SURG_Attachment_01_PerfSpec___1700530.pdf

PERFORMANCE SPECIFICATION FOR SUPPRESSED UPPER RECEIVER GROUP

(SURG) FOR M4A1 CARBINE

5 June 2017

Distribution Statement D: Distribution authorized to the Department of Defense and U.S. DoD Contractors only. Requests for this document shall be referred to: Commander, Crane Division, Naval Surface Warfare Center, Code JXNL, 300 Hwy 361, Crane IN 47522-5001. Distribution authorized to the U. S. Department of Defense, U.S. DoD contractors, and Government Agencies of NATO and FVEY ONLY.

H92222-17-R-0011 Attachment 1 Performance Specification

Contents

1 SCOPE

1.1 REQUIREMENT LEVELS

1.2 TEST CONFIGURATION

1.3 TEST AMMUNITION

2 APPLICABLE DOCUMENTS

2.1 GOVERNMENT DOCUMENTS

Specifications, standards, and handbooks Other Government documents, drawings and publications

2.2 NON-GOVERNMENT PUBLICATIONS

3 REQUIREMENTS

3.1 DESIGN VERIFICATION

3.2 FIRST ARTICLE INSPECTION

3.3 QUALITY CONFORMANCE INSPECTION

3.4 SYSTEM REQUIREMENTS

Major components Size/weight SURG Rail Configuration Suppressor Configuration Charging Handle Positive Bolt Closure Device Firing Pin Surface Finish Parts Interchangeability

3.5 INTERFACE AND INTEROPERABILITY VERIFICATIONS

Weapon and Accessory Compatibility Bolt Lock/Release Training and Support Gear Compatibility Ammunition Compatibility

3.6 FUNCTIONAL PERFORMANCE REQUIREMENTS

Reliability Precision, Fixture Fired Precision, Shoulder Fired Barrel Life (300yds) Muzzle Velocity Suppression Ergonomics / Safety / Toxic Fumes Heat Control/Mirage Reduction Cyclic Rate

3.7 OPERATIONAL & ENVIRONMENTAL REQUIREMENTS

Altitude and Deep Water Immersion Requirements Drain Time Salt Fog Mud Freezing Rain / Ice Sand / Dust Rain Electromagnetic Interference (EMI) and Electromagnetic Compatibility (EMC) Operating Temperature Chemical Resistance

Drop Test / Rail Mounting Durability and Repeatability Operational Suitability and Effectiveness

3.8 SUPPORT

Marking Workmanship

4 CONTRACT DATA REQUIREMENTS LIST

5 VERIFICATION

5.1 PHASE ONE VERIFICATION (SEE ATTACHMENT 5, TABLE I PHASE 1 REQUIREMENTS VERIFICATION /

REFERENCES

5.2 DESIGN VERIFICATION PHASE ONE

Design Verification Test Rejection

5.3 SYSTEM REQUIREMENTS VERIFICATION METHODS

Major Components Size and Weight SURG Rail Configuration Suppressor Configuration Charging Handle Configuration Positive Bolt Closure Device Surface Finish

5.4 INTERFACE & INTEROPERABILITY VERIFICATION

M4A1 Lower Receiver Group Mounting Bolt Lock/Release

5.5 FUNCTIONAL PERFORMANCE REQUIREMENTS

Fixture Fired Precision Cook Off Stress Test Unlubricated Weapon Suppression Ergonomics / Safety / Toxic Fumes Blocked Bore Heat Control / Mirage Reduction

5.6 SUPPORT

Marking Workmanship

6 PACKAGING

7 NOTES

7.1 DEFINITIONS

q. V/M/S - Visual, Manual, Standard Measuring and Test Equipment

7.2 KEY WORD LISTING

7.3 ABBREVIATIONS

Visual, Manual, Standard

Performance Specification Suppressed Upper Receiver Group (SURG) for the M4A1 Carbine

02 June 2017 1 Scope.

This detail specification defines the technical and performance requirements, and the associated quality assurance provisions and verification procedures for the Suppressed Upper Receiver Group (SURG) for upgrade of the M4A1 Lower Receiver Group (LRG). The SURG allows the Warfighter’s weapon to be optimized for continuous suppressed usage. The SURG requirement is tailored to the current and future needs of Special Operations Forces (SOF) Operators. The needs are based on years of field and training experience. The SURG will provide the most reliable, safe, and dependable assault weapon possible. The SURG program is structured as a commodity procurement project. The United States Special Operations Command (USSOCOM) seeks to obtain the most reliable, safe, ergonomic, and dependable assault weapon system possible.

1.1 Requirement levels.

The original requirements documentation related to this performance specification lists Key Performance Parameters (KPPs) which are firm Go/No-Go criteria. If a product sample fails to meet any of these, it will not be tested further and is not eligible for contract award. Key System Attributes (KSA’s) are also included along with Additional Attributes. These both allow for two

(2) levels of performance based on a Threshold level (T) as the minimum acceptable performance, and the Objective level (O) as a desired level of performance or features which are goals to allow for an operationally significant increase in capabilities due to use of the SURG.

1.2 Test configuration.

Unless otherwise specified, all tests herein will be conducted with the SURG installed on an M4A1 lower receiver. If a different stock system and/or spring and buffer assembly is part of the SURG product sample, they will be installed per vendor instructions. The bolt and carrier group used for testing will be that provided as part of the SURG assembly, regardless of whether it is of M4A1 configuration.

1.3 Test ammunition.

Unless otherwise specified all testing will be conducted with an arrangement of M855A1, MK318 MOD0 and MK318 MOD1 as the primary ammunition types. The particular ammunition used in each portion of testing will be specified in the respective requirements and verification sections. MK318 MOD0 ammunition will be used as the primary MK318 ammunition. In the event that the quantity of MK318 MOD0 ammunition is not able to complete the respective sub-test on all vendor submissions, NSWC Crane will transition to MK318 MOD1 ammunition as a substitute for MK318 MOD0 prior to commencing the sub-test. Each sub-test will be completed with one type of MK318 ammunition across all vendor submittals to ensure equal evaluation across all vendors. LAT data used throughout testing for requirements and objectives will be specific to either MK318 MOD0 or MK318 MOD1 used during the subtest.

Usage of MK318 MOD0 or substituting MK318 MOD1 shall be identified as MK318 MOD0 / MOD1 throughout all performance specification sections and attachments unless otherwise specified. SURG is expected to be fully compatible with all 5.56mm NATO issue ammunition.

2 Applicable documents.

2.1 Government documents.

Specifications, standards, and handbooks.

The following specifications, standards, and handbooks are referenced in the document and are applicable to the requirements they are listed under.

FEDERAL SPECIFICATIONS AND STANDARDS

P-C-111 - Carbon Removing Compound FED-STD-595C – Colors Used in Government Procurement

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-W-63150 (3) NOT 2 - Weapons and Support Materiel Standard Quality Assurance Provisions for MIL-PRF-372E (2) - Cleaning Compound, Solvent (For Bore of Weapons) MIL-PRF-63460F - Cleaner, Lubricant and Preservative for Weapons and Weapons Systems MIL-DTL-71186 (4) – Carbine, 5.56mm: M4A1 MIL-DTL-63989D (4) – Cartridge, 5.56 Millimeter, Ball-M855 MIL-DTL-63990D (4) – Cartridge, 5.56 Millimeter, Tracer - M856 MIL-DTL-32338A (5) - Cartridge, 5.56 Millimeter: Ball - M855A1 MIL-DTL-32395 (2) - Cartridge, 5.56 Millimeter: Tracer - M856A1 MIL-PRF-71208A (2) – Cartridge, 5,56MM, Armor Piercing – M995 MIL-DTL-9963 (5) – Cartridge, 5.56 Millimeter, Ball M193 MIL-DTL-60616D – Cartridge, 5.56 Millimeter, Blank: M200 MIL-PRF-32409 (1) – Cartridge, 5.56 Millimeter, Short Range Training – M1037

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129R - Military Marking for Shipment and Storage MIL-STD-130N - Identification Marking of U.S. Military Property MIL-STD-461G - Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment MIL-STD-464C - Electromagnetic Environmental Effects Requirements for Systems MIL-STD-810G (1) - Environmental Engineering Considerations and Laboratory Tests MIL-STD-1472G - Human Engineering MIL-STD-1474E - Noise Limits MIL-STD-1916 NOT 2- DOD Preferred Methods for Acceptance of Product MIL-STD-2073-1E (1) - DOD Standard Practice for Military Packaging MIL-STD-1913 (1) NOT 2 – Dimensioning of Accessory Mounting Rail for Small Arms Weapons

DEPARTMENT OF DEFENSE HANDBOOKS

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

Other Government documents, drawings and publications.

U.S. ARMY DEVELOPMENTAL TEST COMMAND

TOP 1-2-511A - Electromagnetic Environmental Effects System Testing TOP 3-2-045 – Small Arms – Hand and Shoulder Weapons and Machineguns TOP 3-2-609 - Chemical Compatibility of Nonmetallic Materials Used In Small Arms Systems

(Copies of these documents may be ordered from the US Army Developmental Test Command, ATTN: Publications, 314 Longs Corner Road, Aberdeen Proving Ground, MD 21005-5005, or online at http://www.atec.army.mil/publications/topsindex.aspx)

OFFICE OF THE SECRETARY OF DEFENSE

ITOP 4-2-602 - Rough Handling Tests W/CH 1

NAVAL SEA SYSTEMS COMMAND

SSG800-AG-MAN-010/P-9290 – System Certification Procedures and Criteria Manual for Deep Submergence Systems

Naval Surface Warfare Center (NSWC) CRANE

DS-4083-C02-1273 Rev B - MK262 MOD1 Ammunition DS-JXNN-C08-1621A - Ball, Carbine, Barrier, MK318 MOD0 HS/JXNN/C11/0008 - Reduced Ricochet Limited Penetration, MK255 MOD1 HS/4083/C03/1351 - Dim Trace, MK301 MOD0 HS/4083/C01/1240 Rev C - Frangible, MK311

2.2 Non-government publications.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) INTERNATIONAL

ASTM E 1417 - Non-destructive Testing and Inspection ASTM E 1444 - Standard Practice for Magnetic Particle Testing ASTM D 3951 - Standard Practice for Commercial Packaging

NATO STANDARDIZATION AGENCY

NATO STANAG 4172 - Small Arms Ammunition (5.56 mm) http://quicksearch.dla.mil/ http://www.atec.army.mil/publications/topsindex.aspx

3 Requirements.

3.1 Design verification.

A sample of SURG’s shall be subjected to design verification in accordance with respective table and verification section. Phase One (Go/No Go): Table 1: Requirement Verification Cross Reference Matrix. Phase Two: Table 1: Requirement Verification Cross Reference Matrix and section 5.10. Phase Three: Table 1: Requirement Verification Cross Reference Matrix and section 5.19.

3.2 First Article Inspection.

A sample of SURG’s shall be subjected to First Article inspection in accordance with respective table and verification section. Phase One (Go/No Go): Reference Attachment 5 Table 1:

Requirement Verification Cross Reference Matrix and section 5.3. Phase Two: Table 1:

Requirement Verification Cross Reference Matrix and section 5.11. Phase Three: Table 1:

Requirement Verification Cross Reference Matrix and section 5.20.

3.3 Quality conformance inspection.

A sample of SURG’s shall be subjected to quality conformance inspection in accordance with respective table and verifications section. Phase One (Go/No Go): Table 1: Requirement Verification Cross Reference Matrix. Phase Two: Table 1: Requirement Verification Cross Reference Matrix and section 5.12. Phase Three: Table 1: Requirement Verification Cross Reference Matrix and section 5.21.

3.4 System requirements.

Major components.

a. The SURG shall include an upper receiver group (URG) composed of upper receiver, barrel, operating system assembly and bolt/carrier assembly along with a sound suppressor (may be integral with barrel), operators manual and maintenance manual (T).

b. The SURG may include a folding replacement buttstock if it does not require use of the buffer tube for functionality (O).

Note: In order to meet the objective of including a folding buttstock, specific thresholds pertaining to the folding buttstock kit must be met. Failure to meet these required thresholds constitutes the failure to obtain the folding buttstock objective.

Note: Folding buttstock in the position used to interface with the operators shoulder is referred to as the Deployed position. Folding buttstock in the position used to decrease over all length of the weapon is referred to as the Stowed position.

3.4.1.b.1 Weapon must fire as normal/intended with folding buttstock in stowed and deployed position, if folding buttstock is utilized on lower receiver group (LRG) (T).

3.4.1.b.2 Weapon must function per all required thresholds with respect to accuracy, reliability and endurance if folding buttstock or standard buffer tube and buttstock are utilized (T).

3.4.1.b.3 Folding buttstock must be capable of being opened (deployed) and closed (stowed position) for lifespan of SURG kit without failure (T).

3.4.1.b.4 Folding buttstock kit must not interfere with the normal operation of any SURG or LRG weapon controls in either the deployed or stowed positions (T).

3.4.1.b.5 Any armorer modifications to utilize folding buttstock kit must be achievable within 20 minutes without permanent modification of M4A1 LRG (T).

3.4.1.b.6 SURG equipped M4A1 with installed folding buttstock kit shall pass drop testing per TOP 3-2-045 rough handling section in the deployed (T), and stowed positions (T).

c. The SURG shall incorporate a design that prevents external debris from entering the upper receiver operating group (T).

Note: The standard M16/M4 family of weapons ejection port cover meets this threshold requirement but is not limited to that particular design. Threshold does not refer to mitigation of debris in handguard area of weapon, only operating assembly(s).

d. The SURG shall include a Blank Firing Adapter (BFA) (T). The BFA adapted SURG should be of the same size and weight as the standard configuration SURG (O).

e. The SURG shall include any conversion parts needed to allow for 5.56mm UTM Man

Marker Round (MMR) as well as Simunition® FX® marking round firing to include a properly weighted dummy suppressor if the actual suppressor is not compatible with the use of the rounds (T). The SURG should be compatible with the Simunition® FX® bolt carrier assembly and UTM M4 bolt carrier assembly as well as with their Battlefield Blank Rounds (BBR) (O).

Note: MMR and BFA kits will not be required with the SURG kits until Phase Two (2).

Note: If necessary to optimize rate of fire and/or recoil mitigation, a replacement action spring and buffer assembly may be included with the SURG.

Size/weight.

a. SURG shall be no longer than 25.5 inches (T), no longer than 21.0 inches (O). KPP

b. Barrel shall be no less than 11.5 inches in length (T).

c. The SURG with all internal and external components necessary for firing SURG unit, and affixed suppressor including all internal components shall not weigh more than 7.0 pounds (T), 4.5 pounds (O). Threshold and objective do not include accessory rails or sights.

Note: Barrel length is measured from the bolt face, when locked in battery, to the end of the rifling.

SURG Rail Configuration.

a. The SURG shall have a continuous/coplanar MIL-STD-1913 rail along the entire length of the upper receiver and forend in the 12 o'clock position to include a minimum of 4.75 inches of slotted area on the upper receiver and a minimum of 9.5 inches of slotted area on the forend (T) with the minimum number of MIL-STD 1913 slots being 24.

b. Timing of the MIL-STD-1913 slots across the handguard to receiver gap (if present) shall match timing allowing accessories to be mounted across receiver and handguard (T). MIL-STD-1913 dimensions for rail slots shall be continuous across full length of receiver and handguard, no section will inhibit a cross bolt to mount an accessory regardless of handguard to receiver gap or continuous rail surface (O).

c. The SURG forend shall accommodate three (3) inches or nine (9) slots of MIL-STD- 1913 in the three (3) and nine (9) o’clock positions at the muzzle end of the forend (T).

d. The SURG forend shall accommodate removable MIL-STD-1913 rail sections at the 3, 6, and 9 o’clock positions that are configurable at locations along the forend for no less than 9.0 inches in the six (6) o’clock position and six (6) inches in the three (3) and nine

(9) o’clock positions. MLOK rail sections shall attach with point of aim (POA) repeatability of 1.0 Minute of Angle (MOA) (T), 0.5 or less MOA (O).

Suppressor Configuration.

a. The SURG suppressor shall be capable of disassembly/reassembly to perform cleaning and barrel maintenance (T).

b. The SURG suppressor shall be rebuildable to include replacement of any wear components (T).

c. Rebuildable components of suppressor must last 15,000 rounds (T), 20,000 rounds (O).

d. Only one (1) element of the sound suppressor shall require serialization, suppressor serial number shall be repeated on the Upper Receiver Cartridge to allow weapon identification without disassembly (T).

e. Serialized element of suppressor must last the life of an M4A1 lower receiver, 125,000 rounds.

f. Suppressor shall not be capable of incorrect assembly into a hazardous configuration (T). Suppressor shall not be able to be improperly assembled when all parts are used (O).

g. The SURG equipped M4A1 suppressor shall not vibrate loose due to firing (T).

Charging Handle.

a. The SURG shall have an ambidextrous charging handle. Charging handle can be changeable to left or right hand orientation by user without tools. No parts replacements are allowed, only reconfiguration of charging handle. (T)

b. The SURG shall have an ambidextrous charging handle. Charging handle will be fully ambidextrous constantly without reconfiguration of the charging handle or any SURG assemblies (O).

c. The charging handle shall be fully operable with the stock in any position (T).

d. The charging handle shall be of a non-reciprocating design (T).

Positive Bolt Closure Device.

The SURG shall be fitted with a positive bolt closure device so as to ensure chambering of the round and locking of the bolt (T). The bolt closure device should be optimized for right or left handed users (O).

Note: M16/M4 family of weapon forward assist meets the threshold requirement, but design is not limited to such a positive bolt closure device.

Firing Pin.

a. The firing pin design and operation shall not contribute to primer malfunctions that can be related to excessive deformation of the primer (e.g. pierced primers, loose primers, escape of gas around the primer cup, etc.) (T).

b. The firing pin shall deliver enough energy to reliably ignite the primers of all of the ammunition types fired when used with the standard M4A1 lower receiver group in both semi-automatic and full-automatic fire modes (T).

c. The firing pin indent shall meet the performance requirements of MIL-DTL-71186A w/

AMD 3.

Surface Finish.

a. The SURG assembly to include suppressor, and any associated parts and components shall be protected with a durable corrosion resistant surface finish (T), corrosion proof surface finish (O), for use in all Special Operations Forces (SOF) climatic environments.

b. The SURG assembly to include suppressor, and any associated parts and components shall be constructed of corrosion resistant materials, which are abrasion, impact, and battlefield chemical resistant (T).

c. The surface finish shall minimize dust attraction and contamination (T). The surface finish should withstand NBC decontamination procedures (O).

d. All external and visible surfaces shall be of a rough, dull, non-reflective surface finish that retains paint (T).

e. All visible SURG surfaces shall be Color Coyote 498 (20150) not lighter than 481 (20220) Light Coyote in FED-STD-595C (T).

f. If SURG unit does not utilize an external debris mitigation cover (ejection port cover), the bolt carrier assembly shall be Color Coyote 498 (20150) not lighter than 481 (20220) Light Coyote in FED-STD-595C surface finish (T). If SURG unit utilizes an external debris mitigation cover then bolt carrier group is not required to have a Coyote finish between 498 and 481 per FED-STD-595C, but is required to have a dull/non-reflective finish showing through the ejection port with bolt closed (T).

g. All surface finishes shall be resistant to peeling, flaking, chipping, and require a minimum of operator preventative maintenance (T). Minimum preventative maintenance is defined as equal to or less than the current M4A1 preventative maintenance.

h. Internal surface finish(s) shall be lubricious/low friction (T), eliminate the use of lubricants (O).

i. Non-metallic components shall be fungus and chemical resistant (T).

j. All polymer components shall resist moisture absorption (T).

Parts Interchangeability.

a. The SURG component parts to include suppressor and any associated parts removable/rebuildable by operator or intermediate maintenance personnel shall be fully interchangeable with other like SURG components (T). Suppressor and receiver with matching serial numbers are excluded from requirement to be interchangeable on an operator or intermediate maintenance personnel level.

b. Bolts shall remain within safe headspace range 1.4646 in.-1.4730 in. [37.20mm – 37.41mm] when interchanged among alternate SURG upper receiver/barrel assemblies (T).

c. Interchanged systems shall still meet precision requirement as well as rate of fire and firing pin indent requirements (T).

3.5 Interface and Interoperability Verifications.

Weapon and Accessory Compatibility.

a. SURG shall be interoperable with the M4A1 lower receiver that utilizes the current 2 pin upper receiver group attachment method (T). (KPP)

b. Armorer level modifications within 20 minutes or less are required for installation and removal of folding buttstock kit (T).

c. SURG system must not require folding buttstock to meet system requirements (T).

d. No permanent modifications to the lower receiver are allowed (T).

e. The SURG shall remain compatible and fully functional with a standard M4A1 lower receiver and buffer tube (T).

f. SURG shall be compatible with the operation of existing mini day night sight (MDNS) weapon accessories (SU-230/PVS, SU-230B/PVS, SU-231A/PEQ, SU-271/PAS, SU- 279A/PVS, SU-278/PVS, and LA-5D/PEQ, Mini Aiming Laser (MAL), and Backup Iron Sights (T).

Bolt Lock/Release.

a. The SURG bolt shall remain locked to the rear after ejection of the last round from the magazine due to magazine follower activation of the standard M4A1 bolt lock (T).

b. Activation of the M4A1 bolt release shall allow the bolt to close and chamber a round from a fully loaded 30 round magazine without any lubrication (T).

c. Release of the bolt in a muzzle down position shall not be cause more than .008 in.

[.203mm] of indent on a chambered copper compression cylinder (T).

Training and Support Gear Compatibility.

a. The SURG kit shall provide the ability to use current UTM 5.56mm Man Marker Rounds (MMR) to include all necessary parts to reliably function (T). The SURG equipped M4A1 should be able to function MMR’s using the UTM M4 bolt and carrier assembly (O). It should also function using UTM Battlefield Blank Rounds (BBR) (O).

b. The SURG kit shall provide the ability to use current Simunition® FX® 5.56mm marking rounds to include all necessary parts to reliably function (T). The SURG should be able to function using the Simunition® FX® replacement M4 bolt and carrier assembly (O).

c. The SURG shall include any non-standard supplies necessary to clean weapon (T).

Common cleaning tools and expendables should be compatible (O).

d. SURG shall not require any tools for field strip (T), or any tools for detailed disassembly or reassembly (O). Tool is defined as anything other than bare hands.

Field strip is defined as the minimum necessary disassembly to clean weapon on an operator’s level for extended field usage.

e. The SURG equipped M4A1 shall be fully compatible with the small Modular Airborne Weapons Case (MAWC) NSN 1670-01-618-5844 for use in static line jumping.

f. The contractor will provide adequate, up-to-date training to Field Training Teams

(FTTs), Certificates of Completion shall be issued upon graduation. Contractor shall provide all technical documentation, Technical Training Equipment (TTE), and a complete training package. All training materials shall be provided and include all manuals, Training Support Packages (TSPs), Periods of Instruction (POIs), lesson plans, and any other necessary documents.

Ammunition Compatibility.

a. All SURG product samples shall be proof tested, inspected and certified by the vendor prior to acceptance for test and evaluation. This will include 1 proof round “5.56mm NATO, Test, High Pressure, M197” or equivalent cartridge followed by 3 standard 5.56mm NATO rounds and then inspection. (T)

b. The SURG should have chamber and headspace dimensions and tolerances as specified in NATO STANAG 4172 (5.56mm) (T).

c. The SURG equipped M4A1 shall be capable of safely firing all current NATO and US standard 5.56x45mm ammunition (T).

d. The SURG equipped M4A1 shall successfully complete TOP 3-2-045 section 4.17 ammunition compatibility (T).

e. The SURG equipped M4A1 shall be optimized to fire the M855A1 and the MK318 MOD0 / MOD1cartridges (T).

f. The SURG equipped M4A1 shall be compatible with the following ammunition (T):

MK318 MOD1 conforming to PS/JXNN/F16/0054Cal. 5.56mm Ball, Carbine, Barrier MK318 MOD0 conforming to DS-JXNN-C08-1621A Cal. 5.56mm Ball, Carbine, Barrier MK262 MOD1 conforming to DS-4083-C02-1273 Rev B M855 Ball conforming to MIL-DTL-63989D w/AMD 4 M856 Tracer conforming to MIL-DTL-63990D w/AMD 4 M855A1 EPR conforming to MIL-DTL-32338A w/AMD 4 M856A1 EPR-T conforming to MIL-DTL-32395A w/AMD 4 MK255 MOD1 Reduced Ricochet Limited Penetration conforming to HS/JXNN/C11/0008 MK311 Frangible conforming to HS/4083/C01/1240 Rev C M193 Ball conforming to MIL-DTL-9963G w/AMD 3

M995 AP conforming to MIL-PRF-71208A w/AMD 2 MK301 MOD0 Dim Trace conforming to HS/4083/C03/1351 M200 Blank conforming to MIL-DTL-60616D w/AMD 3 M1037 SRTA (MMR) conforming to MIL-PRF-32409

3.6 Functional Performance Requirements.

Reliability.

a. The SURG equipped M4A1 reliability shall meet the standard listed in Table I:

Permissible Failures, while using either USGI Tan Follower magazines (NSN: 1005-01- 561-7200) or Magpul M3 PMAGs magazines (PN: MAG557-BLK) while firing MK318 MOD0 / MOD1 (T) or M855A1 (O). The SURG equipped M4A1 should function reliably with all ammunition types listed in 3.5.4 (O).

Note: Firing schedule is shown in Table IV: Reliability Firing Schedule.

Note: Ammunition is expected to perform within temperature limitations of its specifications.

Note: Lubrication will be exclusively CLP per MIL-PRF-63460E w/AMD 4. Cleaning may be supplemented with bore cleaner per MIL-PRF-372 and carbon remover per P-C-111.

b. Manufacturer will provide parts replacement schedule and necessary parts kit to complete 20,000 rounds of fire for each SURG unit submitted. Parts replacement schedule shall be in increments of 1200 rounds. Only at 1200 round cleaning cycles will any required SURG maintenance, per manufacturer’s schedule, be conducted.

Every 600 rounds weapons will be lubricated per manufacturers provided instructions (T).

c. Barrel, bolt and suppressor (to include rebuildable components) shall be required to meet or exceed requirements to 15,000 rounds without replacement parts (T), 20,000 rounds (O). All other parts are to meet or exceed similar or identical parts in the replacement schedule of the M4A1 (T).

d. The SURG equipped M4A1 should function reliably without lubrication for 1200 rounds (O).

e. The SURG & BFA equipped M4A1 shall:

3.6.1.e.1 Function reliably using M200 Blanks (T). Function reliably is defined as equal to or better than the current M4A1 equipped with BFA firing M200 blanks with identical firing schedule.

3.6.1.e.2 Safely catch one (1) round MK318 MOD0 / MOD1 round (T), three (3) MK318 MOD0 / MOD1 rounds (O).

3.6.1.e.3 SURG BFA life should meet or exceed 5000 rounds (T).

f. The SURG equipped M4A1 should be able to reliably function if the suppressor or the suppressor’s rebuildable components are removed (O).

Table I: Permissible Failures

Failure Class MRBS/MRBF Maximum allowable Failures permitted in 15,000 rounds

I (MRBF) 2,000 8

II (MRBF) 8,000 2

III (MRBF) 15,000 1*

TOTAL 15,000 8

* The SURG cannot have more than 1 broken part causing weapon to cease function or more than 1 suppressor baffle/end cap strike without being declared at end of life.

Failure Classification:

Class I: A failure (stoppage) that may be immediately clearable by the operator within 10 seconds or less while following prescribed immediate action procedures.

Class II: A failure (stoppage) that may be operator clearable requiring more than 10 seconds but not more than 10 minutes. Only the equipment and tools issued with the weapon may be used to clear the weapon.

Class III: A failure of a severe nature. The failure; (1) is operator correctable but requires more than 10 minutes, (2) operator cannot correct and requires assistance (no time limit), (3) requires higher level of maintenance, or authorized operator correction cannot be accomplished because of unavailability of necessary tools, equipment or parts, or (4) damage to any interior components of suppressor caused by projectile impact.

Note: Baffle strike is defined as: an impact on baffle or end cap that dimensionally changes the area in which the bullet passes through during normal unimpeded flight. Photographs documenting baffle or end cap strikes will be taken and logged with round count and any other pertinent data for the situation.

Failure Scoring:

The maximum number of failures permissible is eight (8). These failures may be in any combination of Class I, II, or III up to the maximum permitted as indicated in the Table I above.

Receivers, barrels, bolt or suppressor including rebuildable components becoming unserviceable after meeting their life requirements shall not be considered as chargeable failures.

Unserviceable parts discovered after the reliability firing is completed shall not be scored as a reliability failure.

g. Attitude Testing. Weapon will be tested IAW TOP 3-2-045 section 4.11, no Class II or

Class III malfunctions (T), no malfunctions (O).

h. Unrestrained Firing. Weapon shall be capable of being fired without shoulder support.

No Class II or Class III malfunctions (T), no malfunctions (O).

i. Stress Test Reliability. The SURG equipped M4A1 shall withstand 6 complete cycles of the firing schedule in Table II below using MK318 MOD0 / MOD1 ammunition (T).

SURG allowed cooling to 120°F after each cycle. The SURG equipped M4A1 should withstand 20 cycles of the firing schedule in Table II below (O).

Table II: Stress Test Firing Schedule

30 round Magazine # Rate of Fire

1 1 shot /sec.

2 2 shots / sec.

3 1 shot /sec.

4 3 to 5 shot bursts

5 1 shot /sec.

6 2 shots / sec.

7 1 shot /sec.

8 30 shot burst

Allow to Cool 1 Cycle = 240 shots

Precision, Fixture Fired.

a. The SURG equipped M4A1 firing MK318 MOD1 for 5 groups of 10 rounds each suppressed, shall average over the five (5) groups no more than 1.50 MOA Extreme Spread (ES) beyond the ammunition Lot Acceptance Test (LAT) average ES at 300 yards (T), equal to or better than ammunition LAT average ES at 300 yards (O).

b. The SURG equipped M4A1 firing M855A1 for 5 groups of 10 rounds each suppressed, shall average over the five groups equal to or better than ammunition LAT average ES at 300 yards (O).

Note: Ammunition LAT will be determined by firing 3 groups of 10 rounds each from 3 each

11.5 inch test barrels (1:7 twist) with the individual lot of ammunition used for SURG testing at 300 yards.

c. SURG suppressor shall maintain zero when removed for cleaning and re-installed.

Point of impact to stay within 0.5 MOA at 300 yards (T), within 0.0 MOA at 300 yards (O).

Precision, Shoulder Fired.

SURG equipped M4A1 shall be capable of 70% or greater hit probability when shoulder fired from supported prone position at “E” type targets at 600m using high powered magnified day optics (O).

Barrel Life (300yds)

a. The SURG shall have a maximum ES Average of 1.50 MOA over LAT using MK318

MOD0 / MOD1 ammunition from 0 to 10,000 rounds fired (T).

b. The SURG shall have an average ES of 3.0 MOA over LAT using MK318 MOD0 /

MOD1 ammunition from 10,000 rounds to 15,000 rounds (T), 1 MOA over LAT ES at 0 to 15,000 rounds (O), an average ES of 3.0 MOA over LAT at 20,000 rounds (O).

c. The SURG shall have a minimum barrel life of 15,000 rounds AVG ES with a maximum 1.0 MOA over LAT using M855A1 ammunition (O), 3.0 MOA ES AVG over LAT at 20,000 rounds (O).

d. The SURG equipped M4A1 should meet LAT + 1.0 MOA AVG ES with alternate types of ammunition throughout its barrel life (O).

Note: Firing schedule is shown in Table IV: Reliability Firing Schedule.

Muzzle Velocity.

a. The SURG ten shot average muzzle velocity shall not drop more than 200 fps throughout barrel life with respective ammunition over established baseline (T).

Baseline will be established upon receipt of SURG units post bore cleaning.

Suppression.

a. The SURG equipped M4A1 shall not exceed 140 dB ten shot average sound pressure level at shooter’s ear during barrel life minimum (15,000 rounds) (T). Suppressor shall be capable of providing 135 dB or less ten shot average sound pressure level at shooter’s ear (O). Suppressor shall be cleaned at a cycle of every 1200 rounds, per manufacturer’s instructions with current approved DoD authorized materials. 30 minutes or less cleaning time required (O).

Note: Shooters ear sound pressure levels will be verified baseline, every 2400 rounds during endurance and at the end of endurance testing.

Note: Shooters ear position referred to as Basic Sound measurements in verification section.

b. The SURG equipped M4A1 shall not exceed 140 dB sound pressure level when tested per TOP 3-2-045 multi position testing configuration (O).

Note: TOP sound pressure level measurements are referred to as Full Sound measurements in verification section.

c. The SURG equipped M4A1 shall not produce visible flash in both duration and intensity in excess of suppressed MK18 MOD1 System (T). The SURG suppressor should eliminate all visible flash (O).

d. The SURG equipped M4A1 shall not produce infrared (IR) flash in both duration and intensity in excess of suppressed MK18 MOD1 System (T). The SURG suppressor should eliminate all IR flash (O).

e. The SURG suppressor should eliminate residual system light emissions after the firing of 60 rounds within 2 minutes in visible and near IR spectrums as seen with an AN/PVS-31 or AN/PVS-24 image intensifier systems (O). Average firing rate will be 1 round every 2 seconds. Testing will be conducted immediately following completion of the 60 rounds and two (2) minutes after the last round fired.

Note: The objective is signature reduction.

Ergonomics / Safety / Toxic Fumes

a. The SURG equipped M4A1 shall not present a cook-off hazard after firing MK318 MOD0 / MOD1 ammunition for 180 rounds of continuous automatic fire (T), 210 rounds (O).

Note: The sequence is fired in 30 round bursts with rapid magazine changes.

b. The SURG equipped M4A1 should have less perceived recoil than the MK18 MOD1 Suppressed (O).

c. The SURG equipped M4A1 shall not present a safety hazard to the operator if fired with entire suppressor or rebuildable suppressor components removed (T). 90 rounds of MK318 MOD0 / MOD1 will be used to identify any safety issues.

d. The SURG equipped M4A1 shall not present a safety hazard to the operator if fired with bore and suppressor full of water (T).

e. The SURG equipped M4A1 should not present a safety hazard to the operator if fired with a projectile lodged in the bore just ahead of the chamber (T).

f. The SURG shall not increase toxic fume exposure to the operator as compared to an M4A1 unsuppressed (T), 75% reduction in toxic fume exposure as compared to an M4A1 unsuppressed (O).

g. The SURG shall pass sub-safe off gas testing per SS800-AG-MAN-010/P-9290 Rev. A section F.4.2 (T).

Heat Control/Mirage Reduction.

a. SURG design shall reduce mirage effect as compared to current issue MK18 MOD1 suppressed (T), should eliminate mirage effect (O).

b. SURG should show using an Infrared (IR) camera a thermal heat signature less than the

MK18 MOD1 signature during firing of 150 rounds in five (5) minutes at a rate of 1 round every 2 seconds ±0.2 seconds (T), 210 rounds in seven (7) minutes at a rate of 1 round every 2 seconds ± 0.2 seconds (O).

c. SURG shall be designed to prevent operator contact or sustained contact burns from the suppressor (or equivalent) through one (1) layer of standard military duty uniform material after firing 210 rounds in seven (7) minutes at a rate of 1 round every 2 seconds ± 0.2 seconds (O). Contact burn will be defined as a peak temperature over 160°F in one (1) second of contact. Sustained contact burn will be defined as a peak temperature over 160°F in five (5) seconds of contact.

Note: Intention is to prevent periphery surface burns from suppressor during operator usage;

suppressor muzzle does not require shielding.

d. SURG shall show using an IR camera a thermal heat signature less than the MK18

MOD1 signature after firing 150 rounds in five (5) minutes at a rate of one round every 2 seconds ± 0.2 seconds at time of completion of firing schedule, post completion of firing at the following intervals: 5 minutes, 15 minutes, every 15 minutes until the hottest point on the weapon identified by the IR camera reaches 120°F (T), 210 rounds in seven (7) minutes at a rate of one round every 2 seconds ± 0.2 seconds at time of completion of firing schedule, post completion of firing at the following intervals: 5 minutes, 15 minutes, every 15 minutes until the hottest point on the weapon reaches 120°F (O).

e. After the firing of 150 rounds of MK318 MOD0 / MOD1 ammunition in semi-auto over 5 minutes, the SURG equipped M4A1 should present a maximum external rail interface temperature not to exceed 160 °F (T), 120 °F (O) degrees. After the firing of 210 rounds of MK318 MOD0 / MOD1 ammunition in semi-auto over 7 minutes, the SURG equipped M4A1 should present a maximum external rail interface temperature not to exceed 160 °F (O). Average firing rate over both 5 minute and 7 minute testing intervals shall be 1 round per 2 seconds ± 0.2 seconds.

Cyclic Rate.

a. The SURG equipped M4A1 should retain a cyclic rate within 50 rpm of its ambient temperature rate during hot and cold evaluations with alternate ammunition types (O).

Note: All rate of fire measurements will be conducted using a single ten round burst.

Note: SURG may incorporate its own M4A1 compatible buffer/spring set to optimize rate of fire.

3.7 Operational & Environmental Requirements.

Altitude and Deep Water Immersion Requirements.

The SURG equipped M4A1 shall be transportable and function without degradation after being exposed to altitudes up to 30,000 feet [9144 meters] above sea level (4.3 psi) and down to 66 feet [20.1 meters] deep in salt or fresh water (44.1 psi) for 8 hours (T).

Drain Time.

SURG equipped M4A1 shall be fully functional when removed from fully submerged position, with a drain time equal or less than 3 seconds (T), 0 seconds (O).

Salt Fog.

a. The SURG external surface finishes shall be rust and salt water corrosion resistant (T).

The SURG internal surface finishes shall be rust and salt water corrosion resistant (O).

b. The SURG immediately following the second 48 hour salt fog test must reliably function 120 rounds after cleaning and lubricating (T), without cleaning and lubricating (O).

Note: All test magazines used will be fully loaded and exposed to the salt fog and drying environments on the same schedule as the weapon itself.

Mud.

a. Wet Mud. The SURG shall have no more than 1 stoppage in 30 rounds fired and no failures after being covered with wet mud (T). TOP 3-2-045 4.5.5 Stage 1.

b. Dry Mud. The SURG shall have no more than 1 stoppage in 30 rounds fired and no failures after being covered with mud which has been allowed to dry (T). TOP 3-2-045

4.5.5 Stage 2.

Note: Suppressor muzzle will be taped over during mud applications.

Freezing Rain / Ice.

The SURG shall be able to operate with 3 to 6 mm of ice accumulation on external surfaces with no more than 1 stoppage in 30 rounds fired and no failures (T). TOP 3-2-045 4.5.8 and MIL- STD-810G, Method 521.4 general conditions light loading.

Note: Suppressor muzzle will be taped over during freezing rain / ice applications.

Sand / Dust.

The SURG shall be able to operate after exposure to a sand and dust environment with no more than 1 stoppage in 120 rounds fired and no failures (T). TOP 3-2-045 4.5.4 static test only.

Note: Suppressor muzzle will be taped over during exposure.

Rain.

The SURG shall be able to operate in rain environments with no more than 1 stoppage in 120 rounds fired and no failures (T). TOP 3-2-045 4.5.3 Water Spray (rain) Test.

Electromagnetic Interference (EMI) and Electromagnetic Compatibility (EMC).

The SURG shall not interfere with other nearby systems or be affected by electromagnetic emissions from battlefield electrical device operations in the immediate vicinity (up to 3 meters) of the system (T). The SURG shall remain fully functional during and after exposure to Electromagnetic energy/pulses (T). Reference MIL-STD-461F, MIL-STD-464C, TOP 1-2-511.

Operating Temperature.

The SURG equipped M4A1 shall be fully functional when weapon and ammunition are exposed to extreme temperatures ranging from -60+/-5°F to +160+/-5°F [-51°C to 71°C] (T) testing done per TOP 3-2-045 section 4.5.1.

Note: Fully Functional defined as zero stoppages.

Chemical Resistance.

The SURG shall demonstrate no adverse effects per TOP 3-2-045 after exposure to petroleum, oil, and lubricant products, insect repellents and other common battlefield compounds (T). The SURG shall not be adversely affected by common approved armory cleaning tank solutions (T).

Drop Test / Rail Mounting Durability and Repeatability.

a. SURG equipped M4A1 shall be of a durable design capable of seven (7), five (5) foot sequential drops. Reference TOP 3-2-045 for drop orientations. The third drop orientation (muzzle down) will be repeated 3 times. Drops will be onto plywood backed by concrete. SURG equipped M4A1 shall not fire a primed case in the course of drop testing (T), SURG equipped M4A1 shall complete seven (7) drops without the safety lever moving from “SAFE” position (O). No safety related portion of SURG equipped M4A1 shall fail to safely function upon completion of seven (7) drops (T).

SURG equipped M4A1 shall be dropped without accessory rails or sights.

Note: Safely function includes operation of suppressor heat shield to prevent operator from being burned by periphery surfaces of suppressor.

Note: A confirmable failure due to lower receiver group will not be held against the SURG unit.

b. Forend mounted rail sections will also be confirmed to retain point of aim with respect to top receiver rail within 1.0 MOA (T), 0.5 MOA or less (O). Method used for verification is loose cargo testing per TOP 3-2-045.

Note: All references to MOA are true MOA values unless notated otherwise.

Operational Suitability and Effectiveness.

Operator acceptance shall be based on the ability of the SURG system to meet all stated threshold requirements as well as Operators’ (subjective and objective) consideration of operational suitability, effectiveness, and ergonomic acceptability. Factors include but are not limited to: live-fire hit scores, speed/accuracy of engagement and function, controllability while firing, handling qualities, ease of operation, weight, perceived recoil and snag free movement through vegetation and battlefield obstacles (T). The SURG equipped M4A1 should have improved performance (hit factor based measure incorporating hits divided by time) as compared to the MK18 MOD1 with FMBS-c Suppressor when targets are engaged by SOF Operators between 0 and 600 meters in both semi and full auto modes (O). The SURG equipped M4A1 shall attain a minimum of 70% probability of hit (Ph) at 600 meters on average when fired at clearly visible “E” targets with appropriate, zeroed optics during fully supported / deliberate semi-auto fire.

3.8 Support.

Marking.

Apply Item Unique Identification (IUID) 2D Data Matrix mark in accordance with MIL-STD- 130M, construct #2, on the upper receiver. The UID mark shall contain the manufacturer's cage code, suppressor part number and serial number (data identifiers "17V”, "1P", and "S"). The 2D Data Matrix symbol shall be error correction code (ECC 200) in accordance with ISO 16022, using ISO 15434 syntax and the semantics of ISO 15418. UID marking shall be durable and shall be capable of surviving sound suppressor temperatures.

Workmanship.

Workmanship and finish shall be in accordance with the best commercial practice (T). Finished weapons and parts shall not exhibit poor material and processing such as seams, laps, laminations, cracks, visible steps, sharp edges, nicks, scratches, burrs, deformations, and missing operations which may affect serviceability, functioning, operation, appearance, or safety (T).

Flashing or other extraneous metal shall be removed from cast or forged parts (T).

4 Contract Data Requirements List.

4.1. Provide information to Contractor relating to performance in delivery to the

Government of CDRL requirements. Further detailed performance requirements should be obtained from DD Form 1423-1 relating to specific CDRLs. Data resulting from the CDRLs shall be marked with Distribution Statement D: Distribution authorized to the U.S. Department of Defense, UK Ministry of Defence, AUS Ministry of Defence, CAN Ministry of Defence and U.S. DoD contractors only. Other requests shall be referred to COMMANDING OFFICER, CODE JXN BLDG 3422, NSWC

CRANE, 300 HIGHWAY 361, CRANE IN 77522-5001.

4.2.Reference. CDRL Listing A001 Commercial Off-the-Shelf (COTS) Manuals and Associated Supplemental Data A002 Commercial Drawings and Associated Lists A003 Maintenance Support Plan A004 Inspection and Test Plan A005 Test/Inspection Report A006 Engineering Change Proposal (ECP) Class I and Class II A007 Request for Deviation (RFD) A008 As Built Configuration List (ABCL)

4.3.1.3 Detail Information.

4.3.1.4 CDRL A001 Commercial Off-the-Shelf (COTS) Manuals and Associated Supplemental

Data. Contractor shall provide Operator's and Maintenance technical manuals.

Technical manual(s) shall meet the criteria set forth in MIL-DTL-24784C Supplement 1, MIL-PRF-32216A and MIL-STD-40051-1C or MIL-STD-40051-2C, as applicable.

Technical manual(s) shall contain but not be limited to: safety precautions and health hazards; warnings and cautions; table of contents and index; preparation for use;

principles of operation; operating instructions; maintenance and servicing instructions (preventive and corrective); preparation for shipment; parts list; and operational and maintenance illustrations.

4.3.1.5 CDRL A002 Commercial Drawings and Associated Lists. Contractor shall provide commercial drawings and associated lists for the SURG. The data shall be reflective of the Engineering Test Unit (ETU) hardware configuration delivered to the Government.

4.3.1.6 CDRL A003 Maintenance Support Plan. Contractor shall provide a Preventive

Maintenance and Parts Replacement Schedule and Instructions) for the SURG.

Government will utilize this deliverable to support 125,000 rounds per system. Vendor shall include whether parts can be changed at rounds-count intervals or by gauging. If gauging, instructions on gauge use shall be included and vendor must provide gauge drawings and certification criteria.

4.3.1.7 CDRL A004 Inspection and Test Plan. Contractor shall provide an Inspection and Test

Plan to document Acceptance Test procedures for the SURG, per the Performance Specification. The plan shall specify the SURG configuration to be tested.

4.3.1.8 CDRL A005 Test/Inspection Report. Following Acceptance Test procedures for

SURG, Contractor shall provide Test Report(s) to document Acceptance Test results, per the Performance Specification. Each report shall specify the configuration tested.

4.3.1.9 CDRL A006 Engineering Change Proposal (ECP) Class I and Class II. Contractor shall include a cover page for each ECP submitted in accordance with (IAW) this CDRL. The cover page shall, as a minimum, contain ECP number, ECP title, date, contract number, CDRL number, and statements required by block 9 of this CDRL. All deliverables shall be in the English language.

4.3.1.10 CDRL A007 Request for Deviation (RFD). Prior to the manufacture of the SURG system, if Contractor considers it necessary to temporarily depart from the mandatory requirements of the specification or drawings, Contractor may request a deviation be authorized. Contractor shall submit an RFD to request departure from the contractually-specified configuration documentation for a specific number of units or for a specified period of time. Contractor shall prepare NOR for each RFD that will require changes to SURG drawings, associated lists, or other technical documentation.

4.3.1.11 CDRL A008 As Built Configuration List (ABCL). Contractor shall provide an ABCL for the SURG system. Contractor shall include an IPB (e.g., illustrations, photographs, and drawings), nomenclatures, and part numbers in the ABCL to support evaluation and developmental testing and to serve as a maintenance aid. Contractor shall submit functional/product baselines in the form of specifications, drawings, associated lists, interface control documents, and other applicable documentation to be used by Government as the baseline for judging future changes to the SURG.

4.3.1.12 Proof Firing; Rough Handling; Bore Obstruction specification provided if other than

ANSI/SAMMI; test data showing velocities, chamber pressures, and number of rounds fired in acquiring the data; total number of systems produced and marketed to other countries, militaries, and/or civilian market; copy of DOT EX Number or DOT Certificate of Compliance.

4.3.1.13 Provisioning Parts List ((PPL), also known as spares). Provisioning is the management process of determining and acquiring the range and quantity of support items necessary to operate and maintain an end item of materiel. The PIO CLIN is required to support the provisioning process and is assigned a predetermined not to exceed (NTE) dollar amount. The Government may procure spares, repair parts, and support equipment through delivery orders with pricing to be determined at the time the requirement arises and an order is placed over the length of this 5 year contract.