes

Once installed on the impression cylinder, the rigging system (comprised of the rigging boards and drawsheet) may be subjected to printing pressures of up to

2.5 tons per linear inch as often as 2,000 times per hour for the I-8 presses;

2,500 times per hour for the I-10 presses; and 3,334 times per hour for the Super Orlof presses. The rigging system may be subjected to temperatures of up to 93o

C (199.4° F) during printing.

6.2 Definitions. Certain words and phrases are frequently used in this specification. The following rules apply:

6.2.1 “Shall,” the emphatic form of the verb, is used whenever a requirement is intended to express a provision that is binding.

6.2.2 “Will,” is intended to express a declaration of purpose on the part of the Government. It may also be used to indicate simple futurity.

6.2.3 “Should,” is used whenever a non-mandatory characteristic is judged to be desirable for the material. As such, this characteristic may be graded during the evaluation of the material in order to assist in the selection of the best-qualified material.

ATTACHMENTS

FIGURE 1 –Mounting Holes for Types II and III Rigging Boards FIGURE 2 –Mounting Holes for Types IV, V, and VI Rigging Boards

[END]

Supersedes

C L

All dimensions are in millimeters

Tolerance for mounting holes and hole diameter is ± 1.0 mm

Tolerances are not cumulative

DRAWING MAY NOT BE TO SCALE

266.7 mm

197.5 mm 197.5 mm

FIGURE 1

Mounting Holes for Rigging Board – Types II and III

7 Holes

6.35 mm diameter

266.7 mm

133.35 mm 133.35 mm 133.35 mm 133.35 mm

23.81 mm

Supersedes

43.0 mm

C L

All dimensions are in millimeters

Tolerance for mounting holes and hole diameter is ± 0.5 mm

Tolerances are not cumulative

DRAWING MAY NOT BE TO SCALE

160.0 160.0 160.0 160.0 80.0 80.0

FIGURE 2

Mounting Holes for Rigging Board – Type IV, V and VI

6 Holes

4.5 mm