PC_Gen_III_DTL_SPEC_PreSolicitation_Draft_Nov2017.docx

DTL-17001A0029

DETAIL SPECIFICATION

SYSTEM SPECIFICATION

FOR

BODY ARMOR, PLATE CARRIER SYSTEM; GENERATION III

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

Prepared by:

Program Manager Infantry Weapon Systems Marine Corps Systems Command 2200 Lester St, Quantico, VA 22134

CONCURRED BY: _______________________________ DATE: ___________

APRROVED FOR USE AS DATE: ___________

PRODUCT BASELINE BY: __________________________________

Program Manager Infantry Combat Equipment

Dist. D: Distribution authorized to the Department of Defense and U.S. DoD contractors only for Administrative or Operational Use determined on 2 July 2014. Other requests for this document shall be referred to Marine Corps Systems Command, 2200 Lester Street, Quantico, VA 22134.

Comments, Suggestions, or questions on this document should be addressed to Armor Team Lead, Product Manager Infantry Combat Equipment, 2200 Lester St, Quantico, VA 22134 or emailed to PdMICE@usmc.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

DTL-17001A0029

16 Oct 2017

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1. SCOPE

1.1 Description. This specification covers the requirements for the Body Armor, Plate Carrier System, Generation III, consisting of a front and back outer carrier, front and back inner carrier, and front and back ballistic inserts; outer cummerbund assembly, side plate pockets and side ballistic inserts; inner cummerbund assembly; harness. The Plate Carrier (PC) Gen III system consists of a base vest and modular components for tailoring protection levels to defeat multiple ballistic hazards across the battlefield continuum and to manage armor weight. The PC Gen III system is a critical safety item for the warfighter. This specification delineates system, subsystem, component, and subcomponent level performance requirements to accomplish the end item body armor performance.

1.2 Classification. Plate Carrier System consists of six (6) main component subsystems; (1) Base Vest Assembly, (2) Inner Vest Assembly, (3) Outer Cummerbund Assembly, (4) Side Plate Pockets, (5) Inner Cummerbund Assembly, and (6) Harness. The PC Gen III System shall be used in conjunction with the Enhanced Small Arms Protective Inserts (E-SAPI), and Enhanced Side Ballistic Inserts (ESBI). The PC Gen III System will be available in the types as follows:

1.2.1 Classes.

Class 1: Coyote 498 Class 2: Tan 499 Class 3: Black 375

1.2.2 PC Gen III Components. Plate Carrier Gen III; consisting of the base vest assembly, inner vest assembly, outer cummerbund assembly, two side plate pockets, inner cummerbund assembly, and harness.

Outer Cummerbund Assembly 3 sizes; X-Small/Small, Medium, Large/X-Large

DTL-14007A0000

w/ Change 1 7 Oct 2015

AMSC N/A 3 FSC 8470

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.

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 applicable issue of these documents shall be the latest issue listed in the Acquisition Streamlining and Standardization Information System (ASSIST) database, or the issue cited in any solicitation (see paragraph 6.2).

COMMERCIAL ITEM DESCRIPTIONS

DEPARTMENT OF DEFENSE SPECIFICATIONS

DEPARTMENT OF DEFENSE STANDARDS

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094 or https:www.daps.dla.mil using Assist Quick Search.)

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 applicable issue shall be the issue cited in any solicitation (see paragraph 6.2).

PURCHASE DESCRIPTIONS

(Contact contracting activity for the copies of the Purchase Descriptions.)

DRAWINGS

Drawing Numbers:

*Note: The XSAPI drawings are identical to the ESAPI drawings.

TEST OPERATING PROCEDURES

ITOP 4-2-805 Projectile Velocity and Time of Flight Measurements TOP 10-2-210 Ballistic Testing of Hard Body Armor Using Clay Backing

GUIDES

U.S. Army Research Laboratory Security Classification Guide for Armor Materials and Technology

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

2.3 Non-Government publications. The following publications form a part of this document to the extent specified herein. Unless otherwise specified, the issue of the documents which are Department of Defense adopted shall be the latest issue listed in ASSIST, or the issue cited in any solicitation. Unless otherwise specified, the issue of documents not listed in the ASSIST shall be the issue cited in any solicitation.

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

(Applications for copies should be addressed to the American Association of Textile Chemists and Colorists, PO Box 12215, Research Triangle Park, NC 27709-2215 or www.aatcc.org)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

(Applications for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959 or www.astm.org)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/ASQ Z1.4-2003 - Sampling Procedures and Tables for Inspection by Attributes

(Copies of this document are available online at http://www.asq.org or from the American Society for Quality Control, P.O. Box 3005, Milwaukee, WI 53201-3005.)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 11092:1993 - Measurement of thermal and water-vapour resistance under steady- state conditions

(Applications for copies should be addressed to the American National Standards Institute, 25 West 43rd Street, 4th Fl., New York, New York, 10036, Tel: (212)642-4900, Fax: (212)398-0023, http://www.ansi.org)

SAE INTERNATIONAL

AMS-STD-595 - Colors Used in Government Procurement

(Applications to purchase chipsets, fan decks, or individual color chips should be addressed to SAE INTERNATIONAL, Logen Johnson, Aerospace Standards Engineer, 1200 G Street, NW, Suite 800, Washington, DC, 20005, Tel: (724)272-0495, www.sae.org)

2.4 Order of Precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document shall take precedence. Nothing in this document, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First Article. When specified, a sample shall be subject to the first article inspection in accordance with section 4.11.

3.2 Materials and Components. The materials and components shall conform to the applicable specifications, standards, and patterns specified herein.

3.2.1 Cloth Outer Shell. The cloth(s) utilized to fabricate the outer shell shall conform to MIL-DTL-32439, Type III, Class 3 when verified in accordance with paragraph 4.5. .

3.2.2 Cloth, Plate Pocket. The cloth utilized to fabricate the plate pocket shall conform to MIL-DTL-32439, Type IV, Class 2 when verified in accordance with paragraph 4.5. .

3.2.3 Cloth, Liner. The liner cloth shall be 70 Denier 1.9 oz. nylon ripstop. The yarns per inch shall be at a minimum of 97 in the fill direction and 105 in the warp direction. The nylon ripstop shall have a minimum spray rating of 100, 100,100 when tested in accordance with AATCC 22. The liner cloth shall be verified in accordance with paragraph 4.5. .

3.2.4 Cloth, Foam Pockets and Shoulder Covers. The foam pockets and shoulder cover material shall be a plain weave cloth with four way stretch in Coyote or other pattern as specified in a solicitation or contract, conforming to the physical requirements listed in Table I. Tweave 520E Durastretch or equivalent when verified as specified in section 4.5.

Table I: Four Way Stretch Cloth Characteristics

Weight, oz./sq.yd. Minimum Maximum

6.0 7.0

ASTM D 3776

Breaking Strength, pounds (minimum) Warp Filling

ASTM D 5034

Tearing Strength, pounds (minimum) Warp Filling

9.0 23.0

ASTM D 1424

Stretch, % Warp Filling

24-30% 23-29%

ASTM D 2594

Air permeability, cu.ft./min./sq.ft. (minimum)

23.0

ASTM D 737

3.2.5 Cloth, Ballistic Panel Cover. The ballistic panel cover shall be a lightweight water tight nylon ripstop that does not exceed 210 denier and shall be heat sealed around the ballistic filler with a minimum heat seal width of 0.20 inches. The ballistic cover shall be water resistant. The ballistic panel cover shall be verified in accordance with paragraph 4.5.

3.2.6 Outer Laminate Material. The outer shell fabric shall be laminated textured nylon duck conforming to MIL-DTL-32439 Type I Class 3 laminated with textured nylon duck conforming MIL-DTL-32439 Type III Class 3 or equivalent with properties conforming to those specified in Table II below when verified in accordance with paragraph 4.5.

Table II: Outer Laminate Material Requirements

Weight, oz./sq.yd. Minimum Maximum

20.0 24.0

ASTM D 3776

Breaking Strength, pounds (minimum) Warp Filling

ASTM D 5034

Tearing Strength (High Peak), pounds-force Minimum

ASTM D 5034

Water Repellency (minimum) Spray Rating Hydrostatic Resistance (min), cm

100, 100, 90

AATCC 22

AATCC 127

Flame Resistance (minimum) Melt/Drip, drops After –Flame, sec

One

ASTM D 6413 6/

3.2.7 Webbing and Tapes. Webbings and tapes shall be heat cut smooth with no burrs or residual melt. Webbings and tapes shall conform to the following requirements when verified in accordance with paragraph 4.5.

a) 1.0 inch Webbing; A-A-55301, Type III, width 1.0 inch ± 1/16. Alternate construction is not acceptable. Producer colored or piece/yard dyed, textured, filament nylon are acceptable: warp ends: 101 min; binder ends: 15 min; picks/inch: 72 min. Weight: 0.50 oz/yd min; break strength: 1000 lbs min; thickness: 0.039 inch min.

b) 1.5 inch Webbing; A-A-55301, Type VI, width 1.5 inch ± 1/16. Producer colored, textured yarns may be used: warp ends: 144 min; binder ends: 16 min; picks/inch: 80 min. Weight: 1.10 oz/yd min; break strength: 1500 lbs min; thickness: 0.046 + 0.007 inch min.

c) 2.0 inch Webbing; MIL-W-17337, Class 2, width 2.0 inch ± 1/8. Producer colored, textured, filament nylon: warp ends: 160 min, binder ends: 38 min; picks/inch: 72 min. Non-textured filament nylon: warp ends: 193 min; binder ends: 46 min. picks/inch: 72 min. Weight: 1.15 0z/yd min; break strength: 1950 lbs min; thickness: 0.039 inch min.

d) 1.0 inch Tape; MIL-PRF-5038, Type III, Class 2, width 1.0 inch ±1/32. Producer colored, textured, filament nylon (210 denier warp/420 denier fill): weight 0.30 oz./ln-yd min; break strength: 525 lbs min; thickness: 0.015-0.025 inch min.

3.2.8 Webbing, Elastic. Elastic webbing shall be heat cut smooth with no burrs or residual melt. Elastic webbing shall conform to the following requirements when verified in accordance with paragraph 4.5.

a) 4 inch; width – 4 inch ± 0.060, construction – knitted, warp – textured polyester 150/1, filler – textured polyester 750d total, rubber – natural or equivalent, rubber strands – 60, thickness – 0.040-0.045, picks per inch – 50 ± 4, stretch – 110% ± 15%.

3.2.9 Fasteners, Hook and Loop. Hook and loop fasteners located in the shoulders, drag handle, and name tape of the outer base shell shall conform to A-A-55126, Type II, Class 1 in 2.0”and 4.0” widths when verified in accordance with paragraph 4.5.

3.2.10 Fasteners, Hook and Loop Low Profile. Hook and loop fasteners shall be a laser cut or cold cut profile knit sheet loop. The combined extruded hook and knit loop shall have a peel strength of not less than 0.20 lbs./in2 width and a shear strength of not less than 13.0 lbs./in2, the loop tape shall be 100% nylon, warp knit, fabric construction without selvage. The loops shall be suitably napped to form a uniformly disoriented surface of uncut loops capable of being engaged by the hooks of the hook fastener tape. The height of the loop should maintain a minimum of 0.065 inch with a minimum weight of 7.5 ounces per square yards in 1, 1 ½, 2, and 4 inch widths (Velcro® Brand Loop 3610 or equivalent). The extruded hook fastener tape shall have fully formed hooks that are a minimum of 0.035 inch with alternating rows and containing a minimum of 375 hooks per square inch in 1, 1 ½, 2, and 4 inch widths (Velcro® Brand Hook HTH 745 or equivalent). The hook and loop low profile shall be verified in accordance with paragraph 4.5. Color: Coyote 495.

3.2.11 Foam. The foam located in the shoulders shall .be ¼” and the foam located in the lower lumbar pad and upper chest shall be 3/8”. The foam used shall be a closed cell foam with 18% vinyl acetate composition conforming to the requirements listed in Table III below. .Evazote EV50 3.1# Ethylene Vinyl Acetate Copolymer Foam or equivalent when verified in accordance paragraph 4.5.

Table III: Foam Properties

(minimum)

Test Method

3.2.12 Stiffener. The cummerbund stiffener material shall be an 8 ply laser-cut, flame resistance Polypropylene laminate stiffener comprised of multiple layers of self-reinforcing polypropylene plain woven composite or equivalent (Milliken Tegris FR Coyote). The front chest panel stiffener shall be a 6 ply laser cut Polypropylene laminate stiffener comprised of multiple layers of self-reinforcing polypropylene plain woven composite (Milliken Tegris P4500s). The stiffeners shall conform to Table IV below when verified in accordance with paragraph 4.5.

Table IV: Stiffener Characteristics

3.2.13 Non-Ballistic Thread. Thread, Nylon, Bonded, Size E 0r Size F, A-A-59826, Type II, Class A, as required when verified in accordance with paragraph 4.5. .

3.2.14 Ballistic Thread. Aramid, spun staple, Size Tex 50-60 , AA-55217, Type I as required per patterns for use in stitching and tacking of multiple plies of ballistic filler. The ballistic thread shall be verified in accordance with paragraph 4.5.

3.2.15 Male Buckle. The 1.0-inch side release buckle shall be National Molding P/N Heavy Duty Mojave Buckle 8781 or YKK-USA I/C 0098609, or equivalent when verified in accordance with paragraph 4.5.

3.2.16 Female Buckle. The 1.0-inch female side release buckle shall be ITW P/N GTSR 810-1057 or National Molding P/N Heavy Duty Mojave Buckle 8762 or YKK-USA I/C 098610, or equivalent when verified in accordance with paragraph 4.5.

3.2.17 Male Repairable Buckle. The 1.0-inch male side release repairable buckles shall be National Molding P/N Quik Attach Mojave 9393 or equivalent when verified in accordance with paragraph 4.5.

3.2.18 Female Repairable Buckle. The 1.0-inch side release female repairable buckle shall be National Molding P/N Quik Attach Mojave 8478 or equivalent when verified in accordance with paragraph 4.5.

3.2.19 Tension Lock. Trovato Ladderloc TLL150, acetal, ITW P/N 154-0150, or equivalent when verified in accordance with paragraph 4.5.

3.2.20 Loop. 1.5” steel or brass, welded, ITW P/N 01041-20-21887 or equivalent when verified in accordance with paragraph 4.5.

3.2.21 Slider. 1” steel slider, ITW P/N 08090-22-21883 or equivalent when verified in accordance with paragraph 4.5.

3.2.22 Male Quick Release Fastener. The quick release fastener shall be First Spear Tubes 4” Male Split Bar P/N HW-T009-04.000-005 or equivalent when verified in accordance with paragraph 4.5. Equivalent buckles shall demonstrate conformance to the minimum requirements in Table V below:

Table V: Quick Release Fastener Requirements

Must be functional and not have any performance degradation with exposure to sand or salt water.

3.2.23 Female Quick Release Fastener. The quick release fastener shall be First Spear Tubes 4” Female Split-Bar P/N HW-T010-04.000-005 or equivalent when verified in accordance with paragraph 4.5. . Equivalent buckles shall demonstrate conformance to the minimum requirements in Table V above.

3.2.24 Slide Fastener. Slide fasteners shall be A-A-55634, Type I, Style 3, non-locking, single slider on YKK 7.5 Extruded Element Chain or equivalent when verified in accordance with paragraph 4.5.

3.3 Design. The PC Gen III system is a modular vest protecting the upper torso from multiple ballistic threats which is easily configured to defeat predicted mission threat while minimizing system weight. The PC Gen III system consists of: (1) One outer base vest assembly consisting of an outer shell front and back base vest carrier, a front load bearing panel, a back cummerbund adapter panel, and one set of shoulder straps; (2) One inner vest assembly made up of a front and back outer shell soft armor carrier with removable front and back ballistic inserts; (3) One outer cummerbund assembly consisting of two interchangeable left and right sides and two interchangeable tube adapters; (4) Two side plate pockets; (5) One inner cummerbund consisting of two inner interchangeable left and right sides; (6) One harness. Components are attached to or inserted into the PC Gen III outer base vest. The PC Gen III system provides protection from conventional fragmenting munitions and multiple hits from various hand gun threats. The E-SAPI/XSAPI subsystem consists of a set of interchangeable, sized, and contoured plates inserted into front and back pockets inside either the PC Gen III outer base vest or inner base vest to provide vital organ protection against multi-hits of small arms rifle bullets and indirect fire flechettes. The ESBI subsystem consists of a set of interchangeable, contoured plates inserted into the side plate pockets worn inside the left and right outer cummerbund. The PC Gen III outer base vest is compatible with the Improved Modular Tactical Vest (IMTV) yoke and collar component. Laser cut PALS on the front of the outer and inner PC Gen III carrier shells and PALS webbing on the rear outer carrier shell accommodate limited load carrying capabilities.

3.3.1 Patterns. The Government will furnish patterns for the baseline design from which the contractor can use applicable parts to create working cutting patterns. The Government patterns shall not be altered in any way and the working patterns shall be cut to conform exactly to the Government patterns. Compliance with patterns is required to meet interface requirements with fielded individual combat equipment. The contractor is responsible for ensuring that all finished components are constructed in accordance with dimensions of the cut parts provided in the Government patterns. In the event of a conflict between the Performance Specification and the Government patterns, the patterns supersede the Performance Specification. The working patterns shall include size, directional lines, placement marks, notches, and authorized seam allowances. Baseline patterns require a 3/8 inch seam allowance ± 1/16 inch unless otherwise stated on patterns. Except for the ballistic panels, all the components of the vest shall be cut with a tolerance of ±1/16 inch in accordance with the pattern parts indicated except where changes or enhancement(s) to baseline are proposed. The ballistic panels shall be cut with a tolerance of -1/16/ +1/8 inch to ensure maximum coverage and seamless integration between the components Drill holes are not permitted. Conformance to patterns shall be verified in accordance with paragraph 4.6.

3.3.1.2 Cloth, Plate Pocket (MIL-DTL-32439, Type III, Class 3)

3.3.1.3 Cloth, Liner

3.3.1.4 Cloth, Foam Pockets and Shoulder Covers

3.3.1.5 Cloth, Ballistic Panel Cover

3.3.1.6 Outer Laminate

3.3.1.7 Ballistic Panel

3.3.1.8 Webbing, 1 inch (A-A-55301, Type III)

3.3.1.9 Webbing, 1.5 inch (A-A-55301, Type IV)

3.3.1.10 Webbing, 2 inch (MIL-W-17337, Class 2)

3.3.1.11 Tape, 1 inch (MIL-PRF-5038, Type III, Class 2)

3.3.1.12 Webbing, Elastic

3.3.1.13 Stiffener

3.3.1.14 Foam Padding

3.3.1.15 Fasteners, Hook and Loop

3.3.1.16 Fasteners, Hook and Loop Low Profile

3.3.2 PC Gen III Subsystem. The maximum finished weight of the PC Gen III subsystem system for each size is outlined in Table VI when measured as specified in 4.6.3. The minimum area of ballistic coverage for each ballistic panel subcomponent in each size is outlined in Table VII when tested as specified in 4.6.4. Finished base measurements for each component and size are outlined in Table VIII-A through VIII-G when measured as specified in 4.6.1.1. Comment by Jordan CIV Flora M: Weights and finished measurements to be added. Information is in patterns with the exception of weight.

Table VI: PC Gen III Subsystem Maximum Weights (lbs)

Short

Base Vest Assembly: Outer Base Assembly, Inner Base Assembly w/ soft armor inserts, Outer Cummerbund Assembly

Total Weight

Table VII: Minimum Ballistic Panel Area (in2)

Short

Front Panel

Back Panel

(6x6) (6x6)

(6x8) (6x8) (6x8) (6x8) (6x8)

Table VIII-A: Outer Base Vest Finished Measurements (inch)

± ½ Front Width ± ½ Center Back Length ± ½ Back Width ± ½

X-Small Short

X-Small

Small Short

Small

Small Long

Medium

Large

X-Large

TABLE VIII-B: Inner Base Vest Finished Measurements (inch)

± ½ Front Width ± ½ Center Back Length ± ½ Back Width

X-Small Short

X-Small

Small Short

Small

Small Long

Medium

Large

X-Large

Table VIII-C: Soft Armor Finished Measurements (inch)

-0 / + 1/8 Edge Length -0 / + 1/8 Width 1 -0 / + 1/8 Width 2 -0 / + 1/8 Width 3 -0 / + 1/8

X-Small Short

X-Small

Small Short

Small

Small Long

Medium

Large

X-Large

Table VIII-D: Outer Cummerbund Finished Measurements (inch)

± ½ Center Width ± ½ Velcro Panel Length ± ½ Velcro Panel Width

XS-SM

MED

LRG-XLRG

Table VIII-E: Inner Cummerbund Finished Measurements (inch)

± ½ Elastic Length ± ½ Velcro Length

XS-SM

MED

LRG/XLRG

Table VIII-F: Side Plate Pocket Finished Measurements (inch)

± ½ Center Width ± ½

TABLE VIII-G: Bartack

All Cloth

PALS;

Webbing + Cloth

3.4 PC Gen III System Construction. See paragraph 3.3 for PC system configuration. All stitching shall be back-tacked to prevent raveling and demonstrate good stitching quality with no loose ends, consistent stitches per inch, even tension with no loose needle or bobbin thread. Fabric edges shall not ravel. PC Gen III system construction shall be verified in accordance with paragraph 4.7.

3.4.1 Hook and Loop Fastener. Hook and loop fasteners shall not be stitched in the selvage edge to prevent associated fraying durability problems in repeated use (see paragraph 4.5). If Class 4 is used, the hook and loop fasteners shall be stitched 1/8 inch from the edge.

3.4.2 Seams and Stitching. Stitching shall conform to ASTM D-6193, 9-10 stitches per inch. End of seams and stitches (stitch type 301) that are not caught in other seams or stitching shall be securely back tacked or back stitched. Thread breaks or bobbin run-outs occurring during sewing shall be secured by stitching back of the break minimum of 1/2 inch. Thread tension shall be maintained so that there will be no loose stitching resulting in loose bobbin or top thread, or excessively high stitching resulting in puckering of the materials sewn. Thread ends shall be trimmed to a length of not more than 1/4 inch.

3.4.2.1 Seam Types. All seams shall minimize bulk to the maximum extent possible. Seams in the shoulders of the front inner vest assembly panel shall be an overlap or flap seam to minimize bulk and reduce pressure points. An example of the seam type is provided in Appendix C. Comment by Jordan CIV Flora M: Picture or Diagram of stitch type will be included in Appendix C

3.4.3 Automatic Stitching. Automatic stitching machines may be used to perform any of the stitching patterns provided the requirements for the stitch pattern, stitches per inch, size and type of thread are met, and at least three or more tying, overlapping, or back stitches are used to secure the ends of the stitching.

3.4.4 Bartacks. No stitch run-off is allowed and no needle cutting by bartack. Double bartacks (one on top of the other) shall be avoided to prevent needle cutting and weakening of the attachment point.

3.4.5 Bartack/Laser Cut Slit Alignment for Pouch Attachment Ladder System (PALS). The required spacing of vertical bartacks/laser cut slits which is needed for physical compatibility of PALS components on the PC Gen III system is specified below. OLLE attachment points shall be tested according to paragraph.

a) The distance between vertical bartacks on horizontal webbing shall be 1 1/2 inch -0 / +1/16.

b) The distance between non-consecutive horizontal webbing shall be 1 1/8 inch ±1/16.

c) Vertical bartacks on consecutive horizontal webbing rows shall be vertical aligned with an offset of 3/4 inch -0 / +1/16 bottom to top in a vertical straight line.

3.4.6 Buttonholes. Buttonholes shall be straight cut. Position in accordance with the marks indicated on the pattern, with the ends of the buttonholes securely tacked. Size as indicated on patterns.

3.4.7 Binding. All ends of binding not completely encased are to be seared.

3.4.8 Component and Hardware Locations. Components and hardware locations indicated on the patterns shall be within the specified locations within ±1/4 inch unless otherwise specified.

3.4.9 Component and Hardware Attachment. Components and hardware shall be attached as specified (e.g. correct webbing attachment mechanism, correct stitching method, etc.).

3.4.10 Reinforcement Stitching. Reinforcement stitching such as box and box-x stitching as indicated on the patterns shall be placed at the specified locations within ±1/8 inch.

3.5 PC System Operational Performance Requirements. The following requirements apply to all components and subcomponents of the multiple threat body armor system in any of its potential configurations in accordance with paragraph 3.3.

3.5.1 Functional Integration. All components within a size shall be fully interchangeable with every other system of the same size (i.e. back ballistic panel will fit into any PC Gen III inner shell back of same size and inner shell back shall fit into the outer shell back of the same size) with no fabric rolls, lumps, or excessive force. Any configuration of PC Gen III system in accordance with paragraph 3.3 shall be functionally integrated with any configuration of PALS components. Functional integration shall be verified in accordance with paragraph 4.8.1.

3.5.2 Fungus Resistance. All components and parts of the body armor, including interior components, shall be resistant to fungal growth. The visual effects shall be less than 2 when using the Evaluation Scheme for Visible Effects from MIL-STD-810 when tested as specified in paragraph 4.8.2. All components shall show only trace or no susceptibility to fungal growth nor experience damage due to the presence of fungus spores or adjacent fungus growth.

3.5.3 Shade. Table IX outlines the shades for applicable components. . All shades shall be used from standard SAE AMS-595. Shade shall be verified in accordance with paragraph 4.8.3.

Table IX: Shade

Outer Vest Assembly Inner Vest Assembly Outer Cummerbund Assembly Inner Cummerbund Assembly Harness Coyote 498 Coyote 498 Coyote 498 Coyote 498 Coyote 498 Black 375 Black 375 Black 375 Black 375 Black 375

Webbing Binding Tape Hook & Loop Fastener Thread Elastic Webbing Labels Coyote 498 Coyote 498 Coyote 498 or Tan 499 Coyote 498 Coyote 498 or Tan 499 Coyote 498 Black 375 Black 375 Black 375 Black 375 Black 375 Black 375

Hardware Buckles Coyote 498 Coyote 498 Black 375 Black 375

3.5.4 Infrared Reflectance. All exterior components, parts, and hardware of the system shall conform to Tables X, XI and XII as applicable unless otherwise specified. The requirement must be met for initial and after laundering when tested as specified in paragraph 4.8.4.

Table X: Infrared Reflectance Requirements Class 1(Coyote 498) and Class 2 (Tan 499)

WAVELENGTH

(nm)

REFLECTANCE (%)

Table XI: Infrared Spectral Reflectance Requirements for Acetal Hardware for Class 1 (Coyote 498) and Class 2 (Tan 499)

WAVELENGTH

(nm)

REFLECTANCE (%)

REFLECTANCE (%)

Table XIII: Infrared Spectral Reflectance Requirements Class 3 (Black 375)

WAVELENGTH

(nm)

REFLECTANCE (%)

3.5.5 Matching. The cloths shall match the color and appearance of the standard sample when as specified in paragraph 4.8.5.

3.5.6 Drag Strap. The drag strap on the back of the outer rear vest (all sizes) and the vertical drag straps on the back of the inner rear vest shall have a peak strength not less than 400 lbf (increased strength is desirable) when tested in accordance with paragraph 4.8.6.

3.5.7 Buckle. The male buckles shall have a peak strength not less than 225 lbf (increased strength is desirable) when tested in accordance with paragraph 4.8.7 The female split bar buckle shall have a peak strength not less than 100 lbf (increased strength is desirable) when tested in accordance with paragraph 4.8.7.

3.5.8 Quick Release Mechanism. A quick release mechanism shall be provided and be capable of being configured to user preference and allow operation with either hand, with or without gloves on. Upon activation of the mechanism, the system shall be capable of being doffed in 5 seconds or less and reassembled in 30 seconds or less when tested as specified with paragraph 4.8.8

3.5.9 Torso Adjustment. Torso adjustment shall provide the wearer a means to easily secure the vest to the torso. The external adjustment located in front of the wearer, shall be a hard connection point that provides micro adjustment through a hook and loop interface. The external adjustment, located behind the wearer, shall provide macro adjustment capability and utilize hook and loop. The left and right shoulder straps shall utilize friction adjustment and buckle closures. Torso adjustment shall be verified in accordance with paragraph 4.8.9.

3.5.10 E-SAPI/ESBI Integration. The PC Gen III system shall be capable of accepting E-SAPI, XSAPI, 6x6 ESBI, and 6x8 ESBI plate inserts when tested as specified in paragraph 4.8.10 and 4.8.11.

3.6 PC Ballistic System Requirements. The ballistic package shall conform to the specified patterns and tolerances (see Paragraph 3.3.1) and the following operational requirements.

3.6.1 Removable Ballistic Panels. Ballistic panels must be able to be inserted into the PC Gen III inner shell front and back carriers, side plate pockets, and/or cummerbunds. The gap/ease between inner shell carrier and panel shall be no greater than the ease allowed within the baseline patterns when verified in accordance with paragraph 4.9.1.

3.6.2 Areal Density. The maximum ballistic filler areal density shall not exceed 0.88 lb/ft2 when tested as specified in paragraph 4.9.2. Except for ancillary components such as thread, the ballistic filler shall be made entirely of ballistic material. The ballistic filler shall be a uniform areal density.

3.6.3 Thickness. The thickness of the ballistic filler shall not exceed 0.27 inch thickness when tested as specified in paragraph 4.9.3.

3.6.4 Flexibility. The ballistic panels must be flexible enough to be inserted into the soft armor pocket opening within the inner vest and the side plate pockets. Once inserted into the pockets, the panels must be capable of laying smooth with no rigid peaks or crumbled corners when verified in accordance with paragraph 4.9.4.

3.7 Ballistic Performance Requirements. The PC ballistic system shall accomplish the ballistic characteristics specified in paragraphs 3.7.1 and 3.7.2 when tested in accordance with paragraph 4.10. The PC system protection levels are as follows

a) The PC system provides fragmentation protection from conventional fragmenting munitions (see paragraph 3.7.1)

b) The PC system provides multi-hit handgun bullet protection for 9mm, 124 grain (gr.), .357-Sig, 125 grain, and the .357-MAag, 158 grain. (see paragraph 3.7.2)

c) The PC system used in conjunction with E-SAPI or X-SAPI and ESBI or XSBI provide multi-hit small arms projectile protection from:

1) Threat Code A

2) Threat Code B

3) Threat Code C and C1

4) Threat Code D

5) Threat Code E

6) Threat Code F

7) Threat Code X

3.7.1 Fragmentation Protection. The ballistic material system shall provide consistent ballistic performance. Table XIII-A through XIII-E list the required minimum V50 values for the ballistic systems at the specified obliquity when tested with the Fragment Simulating Projectile (FSP) (MIL-DTL-46593) and Right Circular Cylinder (RCC) for the dry, wet, extreme temperature, accelerated aging, and Petroleum, Oils, and Lubricants (POLS) conditions.

Table XIIII-A: 2-grain RCC V50 Testing

(degree) V50 Requirement (ft./sec.)

2-gr. RCC

Table XIII-B: 4-grain RCC V50 Testing

(degree) V50 Requirement (ft./sec.)

4-gr. RCC

Table XIII-C: 16-grain RCC V50 Testing

(degree) V50 Requirement (ft./sec.)

16-gr. RCC

Table XIII-D: 64-grain RCC V50 Testing

(degree) V50 Requirement (ft./sec.)

64-gr. RCC

Table XIII-E: 17-grain FSP V50 Testing

(degree) V50 Requirement (ft./sec.)

17-gr. FSP

Any product improvements in the ballistic performance of the PC Gen III soft armor panels shall not reduce the ballistic performance of the PC Gen III system small arms protection of base vest and E-SAPI subsystem when tested as specified in E-SAPI subsystem performance requirements as specified in the E-SAPI purchase descriptions (see paragraph 2.2.2).

3.7.2 Handgun Protection. The ballistic material system shall be engineered to provide handgun protection. Table XIV-A through XIV-C outlines the ballistic material system minimum dry V50, and V0 acceptance for the 9-mm, 124-gr., Full Metal Jacketed (FMJ) Remington, the .357-Sig., 125-gr. Full Metal Jacketed Flat Nose (FMJFN), and the .357-Mag., 158-gr. Jacketed Soft Point (JSP) against 3 hits at 0 degree obliquity and 2 hits at 30 degree obliquity, with the maximum backface deformation requirement of 44.0 mm when tested and measured in accordance with section 4.10..

Table XIV-A: 9-mm Handgun V50 Testing

(degree) V50 Requirement (ft./sec.)

9-mm, 124-gr. FMJ Remmington

Table XIV-B: .357-Sig. and .357-Mag. V50 Testing

(degree) V50 Requirement (ft./sec.)

.357-Sig., 125-gr. FMJFN

Table XIV-C: Handgun V0 Testing

.357-Sig., 125-gr. FMJFN

3.8 Support or Ownership Requirements. The PC Gen III system shall meet the following support of ownership requirements.

3.8.1 Service Life and Reliability. The finished PC Gen III shall have a service life of 365 days of continuous use in all military field environments with no operational mission failures if not impacted by ballistic projectiles.

3.8.2 Health and Safety. The PC shall be safe to use and not contain any harmful materials. Additionally, the PC will be non-hazardous (non-explosive and have no toxicological or electromagnetic radiation effects) to the individual wearing the PC or troops in the surrounding area. Health and safety shall be verified in accordance with paragraph 4.13.1.

3.8.3 Toxicity. Any finishes on the PC shall not present a dermal health hazard when used as intended. Toxicity shall be verified in accordance with paragraph 4.13.2.

3.8.4 Hazardous Materials. Hazardous materials that can be exposed to personnel or the environment during any operational (to include fabrication, transportation, and setup/tear down) or maintenance procedures, or exposed as a result of damage to equipment, or requiring special disposal procedures, shall be eliminated, consistent with operational requirements. Environmentally acceptable substitutes shall be used without degrading operational function and maintaining cost effectiveness. Hazardous material exposed to personnel shall be controlled to levels below the OSHA Permissible Exposure Limits. The PC shall not present any uncontrolled health hazard throughout the life-cycle of the item. The following shall be included when designing the PC.

a) Avoid use of materials that cause skin irritation or allergies.

b) Utilize materials that are resistant to fungus and bacterial growth.

c) Allow for easy cleaning and/or replacement of parts that could present health hazards to the wearer.

3.8.5 Traceability. The contractor shall maintain traceability records for all ballistic component parts used to manufacture the end item product. When components are purchased as end item to the PC, all component parts Lot Identification shall be traceable via each PC’s serial number and contract number. When purchased separately all component parts Lot Identification shall be traceable via the component part Lot Number. Subcontractor’s Component part Lot information shall enable Traceability to the raw materials used in the Component part. A PC lot can be made from multiple lots of ballistic material, where a lot of ballistic materials is defined as an individual roll of ballistic material. However, in the case where any additional ballistic material is left over from the production run of a PC lot, that material may only be used in the next consecutive PC lot. The contractor shall provide a technical description of the design package which shall include but not limited to build-sheet: design orientation, number of layers, and material identification and type by layer. Records shall be maintained and readily available for Government inspection and audit. For End Item Products identified with individual Serial Numbers, the Traceability requirements listed above shall be traceable via the individual serial number and contract number.

3.8.6 Use and Care Instruction. An instruction pamphlet will be furnished with each delivered PC system. The instruction pamphlet will be printed on a durable, synthetic paper capable of continued use under harsh field conditions.

3.8.7 Size, Identification, and Instruction Label. Labels will be readable under low light conditions; moonlight and red or blue filtered flashlight. All labels shall be applied so that text faces the body when worn. The label shall be of sufficient strength to withstand repeated abrasion during field use and cleaning. Label examples are provided in Appendix D. The labels shall comply with the following: Comment by Jordan CIV Flora M: Labels in Appendix D still require updating with correct nomenclature however the format is correct.

a) The PC Gen III base vest non-ballistic components; base vest outer shell, base vest inner shells, outer cummerbund, and inner cummerbund, shall have labels that include the following information: size and associated measurement (See Table IV below), identification, National Stock Number (NSN), Contract Number, Commercial and Government Entity (CAGE) Code, Date of Production, Lot Number, and instruction label for the entire PC system. Size information is provided in Table XV and XVI below.

b) The PC ballistic components shall have labels that include the following information: size, identification, Serial Number, Lot Number, National Stock Number (NSN), Contract Number, CAGE Code, Date of Production, Part Number, and instruction label for the entire ballistic components.

c) The modular components, side plate pockets, chest panel, back cummerbund adapter, and harness, shall have a label sized and located at the contractor’s discretion. At a minimum, the label shall have the following information: identification, size, NSN, Contract Number, and Cage Code. Bulk Buckles, metal loops and other similar items not practically labeled shall have the appropriate label applied to the unit packaging.

d) The instruction labels shall include do’s and don’ts for use, cleaning instructions, and donning/doffing instructions for the entire PC system.

e) The instruction labels shall be located on the inner side of the vest or ballistic component. The size of the label shall be 4.5 inches wide by 7.75 inches high. The type shall be no smaller than 10 point and shall be in accordance with MIL-DTL-32075, Type VI, Class14.

Table XIV: Sizing and Chest Circumference Measurement for Base Vest Label

(inch)

Table XVI: Sizing and Waist Circumference for Outer and Inner Cummerbund Label

(inch)

3.8.8 Unique Identification Label. PC ballistic components will require a unique identification label. The manufacturer is required to comply with current versions of MIL-STD-130 and the following criteria: In addition to the man readable information listed, a machine readable label with the same information listed above shall be included as provide in either Example A or Example B provided in Appendix E.

a) The label shall include Human Readable Information (HRI) as well as Machine Readable Information (MRI).

b) The HRI shall consist of: CAGE Code, Lot Number, Serial Number, Date of Production, NSN, Part Number, Contract Number and size. HRI will meet the requirements of the latest version of MIL-STD-130.

c) The MRI shall consist of one ECC 200 compliant Data Matrix code containing: CAGE Code, Lot Number, Serial Number, Date of Production, NSN, and Part Number. The tag/label shall comply with the latest version of MIL-STD-130, ANSI MH10.8.2, and Items d and e below. To prevent automated read errors, the Government will not allow other 1D or 2D codes to be printed on this label. This does not restrict the contractor from using other HRI and MRI on labels not associated with the UID label/tag.

d) Data Matrix Construct: The Data Matrix shall be encoded per MIL-STD-130 using only the data identifiers (DI) and criteria shown below. The following DI sequence shall be maintained in the order listed below:

Cage=17V followed by cage code Lot=1T followed by lot number Serial number = S followed by the serial number Date of production = 16D followed by the production date, YYYYMMDD National stock number = N followed by NSN Part number = 1P followed by part number

e) Construct Example:

[)>RS06GS17V52969GS1TE034GSS328185GS16D20080215GSN8470-01-520-7370GS1PABC-123RSEOT

f) Data Matrix Geometry: Data Matrix codes shall be a square ECC200 matrix per ISO 16022. Individual Cell size (element size) of the code shall be between 0.020 and 0.23 inches. A quiet zone of 0.5 inches of Black label/tag material is required around the Data Matrix code.

g) Verification: Data Matrix code quality will be graded to ISO 15415 with a certified verifier and meet a minimum passing grade per the latest release of MIL-STD-130. AS9132 and AIM DPM grading platforms will not be allowed for this project. Contractor must provide the contracting officer with at least two verification reports per ballistic panel for each FAT and LAT. If using laminates or overcoats the label must be verified after placing the laminate of overcoat on the label or tag. No exceptions are allowed. Proof of Verification is subject to inspection at the time of shipment.

h) Validation: Validation checks of the UID must be performed on a routine basis. Contractor is responsible for encoding the UID per above guideline (d and e) and the latest revision of MIL-STD-130. Proof of Validation is subject to inspection at the time of shipment.

3.8.9 Responsibility for Compliance.