Att_1_160914_-_GL-PD-ECH_Purchase_Description_(Ver_L)_-_FINAL.pdf

UNCLASSIFIED

GL-PD-09-04L

Purchase Description (PD) for the

Enhanced Combat Helmet

1 Sept 16

Approved by:

C. A. Bell Product Manager, Infantry Combat Equipment

Beneficial comments (recommendations, additions, deletions) and any pertinent data which may be used in improving this document should be addressed to: Marine Corps Systems Command, CESS, Attn:

PM Infantry Combat Equipment, 2200 Lester Street, Quantico, VA

22134-6050 or via e-mail to kathleen.halo@usmc.mil

Record of Change

Ver Date Paragraph Comment Approval

14 Apr 09 N/A Initial Release

See signature page

A 26 Jan 10 Update from DT I testing

\\Original Initialed\\ 03/09/2010

B 3 Mar

3.5.1, 3.5.6, 3.14.1, 4.4, Table X

Change to size and shape verification and clarifications

\\Original Initialed\\ 03/09/2010

C 24 Jun

3.12.4, 4.19.4, 3.5.5, 3.12.13, Table X, 4.10.3, 4.18, 4.19.4, 6.5.3

Align flame resistance requirement with current fire resistant clothing;

clarifications to other

PD requirements

\\Original Initialed\\ 06/24/2010

D 21 Dec 10 various Update from DT II testing

\\Original Initialed\\ 12/21/2010

E 25 Jan

3.5.6, 3.5.6.3,

3.6.1 3.7, 3.7.1.1, 3.13.1, 3.13.2, 3.13.3, 3.13.5.1, 4.8, 4.12, 4.18.1, 4.21.5, 4.21.6, 4.21.7, 4.12.8, 4.22.1

Combined Color requirements; Clarified pad configuration;

Labeling modification;

clarification of label permanence; clarification of V50 method;

Clarification of washability

\\Original Initialed\\ 01/28/2011

F 13 Apr

3.5.6, 3.5.6.3, 3.5.6.4.1,Table II, Table III, Table IV, 3.7, 3.13, 3.13.1, 3.13.3, 3.13.4,3.13.5.2 , Add 4.1.8, Table IX, Table X, 4.4, 4.15, 4.20, 6.2, 6.9

Changed color of shell to Coyote 498; clarified location and size of markings on helmet shell;

added requirement for unique designator;

deleted packaging requirement for retention systems when purchased as a individual component;

deleted requirement for

UPC; clarified colorfastness requirements do not apply to leather; Added rounding requirement for measurements; updated shade matching test procedures; correct circular reference between 5.1 and 6.2f;

corrected part number for

\\Original Initialed\\ 4/18/2011

ECH X-back.

G 30 Oct

3.7, 3.12.1, 3.12.2, 3.12.5, 3.12.6, 3.12.7, 3.12.8, 4.13.4, 4.18.2.1, 4.18.3, 4.20, 4.21.1, 4.21.2, 4.21.5, 4.21.6, 4.21.7, 4.21.8, 4.21.14, Figure

Clarification of Hook/Loop Adhesion pass/fail criteria;

Addition of IOP PED-003 Exception Memo; Work

Package reference change;

Clarification of USON for environmental conditioning, clarification of standard pad configuration, clarification of blunt impact test

\\Original Initialed\\ 11/4/2011

H 04 May

3.13.1, 4.3, Table IX

Clarification of Label Font Size pass/fail criteria; Updated Table IX to reflect visual inspection of Retention system for LAT.

I 20 May

1.2, 2.2.1, 3.5.6.3, 3.5.6.4, 3.6, 3.6.2, 3.6.3, 3.6.4, 3.13.1, 4.13.2, 4.13.3, 4.13.4, 6.9

Changed Army’s H-back to Improved Retention System; corrected typographical error in marking of helmet shell requirement; changed hook disk test time from 24 hrs to minimum of 24 hrs;

changed “loop tape” to

“loop material”;

clarified that “pads” meant “pad suspension system (pads and hook disk) in several environmental tests

J 23 Oct

3.11, 4.2 (Table IX)

Changed Marking of Retention Systems to a lot test, deleted permanence for marking lot testing, changed blunt impact deformation limit to 0.20 inches.

K 12 Dec

3.13.1, 4.2, 4.3

Font size, added to note 4 of Table IX to clarify what is tested for water absorbency, shell size marking changed from “not smaller” to “smaller”, in

Table X, added shell “marking is metal” to

Table X, L 1 Sept 16 Various Updated for AAO increase reprocurement contract.

1 Sept 16

ENHANCED COMBAT HELMET (ECH)

This specification is approved for use by all Departments and Agencies of the Department of Defense (DoD).

1 SCOPE

1.1 Scope

This specification covers the performance and verification requirements for the Enhanced Combat Helmet (ECH), a protective helmet consisting of a ballistically protective shell, pad suspension system, and 4-point retention system. The ECH is compatible with, and is typically worn in conjunction with, other components of infantry combat equipment such as body armor systems, protective spectacles/goggles and/or prescription glasses, night vision equipment and a camouflage fabric helmet cover. The ECH may be used in lieu of the Lightweight Helmet (LWH) for the U.S. Marine Corps. The ECH will have the shape profile of the Army’s ACH.

1.2 Schedule of Sizes

The helmet assembly is constructed in the following sizes (see Paragraph 6.2).

SCHEDULE OF SIZES

Small (S) Medium (M) Large (L)

Extra-Large (XL)

2 APPLICABLE DOCUMENTS

2.1 General

The documents listed in this section are specified in Sections 3 and 4 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 documents cited in Sections 3 and 4 of this specification, whether or not they are listed.

NOT

MEASUREMENT

SENSITIVE

2.2 Government Documents

2.2.1 Specifications, Standards, and Handbooks

The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the solicitation or contract (see Paragraph 6.2).

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-46593B - Projectile, Calibers .22, .30, .50, and 20 mm Fragment-Simulating

MIL-DTL-32075 - Label: For Clothing, Equipage and Tentage (General Use)

MIL-PRF-372D - Cleaning Compound, Solvent (For bore of small arms and automatic aircraft weapons)

MIL-PRF-2104H - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service

MIL-PRF-6083F - Hydraulic Fluid, Petroleum Base, for Preservation and Operation

MIL-PRF-46170D - Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic Hydrocarbon Base, NATO Code No. H-544

MIL-DTL-83133F - Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP-8 + 100

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N - DOD Standard Practice Identification Marking of U.S. Military Property MIL-STD-662F - V50 Ballistic Test for Armor MIL-STD-810G - Environmental Engineering and Laboratory

Tests MIL-STD-3027 - Testing of Body Armor

(Copies of documents are available online at http://assist.daps.dla.mil or from the Standardization Documents 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 are those cited in the solicitation.

U.S. ARMY RESEARCH, DEVELOPMENT AND ENGINEERING COMMAND, NATICK

SOLDIER CENTER

2-1-2566 - HELMET PADS

2-1-2569 - SHELL, ENHANCED COMBAT HELMET

2-1-2570 - ASSEMBLY, ENHANCED COMBAT HELMET

2005 Visual Guide of Colors Used in Military Items Color Card

(Copies of drawings, publications, and other Government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity.)

PM SOLDIER PROTECTIVE EQUIPMENT

AR/PD-12-01 - Improved Retention System 07-96-101 - Improved Retention System (S-XL), Enhanced

Combat Helmet Drawing 07-99-101 - Improved Retention System (S-XL), Advanced

Combat Helmet Drawing

(Copies of this document are available from Defense Supply Center Philadelphia, ATTN: DSCP-FQSE, 700 Robbins Ave, Philadelphia, PA 19111, or by contacting the Contracting Officer.)

2.3 Non-Government Standards and Other Publications

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents are those cited in the solicitation or contract (see Paragraph 6.2). Non-Government standards and other publications are normally available from the organizations that prepare or distribute the documents. These documents also may be available in or through libraries or other informational services.

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/ASQ Z1.4 - Sampling Procedures and Tables for Inspection by Attributes

(Copies of documents are available online at www.ansi.org or from the American National Standards Institute, 1819 L Street, 6th floor, Washington, DC)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D 76 - Tensile Testing Machine for Textiles ASTM D 910 - Gasoline, Aviation ASTM D 975 - Oils, Diesel Fuel

ASTM D 523-89 - Standard Test Method for Specular Gloss ASTM D 1149-07 - Standard Test Methods for Rubber

Deterioration – Cracking in an Ozone Controlled Environment

ASTM D 6413-08 - Standard Test Method for Flame Resistance of Textiles (Vertical Test)

ASTM E 4 - Standard Practices for Force Verification of Testing Machines

ASTM E 29 - Using Significant Digits in Test Data to Determine Conformance with Specifications

ASTM F 1291 - Standard Test Method for Measuring Thermal Insulation of Clothing Using a Heated Manikin

(Copies of documents are available on line at www.astm.org or from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19426-2959.)

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

AATCC-8 - Colorfastness to Crocking: AATCC Crocking

Method AATCC-15 - Colorfastness to Perspiration AATCC-16 - Colorfastness to Light AATCC-61 - Colorfastness to Laundering, Home and

Commercial: Accelerated AATCC-107 - Colorfastness to Water AATCC-143 - Appearance of Apparel and Other Textile End

Products after Repeated Home Laundering AATCC-169 - Weather Resistance of Textiles: Xenon Lamp

Exposure AATCC Evaluation Procedure 9 - Visual Assessment of Color

Difference of Textiles AATCC Test Method - Concept 2 Consumer Technical Supplement

(Copies of documents are available on line at www.aatcc.org or from the American Association of Textile Chemists and Colorists, P.O. Box 12215, Research Triangle Park, NC 27709-2215.)

DEPARTMENT OF TRANSPORTATION (DOT) FEDERAL MOTOR VEHICLE SAFETY

DOT FMVSS 218 - Department of Transportation Federal Motor

Vehicle Safety Standard (FMVSS) No. 218 Motorcycle Helmets

(Copies of documents are available on line at http://www.nhtsa.dot.gov/cars/rules/standards/safstan2.htm. The complete text of all Federal Motor Vehicle Safety Standards and other National Highway Traffic Safety Administration (NHTSA) regulations can be found in Title 49 of the Code of Federal Regulations (CFR). Title 49 of the CFR is published in seven volumes; the fifth volume (Parts 400-999) is where these regulations can be found. Copies of this volume can be obtained for a cost from the U.S. Government Printing Office, Superintendent of Documents, Mail Stop: SSOP, Washington, DC 20402-9328)

NATIONAL INSTITUTE OF JUSTICE (NIJ)

NIJ Standard 0106.01 - Ballistic Helmets NIJ Standard 0101.06 - Ballistic Resistance of Body Armor

(Copies of documents are available on line at http://www.nist.gov/eeel/ or from the National Institute of Standards, Office of Law Enforcement Standards, 100 Bureau Drive, M/S 8102, Gaithersburg, MD, 20899-8102)

INTERNATIONAL ORGANIZATION OF STANDARDS

ISO/IEC 15415 - Data Matrix Symbol Quality

(Copies of documents are available on line at http://www.iso.org or from the ISO, 1, ch. de la Voie-Creuse, CP 56, CH-1211 Geneva 20, Switzerland.)

U.S. ARMY DEVELOPMENTAL TEST COMMAND, ABERDEEN PROVING GROUND,

MD

ITOP 04-2-805 - FR/GE/UK/US Projectile Velocity and Time-Of Flight Measurement

U.S. ARMY ABERDEEN TEST CENTER, ABERDEEN PROVING GROUND, MD

ATC-MMTB-029 - Blunt Impact Test Procedure

U.S. ARMY TEST AND EVALUATION COMMAND, ABERDEEN PROVING GROUND,

MD

TOP 10-2-217 - Ballistic Testing of Helmets

(Copies of documents are available from Commander, US Army Test and Evaluation Command, ATTN: AMSTE-TM-T, Aberdeen Proving Ground, MD 21105-5055)

2.4 Order of Precedence

In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3 REQUIREMENTS

3.1 Inspections/Tests

3.1.1 First Article

When specified (see Paragraph 6.2), sample(s) shall be subjected to First Article inspection (see Paragraphs 4.1.2 and 6.2). All requirements are listed singularly, (i.e., by themselves). In some cases, verification is performed on a test item that has been previously subjected to another verification test.

Sequencing of specific verifications is listed in Section 4.

3.1.2 Lot Acceptance

When specified (see Paragraphs 6.2), sample(s) shall be subjected to Lot Acceptance inspections (see Paragraphs 4.1.3, 4.2, and Table VIII). Lots shall be of a single size. Unless otherwise noted, all LAT shall be conducted under ambient conditions.

3.2 Materials, Design, and Manufacturing Processes

Unless otherwise specified, the materials, design, and manufacturing processes shall be at the discretion of the contractor provided all articles submitted to the Government meet the requirements of this specification.

3.3 Finished Helmet, Finished Shell and Unfinished Shell

The following definitions shall apply in this document.

a. An unfinished shell shall include the raw shell only, drilled with attachment holes (no primer, paint (coating), texturing aggregate, edging, edging adhesive, or hook disks).

The unfinished shell must include raised or depressed benchmarks. Since the primary need for benchmarks is testing, benchmarks on the unfinished shell need not be present in the finished helmets for production.

b. A finished shell shall include the unfinished shell, any primer, paint (coating) and texturing aggregate, all necessary attachment holes, any edging and adhesive to hold the edging, and labels.

c. A finished helmet includes the finished shell, hook disks, a complete pad suspension system, a complete retention system, and attaching hardware. The standard configuration is the configuration shown in Annex B (seven pad configuration with oblong/oval pads in the vertical pad configuration).

3.4 Design/Construction

The finished helmet and Night Vision Device (NVD) hardware shall meet the design requirements of this specification, referenced drawings, and parts lists. The ECH assembly shall be in four sizes: Small (S), Medium (M), Large (L), Extra-Large (XL). A complete helmet assembly consists of the following components and shall be in accordance with Drawing 2-1-2570:

a. Helmet Shell

b. Suspension Hook Disks

c. Pad Suspension System (3/4-inch) (mandatory source)

d. Retention Assembly (mandatory source)

e. Attaching Hardware

f. Edging, Finish, and Labels

3.4.1 Interchangeability

Components shall be interchangeable and modular such that replacement of any component with another like-sized unit shall have no detrimental effect on any of the requirements herein.

Not all parts need be size specific, and it is desired that the minimum number of unique parts/assemblies capable of meeting the requirements of this specification be used. Verification shall be in accordance with Paragraph 4.1.4.

3.5 Shell Design/Shape

The shape of the unfinished shell, prior to the application of any edging or finish, shall be as specified herein and shall have the same shape as shown on Drawing 2-1-2569 and all subsidiary drawings and parts lists. The measurements shall be taken to the inside surface only. Contractors will use the drawings as guidance to produce helmets that meet the overall shape and edge cut, while maintaining smoothed geometries. Once contractor-developed drawings are submitted and approved, they become part of the contract and no deviation is permitted without written approval from the Government. The outside surface is defined by the inside surface plus the thickness (see

Paragraph 3.5.2). Testing shall be conducted in accordance with Paragraph 4.4.

3.5.1 Shell Construction

After shell molding and before any subsequent operations, the outer and inner surfaces of the unfinished shell shall be finished smooth and even. The requirements of shell construction exclude areas that would be covered by the edging on a finished helmet. If fabric construction is used, there shall be no exposed ends of the fabric fiber showing. Both the inside and outside surfaces of the unfinished shell shall be free from any hole, void, delamination, blister, cracking, crazing, dry spot, area of non-resin flow, and any pit greater than 1/8-inch diameter or the depth of one ply of the ballistic material, whichever is less, in order to provide a smooth continuous surface. There shall be no raised fibers, raised pleats, raised wrinkles, or raised creases longer than one inch on the interior or exterior surfaces. Processing procedures and methods capable of providing uniform properties shall be used.

Patching or repair of any ballistic material (i.e., non-cosmetic repair of the helmet shell) shall not be performed after the material has been molded. Remolding helmet shells is not permitted. More than one material (hybrid construction) may be used to achieve best combination performance requirements listed in this document. Metallic fasteners that remain in the shell material shall not be used. Testing shall be conducted in accordance with Paragraph 4.3.

3.5.2 Shell Thickness and Uniformity

The following dimensional criteria are based on an unfinished shell. The maximum thickness for the helmet shells shall not exceed 0.500 inches regardless of the nominal thickness of the helmet. Thickness variations in the helmet shall be gradual.

The shell thickness shall not vary by more than 0.100 inch over the entire surface of the helmet. Testing shall be conducted in accordance with Paragraph 4.5.

3.5.3 Benchmarks

Benchmarks, per Drawing 2-1-2569, shall be located on both the inside and outside periphery and inside crown of the unfinished shell. Periphery benchmarks may be located on a structural edging and shall be at least 0.2 inches long. If benchmarks are not located on the structural edging, they shall extend past the helmet shell edge or edging at least 0.2 inches. The benchmark at the crown shall be a “+” with each leg of the “+” 0.25 (±0.06) inches long with one leg of the “+” pointing toward the front of the helmet, one to the rear, and one each to the left and right sides of the helmet. The benchmarks shall be clearly visible. Verification shall be in accordance with Paragraphs

4.3 and 4.6.

3.5.4 Attachment Holes

Holes to attach components to the helmet shell shall be made before application of the coating (see Paragraph 3.5.8.1).

There shall be no delamination greater than 0.125 inches from the edge of the hole or other damage of the shell material as a result of making the hole. There shall be minimal fraying, (i.e., uncut material attached at the edge of the hole) as a result of making the hole. At a maximum, the length of the uncut material shall be no more than 0.125 inch. Additionally, the hardware that passes through the hole shall pass through the hole freely and not be impeded or obstructed by any frayed material. Testing shall be conducted in accordance with Paragraph 4.7.

3.5.5 Retention System Holes

Holes for the Retention System shall be of the diameter and in the location shown on Drawing 2-1-2569. Testing shall be in accordance with Paragraph 4.4.

3.5.6 Night Vision Device Hole(s)

The NVD hole placement shall be located according to Drawing 2- 1-2569 and shall be located to integrate with ECH Bracket (Tobyhanna Army Depot Drawing Number 136-00-0001) and helmet cover to the specific contractor helmet design. The hole shall be placed in a consistent location on each helmet (consistent helmet to helmet within a size). Testing shall be in accordance with Paragraph 4.8.

3.5.7 Edging

The finished shell shall have a firmly bonded or an integrally molded edging that protects the periphery of the shell from delamination, wear, cuts, and tears. An integrally molded edging is an edging that is co-molded at the time of shell molding, not applied in an operation subsequent to shell molding. A structural edging is an edging that is intended to add rigidity to the shell edge. The edging itself shall not be susceptible to cutting, wear, or tear. The edging shall completely cover the bottom edge of the shell and extend up the sides a minimum of 0.30 inches of the helmet shell. If the edging is a non-integral component of the molded shell, then the edging shall consist of a one-piece molded construction or one piece cut to length. If the edging is cut to length, the cut end shall be placed at the rear center of the shell, the butt ends shall not overlap, and any gap between the ends shall not exceed 0.060 inches. The edging shall be firmly and completely attached to the shell, (i.e., there shall be no unbounded areas). The edging shall be rounded at the corners with a minimum radius of 1/16 inch. A corner shall be defined as the transition between the edge of the shell and the inside of the shell and the edge of the shell and the exterior of the shell, (i.e., the “lower” part of the edging.) The standoff of the edging against the sides (as opposed to the edge or rim) shall be a maximum of 0.125 inches from both inside and outside surfaces. Testing shall be conducted in accordance with Paragraphs 4.3 and 4.9.1.

3.5.7.1 Edging Adhesion

The edging shall remain firmly attached to the finished shell when tested as specified in Paragraph 4.9.2.

3.5.7.2 Edging Adhesion After Heat Aging

For non-structural edging, the edging shall not peel back more than 0.25 inch when tested as specified in Paragraph 4.9.3. For structural edging, the edging shall not move more than 0.125 inch when tested as specified in Paragraph 4.9.3 for structural edging.

3.5.8 Coating

Following the surface preparation specified in Paragraph 3.5.8.1, coating shall be applied to the exterior of the helmet shell including the outside of the edging. The coating shall completely and uniformly cover the shell surface and the outside of the edging. The coating shall be applied in accordance with the manufacturer’s instructions, if applicable. The final coat made to the exterior shall contain the texturing aggregate specified in Paragraph 3.5.8.2 and shall be applied uniformly on the exterior surface of the helmet shell including the outside of the edging, but not the bottom and inside edge of the edging.

After drying, no cracks, scuffed areas, blemishes (such as peeling, blistering or flaking), foreign matter embedding in or appearing on the finish shall be visible on the coating. While coating of the interior of the shell is not required, it shall be a subdued color. Hardware exposed on the exterior and interior of the shell (e.g., screw heads) shall not be coated.

The helmet shell shall be finished (coated) before installation of the retention system. Coating shall not be wet or tacky to the touch at time of final packaging for delivery. Testing shall be conducted in accordance with Paragraph 4.3.

3.5.8.1 Surface Preparation

Prior to the application of any coating to the surface of the helmet shell, the shell shall be appropriately prepared in order to meet the requirements for finish provided by the coating manufacturer. Permissible surface gaps and pits on the surface of the helmet shell (see Paragraph 3.5.1) may be filled with suitable materials to provide a smooth and continuous surface.

The rework of defects in ballistic material, such as cutting and filling of any blisters or other defects of the ballistic material of any size is not permissible. If surface preparation includes abrading, then the ballistic material shall show no signs of being visibly cut, gouged, or raised. Before application of the final coating the surface shall be free of any contaminants including dust, oil, grease, or any other foreign matter. Testing shall be conducted in accordance with Paragraphs 4.1.4 and 4.3.

3.5.8.2 Texturing of Coating

Texturing aggregate incorporated in the final coat for the exterior of the helmet shall be sand or walnut shell flour texturing in accordance with Paragraph 3.5.8.2.1 or Paragraph

3.5.8.2.2. The aggregate shall be uniformly applied to cover

the entire exterior of the shell including the outside of the edging. Testing shall be conducted in accordance with Paragraph 4.3.

3.5.8.2.1 Sand Texturing

The aggregate for sand texturing shall be banded silica sand that is water washed and kiln dried, free of salts and deleterious matter, and containing not more than 1.5% of dirt or foreign matter. The sand aggregate shall be that known commercially as No. 70 and shall have a screen analysis in accordance with Table I. Verification shall be conducted in accordance with Paragraph 4.1.4.

Table I: Sand Texturing

Sieve No.

(U.S. STD)

Percent cumulative

No. 40 0.5 maximum No. 50 6.0 (+3) No. 70 34.0 (+5) No. 100 82.0 (+5) No. 140 97.0 (+3, -5)

The coating-sand mixture shall contain six pounds of sand to one base gallon of coating and shall be reduced to spraying consistency.

3.5.8.2.2 Walnut Shell Flour Texturing

The aggregate for walnut shell flour texturing shall be 40/100-mesh walnut shell flour. The coating-walnut shell flour mixture shall contain 10 to 12 ounces of walnut shell flour per base gallon of coating. Verification shall be conducted in accordance with Paragraph 4.1.4.

3.5.8.3 Color

The color of the outer surface of the helmet shell, edging and visible attachment hardware (if used) shall be Coyote 498 of the 2005 Visual Guide of Colors Used in Military Items Color Card (see Paragraph 6.2). The Coyote 498 shall conform to requirements in Paragraphs 3.5.8.4 and 3.5.8.5. The interior helmet shell and the remainder of the edging shall be the same shade as the exterior, unless approved otherwise. The retention system shall be Tan 499 as specified in AR/PD-12-01. The pad suspension system shall be Foliage Green 504. The exterior color of the Hook Disks (side facing the pad) shall be black.

Verification shall be conducted in accordance with Paragraph 4.15.

3.5.8.4 Infrared Reflectance

Infrared reflectance (IR) requirements apply to the finished shell and select components of the retention system (as specified in AR/PD-12-01).

3.5.8.4.1 Texturing and Coating of Finished Shell

The texturing and Coyote 498 color coating (for the finished shell) shall meet the spectral reflectance requirements of Table II when verified in accordance with Paragraph 4.16.

Table II: Infrared Reflectance Requirements for Finished Shell

Wavelength(nm)

Coyote 498 Reflectance (%)

Min Max 600 8 20 620 8 20 640 8 22 660 8 24 680 12 24 700 12 34 720 16 42 740 22 46 760 30 50 780 34 54 800 36 56 820 38 58 840 38 58 860 40 60

3.5.8.5 Specular Gloss

The outer surface of the finished shell shall have a specular gloss as specified in Table III. Verification shall be conducted in accordance with Paragraph 4.17.

Table III: Specular Gloss Angle Min Max

60 degree - 1.0 85 degree - 3.5

3.5.8.6 Adhesion of Coating

The coating, when cut into squares, shall not lift when tested in accordance with Paragraph 4.10. Testing shall be conducted on the exterior and interior (if coating is used).

3.6 Retention System

The retention system shall be in accordance with all requirements specified in the Product Manager Soldier Protective Equipment (PM SPE) Purchase Description (PD), AR/PD 12-01, and either drawing 07-99-101 or drawing 07-96-101 or both.

Verification shall be conducted in accordance with the requirements and verifications contained within AR/PD 12-01. In addition, the shell shall be compatible with the X-back retention system (NSN 8470-01-599-0785 thru -0788) and Ceradyne part numbers 10010614 (bolt s,m,l), 10010615 (bolt xl) and 10010616 (nut).

3.6.1 Retention System Attachment Points

Four attaching points shall be used for the retention system, two on the front half of the helmet and two on the rear half, each symmetric about the helmet mid-sagittal centerline. The attaching points shall use the holes referenced in Paragraph

3.5.5. The attaching points shall be in accordance with Drawing 2-1-2569. Testing shall be in accordance with Paragraphs 4.11.1 and 4.4.

3.6.2 Retention System Attaching Hardware

The retention system hardware shall be in accordance with all requirements specified in the PM SPE PD, AR/PD 12-01, and drawing 07-97-101 or 07-99-101. The AR/PD 12-01 hardware shall be capable of withstanding and resisting impact from the 9 mm Full Metal Jacketed (FMJ) Round Nose (RN). Verification is in accordance to Paragraphs 4.3, 4.11.2 and 4.18.2.1. AR/PD 12-01 attaching hardware shall be tightened to the recommended minimum torque supplied by hardware manufacturer or established by the contractor. Verification is in accordance with 4.11.2. The bolt of the Improved Retention System attaching hardware may protrude thru the nut (post). Verification is in accordance with 4.11.2.

Compatibly of the X-back retention system and Ceradyne hardware shall be verified by installing in shell and checking protrusion in accordance with 4.11.2 when tightened to the specified torque. The bolt of the X-back attaching hardware may prodtrude thru the the post.

3.7 NVD Bracket and Attaching Hardware

The helmet shell shall be compatible with the ECH Bracket (Tobyhanna Army Depot Drawing Number 136-00-0001). The contractor shall provide and install the hardware to securly attach the NVD bracket to the shell. There shall be at most three different pieces of hardware to attach the bracket to all the sizes of shells: (1) one length nut (post) and two length bolts, (2) two length nuts (posts) and one length bolts, or (3) one length nut (post), one length bolt, and a spacer, washer, or shim. If two length bolts or two length nuts (posts) are used, they shall be colored tan and green to differentiate one from the other. The hardware that rests on the inside of the shell shall contact the shell uniformly. The hardware shall not protrude beyond the recess in the bracket allowing the viewer bracket (horn)(NSN 5855-01-551-4525) to firmly attach to the bracket. Additionally, the hardware (bolt portion) shall not protrude past the nut portion if a nut is used on the inside of the shell. The hardware on the inside of the shell (standoff) shall not be thicker than 0.105 inches. Verification is in accordance with 4.11.2. Attaching hardware shall be tightened to the recommended minimum torque supplied by hardware manufacturer or established by the contractor. Verification is in accordance with 4.11.2. The hardware shall be capable of withstanding and resisting impact from the 9 mm FMJ RN). Verification is in accordance to 4.18.2.1.

3.8 Pad Suspension System

The helmet shall utilize a modular pad suspension system consisting of a series of pads (mandatory source) that act as the suspension system between the wearer’s head and the helmet shell. The pads shall possess means of easy attachment, removal, and reattachment to the inside helmet shell. The pad suspension system shall attach, remove, and reattach to the helmet shell via hook disks permanently adhered to the inside of the helmet shell. The pads shall remain firmly in place when attached. The ease of attachment of the pads and the ability to attach the pads where the wearer desires (i.e., in a variety of locations) shall permit accommodations among different size and shape heads. A complete pad suspension kit shall consist of seven pads as follows: one round pad (crown), two trapezoidal pads (front and back), and four oblong pads (distributed around the perimeter to achieve comfort and stability while still covering the inside of the retention hardware). Drawing 2-1- 2566 shows the shapes and dimensions of the pads. There shall be only 3/4-inch thick pads. The shape of the pad shall meet the shapes shown in Drawing 2-1-2566 with a tolerance of ± 1/8-inch. Testing shall be conducted in accordance with Paragraphs

4.12.1 and 4.3. The mandatory source for this component shall be in accordance with Paragraph 6.5. Standard pad configuration is shown in Figure 1. The oblong pads should be placed such that the edge of each pad is flush with the rim of the finished helmet and centered over the hardware if possible. Additionally, the long axis of the oblong/oval pad is orientated toward the center crown benchmark of the helmet and the crown pad will be centered equal distance between the front and rear trapezoidal pads.

3.8.1 Pad Construction

The pad shall have at least three basic layers or be designed in such a way as to function in three ways: an inner layer shall contact the wearer’s head, a padding layer shall provide the standoff, comfort, protection and stability, and an outer material layer that attaches the pad to the hook disks inside the helmet shell. The three layers shall be permanently joined around the perimeter to prevent disassembly. Verification shall be conducted in accordance with Paragraph 4.3.

3.8.1.1 Inner Layer Material

The inner material that contacts the wearer’s head shall wick moisture away from the wearer’s head and absorb it. The average wicking times to reach the 20 mm and 30 mm marks in each direction shall not exceed the times specified in Table IV.

Testing shall be conducted in accordance with Paragraph 4.12.4.

Table IV: Inner Layer Wicking Requirements

Length and Direction Maximum Time

(seconds) 20 mm (machine and cross - machine direction)

30 mm (machine and cross - machine direction)

3.8.1.2 Padding Layer Material

The padding material shall provide standoff, comfort, protection and stability. The padding material shall not absorb or hold moisture when tested in accordance with 4.12.3. It may itself consist of multiple layers. Thickness of this layer shall provide for the bulk of the overall pad thickness required.

Verification shall be accordance with Paragraph 4.3.

3.8.1.3 Outer Layer Material

The outer material shall be made of a loop-type material and allow the pad to be attached to the inside of the helmet shell.

It is desirable that the outer material interface with the currently fielded hook disk (3M part number SJ3572). The outer material shall interface with the hook disks. Testing shall be conducted in accordance with Paragraph 4.3.

3.8.2 Pad Compression Durability

The pads shall be constructed such that they can withstand multiple compressions without failing. Each pad shape and thickness shall be subjected to repeat 1/4-inch compressions and show no signs of degradation. Degradation includes, but is not limited to, the structure of the pad losing its resiliency and thickness, and not returning to its original shape. There shall be no physical damage to any of the pad components. Physical damage includes, but it is not limited to, breakage of stitches (if used), seams, and closures, or damage to any of the components such that they do not return to their original shape and thickness. Testing shall be in accordance with Paragraph 4.12.2.

3.9 Hook Disks

Hook disks shall interface with the outer material of the pads and attach the pads to the inner surface of the helmets. The hook disks are attached to the inside of the helmet shell by means of a pressure sensitive adhesive. One side of the disk shall be comprised of a means to attach the pad and the other side shall be coated with a self-stick adhesive (pressure sensitive). Verification shall be conducted in accordance with Paragraph 4.3.

3.9.1 Hook Disk Shape and Coverage

Hook disk shape shall be a circular shape, 1 7/8 + 1/8 inch in diameter. An adequate number of hook disks shall be installed on the interior of the finished shell to allow movement of the pads into any position and to allow securing of the helmet cover. At a minimum, enough hook disks shall be installed to allow the smallest pad to be placed anywhere inside the shell and have at least 1/2 of the pad’s surface in contact with a hook disk. After installation, no hook disks should have air bubbles or gaps between the hook disk and the shell. There should be no hook disks installed in the ear dome area of the shell. Additionally, no hook disks shall cover any of the molded in markings as required in Paragraph 3.14.1. Testing shall be conducted in accordance with Paragraph 4.13.1.

3.9.2 Hook Disk Durability

At no time shall removal of any helmet pad cause the hook material to become separated from the helmet shell. The adhesive shall firmly attach the disk to the inner surface of the helmets with no lifting of the hook disks on any contours within the helmets. Testing shall be in accordance with Paragraphs 4.13.2 and 4.13.3.

3.9.3 Hook/Loop Adhesion

The adhesion between the hook disk and the outer material on the pad shall be a minimum of 2.8 lbs/inch of width. Testing shall be in accordance with Paragraph 4.13.4.

3.10 Ballistic Protection

The helmet shell shall provide ballistic protection from fragments, 9 mm projectiles, and small arms. Protection shall meet the requirements set forth in this document throughout the entire surface area of the helmet unless specified otherwise in this document.

3.10.1 V50 Ballistic Protection Limits (V50 BL(P))

The finished shell shall be capable of providing the minimum V50 BL(P)s listed in Table V at 0° obliquity against the specified projectiles when tested in accordance with Paragraph 4.18.1 and Classified Annex A under the following conditions:

a. Ambient (68°F)

b. Extreme hot (160°F)

c. Extreme cold (-60°F)

d. After immersion in seawater, tested at ambient temperature

e. After exposure in weatherometer, tested at ambient temperature (17-grain Fragment Simulating Projectile (FSP) only)

f. After Accelerated Aging, tested at ambient temperature

(17-grain FSP only)

Table V: Minimum V50 BL(P)s

Projectile V50 BL(P) (ft/sec)

0° Obliquity 45° Obliquity 2-grain RCC 1/ 5670 Gov’t Ref 4-grain RCC 1/ 4700 Gov’t Ref 16-grain RCC 1/ 3340 Gov’t Ref 64-grain RCC 1/ 2360 Gov’t Ref 17-grain FSP 2/ 2970 Gov’t Ref Small Arms Defined in the Classified Annex A 1/ Right Circular Cylinders (RCC) shall be in accordance with Figure 3.

2/ FSP shall be in accordance with MIL-DTL-46593B except that hardness may be measured on samples from each projectile lot.

V50 ballistic limit testing shall be performed in accordance with Paragraph 4.18.1. Multiple finished shells may be required to determine the V50 BL(P) for a particular projectile, obliquity, and environmental condition. Testing at 45° obliquity may be conducted for Government reference only for the threats in Table V.

3.10.2 Resistance to Penetration

The helmet shell shall meet the following resistance to penetration (RTP) requirements.

3.10.2.1 Resistance to Penetration – 9 mm

The finished helmet, including any hardware exposed on the outside of the shell (retention system and NVD), shall be resistant to penetration from a 9 mm FMJ RN bullet with a nominal mass of 124 grains in accordance with National Institute of Justice (NIJ) Standard 0106.01 at 1400 (+50 –0)ft/sec at 0° obliquity when tested in accordance with Paragraphs 4.18 and

4.18.2.1 under the following environmental conditions:

a. Ambient (68°F)

b. Extreme hot (160°F)

c. Extreme cold (-60°F)

d. After immersion in seawater, tested at ambient temperature

3.10.2.2 Resistance to Penetration – Small Arms

See Classified Annex A.

3.10.3 Ballistic Transient Deformation

Ballistic Transient Deformation (BTD) of the finished helmet shell shall not cause a deformation in clay in excess of 0.63 inches (16.0 mm) against 9 mm projectile under the environmental conditions specified in Paragraph 3.10.2.1 at 1400 (+50 –0) ft/sec at 0° obliquity for shots made to the right side, left side, and crown. Shots made to the front and back shall not exceed 1.0 inch (25.4 mm). Testing with small arms threats outlined in the Classified Annex A will be conducted for Government reference only. Testing shall be conducted in accordance with Paragraphs 4.18, 4.18.3, and Classified Annex A.

3.11 Weight

The threshold maximum weight of the finished helmet shall not exceed the weights listed in Table VI. The finished helmet shall be weighed with the 3/4-inch thick pads (mandatory source). Finished helmets weighing less than the weights in Table VI are desired. Testing shall be conducted in accordance with Paragraph 4.19.

Table VI: Weight

Size Maximum Weight (pounds) Extra-Small (XS) 2.82 Small (S) 2.94 Medium (M) 3.06 Large (L) 3.31 Extra-Large (XL) 3.88 Extra Extra-Large (XXL) 4.00

3.12 Bump or Blunt Impact Protection

The finished helmet shall provide non-ballistic impact protection to the wearer by reducing acceleration of the head during low velocity blunt impact events at various temperatures.

As a threshold, for each size helmet with 3/4-inch thick pads (mandatory source), and for all tests including the various impact sites and temperatures specified as well as both first and second impacts, no individual acceleration shall exceed 150 G (gravitational constant). Greater impact protection (i.e., fewer G) is desired as an objective. Following blunt impact testing, there shall be no physical damage to the helmet shell such as shell fracture, defined as a separation/split of the ballistic material through the entire thickness of the helmet shell, or indentation depth in excess of 0.20 inches (delamination and ply separation are permitted). If physical damage is evident after blunt impact testing, helmets shall be ballistically tested to determine if the helmet has been operationally degraded. Additionally there should be no damage to any part of the retention system or pad suspension system.

Testing shall be in accordance with Paragraph 4.20.

3.13 Operating Environment

All helmet components shall be constructed such that they can withstand various environmental extremes without degradation.

3.13.1 Seawater Resistance

There shall be no structural, visible, or operational degradation to the finished shell when subjected to immersion in seawater. The finished shell shall show no evidence of softening, peeling, blistering, cracking, delamination, or increase in weight of greater than 3.0% over dry weight or when tested in accordance with Paragraph 4.21.1 and 4.19. If the helmet shell exhibits these visual defects, helmets shall be ballistically tested to determine if the helmet has been operationally degraded. The finished shell thickness will be measured before and after conditioning as Government Reference Only in accordance with Paragraph 4.5. Also, the requirements of Paragraphs 3.10.1 and 3.10.2 shall be met after seawater exposure.

3.13.2 Weatherometer Resistance

There shall be no structural, visible, or operational degradation to the finished shell when subjected to weatherometer exposure. The finished shell shall exhibit no evidence of cracking, blistering, delamination, and ply separation, separation of edging, finish defects, or ballistic degradation when tested in accordance with Paragraph 4.21.2. If the helmet shell exhibits these visual defects, helmets shall be ballistically tested to determine if the helmet has been operationally degraded. The finished shell thickness will be measured before and after conditioning as Government Reference Only in accordance with Paragraph 4.5. Also, the requirements of Paragraph 3.10.1 shall be met after weatherometer exposure.

3.13.3 Field Agent Resistance

The finished shell, when exposed or subjected to the following agents, shall show no evidence of softening, peeling, delamination, ply separation, or tackiness. As an alternate, the unfinished shell (i.e., no coating or edging) may be tested.

Testing shall be conducted in accordance with Paragraph 4.21.3.

a. DEET Insect Repellent, NSN 6840-01-284-3982

b. Gasoline, ASTM D-910

c. Motor Oil, MIL-PRF-2104H

d. Hydraulic Fluid, Petroleum Base, MIL-PRF-6083F

e. Fire Resistant Hydraulic Fluid, MIL-PRF-46170D

f. Fuel Oil, Diesel, ASTM D-975

g. Turbine Fuel, Aviation, JP-8, MIL-T-83133F

h. Rifle Bore Cleaning Compound, NSN 6850-00-224-6656, MIL-

PRF-372D

i. Lubricating Oil, Weapons (LSA), NSN 9150-00-935-6597

j. Lubricating Oil, Arctic, Weapons, NSN 9150-00-292-9689

k. Face Paint, NSN 6850-01-493-7309

l. Reactive Skin Decontamination Lotion (RSDL), NSN 6505-

01-507-5074

m. Bleach, NSN 6850-01-014-1324

n. Hypochlorous Acid (HTH), NSN 6810-00-255-8471

o. Sorbet Decontamination System (M100-SDS) A-200-SiC-

10005S, NSN 4230-01-466-9095

Chemical Name CAS Number Alumina 1344-28-1 Carbon Powder 7440-44-0 Silicon Dioxide

1314-23-4

Sodium Oxide 1313-59-3

p. M291 and M259 Decontamination Kits

(1) M291, NSN 6505-01-276-1905

(2) M259, NSN 6850-01-357-8456

Chemical Name CAS Number Synthetic Graphite 7440-44-0 Strong Base Anion Exchange Polymer, Hydroxide ION

9017-79-2

Strong Acid Cation Exchange Polymer Hydrogen Ion

65405-46-1

Silica, Amorphous 7631-86-9

3.13.4 Flame Resistance

The finished shell shall be self-extinguishing with no after-flame greater than 2.0 seconds (Threshold), 0.5 seconds (Objective). Flaming before the withdrawal of the flame source is permitted according to ASTM D 6413-08. There shall be no dripping. Finished shells may undergo simulated wear and tear and shall be tested as Government reference only. Testing shall be conducted in accordance with Paragraph 4.21.4.

3.13.5 High Temperature Storage and Use

All helmet components of the finished helmet, including the finished shell, pad suspension system, retention system, and hardware, shall exhibit no structural, visible, or operational degradation or physical damage when subjected to elevated temperature exposure. The finished shell shall exhibit no cracking, delamination, separation of plies, distortion, softening, or other deterioration. If the helmet shell exhibits these visual defects, helmets shall be ballistically tested to determine if the helmet has been operationally degraded. The retention system shall be operable (webbing slides, retention system can be cinched down, etc.) and shall have no cracked or damaged components. The suspension system (pads and hook disks) shall not have suffered any degradation or damage. Testing shall be in accordance with Paragraph 4.21.5. The finished shell thickness will be measured before and after conditioning as Government Reference Only in accordance with Paragraph 4.5.

Also, the requirements of Paragraphs 3.10.1 and 3.10.2 shall be met after high temperature exposure. Lastly, the paint (coating) shall suffer no degradation or deterioration after exposure. The coating shall meet the requirements of 3.5.8.6 after exposure when tested shall be in accordance with 4.10.

3.13.6 Cold Temperature Storage and Use

All helmet components of the finished helmet, including the finished shell, pad retention system, retention system, and hardware, shall exhibit no structural, visible, or operational degradation, or physical damage when subjected to low temperature exposure. The finished shell shall exhibit no cracking, delamination, separation of plies, distortion, softening, or other deterioration. If the helmet shell exhibits these visual defects, helmets will be ballistically tested to determine if the helmet has been operationally degraded. The retention system shall be operable (webbing slides, retention system can be cinched down, etc.) and shall have no cracked or damaged components. The suspension system (pads and hook disks) shall not have suffered any degradation or damage. Testing shall be in accordance with Paragraph 4.21.6. The finished shell thickness will be measured before and after conditioning as Government Reference Only in accordance with Paragraph 4.5.

Also, the requirements of Paragraphs 3.10.1 and 3.10.2 shall be met after cold temperature exposure. Lastly, the paint (coating) shall suffer no degradation or deterioration after exposure. The coating shall meet the requirements of 3.5.8.6 after exposure when tested shall be in accordance with 4.10.

3.13.7 Temperature Shock

All helmet components of the finished helmet, including the finished shell, pad suspension system, retention system, and hardware, shall exhibit no structural, visible, or operational degradation, or physical damage when subjected to temperature shock, hot to cold, and cold to hot. The finished shell shall exhibit no cracking, delamination, separation of plies, distortion, softening, or other deterioration. If the helmet shell exhibits these visual defects, helmets shall be ballistically tested to determine if the helmet has been operationally degraded. The retention system shall be operable (webbing slides, retention system can be cinched down, etc.) and shall have no cracked or damaged components, or other deterioration. The suspension system (pads and hook disks)shall not have suffered any degradation or damage. Testing shall be in accordance with Paragraph 4.21.7. The finished shell thickness will be measured before and after conditioning as Government Reference Only in accordance with Paragraph 4.5.

Lastly, the paint (coating) shall suffer no degradation or deterioration after exposure. The coating shall meet the requirements of 3.5.8.6 after exposure when tested shall be in accordance with 4.10

3.13.8 Altitude

All helmet components of the finished helmet, including the finished shell, the pad suspension system, retention system, and hardware, shall exhibit no structural, visible, or operational degradation, or physical damage when subjected to altitudes from sea level to 15,000 feet equivalent pressure and 40,000 feet equivalent pressure. The test temperature at the 40,000 feet equivalent pressure should be approximately -60oF (±5oF)/-52oC (±3oC). The finished shell shall exhibit no cracking, delamination, separation of plies, distortion, softening, or other deterioration. If the helmet shell exhibits these visual defects, helmets shall be ballistically tested to determine if the helmet has been operationally degraded. The retention system shall be operable (webbing slides, retention system can be cinched down, etc.) and shall have no cracked or damaged components, or other deterioration. The suspension system (pads and hook disks) shall not have suffered any degradation or damage. Testing shall be in accordance with Paragraph 4.21.8.

The finished shell thickness will be measured before and after conditioning as Government Reference Only in accordance with Paragraph 4.5.