FRP - ATTACHMENT D - FRP GROUT KIT SPECS 29 JAN 21.pdf

ATTACHMENT D - FRP GROUT KIT INDIVIDUAL ITEM SPECIFICATIONS

This specification is approved for use by all Departments and Agencies of the Department of Defense within the distribution limitations noted at the bottom of the page.

D1. BACKGROUND

D1.1. Scope. This technical characteristics describes the requirements for procuring the required rapid setting grout material and the ISO container for the FRP grout kit, needed to install the bolt- together fiber-reinforced polymer (FRP) panel assembly. The FRP mats function as expedient foreign object debris (FOD) covers for crushed- stone or debris backfill crater repairs as part the airfield damage repair (ADR) program.

D2. FRP RAPID SETTING SPALL REPAIR/GROUT MATERIAL REQUIREMENTS

D2.1. Rapid Setting Spall Repair/Grout Material. The Engineering Research and Development Center (ERDC), Vicksburg, MS, is the Department of Defense’s lead pavement research facility for roadways, permanent airfields, contingency airfields, and railroads. ERDC is the approving agency for all Air Force ADR related repair materials.

Due to the critical nature of performing emergency airfield repairs, presumably after an act of war, and the requirement to support heavy aircraft loads, materials must be pre-qualified for procurement and use. Failure of the materials to meet performance metrics could result in failure to restore flight operations, failure in contingency operations plans, damage to or loss of individual aircraft, material and personnel. See Table 1 on spall repair/grout material specifications.

D2.1.1. Approved Spall Repair/Grout Material Information. Currently, nine products meet the spall repair/grout performance specifications. Although, contractor must verify product compliance with AFCEC/CXXM per task order. See Figure D2.1.1.

Figure D2.1.1.

D2.1.2. Grout Material Recommendation. ERDC/AFCEC recommend using any of the approved material above (see Figure D2.1.1.) with aggregate being smaller than 3/8-inch minus, such as material #5 on the list (Rapid Set Mortar Mix by CTS Cement Corp); due to the nature of placing the mortar material for securing the tri-talon anchors.

D2.1.3. Grout Material Packing Requirements. The grout material must be packaged in 5-gallon buckets (50-lbs of dry material) with sealed lids. The bucket must allow for the addition of water and mixing operation.

D2.1.4. Grout Material Shelf Life Requirements. The minimum shelf life requirement for the material are:

• Outside covered – minimum 18 months

• ISO Container Stored – minimum 36 months

D-1

D2.1.5. Grout Material Safety/Hazardous Chemical Issues. The material’s Safety Data Sheets (SDS) will be evaluated against that of standard cementitious material. If additional precautions are required, the effect to the spall repair process will be evaluated and if deemed unacceptable, the material will be rejected.

TABLE 1. Spall Repair and Grout Material Specifications

Test Description Testing Specifics Criteria

Compressive Strength ASTM C39

≥ 3000 psi @ 2-hr ≥ 5000 psi @ 1 day ≥ 5000 psi @ 7 day ≥ 5000 psi @ 28 days

Flexural Strength ASTM C78 ≥ 350 psi @ 2-hr ≥ 600 psi @ 7 days ≥ 600 psi @ 28 days

Bond Strength ASTM C882 Repair Material to Repair Material ≥ 1000 psi @ 1 day Repair Material to Ordinary PCC ≥ 1000 psi @ 1 day

Modulus of Elasticity ASTM C469 2 ≤ x ≤ 6 Mpsi @ 2-hr 2 ≤ x ≤ 6 Mpsi @ 28 day

Time of Set ASTM C191 Initial Set: ≥ 15-min Final Set: 25 - 35-min

Slump ASTM C143 Within 5-min of added water ≥ 3 inch

Length Change ASTM C157 Stored in air - 0.04% ≤ x ≤ +0.03%

@ 28 day Stored in water Coeff. of Thermal Expansion ASTM C 531 Begin test @ 7 days ≤ 12∙10‐6 °F‐1

Shrinkage Potential ASTM C1581 ≤ 40 με @ 14 days No cracking @ 28 days

D3. FRP GROUT KIT COMPONENTS REQUIREMENTS

D3.1. Rapid Set Mortar Mix, Bucket, 50-lb, 5-gal. 140 Rapid Set Mortar Mix, buckets, 50-lb, 5-gal, are required in the FRP Grout Kit. These Rapid Set Mortar Mix, buckets, 50-lb, 5-gal, are mixed with water and poured into the holes augured through the airfield pavements and base course materials to secure the tri-talon anchor assemblies into the base course materials under the airfield pavements during the installation of and/or the maintenance of installed FRP mat panel assemblies. Rapid Set Mortar Mix, buckets, 50-lb, 5-gal, shall be CTS Cement part# 433RSMM55 or equivalent (see D3.1.1)

D3.1.1. Rapid Set Mortar Mix, bucket, 50-lb, 5-gal, property.

• Material must meet the specifications in Section D2.1. thru D2.1.5. of this attachment.

D3.2. Bucket Lid Opener. Four (4) bucket lid openers, are required in the FRP Grout Kit. These bucket lid openers, are required open the buckets of Rapid Set Mortar Mix, during the installation of and/or the maintenance of the installed the FRP mat panel assembly. The bucket lid opener, shall be Kraft Tool part# 35EM46 or equivalent (see D3.2.1.).

D3.2.1. Bucket lid opener property.

• Size: 8-1/4-in L x 2-5/8-in W x 1/-1/4-in W.

• Construction Material: Durable Plastic

• Characteristics: Sturdy, easy to use

D-2

• Application: Opening buckets

• For Use With: 5-gal buckets

D3.3. Wood Pallet, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom. Four (4) wood pallets, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom, are required in the FRP Grout Kit. These wood pallets, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom, are required for stacking the buckets of Rapid Set Mortar Mix, during shipment and long term storage of the kit, and for moving the buckets of material during the installation of and/or the maintenance of the installed the FRP mat panel assembly. The wood pallet, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom, shall equivalent to (see D3.3.1.).

D3.3.1. Wood Pallet, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom property.

• Size: 48-in wide with forklift pocket opening x 44-in long (no forklift opening required on this side)

• Material: Wood, Heat Treated per ISPM 15

• The contractor shall place and secure two (2) 48-in wide x 44-in long x 3/8-in thick Heat Treated per ISPM

15 plywood to the top and bottom of each 48-in x 44-in wood pallet, as depicted in the diagram below.

• Contractor shall provide ISPM 15 Certification with each/all wood pallets.

• Material Spec: ISPM 15

D4. FRP KIT ISO QUADRUPLE (QUADCON) REQUIREMENTS AND COMPENENTS

D4.1. Quadruple Container (QUADCON). One (1) QuadCon (NSN 8150-01-533-8677), is required for the FRP Grout Kit. This QuadCon stores and secures all items within the FRP Grout Kit for shipment, long term storage and for use during the installation of and/or maintenance of the installed FRP mat panel assembly. The QuadCon, NSN 8150-01-533-8677 or equivalent (see D4.1.1.).

D4.1.1. Quadruple Container (QUADCON) property.

• QuadCon shall have corrugated steel sides, roof, and swing doors on both sides.

• QuadCon shall have a heavy-duty steel floor.

• QuadCon shall have four-way fork lift pockets.

• QuadCon shall be in good condition.

• QuadCon shall be the following dimensions:

o Exterior Length – 4-ft, 9 3/8-in o Exterior Width – 8-ft o Exterior Height – 8-ft o Interior Length – 4-ft, 6-in o Interior Width – 7-ft, 6-9/16-in o Interior Height – 7-ft, 5-in o Door Width – 4-ft, 5-1/2-in o Door Height – 7-ft, 1-1/8-in

• QuadCons shall have dual swing doors on two opposite sides. Doors shall incorporate gaskets for a weatherproof seal when closed.

• QuadCons shall be forest green, tan, or brown in color, in priority order.

• The contractor shall mark each QuadCon according to the uniform procedures detailed in Defense

Transportation Regulation (DTR) – Part VI, chapter 603 (paragraph 5).

• Serial numbers shall be displayed on all four sides and on top of the QuadCon.

• ISO containers shall be weatherproof.

• Maximum tare weight shall not exceed 2,120 lbs. and maximum payload capacity shall not exceed 9,040 lbs.

• QuadCon shall have vents, two (2) each in door panels.

• QuadCon shall have connecting couplers, three (3) per QuadCon.

• QuadCons shall be CSC certified and cargo worthy, Reference: MIL-HDBK-138B, Guide to Container

Inspection for Commercial and Military Intermodal Containers, 01 Jan 2002

D-3

D4.2. Snap Hook Ratchet Strap, Heavy Duty, 2-in x 30-ft. Two (2) snap hook ratchet straps, heavy duty, 2-in x 30-ft, are required for the FRP Grout Kit. These snap hook ratchet straps, heavy duty, 2-in x 30-ft, are used to secure pallets of Rapid Set Mortar Mix buckets within the FRP Grout Kit for shipment and long term storage. The snap hook ratchet strap, heavy duty, 2-in x 30-ft, US Cargo part# US-2HDRFS-Y or equivalent (see D4.2.1.).

D4.2.1. snap hook ratchet strap, heavy duty, 2-in x 30-ft property.

• Length: 30-ft

• Wide: 2-in

• Material: Polyamide nylon webbing and steel connector snap

• Special features: 30-ft long and web strength of 12,000-lbs

• Tightening device: Ratchet w/integral hooks and operating strength of 11,000-lbs for the ratchet and

10,000-lbs for the hooks.

D4.3. Lock, Combination, Government. Two (2) locks, combination, government (NSN 5340-00-292-0896), are required for the FRP Grout Kit. These locks, combination, government, are used to secure both sets of doors on the QuadCon during shipment and long term storage. The lock, combination, government, (NSN 5340-00-292-0896) or equivalent (see D4.31.).

D4.3.1. Lock, combination, government property.

• Size: 5/16-in diameter, 2-1/4-in high, 1-in wide shackle.

• 2-in wide laminated steel body padlock.

• Hardened steel shackle for extra cut resistance.

• Combination change instructions and change tool included.

• 4-digit dialing allows for thousands of possible combinations.

• Without chain.

• Spec Number (CID): ASTM F883 A-A-1928

D5. FRP GROUT KIT PACKAGING

D5.1. Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see A7.2.). When actual packaging of material is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point’s packaging activity within the Military Department or Defense Agency, or within the Military Department’s System Command. Packaging data retrieval is available from the managing Military Department’s or Defense Agency’s automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

D5.2. FRP Grout Kit Packaging Requirements. The following list of packaging requirements are used to package each FRP grout kit for shipping.

D5.2.1. Metal Strapping (Banding) 1/2-in x .020-in. ~750-ft of metal strappings (banding) 1/2-in x .020-in, are required in the FRP Grout Kit. These metal strappings 1/2-in x .020-in, are used to secure the Rapid Set Mortar Mix buckets together on each of the four (4) pallets. Metal strapping 1/2-in x .020-in, shall be Uline part #S-825 or equivalent (see D5.2.1.).

D5.2.1.1. Metal strapping 1/2-in x .020-in property.

• Material: Low carbon cold-rolled steel (not stainless or galvanized or zinc coated)

• Finish: Painted and waxed

• Width: 1/2-in

• Thickness: .020-in

• Breaking Strength: 1,200-lbs

D5.2.2. Metal Strapping (Banding) Seals (Clips), 1/2-in. 48 metal strapping (banding) seals (clips), 1/2-in, are required in the FRP Grout Kit. These metal strapping (banding) seals (clips), 1/2-in, are used to secure the metal

D-4 strapping around each of the four (4) pallets with Rapid Set Mortar Mix buckets. Metal strapping (banding) seals (clips), 1/2-in, shall be Uline part #S-827 or equivalent (see D5.2.2.1.).

D5.2.2.1. Metal Strapping (Banding) Seals (Clips), 1/2-in property.

• Material: Rust resistant zinc coating (not stainless steel)

• Type: Open

• Fits Strapping Width: 1/2-in

• Seal Length: 1-in

• Compatibility:

o High Tensile: H-529 o Standard: H-36 o Industrial: H-351 o Deluxe: H-662

• Standards: Meets ASTM D3953, Finish B-Grade 2, Class R-Regular Duty, Style I-Open

D5.3.1. Stretch Wrap, 80 GA. ~1,250-ft of Stretch wrap, 80 GA, is required in the FRP Grout Kit. This stretch wrap, 80 GA, is used to secure the Rapid Set Mortar Mix buckets together on each of the four (4) wood pallets. The stretch wrap, 80 GA, shall be Uline part #S-11499 or equivalent (see D5.3.1.).

D5.3.1.1. Stretch wrap, 80 GA property.

• Material: LLDPE (Liner Low Density Polyethylene)

• Features: Exterior surface treated to prevent slippage

D5.4.1. Corrugated Fanfold, 200-lb Test. ~200-ft of corrugated fanfold, 200-lb Test, is required in the FRP Grout Kit. This corrugated fanfold, 200-lb Test, is used to secure the Rapid Set Mortar Mix buckets together on each of the four (4) wood pallets. The corrugated fanfold, 200-lb Test, shall be Uline part #S-11499 or equivalent (see D5.3.1.).

D5.4.1.1. Corrugated fanfold, 200-lb Test property.

• Material: C flute

• Style: Corrugated sheets, corrugated runs widthwise

• Appearance: NOT pre-scored

• Test: 200#

D6. IDIQ RESUPPLY UNIT OF ISSUE

D6.1. IDIQ Unit of Issue per Item for FRP Grout Kit. Table 2, shows what the unit of issue for each item in the FRP grout kit listing, when NOT procured as a full kit.

TABLE 2. IDIQ Quantities per Item for FRP Grout Kit Item Unit of Issue Rapid Set Mortar Mix, 50-lb, 5-gal buckets 1 pallet of 12 buckets Bucket Lid Opener 1 package of four (4) Wood Pallet, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom

1 set of four (4)

QuadCon 1 each Snap Hook Ratchet Strap, Heavy Duty, 2-in x 30-ft 1 set of two (2) Lock, Combination, Government 1 set of two (2)

D7. PACKAGING FRP GROUT KIT IN ISO QUADCON

D7.1. Wood Pallet, 48-in x 44-in, HEAT TREATED (per ISPM 15) with 3/8-in plywood top and bottom.

Stack/place/secure 42 buckets of Mortar Mix on two (2) of the wood pallet, and 28 buckets of Mortar Mix on two

(2) of the wooden pallets per drawings/inventory on page D-8.

D-5

D7.2. QuadCon. Package the one (1) QuadCon with the appropriate items per drawings/inventory on pages D8 and D-9.

D7.3. Material Safety Data Sheets & ISPM 15 Certification. The material SDS and ISPM 15 certifications will be secured in some kind of plastic document protector and placed inside the QuadCon or attached to the inside of one of the container doors.

D7.4. Container Inventory & Packaging Diagram. The vendor shall provide a full container inventory listing and packaging diagram. The container inventory listing and packaging diagram will be secured in some kind of plastic document protector and placed inside the QuadCon or attached to the inside of one of the container doors.

D7.5. Full FRP Drawing Package. The vendor shall furnish to the gov’t a full FRP grout kit drawing package. This drawing package shall include a complete inventory listing with National Stock Numbers (NSNs)/manufacturer’s part numbers (if not a NSN has been created for item), packaging drawings with item details (as seen in drawings on pages D-7 thru D-9), be gov’t owned, and have the AFCEC logo on each page. If there are any approved (gov’t) changes to any item in this FRP mat panel assembly, the vendor shall provide updated revisions of the drawing package within 90 days of each approved change.

D8. FRP GROUT KIT COMPONENTS VERIFICATION

D8.1. Classification of Inspections of FRP grout kit components. The inspection requirements specified herein are classified as follows:

• First article inspection.

• Conformance inspection.

D8.1.1. First Article Inspection. The purpose of this inspection shall be to determine FRP Grout Kit’s conformity with the contract. Acceptance of the First Article inspection shall not constitute a waiver by the Government of its rights under the provisions contract document or relieve the manufacturer from any requirements defined in this specification. Failure to meet inspection criteria shall constitute cause for rejection.

D8.1.2. Conformance Inspection. The conformance inspection shall be conducted on all full FRP Grout Kits prior to the vendor shipping the FRP Grout Kits as stated in SOW paragraph 3.1.1.

D-6

DESCRIPTION REV DATE APPROVED

INITIAL RELEASE -- 5/11/2018 JBB

UPDATED A 4/26/2019 JBB

PART NO ITEM NO QTY U/I DESCRIPTION MATERIAL MATERIAL SPEC NSN

UNIT WEIGHT

(LBS)

TOTAL

WEIGHT (LBS) NOTES

FRP-GK-QC 0002 1 FIBER-REINFORCED POLYMER (FRP) GROUT KIT 10198

AMS NETWORK, LLC

CONSISTS OF ITEM 0002-01

THROUGH 0002-14

433RSMM55 0002-03 140 EA RAPID SET MORTAR MIX, BUCKET, 50 LB MORTAR N/A N/A 54.00 7560.00 CTS CEMENT SB812.0 0002-01 1 EA QUADCON TY II W/3 EACH CONTAINER CONNECTORS STEEL N/A 8150-01-533-8677 2120.00 2120.00 SEA BOX 35EM46 0002-12 4 EA BUCKET LID OPENER YELLOW PLASTIC N/A N/A 0.50 2.00 KRAFT TOOL PALLET A 0002-06 4 EA 48 X 44-in WOOD PALLET HEAT TREATED PER ISPM 15

W/ 3/8-in PLYWOOD TOP & BOTTOM

WOOD ISPM 15 N/A 80.00 320.00 SECURE IN MOTION

S-825 0002-08 750 FT 1/2 X .020-in METAL STRAPPING METAL COMML N/A 0.10 75.00 ULINE S-827 0002-09 48 EA 1/2-in METAL BANDING SEALS METAL COMML N/A 0.10 4.80 ULINE S-11499 0002-10 1250 SF CAST 80 GA STRETCH WRAP PLASTIC COMML N/A 0.01 12.50 ULINE S-16476 0002-11 200 SF 200 LB TEST CORRUGATED FANFOLD CORR COMML N/A 0.30 60.00 ULINE HT384688 0002-15 2 SHT 3/8-in 48 X 44-in HEAT TREATED PLYWOOD WOOD COMML N/A 14.00 28.00 SECURE IN MOTION US-2HDRFS-Y 0002-16 2 EA 2-in SNAP HOOK RACHET STRAPS H.D. 30FT-YELLOW POLYESTER COMML N/A 5.00 10.00 RATCHET STRAPS USA

179LH 0002-14 2 EA COMBINATION GOVERNEMENT NSN PADLOCK METAL COMML 5340-00-292-0896 1.50 3.00 MASTER N/A 0002-07 1 EA ISPM 15 CERTIFICATION PAPER COMML N/A 1.00 1.00 SECURE IN MOTION

N/A 0002-05 1 EA SDS PAPER COMML N/A 1.00 1.00 AMS NETWORK, LLC

N/A 0002-04 1 EA INVENTORY LIST PAPER COMML N/A 1.00 1.00 AMS NETWORK, LLC

PREPARED: J.B.B DATE: 4/26/2019

CHECKED: N/A DATE: 4/26/2019

ENGINEER: J.B.B. DATE: 4/26/2019

APPROVED: J.B.B. DATE: 4/26/2019

SCALE: NONE

4 3 2 1

FIBER-REINFORCED POLYMER (FRP) GROUT KIT

C C

B B

A A

TITLE:

FIBER-REINFORCED POLYMER

(FRP) KIT

THIRD ANGLE PROJECTION

CAGE CODE:

65S22

DRAWING NO:

6833284-02

REV:

A

SHEET

4 3 2 1

D-7

INITIAL RELEASE -- 5/11/2018 JBB

UPDATED A 4/26/2019 JBB

PREPARED: J.B.B DATE: 4/26/2019

CHECKED: N/A DATE: 4/26/2019

ENGINEER: J.B.B. DATE: 4/26/2019

APPROVED: J.B.B. DATE: 4/26/2019

SCALE: NONE

DRAWING NO:

6833284-02

REV:

A

SHEET

4 3 2 1

A A

TITLE:

FIBER-REINFORCED POLYMER

(FRP) KIT

THIRD ANGLE PROJECTION

CAGE CODE:

65S22

BB

C C

4 3 2 1

16 2-IN SNAP HOOK RATCHET STRAPS ATTACHED TO

CONTAINER SIDEWALLS X 2 EA

16 2-IN SNAP HOOK RATCHET STRAPS ATTACHED TO CONTAINER

SIDEWALLS X 2 EA

D-8

INITIAL RELEASE -- 5/11/2018 JBB

UPDATED A 4/26/2019 JBB

PREPARED: J.B.B DATE: 4/26/2019

CHECKED: N/A DATE: 4/26/2019

ENGINEER: J.B.B. DATE: 4/26/2019

APPROVED: J.B.B. DATE: 4/26/2019

SCALE: NONE

DRAWING NO:

6833284-02

REV:

A

SHEET

4 3 2 1

A A

TITLE:

FIBER-REINFORCED POLYMER

(FRP) KIT

THIRD ANGLE PROJECTION

CAGE CODE:

65S22

B

C

4 3 2 1

C

B

D-9