EESSS PD.pdf

INCH-POUND

PD19WRWNSEV04

CAGE 98752

23 January 2018

Comments, suggestions, or questions on this document should be addressed to:

AFLCMC/WNZ, 235 BYRON ST STE 19A, Robins AFB GA 31098-1813. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil .

AMSC N/A FSC 5419

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

PURCHASE DESCRIPTION

Shelter System, Small, Energy Efficient

1. SCOPE

1.1 Scope. This document describes the Energy Efficient Small Shelter System (EESSS) required by the United States Air Force. The EESSS will provide an energy efficient, modular and durable solution to the military’s need for a quickly deployable expeditionary shelter system. Once fielded, the EESSS will be used primarily as office and billeting space for bases in austere locations.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the specific revision listed below, form a part of this specification to the extent specified herein.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-20696 Cloth, Waterproof, Weather Resistant MIL-PRF-24712 Coatings, Powder (Metric) MIL-PRF-26915 Primer Coating, for Steel Surfaces MIL-PRF-44103 Cloth, Fire, Water and Weather Resistant MIL-DTL-53030 Primer Coating, Epoxy, Water Based, Lead and

Chromate Free

MIL_DTL-5541

MIL-DTL-81706

Chemical Conversion Coatings on Aluminum and Aluminum Alloys Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys

DEPARTMENT OF DEFENSE STANDARDS

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

Laboratory Tests MIL-STD-882 System Safety MIL-STD-889 Dissimilar Metals MIL-STD-1366 Transportability Criteria

MIL-STD-1472

MIL-STD-1791

MIL-STD-1798

Human Engineering Designing for Internal Aerial Delivery in Fixed Wing Aircraft Mechanical Equipment and Subsystems Integrity Program

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-310

MIL-HDBK-138

Global Climactic Data for Developing Military Interface Standard for Transportability Criteria

(Copies of these documents are available online at http://quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia PA 19111-5094.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AIR FORCE INSTRUCTION (AFI)

AFI 32-7086 Hazardous Materials Management

(Copies of this document are available online at http://www.e-publishing.af.mil/.)

NATICK RESEARCH, DEVELOPMENT AND ENGINEERING CENTER (NRDEC)

NRDEC Drawing 5-4 3370 Vestibule NRDEC Drawing 5-4 3371 Vestibule Door

(Copies of this document are available online at https://vdls.atc.army.mil/ .)

TEST OPERATIONS PROCEDURE (TOP)

TOP 1-2-621 Outdoor Sand and Dust Testing, 6 February 2009 TOP 10-2-175 Tents and Shelters, dated 15 July 2010

(Copies of this document are available online at https://vdls.atc.army.mil/ .)

2.3 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

AATCC 30-2004 Antifungal Activity, Assessment on Textile Materials:

Mildew and Rot Resistance of Textile Materials

(Copies of this document are available online at http://www.aatcc.org/ or from AATCC, PO Box 12215, Research Triangle Park, NC 27709-2215.)

ASTM INTERNATIONAL (ASTM)

ASTM D2136 Standard Test Method for Coated Fabrics—Low- Temperature Bend Test

ASTM D6413-08 Standard Test Method for Flame Resistance of Textiles (Vertical Test)

ASTM B633 Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

(Copies of this document are available online at http://www.astm.org . Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken PA 19428-2959.)

ILLUMINATING ENGINEERING SOCIETY (IES)

Lighting Handbook 10th Edition

INDUSTRIAL FABRICS ASSOCIATION INTERNATIONAL (IFAI)

USIFI-PRF-44103 Performance Specification, Cloth, Fire, Water and Weather Resistant

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

WD 6 2002 Wiring Devices-Dimensional Specifications

(Application for copies should be addressed to NEMA, 1300 North 17th Street, Suite 1847, Rosslyn VA 22209, www.nema.org.)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 2014 National Electrical Code

(Application for copies should be addressed to NFPA, 11 Tracy Drive, Avon, MA 02322, www.nfpa.org.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

AMS-STD-595 - Colors Used in Government Procurement

(Application for copies should be addressed to SAE International Customer Service, 400 Commonwealth Drive, Warrendale PA 15096, http://www.sae.org/.)

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

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), two samples shall be subjected to first article inspection in accordance with 4.2.

3.2 Energy Efficient Small Shelter description. The EESSS is intended to be a lightweight, energy efficient expeditionary shelter system, to be used by the USAF for the purposes of billeting, storage, and work space. The EESSS shall be a tension fabric structure, measuring approximately 20 feet in width, by 32 feet in length, configurable to allow multiple shelters to be connected and shall meet all requirements specified henceforth.

3.3 System size.

3.3.1 Useable floor space. Useable floor space for the shelter system is defined as the unencumbered floor space of the shelter (no center poles allowed) measured at the floor level. The usable interior floor space for the shelter system shall be 650 square feet (+/- 5%).

3.3.2 Interior peak height. The minimal interior (liner) peak height shall be no less than eight feet measured at the center of the shelter.

3.3.3 Width. The distance between any two opposite interior (liner) walls of the shelter shall be a minimum of 18 feet at floor level.

3.3.4 System weight. The EESSS system weight shall not exceed 1100 pounds (threshold) or 850 pounds (objective). The EESSS system weight shall encompass the shelter along with all supplied components, including, but not limited to: fabric skin, support structure, interior insulating liner, solar shade fly, electrical system, lighting, repair kit, flooring, plenums, Tent, Extendable Modular Personnel (TEMPer) interface, wind lines, anchoring system, repair kit, manual, supplied tools (such as lift poles, etc.) and any other additional gear needed to complete the shelter system. All components required to meet energy efficiency performance requirements shall be considered part of the shelter system. Individual shelter components shall not exceed crew size lifting limits.

3.3.5 Modular design. The EESSS shall be of such a design, that personnel in the field can extend the shelter by one or more sections to achieve over-stock shelter lengths. EESSS shelters shall also be easily connectable in an end-to-end configuration.

3.4 Deployment and recovery time.

3.4.1 Erect time. The EESSS shall be fully erectable within 40 minutes (threshold) or 25 minutes (objective) with a maximum of six personnel wearing individual protective equipment (i.e. helmet and individual body armor) in the full range of temperatures described in 3.5.6. Erect Time is defined as the time it takes to set up the shelter system beginning with the system on the ground in its storage container and ending when it achieves Full Operational Capability (FOC). FOC is defined as the point in time when the shelter is completely set up, is providing shelter, and is meeting all of the minimum requirements set forth in this PD.

3.4.2 Strike time. The shelter system shall achieve Strike Time within 40 minutes (threshold) or 30 minutes (objective) with a maximum of six personnel wearing individual protective equipment (i.e. helmet and individual body armor) in the full range of temperatures described in 3.5.6. Strike Time is defined as the time it takes to break down and stow a shelter system in its storage container setting on the ground and ready for transport, beginning with the shelter system at FOC as defined in 3.4.1.

3.5 Environmental conditions.

3.5.1 Wind load. The shelter system shall withstand a steady wind speed of at least 80 mph (threshold) or 90 mph (objective) for a 30 minute duration with three gusts of 90 mph (threshold) or 100 mph (objective) for a duration of two minutes per gust, when tested in accordance with the procedures described in ATEC TOP 10-2-175.

3.5.2 Rain intrusion. The EESSS shall, prevent water intrusion when during exposure to steady rain, wind driven rain (using the wind loads specified in 3.5.1), and water spray testing in accordance with TOP 10-2-175. In addition, the EESSS shall sustain no damage during testing, and water shall not pool on or in any part of the shelter. Leakage definitions are as follows:

NEGLIGIBLE - damp spots, barely noticeable; MINOR - droplets forming on the fabric or at the seams, but not falling under ordinary circumstances in a way to impair the intended use of the shelter, and MAJOR - water continually leaking and dropping off or running down the shelter’s inner surface in a way that impairs the intended military use. When tested in accordance with the procedures of ATEC TOP 10-2-175, NEGLIGIBLE or MINOR leaks are acceptable. Blowing rain shall only have minor intrusion sunder same wind condition in accordance with MIL-STD-810.

3.5.3 Snow load. The EESSS, deployed without the solar fly shall withstand a snow load of 10 lbs per 1 square foot (threshold) and 20 lbs per 1 square foot (objective) for a period of 12 hours without damage when fully erected. Damage is defined as the permanent deflection that requires any support items to be replaced in order to complete the mission. The shelter roof area calculations and test procedures shall be conducted in accordance with ATEC TOP 10-2-175.

Under Snow Load conditions, allowable deflection of the shelter shall measure no less than eight feet from the interior (liner) peak height to the floor.

3.5.4 Salt fog. The EESSS shall be capable of storage and operation in high temperature, high humidity, salt laden, and sea coast environments without damage or deterioration of performance when tested in accordance with MIL-STD 810.

3.5.5 Sand and dust. The EESSS shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance when tested in accordance with MIL-STD 810.

3.5.6 Operational temperature range. The shelter system shall be operational and serviceable (to include under canopy, erect and strike) from -25 °F to +125 °F (threshold) or -40°F to +130 °F (objective). The shelter exterior fabrics and solar shade fly shall resist formation of “cold crack” at-25°F in accordance with ASTM D2136. Shelter fabrics shall remain sufficiently pliable at -25 °F to accomplish strike/erect function without eternal heating.

3.5.7 Solar radiation. When tested in accordance with MIL-STD-810, the EESSS shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments and high altitudes.

3.6 System design parameters.

3.6.1 EESSS fabric skin. The EESSS’s fabric skin shall be Desert Tan IAW MIL-PRF-44103D (same color as FED-STD-595B, Sand Matte, and color number 33446). The fabric skin shall also be available in Class 1 (camouflage Green 483). Chemical Agent Resistant Coating (CARC) shall not be used.

3.6.2 Floor. The shelter system shall be equipped with a detachable/replaceable fabric floor. The floor shall be durable and resistant to puncture, tearing, and resist the penetration of ground water.

The fabric floor shall comply with the flame resistance requirement. The EESSS’s floor shall comply with the performance characteristics of MIL-PRF-44103D, Class 3&4. The floor shall be replaceable without striking the shelter. An energy efficient hard flooring system shall be offered as an available option (objective). The hard flooring with a minimum energy efficiency of R-3 shall be installed without striking the shelter by 2 people in a maximum of one hour. All components of the hard flooring shall comply with a 2-man lift.

3.6.3 Shelter frame. The EESSS shelter frame system shall be capable of supporting a standard fabric shade fly and a (objective) Photovoltaic (PV) system weighing up to 600 pounds while meeting the requirements of 3.5.1 and 3.5.3. If the EESSS shelter frame requires a separate exoskeleton frame to support the weight of the PV system, the PV supports must be the same color as the shelter and is not considered part of the EESSS.

3.6.4 Energy efficiency. When connected to a single 5-Ton Environmental Control Unit (ECU) two EESSSs, including solar shade flys and liners shall provide an inside temperature at least 45 °F (threshold) or 50 °F (objective) cooler than outside ambient temperature throughout the entire operating temperature while in cooling mode. When connected to a single 130K BTU fuel fired heater, two EESSS’s, including solar shade flys and liners shall provide an inside temperature no less than 80 °F (threshold) or 90 °F (objective) warmer than outside ambient temperature throughout the system’s operational temperature range.

3.6.4.1 Solar shade fly. The EESSS shall include a solar shade fly designed to decrease solar irradiance on the shelter during use.

3.6.4.2 Insulating liner. The shelter system shall include an interior insulating liner, white in color, on the interior side.

3.6.5 Doors. The EESSS shall be supplied with both hard and soft doors. All doors shall be designed to interface to the vestibule systems.

3.6.5.1 End & side wall Soft door. The soft door shall be zippered material and located on opposite end of hard door for emergency egress. The soft door shall have ties to allow the door to be stowed above, or to the side out of the way when desired.

3.6.5.2 Hard door. The hard door shall have a height of at least 80 inches, 32 inches in width and be framed with fabric skin and insulated. The hard door shall be supplied with spring loaded slide door latch type hardware with webbing pull handle attached to resist jamming on uneven terrain.

The hard door shall have simple provisions (spring hinges, bungee chains, etc.) designed to ensure automatic closure when not in use. The modified hard door shall have a small window (approx.

5”W X 10”H, +/-1”) with a blackout curtain located at eye level.

3.6.5.3 Vestibule. The EESSS vestibule shall have interior dimensions of 6 feet wide, 6 feet long and 7 feet height with a modified hard door.

3.6.6 Heating ventilation and air conditioning (HVAC) ports. The EESSS shall have two sets (a set is one supply and one return port) of ports to allow for the entry of spiral frame flexible ducting into the shelter. One set of ports shall be located on each side wall at the rear of the shelter. The EESSS heating ventilation and air conditioning (HVAC) ports shall accommodate and seal around flexible ducting ranging in outside diameter up to 18 inches. HVAC ports shall be sealable when not in use.

3.6.7 Heating ventilation and air conditioning (HVAC) Duct Adapters. The EESSS shall include two “Y” adapters to connect 12” heater ducts to standard 16” ECU duct systems. The “Y” adapters shall be designed to balance airflow between the shelters without requiring the removal of dampers. “Y” adapters shall include insulated wraps for the system.

3.6.8 Internal plenums. The EESSS shall include a collapsible air sock type internal plenum designed to uniformly distribute air over the shelter’s interior. This plenum shall connect to HVAC ducting ranging in outside diameter from 12 to 18 inches at or near the HVAC entry ports. The EESSS plenum shall impose the least impedance possible on the shelter’s usable interior space.

3.6.9 Ventilation. The shelter system shall be designed to promote the natural ventilation of fumes, smoke, steam, or heat without the aid of powered ventilating systems.

3.6.10 Electrical system. The EESSS electrical system shall be capable of connecting to BEAR Base 25KW Power Distribution Panels via L6-20P twist lock connectors. The EESSS electrical system shall provide a minimum of eight cable drops (four evenly spaced along each shelter side wall). Each cable drop shall have three 120 volt, single phase, 20 Amp NEMA 5-20R duplex receptacles evenly spaced along the interior side walls of the shelter. Plugs and receptacles used in the EESSS electrical system shall be in accordance with NEMA WD 6. All cables between the EESSS electrical panel and the cable drops shall be run overhead, closely following the shelter ceiling to minimize snagging and interference. The shelter electrical system shall have a dedicated ground conductor through the electrical power input cable back to the power source ground. All wiring, fixtures, switches, etc. shall meet the requirements of NFPA 70: National Electric Code.

A preliminary wiring diagram shall be supplied with all EESSS proposals.

3.6.11 Interior lighting. The EESSS shall be supplied with a ruggedized overhead energy efficient screw-in style LED lighting system. The EESSS lighting system shall provide a minimum of 30 foot-candles three feet above the floor over the entire usable shelter space (shelter area where liner height is 5 feet or more). The EESSS lighting system shall interface with and draw power from the EESSS electrical system. The EESSS interior lighting system shall be operated by a switch located near the shelter’s front/hard door entrance.

3.6.12 Utility ports. Each EESSS shall have two utility ports to allow for the passage of cable bundles, up to six inches in diameter, into the shelter without damage or alteration of the shelter fabric. One utility port shall be located with each set of HVAC ports, no more than 12 inches above the ground. Utility ports shall be sealable, when not in use.

3.6.13 Interior support fasteners. The EESSS shall have interior support fasteners distributed throughout the shelter to facilitate the suspension of electrical system wiring and shelter lighting.

Outlet drops shall have Velcro type channels/holders to attach to interior walls.

3.6.14 Non-reflective hardware. All hardware (to include but not limited to bindings, plastic components, fastener tape, webbing, grommets, straps, slips and guy lines, etc.) visible from the shelter exterior, shall be the color of the shelter exterior or shall be flat black.

3.6.15 Repair kit. The shelter system shall include a user level field expedient (operator) repair kit as part of its shelter system. The identified repair kit shall be supplied by the manufacturer with enough corresponding components to support erect/strike cycle testing as noted in section

3.8.1. The repair kit will be capable of completing repairs and returning the shelter system back into operation within 15 minutes with minimum training and shall include no hazardous materials.

3.6.16 Anchoring system. The shelter system shall include a general purpose anchoring system and a means to insert the anchoring system to ensure proper anchoring in all applicable soil types (sand, hard packed soil, or bedrock). The anchoring devices shall be designed for installation by an individual war fighter without requiring the use of power equipment.

3.6.17 Hazardous environment protection. The shelter shall accommodate specific ballistic splinter protection kits to protect occupants/contents against small arms and small fragmenting munitions as defined in National Institute of Justice (NIJ) Standard 0101.06, Type IIA. This protection kit shall provide complete surround and overhead protection and be emplaced within one hour by two persons (threshold). (objective: NIJ Standard 0101.06, Type III)

3.6.18 TEMPer interface. The shelter system doorways shall have a means to interface with the standard TEMPer vestibule on each doorway provided (Refer to: NRDEC Drawing 5-4-3370 Vestibule, NRDEC Drawing 5-4-3371 Vestibule Door).

3.6.19 Flame resistance. All fabric materials (exterior, floor, insulating liner, plenums, solar shade fly, etc.) used in the shelter system shall be flame resistant both initially and throughout the shelter service life IAW MIL-PRF-44103D.

3.6.20 Fungus resistance. All textiles and fabric materials used in the EESSS system shall be resistant to the deteriorating effects of rot, fungus, mildew or corrosion under both operational and storage conditions, wet or dry. All materials shall allow for shelter striking for storage with minimal drying time to preclude mildew. This capability shall be in compliance with AATCC 30.

The interior lining shall be made from a material that is easily cleaned.

3.6.21 Vector intrusion. The EESSS shall be designed to prevent intrusion by flying or crawling insects/animals. The shelter system shall include screens for the windows (as defined in section 3.6.5) with a mesh size no larger than 16 by 16 (screen grids per inch) to minimize vector intrusion.

All HVAC and Utility ports on the shelter shall have cinch-able external boots to allow for tight fit to HVAC ducts and cable bundles and port closure when not in use.

3.6.22 Uneven Terrain. The shelter system shall allow erect and use without damage or permanent distortion to the shelter and components on terrain that varies in slope as much as 6 inches per 9.8 feet (threshold) or 8.2 feet (objective) of linear distance.

3.6.23 Quick reference instructions. The shelter system shall include quick reference instructions for conducting Erect and Strike actions. Those instructions shall be permanently attached to each shelter system at or near an inside doorway opening and they shall also be permanently attached to all transport container(s).

3.6.24 Protective coating and finishes

3.6.24.1 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the EESSS shall not be used or shall have means of protection against such deterioration. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used.

Small commercially procured items, such as miscellaneous handles, brackets, linkages, cables, etc., used as components of the EESSS may be prepared and coated in accordance with the manufacturer’s standard practice, provided it is compatible with the exterior finish color. However, larger procured items shall have the protective coatings required herein in accordance with the respective material substrates.

3.6.24.2 Fungus and moisture resistance. The electrical circuitry, including all components and connections shall be protected from the effects of fungus growth and moisture. Hermetically sealed components may not be treated for fungus growth and moisture.

3.6.24.3 Surface preparation and pretreatment for aluminum material. Structures shall be cleaned, degreased, and prepped prior to application of any pretreatment. Aluminum surfaces shall have MIL-DTL-81706, Type I, Class 1A, Form I, Method C chemical conversion coating applied in accordance with MIL-PRF-5541, Type I, Class 1A. Alternatively, in areas and locals where use of hexavalent chrome is not permitted by regulatory authority, aluminum surfaces shall have MIL-DTL-81706, Type II, Class 1A, Form I, Method C chemical conversion coating applied in accordance with MIL-PRF-5541, Type II, Class 1A. Surface preparation and pretreatment shall be applied prior to application of respective powder coat used as a topcoat.

3.6.24.4 Surface preparation and pretreatment for ferrous material. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications.

Structures shall be cleaned, degreased, and scuffed or blasted prior to priming; blasting media shall be free of all oil/grease, fines, and materials not allowable in the manufacturer of the blasting media’s specification. Ferrous surfaces (other than stainless steel, mill-galvanized steel, electro-zinc coated or mill-aluminized) shall be treated with a TT-C-490 Type IV zinc phosphate pretreatment applied in accordance with the manufacturer’s directions prior to the application of any primer. Primer shall be applied before any oxidation or rusting occurs; raw metal edges, to include fastener and drain holes, shall be coated with primer before applying topcoat.

3.6.24.5 Ferrous material primer. Type II Epoxy Resin, Zinc Rich Powder coating, Class 1 Exterior Primer of a 2-Coat System per MIL-PRF-24712B shall be utilized for ferrous based material. This exterior primer of the 2-coat system shall yield a dry film thickness (dft) of 8 to 10 mils. Manufacturer specifications to accomplish application of the coating system shall be utilized.

3.6.24.6 Topcoat. All EESSS components, except for small commercially purchased components, plastic, rubber, shall be top coated with powder coat. Type III, Class 3 powder per MIL-PRF-24712B shall be applied and cured at temperatures below 300 degrees F. When fully cured, the topcoat shall yield a dft of 3 to 4 mils free from runs, sags, orange peel, or other defects. The Contractor shall utilize manufacturer specifications to accomplish application of the coating system. Chemical Agent Resistant Coating (CARC) shall not be used.

3.6.24.7 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotive compatible abutting surfaces is acceptable. The use of dissimilar metals when separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

3.6.27.8 Finish. The exterior finish color of the item shall be Camo (tan), Color Number 686A conforming to SAE AMS STD 595. Finish shall be warranted for 10 years from date of manufacture.

3.6.24.9 Placard. Regardless of priming system used, a placard shall be permanently affixed (i.e.

riveted) to the end item, in a conspicuous area adjacent to the identification placard, to denote type(s) of primer and topcoat applied to the end item.

3.6.25 Human engineering. The EESSS shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of MOPP level 2 protective equipment, individual protective equipment (i.e. helmet and individual body armor) and arctic mittens.

3.6.26 Welders and welding. Welding procedures shall be in accordance with a nationally recognized welding code. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings. Cast components, structural steel components with an ultimate tensile strength greater than 100,000 psi, and threaded fasteners (except for weld studs and weld nuts) shall not be welded. Heat treated components shall be in the annealed, normalized condition when welded.

3.6.27 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins, lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial components. Tapped threads shall have a minimum thread engagement in accordance with Table I.

TABLE I. Minimum thread engagement.

Material

Minimum Thread Engagement

Steel 1.0 times the nominal fastener diameter Cast iron, brass, or bronze 1.5 times the nominal fastener diameter Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.6.28 Fluid traps and faying surfaces. There shall be no fluid traps on the EESSS. Faying surfaces of all structural joints, except welded joints, shall be sealed to preclude fluid intrusion.

3.6.29 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130. Markings shall be applied with decals and shall be 1-inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than ½-inch high. Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of SAE AMS STD 595, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of SAE AMS STD 595.

3.6.30 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the EESSS in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). The EESSS and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a bar code and human readable markings. The “CE” marking shall be affixed in accordance with EU requirements on or adjacent to the identification plate.

3.7 Useful life.

3.7.1 Erect/strike cycles. The EESSS system shall be able to be erected 20 times, struck 20 times and packed into container 20 times (threshold) or erected 30 times, struck 30 times and packed into container 30 times (objective) without any system failure. System failure is defined as any failure that reduces FOC as defined in section 3.4.1, and which cannot be corrected within 30 minutes (threshold) or 15 minutes (objective) by employing the use of the shelter system repair kit.

3.7.2 Service life. The shelter system shall have a minimum field service life of three (3) years (threshold), five (5) years (objective) with no significant degradation due to weathering effects and with no visible effects of dry rot, mildew and petroleum degradation due to exposure -25 °F to 125 °F climatic conditions. Exterior fabrics shall resist damage by petroleum products used by the military such as, but not limited to, diesel and jet fuel. The definition of damage includes visual evidence of permanent discoloration, or material breakdown including pitting, shredding, softening, or weakening of the fabric material.

3.7.3 Shelf life. The shelter system shall have a minimum shelf life of twenty (20) years when stored in ship/store ISO containers in temperatures ranging from -65 °F to 180 °F. The stored shelter system shall be resistant to the deteriorating effects of rot, fungus, or mildew. The shelter system components shall not lose strength or show evidence of increased water permeability as a result of storage and transportation. The shelter system setup after storage shall show no evidence of damage, degradation, or loss of operational use.

3.8 Safety.

3.8.1 System safety. The design of the EESSS shall not contain any system safety mishap risk categories greater than medium as defined in Table III of MIL-STD-882.

3.8.2 Hazardous material. The design shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials and the generation of toxic or noxious gases. The EESSS shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. The EESSS shall not contain or use hexavalent chromium.

For the purposes of this requirement, the Class I ODS and controlled substances identified in Chapter 4 of AFI 32-7086 shall not be used in any system, component, or process.

3.8.3 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard. All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located so as to provide adequate clearance from moving parts and high operational temperatures.

Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

3.8.4 Electrostatic discharge (ESD). The design of the EESSS shall preclude equipment damage due to ESD, protect personnel from electrical shock due to static charging, and prevent ignition of explosive atmospheres due to sparking.

3.9 Transportability.

3.9.1 Transportation containers. The EESSS shall be transported and stored in government furnished ISU-90 or Tricon type containers. When in packed configuration, the EESSS shall not have any member or dimension exceeding 90 inches. Three full shelter systems in packed configuration shall fit in one ISU-90 type container.

3.9.2 Surface transportability. The EESSS shall be transportable via all modes of surface shipment (highway, rail, and water) in accordance with MIL-STD-1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport, except that design for rail impact testing (see 5.2.5 of MIL-STD-1366) is not required.

3.9.3 Air transportability. The EESSS shall be transportable on C-130, C-17, and C-5 aircraft in accordance with MIL-STD-1791. In all air transport configurations, the EESSS shall be capable of being restrained and withstanding, without loss of serviceability, 2.0 G up and 4.5 G down accelerations, and shall be capable of being restrained and withstanding, without loss of structural integrity, 3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations. The EESSS shall be equipped with pressure relief devices or configured for air transport to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure.

3.10 Maintenance.

3.10.1 Maintainability. The EESSS shall be designed for maintainability in accordance with 5.9 through 5.9.18 of MIL-STD-1472; forces shall not exceed those specified for both males and females. The EESSS shall be designed with a 365 day (threshold) or 730 day (objective) “Mean Time Between (Operational Mission) Failure” as determined in MIL-STD-1798. The EESSS components shall be selected and located for maximum ease of operation, maintenance, and cleaning.

3.10.2 Preventive maintenance. The contractor shall provide a list of all recommended preventative maintenance tasks and associated maintenance intervals required by the EESSS while in storage as well as an operational state. Preventive maintenance tasks shall not require more than one man-hour. Mean time between maintenance shall be seven days.

3.10.3 Relative accessibility. Critical items that require rapid maintenance shall be most accessible. When relative criticality is not a factor, items that require the most frequent access shall be most accessible. High failure rate items shall be accessible for replacement without moving non-failed items.

3.10.4 Error-proof design. The design of the EESSS shall incorporate error-proofing in equipment mounting, installing, interchanging, connecting, and operating.

a. Equipment shall include physical features (for example, supports, guides, size, or shape differences, fastener locations, and alignment pins) that prevent improper mounting. In the absence of physical features, equipment shall be labeled or coded to identify proper mounting and alignment.

b. Equipment that has the same form and function shall be interchangeable throughout a system and related systems. If equipment is not interchangeable functionally, it shall not be interchangeable physically.

c. Connectors serving the same or similar functions shall be designed to preclude mismating or misalignment.

d. Design, location, procedural guidance, and suitable warning labels shall be provided to prevent damage to equipment while it is being handled, installed, operated, or maintained.

3.10.5 Special tools. The design of the EESSS shall not drive the requirement for any special tools as defined in 6.3.3.

3.10.6 Mean Corrective Maintenance Time. Mean corrective maintenance time shall be ≤ 30 minutes (threshold), 15 minutes (objective).

3.11 Workmanship.

3.11.1 General workmanship. The EESSS, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.11.2 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred.

Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.11.3 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.11.4 Cleaning. The EESSS shall be thoroughly cleaned. Loose, spattered, or excess solder;

welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; loose threads and fabric portions and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Operational inspection (see 4.3).

c. Conformance inspection (see 4.4).

Requirements shall be verified in accordance with Table II.

TABLE II. Requirement verification matrix.

Section 3 Requirement Verification Method

Section 4 Verification

3.1 First article test.

Not Applicable (N/A)

3.2 Energy Efficient Small Shelter

description.

N/A

3.3 System size. Examination 4.6.1 Examination of product.

3.3.1 Useable floor space. Examination 4.6.1 Examination of product.

3.3.2 Interior peak height. Examination 4.6.1 Examination of product.

3.3.3 Width. Examination 4.6.1 Examination of product.

3.3.4 System weight. Test 4.6.2 System weight test.

3.3.5 Modular design. Demonstration

4.6.3 Modular design

demonstration.

3.4 Deployment & recovery time. N/A

3.4.1 Erect time. Demonstration 4.6.4.2 Erect time demonstration.

3.4.2 Strike time. Demonstration 4.6.4.3 Strike time demonstration.

3.5 Environmental Conditions. N/A

3.5.1 Wind load. Test 4.6.4.4 Wind load test.

3.5.2 Rain intrusion. Test 4.6.4.5 Rain intrusion test.

3.5.3 Snow load. Test 4.6.4.6 Snow load test.

3.5.4 Salt fog. Test 4.6.4.7 Salt fog test

3.5.5 Sand and dust. Test 4.6.4.8 Sand and dust test.

3.5.6 Operational temperature range.

Certification

4.6.4.9 Fabric cold crack

certification.

Demonstration

4.6.4.10 Cold weather simulation.

4.6.10.2 Repair kit demonstration.

3.5.7 Solar radiation. Test 4.6.4.11 Solar radiation test.

3.6 System design parameters. N/A

3.6.1 EESSS fabric skin. Test 4.6.6.1 EESSS fabric skin tests.

3.6.2 Floor.

Examination 4.6.1 Examination of product.

Test 4.6.6.2 Floor tests.

3.6.3 Shelter frame.

Examination 4.6.1 Examination of product.

Test

4.6.4.4 Wind load test.

4.6.4.6 Snow load test.

3.6.4 Energy efficiency. Test 4.6.6.3 Energy efficiency tests.

3.6.4.1 Solar shade fly. Examination 4.6.1 Examination of product.

3.6.4.2 Insulating liner. Examination 4.6.1 Examination of product.

3.6.5 Doors. Examination 4.6.1 Examination of product.

3.6.5.1 End wall soft doors. Examination 4.6.1 Examination of product.

3.6.5.2 Hard door. Examination 4.6.1 Examination of product.

3.6.5.3 Vestibules. Demonstration 4.6.6.4 Vestibule demonstration.

3.6.6 HVAC ports. Examination 4.6.1 Examination of product.

3.6.7 HVAC duct adapter. Examination 4.6.1 Examination of product.

3.6.8 Internal plenums. Examination 4.6.1 Examination of product.

3.6.9 Ventilation. Examination 4.6.1 Examination of product.

3.6.10 Electrical system. Certification 4.6.1 Examination and certification

3.6.11 Interior lighting. Test 4.6.6.5 Interior lighting test.

3.6.12 Utility ports. Examination 4.6.1 Examination of product.

3.6.13 Interior support fasteners. Demonstration

4.6.6.7 Interior support fastener

demonstration.

3.6.14 Non-reflective hardware

Examination 4.6.1 Examination of product.

3.6.15 Repair kit.

Examination 4.6.1 Examination of product.

Demonstration

4.6.7.1 Erect/strike cycle

demonstration

4.6.10.2 Repair kit demonstration.

3.6.16 Anchoring system. Examination 4.6.1 Examination of product.

3.6.17 Hazardous environment

protection

3.6.18 TEMPer interface. Examination 4.6.1 Examination of product.

3.6.19 Flame resistance. Test 4.6.6.8 Flame resistance test.

3.6.20 Fungus resistance. Test 4.6.6.9 Fungus resistance test.

3.6.21 Vector intrusion. Examination 4.6.1 Examination of product.

3.6.22 Uneven terrain. Demonstration 4.6.6.10 Uneven terrain.

3.6.23 Quick reference instructions. Examination 4.6.1 Examination of product.

3.6.24 Protective coatings & finish N/A

3.6.24.1 Protective coatings Examination 4.6.1 Examination of product.

3.6.24.2 Fungus and moisture

resistance.

Examination 4.6.1 Examination of product.

3.6.24.3 Surface preparation and

pretreatment for aluminum material.

Examination 4.6.1 Examination of product.

3.6.24.4 Surface preparation and

pretreatment for ferrous material.

Examination 4.6.1 Examination of product.

3.6.24.5 Ferrous material primer. Examination 4.6.1 Examination of product.

3.6.24.6 Topcoat. Certification

3.6.24.7 Dissimilar metals.

3.6.24.8 Finish.

3.6.24.9 Placard. Examination 4.6.1 Examination of product.

3.6.25 Human engineering.

Examination 4.6.1 Examination of product.

Demonstration

4.6.7.1 Erect/strike cycle

demonstration.

4.6.10.1 Preventative maintenance

demonstration

4.6.10.2 Repair kit demonstration.

3.6.26 Welders and welding. Examination 4.6.1 Examination of product.

3.6.27 Fastening devices. Examination 4.6.1 Examination of product.

3.6.28 Fluid traps and faying

surfaces.

Examination 4.6.1 Examination of product.

3.6.29 Markings. Examination 4.6.1 Examination of product.

3.6.30 Identification plate. Examination 4.6.1 Examination of product.

3.7 Useful Life. N/A

3.7.1 Erect/strike cycles. Demonstration

4.6.7.1 Erect/strike cycle

demonstration.

3.7.2 Service Life. Certification

4.6.7.2 Service/shelf life

certification.

3.7.3 Shelf Life. Certification

4.6.7.2 Service/shelf life

certification.

3.8 Safety. N/A

3.8.1 System safety. Analysis

4.6.8.1 System safety hazard

analysis.

3.8.2 Hazardous material. Examination 4.6.1 Examination of product.

3.8.3 Component protection. Examination

4.6.1 Examination of product.

4.6.10.1 Preventative maintenance

demonstration.

3.8.4 Electrostatic discharge (ESD). Analysis

4.6.8.2 Electrostatic discharge

analysis.

3.9 Transportability. N/A

3.9.1 Transportation containers. Demonstration 4.6.9.1 Transportation containers.

3.9.2 Surface transportability. Demonstration 4.6.9.1 Transportation containers.

3.9.2 Air transportability. Demonstration 4.6.9.1 Transportation containers.

3.10 Maintenance. N/A

3.10.1 Maintainability. Demonstration

4.6.10.1 Preventative maintenance

demonstration.

4.6.10.2 Repair kit demonstration.

3.10.2 Preventative maintenance. Demonstration

4.6.10.1 Preventative maintenance

demonstration.

3.10.3 Relative accessibility. Demonstration

4.6.10.1 Preventative maintenance

demonstration.

4.6.10.2 Repair kit demonstration.

3.10.4 Error-proof design. Demonstration

4.6.10.1 Preventative maintenance

demonstration.

4.6.10.2 Repair kit demonstration.

3.10.5 Special tools. Demonstration

4.6.10.1 Preventative maintenance

demonstration

4.6.10.2 Repair kit demonstration.

3.10.6 Mean Corrective Maintenance

Time.

Demonstration

4.6.10.1 Preventative maintenance

demonstration.

3.11 Workmanship. N/A

3.11.1 General Workmanship. Examination 4.6.1 Examination of product.

3.11.2 Bolted connections. Examination 4.6.1 Examination of product.

3.11.3 Riveted connections. Examination 4.6.1 Examination of product.

3.11.4 Cleaning. Examination 4.6.1 Examination of product.

4.2 First article inspection. Two first article EESSS systems shall be subjected to the analyses, demonstrations, examinations, and tests described in 4.6.1 through 4.6.10.2. The contractor shall provide or arrange for all test equipment and facilities. Unless otherwise approved by the procuring activity, changes shall not be made to the first article EESSS systems’ configurations during the first article inspection. All components of the base EESSS supplied during production shall be of the exact same configuration and design as the components of the base EESSS supplied for first article inspection.

4.3 Operational inspection. All operational inspections shall be satisfactorily completed and approved prior to final first article acceptance.

4.4 Conformance inspection. Each production EESSS shall be subjected to the examination described in 4.6.1.

4.5 Inspection requirements.

4.5.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

4.5.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data or shorter intervals shall be provided as appropriate for any specific test.

a. Date.

b. Time started.

c. Time finished.

d. Ambient temperature.

e. Ambient humidity.

4.5.3 Test rejection criteria. Throughout all tests specified herein, the EESSS shall be closely observed for the following conditions, which shall be cause for rejection.

a. Failure to conform to design or performance requirements specified herein or in the contractor's technical proposal.

b. Structural failure of any component, including permanent deformation, or evidence of impending failure.

c. Evidence of excessive wear. If excessive wear is suspected, the original equipment manufacturer’s (OEM’s) specifications or tolerances shall be utilized for making a determination.

d. Evidence of corrosion or deterioration.

e. Misalignment of components.

f. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

4.5.4 Failure reporting, analysis, and corrective action system (FRACAS). A closed loop system shall be used to collect data, analyze, and record timely corrective action for all potential failures that occur during the first article and operational tests. The contractor's existing FRACAS shall be utilized with the minimum changes necessary to conform to this specification. The system shall cover all test samples, interfaces between test samples, test instrumentation, test facilities, test procedures, test personnel, and the handling and operating instructions. The contractor shall establish and maintain a FRACAS database; all information shall be entered into the database.

Authorized procuring activity personnel shall have read-only access to the FRACAS database.

4.5.4.1 Problem and failure action. At the occurrence of a problem or potential failure that affects satisfactory operation of a test sample, entries shall be made in the appropriate data logs and the failed test sample shall be removed from test, with minimum interruption to the other test samples continuing on test.

4.5.4.1.1 Problem and failure reporting. A failure report shall be initiated at the occurrence of each problem or potential failure of the contractor hardware or software or Government furnished equipment (GFE). The report shall contain the information required to permit determination of the origin and correction of the failure. The contractor’s existing failure report form may be used with minimum changes necessary to conform to the requirements of this specification. The failure report form shall include the information specified in a through c:

a. Descriptions of failure symptoms, conditions surrounding the failure, failed hardware identification, and operating time (or cycles) at the time of failure.

b. Information on each independent and dependent failure and the extent of confirmation of the failure symptoms, the identification of failure modes, and a description of all repair actions taken to return the test sample to operational readiness.

c. Information…