02_Att_1-_11m_Mk4_Specification_20Oct16_REV_A.docx

UNITED STATES NAVY

11 METER RIGID INFLATABLE BOAT MK4

for FLEET FORCES COMMAND

SPECIFICATION

REV. A

20 October 2016 11m RIB Mk4 Specification 20 October 2016

REVISION HISTORY

-Section 100-2: Added SAN to allowable core materials -Section 303: Deleted AC breaker section, changed DC breaker to be applicable to AC breakers A

TABLE OF CONTENTS

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background The 11 meter Rigid Inflatable Boat (11m RIB) is a multi-purpose platform with several distinct missions. The terrorist attacks on the USS COLE (12 October 2000) and on multiple United States (U.S.) homeland targets (11 September 2001) added multiple missions to the traditional functions of a U.S. Navy boat. The current missions for the 11m RIB include:

· Anti-terrorism/Force Protection (AT/FP)

· Maritime Interdiction Operations (MIO)

· Visit, Board, Search and Seizure (VBSS)

· Safety Boat / Escort

· Tow and Recovery Boat

· Personnel and Cargo Transfer The ability to be carried aboard and deployed from a variety of U.S. Navy ship classes is a critical operational requirement for U.S. Navy 11m RIBs. For the boats to be deployable from multiple ship classes, each boat must be compatible with a variety of existing shipboard handling and stowage systems including traditional davits and stowage chocks, and a variety of ship class specific launch, recovery, and handling systems.

A variant of the 11m RIB configured with a lifting frame and Cranston Eagle hook for interface to the Positive Control Derrick Head (PCDH) on a knuckle-boom crane and Caley davit docking head is used onboard the LPD-17 Class ships.

A variant of the 11m RIB referred to herein as the Enhanced VBSS (EVBSS) variant incorporates increased AT/FP, MIO, and VBSS capabilities. This variant uses the 11m RIB LPD-17 configuration as a baseline with increased engine horsepower to meet higher cruise and sprint speed requirements.

The 11m RIB platform entered service with the U.S. Navy in the early 2000s. Since then sequential Mk numbers designate major changes to the 11m RIB configuration. This Specification refers to the 4th version of this boat, the 11m RIB Mk4.

040-2 Variants This Specification describes three (3) variants of the 11m RIB Mk4: the base Open Center Console (OCC) variant, the LPD-17 variant, and the EVBSS variant.

Specification section headers and Contract Drawing titles indicate where features are unique to only a specific variant. The below table summarizes the differences between the variants throughout this Specification. Commonality shall be maintained for all major components such as engines, trailers, hoisting slings, and tie down straps on all variants. Commonality shall be maintained in other respects as much as practicable.

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General Requirements This Specification describes the general requirements of the 11m RIB Mk4 (also referred to herein as “the boat”) and describes the essential features, functions, and arrangements but not necessarily the details of the design. Together with the Contract Drawings, it defines the boat as to dimensions, structure, arrangement, performance, and power.

With respect to components, this Specification in conjunction with the Contract Drawings indicates the quantity of each major component required, together with such data as size, capacity, rating or power, and applicable specifications and standards or other technical requirements, which will enable the Contractor to procure or build the component.

With respect to systems, this Specification, in conjunction with the Contract Drawings, defines the characteristics of each system to be provided. It contains additional data such as capacity of the systems under various conditions and the flexibility and segregation requirements, which will enable the Contractor to prepare construction drawings and build the systems.

With respect to materials of construction and items of machinery, equipment, and outfit, which by their nature may be manufactured or procured as distinct items; this Specification contains only the requirements and information that pertain to selection, installation, onboard performance, onboard inspection and tests, pre-installation handling, inspection and tests by the Contractor. Requirements such as physical or chemical properties, manufacturer test and inspection requirements, or other requirements applicable only to manufacturers, are contained in specifications or standards, drawings, or in other documents referenced herein.

Where manufacturer's type, model, or other commercial designation is referred to herein, the characteristics in effect on the date of this Specification shall apply. Where model numbers or other commercial designations have been superseded since the date of this Specification, new model numbers or designations may be utilized provided the equipment characteristics associated with the new designation are equal to those associated with the superseded designation.

The Contractor is responsible for carefully and critically reviewing the Contract Drawings and this Specification prior to commencing the engineering design effort. If the Contractor finds any error, omission, discrepancy, or lack of clarity, he shall notify the Government’s Contracting Officer, in writing, not less than fifteen (15) days before commencing any work affected thereby, and request approval of the Contractor's resolution of the problem.

042-2 Definitions The Government is the United States Government.

NAVSEA is the Headquarters of the Naval Sea Systems Command.

NSWCCD is the Naval Surface Warfare Center Carderock Division.

A Contractor is a firm holding a prime contract with the Government for design and/or construction of a boat.

A Contract Drawing is a Government Furnished Drawing forming part of the Specification, which illustrates features of the boat that are mandatory requirements.

042-3 Contract Drawings The following Contract Drawings form a part of this Specification. Hereinafter, wherever a reference is made to "the drawings" without further identification, it shall be understood to apply to the following listed Contract Drawings.

CONTRACT DRAWINGS

In the development of construction drawings or construction of the boat by the Contractor, no departure from Contract Drawings is permitted unless such departure is specifically approved by the Government. The Contractor shall be responsible for developing all additional details necessary for the construction of the boat and correcting any and all interferences that may arise during development of construction drawings or construction of the boat (see Section 085). Quantities given on Contract Drawings are for estimating purposes only; the Contractor is required to ascertain the exact quantities required. Reference dimensions are approximate and the Contractor is required to verify those dimensions by the use of lofting techniques, templates, etc.

A piping diagram is a Contract Drawing used to depict features, routing, functional relationships, relative locations, and nominal arrangements of the major components forming a fluid system without regard to actual physical size, shape or precise location of components.

A schematic or wiring diagram is a Contract Drawing used to depict features, routing, functional relationships, relative locations, and nominal arrangements of the major components forming an electrical system without regard to actual physical size, shape or precise location of components.

042-4 Referenced Documents The following standards and specifications are referenced in this Specification. Where reference is made to a voluntary compliance or best practice standard, the recommended standards and practices shall be considered mandatory under this Contract.

· 49 CFR Part 393, Parts and Accessories Necessary for Safe Operation

· 49 CFR Part 571, Federal Motor Vehicles Safety Standards

· ABYC, Standards and Technical Information Reports for Small Craft, July 2014-2015

· ANSI/ASME B46.1, Surface Texture (Surface Roughness, Waviness, and Lay), 2009

· ASME Y14.100, Engineering Drawing Packages, 2013

· ASTM B33, Standard Specification for Tin-Coated Soft or Annealed Copper Wire for Electrical Purposes, 2014

· ASTM B928, Standard Specification for High Magnesium Aluminum-Alloy Sheet and Plate for Marine Service and Similar Environments, November 2015

· ASTM D2584, Standard Test Method for Ignition Loss of Cured Reinforced Resins, 2011

· ASTM D2734, Standard Test Methods for Void Content of Reinforced Plastics, 2009

· ASTM D3846, Standard Test Method for In-Plane Shear Strength of Reinforced Plastics, 2008

· ASTM D6272, Standard Test Method for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials by Four-Point Bending, 2010

· ASTM D638, Standard Test Method for Tensile Properties of Plastics, 2014

· ASTM D570, Standard Test Method for Water Absorption of Plastics, 1998e1

· ASTM F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs, February 2013a

· ASTM F594, Standard Specification for Stainless Steel Nuts, 2009

· ASTM F1166, Standard Practice for Human Engineering Design for Marine Systems, Equipment, and Facilities, 2007

· ASTM F1321-14 Standard Guide for Conducting a Stability Test

· AWPA Standard U1 Category UC3B, Above Ground, Exposed, 2015

· AWPA Standard U1 Category UC4A, Ground Contact, General, 2015

· FED-STD-595C, Colors Used in Government Procurement, 16 January 2008

· IEC Standard 60529 IP, Degrees of Protection Provided by Enclosures (IP Code), 2001-02

· IEEE 45, Recommended Practice for Electric Installations on Shipboard, 2002

· IEEE 1580, Recommended Practice for Marine Cable for Use on Shipboard and Fixed or Floating Facilities, 2010

· International Regulations for Preventing Collision at Sea, 1972 (72 COLREGS) For the purposes of this specification, the U.S. Coast Guard Navigation Rules and Regulations Handbook (available at http://www.navcen.uscg.gov/?pageName=navRuleChanges) shall be interpreted as representing the requirements of the International Regulations for Preventing Collision at Sea, 1972 (72 COLREGS).

· MIL-STD-209K, Interface Standard for Lifting and Tiedown Provisions, 22 February 2005

· MIL-STD-2035A, Department Of Defense Test Method: Nondestructive Testing Acceptance Criteria, 15 May 1995

· Naval Ship’s Technical Manual (NSTM) Ch. 583, Boats and Small Craft, July 2012

· NAVSEA S9086-C6-STM-010, Naval Ships’ Technical Manual, Chapter 096, Weights and Stability

· NAVSEA T9008-B4-MAN-010, Inspection and Repair Manual for Fiber Reinforced Plastic Boats and Craft

· NAVSEA T9074-AS-GIB-010/271, Requirements for Nondestructive Testing Methods, September 2014

· NAVSEA DWG 602-5109421, Boat Contact Information Label Plate for All U.S. Navy Boats and Craft

· NAVSEA TO300-AU-SPN-010 A, Fabrication, Welding and Inspection of Small Boats and Craft, Aluminum Hulls,

· NSWCCD-23-TM-2009/58 Rev B, U.S. Navy Boat Electrical Practices, August 2012

· NSWCCD-23-TM-2009/61 Rev A, U.S. Navy Boat Example Data Package, November 2011

· NSWCCD-23-TM-2011/05 U.S. Navy Craft Mechanical Practices, November 2011

· NSWCCD-80-TR-2014/038, Weight Management Process Guidance for Boats and Craft, December 2014

· RR-C-271F, Chains and Attachments, Carbon and Alloy Steel, 5 July, 2011

· SAE J1273, Recommended Practices for Hydraulic Hose Assemblies, 17 September, 2014

· SAE J1527, Marine Fuel Hoses, 01 February 2011

· SAE J1942, Hose and Hose Assemblies for Marine Applications, 29 July, 2009

· SAE J2006, Marine Exhaust Hose, 08 February 2013

· UL 489, Molded-Case Circuit Breakers, Molded-Case Switches, and Circuit Breaker Enclosures, 15 January 2013

· UL1426, Standard for Electrical Cables for Boats, December 2010

· WSTDA-T-1, Recommended Standard Specification for Synthetic Web Tie Downs, 2015

042-5 Order of Precedence In case of inconsistency between the requirements of the Contract, this Specification, and the documents referenced in this Specification, the following order of precedence applies:

1. The Contract requirements,

2. This Specification requirements,

3. The Contract Drawings,

4. Other Government specifications and standards, industry standards, and similar referenced documents.

The following are not considered inconsistencies subject to an order of precedence determination:

a. Silence of one document with respect to details shown in another.

b. Broad boat requirements compared to detailed system or component requirements.

042-6 Contractor's Warranty The Contractor shall provide a Contractor's Warranty for the boat, trailer, and all installed equipment, for minimum of one (1) year, starting from the date the boat enters service with the Navy's end-user. Notification of official in-service date will be provided to Contractor by the United States (U.S.) Navy Boat Inventory Manager.

Due to ship construction lead time, ship's boats procured for the Navy may be held in stock (enclosed warehouse) for up to twenty-four (24) months prior to issue to the Navy end-user.

042-7 Alternate Items Where components or equipment are specified by brand name or manufacturer and model number, such identification is intended to be descriptive, not restrictive, and is intended to indicate the required characteristics of the product. The Contractor may propose the use of other products that are equal to the specified make and model products. The following general requirements shall form the basis for determining the equivalence of alternate products unless additional specific or alternate requirements are designated within the applicable sections of this Specification.

· The major attributes of form, fit, function, interface, and material of an alternate item shall not degrade the performance of the system within which it is used, nor the boat as a whole. The alternate item shall require no more space or volume than the designated item for installation, operation, or maintenance. The alternate item shall weigh no more than the designated item. The connection fittings required to incorporate the alternate item into a system shall be identical to those necessary to incorporate the specified item. The principles of operation of the alternate item shall be the same as those of the designated item (e.g., hydraulic cylinders shall not be used in lieu of springs, etc.). Input power, capacity, and other operating requirements for the alternate item shall be no greater than those required by the designated item. Output power, capacity, and other performance parameters of the alternate item shall be no less than those required for the designated item and not so much greater than those of the designated item as to require an increased capacity of the system within which the item is installed.

· The materials of construction of the alternate item shall be the same as those of the designated item unless the Contractor can demonstrate to the Government that the proposed alternate material will not adversely affect performance or service life of the item, the system within which it is installed, or the boat as a whole.

· The reliability and maintainability of an alternate item shall be equal to or better than the specified item. The Contractor shall provide evidence of the reliability and maintainability of the alternate item. This evidence may include such things as results of testing, service histories, documentation of successful use in similar applications, planned maintenance requirements, etc. Where the reliability and maintainability of the specified item has been established by testing, the Government may require that the alternate item undergo similar testing to demonstrate its reliability and maintainability. Such testing, if required, shall be at the Contractor's expense.

· An alternate item shall conform to the same industry specifications or standards as the specified item. Where a specified item has been approved or certified by a regulatory or testing agency, such as USCG or Underwriters' Laboratories, the alternate item shall also be approved or certified. The cost of demonstrating compliance with specifications or standards, or of obtaining approval or certification, shall be borne by the Contractor.

· If the specified item is one with established logistic support any alternative item shall have equivalent logistic support. If equivalent logistic support has not been established for the alternate item, the Contractor shall bear the expense of establishing equivalent support. Logistic support shall include, as applicable: maintenance planning and analysis; training and training support, including training equipment, curricula, and instruction materials; supply support; support equipment such as special tools and test equipment; technical documentation including technical manuals, Product Technical Description (PTD), Planned Maintenance System (PMS), Technical Repair Standards (TRS), and software documentation; computer resource support; facilities for maintenance and training; unique packaging, handling, storage, and transportation requirements; and human engineering considerations.

070 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

070-1 Vessel Characteristics

· Length Overall (LOA): 39.0 feet (ft)

· Beam Overall (BOA): 11.8 ft

· Chine Beam: 8.8 ft

· Deadrise: 19 degrees at transom (variable)

· Total Installed Fuel Capacity: 280 gallons

· Design Hoisting Weight (maximum): 17,640 lbs (8,000 kg)

· Design Full Load Weight (maximum): 21,400 lbs

· Design Draft: 2.0 ft at Full Load

· Capacity (including crew): 26 persons

070-2 Environmental Conditions The boat shall be capable of operating in ambient air temperatures between 0o F and 125o F and water temperatures between 28o F and 95o F.

The boat shall be capable of full operation in up to Sea State 3 (4.6 foot significant wave height). The boat shall survive up to Sea State 5 conditions (12 foot significant wave height) at minimum headway speed and best heading.

The boat materials shall be capable of withstanding ambient temperatures up to 150o F during full exposure to ultraviolet (UV) rays when onboard ships in open stowage areas.

070-3 Load Conditions The following load conditions are defined for reference throughout this Specification for the OCC, LPD-17, and EVBSS Variants. These definitions apply to the engineering design values for weight and moments of the vessel in the described condition. Weight Management Process Guidance for Boats and Craft, NSWCCD-80-TR-2014/038 may be used for guidance.

· Service Life Allowance (SLA): The SLA shall be 800 lbs at the Longitudinal Center of Gravity (LCG).

NOTE: The SLA for the LPD-17 and EVBSS variants shall be reduced by the weight of the single point lift frame (including permanent mounting brackets and hardware, removable lift frame structure, and Cranston Eagle hook; see Section 611).

· Payload (OCC and LPD-17 Variants): The boat shall support 4,870 lbs total payload. The notional breakdown of payload is twenty-six (26) personnel at 185 lbs each (including crew) and the 60 lbs 4-leg sling set. Note: guns, ammunition, or other mission gear, when carried, will be considered part of the defined payload weight.

· Payload (EVBSS Variant): The boat shall support 4,220 lbs total payload. The notional breakdown of payload is twelve (12) EVBSS personnel at 285 lbs each, four (4) crew at 185 lbs each, and the 60 lbs 4-leg sling set. Note: guns, ammunition, or other mission gear except DICP, when carried, will be considered part of the defined payload weight.

· Light Ship: The boat complete in all respects including outfit (defined in Section 670), and ready for service with liquids in machinery at operating levels but no personnel, fuel, or other variable loads. Each variant will have a different Light Ship weight. Add an allowance for the DICP (255 lbs) for the EVBSS variant.

· Boat Scale Weight Condition: Light Ship plus full fuel. If the boat is weighed without full fuel, the fuel weight shall be added using a density of 7.1 lbs/gallon.

· Full Load Condition: Light Ship plus full fuel plus Payload plus SLA.

· Builder’s Trials (BT) Load Condition: Light Ship plus full fuel plus four (4) people @ 200 lbs each.

· Pre Delivery Inspection Trials (PDIT) Load Conditions:

· Full Load Condition and

· BT Load Condition

· Boat Over-the-Road (OTR): Light Ship plus full fuel plus SLA.

· Trailer Curb Weight: Trailer complete in all respects, including all tools/stowages on trailer, OTR tie-down straps, and miscellaneous material required for OTR transport (e.g. boat covers, tie-down strap chafe protection, etc.).

· Gross Vehicle Weight (GVW): Boat OTR plus Trailer Curb weight.

· Boat Design Hoisting (at sea): Light Ship plus full fuel plus SLA plus 6 people @ 185 lbs each. The actual (as-weighed) Boat Hoisting weight shall not exceed 17,640 lbs (8,000 kg).

· Trailer Design Hoisting: Trailer Curb weight.

· Combined Boat and Trailer Design Hoisting: Boat OTR plus Trailer Curb weight.

070-4 Configuration Management The Contractor shall practice configuration management of each of the boat variants. To achieve ready replacement of parts, the Contractor shall standardize on selection of equipment, fittings, and fabrication methods within all boats under the Contract. Components and equipment which are functionally interchangeable shall be identical. The boat shall use the least practicable variety of types and sizes of items with multiple applications.

070-5 American Boat and Yacht Council (ABYC) Standards The boat shall meet ABYC standards and recommended practices, unless otherwise specified.

070-6 Alterations Alterations to Original Equipment Manufacturer’s (OEM) products by the Contractor or distributer are highly discouraged. If alterations are necessary, documentation of the change shall be provided with the Technical Data Package (TDP).

070-7 Equipment Installation Unless otherwise specified, OEM recommendations for design and installation of their products into the boat shall be followed. Systems and components shall be selected for durability, longevity, safety, and ruggedness. Components shall be selected to maximize the use of Commercial-off-the-shelf (COTS) products and commonality between hulls. Systems and components shall be installed with proper tools and aligned with best industry practices.

All systems should be free from leaks and safety hazards. Workmanship shall be in accordance with industry best practices. Equipment, components, wiring and piping shall be supported clear of the bilge to the maximum extent practicable.

Galvanically dissimilar metals shall be isolated using insulating materials to prevent any path for electrical current.

Foundations and brackets for equipment shall be configured to provide access for cleaning, painting, preservation, and maintenance, and to prevent accumulation of water, dirt, and foreign material.

Connecting piping and wiring shall be run to minimize exposure to weather. Bulkhead and deck penetrations shall be as close as practicable to the equipment being served, preferably by direct connection through the adjacent deck or bulkhead.

Systems, equipment, and components shall be installed to facilitate accessibility for operating efficiency and for inspection, adjustment, and repair. Permanent fittings and structure shall be kept clear of routes required for the removal of machinery and equipment. The space behind equipment may be inaccessible after installation; this factor shall be considered in providing proper preservation in way of such equipment and in selecting the location of pipes, ducts, wireways, and other permanent fittings behind such equipment. Nooks, cracks, and openings where water, dirt, dust, or foreign material can accumulate shall be avoided.

Protection of personnel against operating hazards shall be provided. Shafting, couplings, gears, flexible shafts, and similar items shall have adequate guards installed for protection of personnel. Such protective guards shall be removable without dismantling the machinery surrounded.

Guards shall be as light as is consistent with required protection and strength. Guards shall be of sufficient strength to be used as steps or hand holds if located where such use may be anticipated.

Protective guards or insulation shall be installed to prevent contact with equipment where surface temperatures exceed 200 oF.

Protective guards shall be installed as barriers to prevent personnel from inadvertently contacting energized and exposed electrical circuits, components, and terminals.

Equipment shall be protected against the hazard of personnel brushing against or being thrown against the equipment, particularly under heavy sea conditions, and inadvertently causing damage to exposed components or resulting in maladjustment of exposed functional controls such as push buttons, knobs, and switches. Protection shall be provided by equipment arrangement or design or by installation of enclosures, screens, or guard rails. All sharp edges exposed to personnel shall be dressed, ground or rounded to avoid injury to personnel.

070-8 Tolerances Where tolerances are not otherwise indicated by specific dimensions on the drawings the following tolerances shall apply:

1. Dimensions given decimally:

in inches (inch-pound);

.X - ±0.06 inch .XX - ±0.03 inch .XXX - ±0.005 inch

2. Dimensions given in inches and fractions:

linear - ± 1/16 diameters, other than bolt holes, ± 1/16 radii - ± 1/16

3. Dimensions given in feet and whole inches - ±1/8 inch

4. Angles:

Whole degrees - ±1/2 degree Degrees and minutes - ±5 minutes

The tolerances shall apply to all fabrication performed from the Contract Drawings and the Contractor developed Construction Drawings, except where deviation to either relax or tighten the tolerance is noted on the drawings or required elsewhere in this Specification.

071 ACCESS

071-1 Accessibility Electrical and mechanical components shall be accessible for maintenance and repair. All items requiring operation or maintenance (e.g. switches, valves, filters, strainers, seacocks, etc.) shall be readily accessible while in shipboard stowage, at the dock, or underway. Stowage and securing of arches, antennas, masts or other items shall not prevent access to critical items such as battery switches, fuel shut off valves or other items that need to be checked, secured or operated for any of the required transport modes.

Where accessibility for operation or maintenance is not evident during PDIT the Contractor shall be prepared to demonstrate accessibility by operating, removing or otherwise manipulating the necessary components under realistic conditions.

073 NOISE, VIBRATION, AND RESILIENT MOUNTINGS

073-1 Mechanical Vibration

074 WELDING AND ALLIED PROCESSES

074-1 General If a subcontractor is used to fabricate custom built welded assemblies the Contractor shall include these requirements in the subcontracting agreement and be responsible for assuring they are fulfilled.

074-2 Visual Inspections All welds shall be visually inspected.

Welds shall be free of slag, weld splatter, cracks, sharp irregularities and incomplete fusion.

The weld edge shall not form a reentrant angle with the base metal less than 90 degrees due to lack of fusion, undercut or excessive convexity.

Fillet welds dimensioned 3/8 inch or less shall not vary below the specified size by more than 1/16 inch for a total distance greater than 25 percent of the joint length. Fillet welds dimensioned 7/16 inch and larger shall not be less than the specified size. Fillet welds in excessive of the required dimensions shall be avoided; however, oversized welds will be acceptable provided they meet the contour requirements and do not interfere with proper operation of the boat or its components.

Undercut shall not reduce the base metal thickness by more than 1/32 inch.

Welds shall not exhibit porosity or worm holes in excess of two indications 1/16 inch or larger in any 6 inch length of weld, exclusive of weld crater porosity.

Grinding to correct the weld profile shall not reduce the base metal thickness by more than 1/32 inch.

074-3 Critical Welded Assemblies The bow and stern posts, gun foundations, bow eye, lifting frames and hoisting fittings are critical welded assemblies. The following additional requirements apply for critical welded assemblies:

· Welder and weld procedure qualification - weld procedures and welder qualification, including the associated record keeping requirements, shall be in accordance with the American Society of Mechanical Engineers (ASME), the American Welding Society (AWS), or NAVSEA TO300-AU-SPN-010 A, dated 5 October, 1992 (NAVSEA SPN-10).

The Contractor shall select one of these welding codes and adhere to all requirements of the selected document for each welding procedure specification. The Contractor may select different regulating codes for different weld procedures; however, all documentation, welding and welder requirements for each procedure (for example, the Welding Procedure Specifications (WPSs), the Procedure Qualification Records (PQRs) and the welder qualification and testing of the welds) must follow the same code.

All documentation pertaining to welder and weld procedure qualification shall be maintained by the Contractor, available for inspection by the Government.

· Fillet weld root openings - Fillet weld root openings shall not be greater than 1/16 inch.

· Dye Penetrant Testing (PT) - Welds shall be dye penetrant tested before and after load testing. Welds and 1/2 inch of base metal on either side of the weld shall be free of linear indications greater than 1/16 inch long.

075 FASTENERS

Contractor assembled threaded fasteners shall be stainless steel, except as specified by detailed requirements or the OEM. Fasteners used for structural applications shall meet ASTM F593, type 316. Self-locking hardware shall be used unless otherwise specified.

If higher strength fasteners are required they shall be painted or preserved with a corrosion inhibitor and documented as a maintenance item.

Component mounting shall be through-bolted with ASTM F594 type 316 nylon insert lock nuts and flat washers wherever practicable to suit fastener reinstallation during maintenance and repair. Threaded fasteners shall fully engage nuts with thread protrusion. Excessive thread protrusion that pose a personnel hazard shall be avoided.

Fasteners may be threaded into structural or non-structural materials only with Government approval. Pins used for folding, removable, or stowable features shall be 316 stainless steel secured with a stainless steel lanyard to prevent loss. Pin handles may be aluminum.

Strength fittings shall not be attached to FRP hulls using tapped threaded fasteners. All strength fittings on FRP hulls shall have backed and through-bolted connections.

Certain equipment installations may require other fasteners as specified by the OEM; these are acceptable provided they are installed according to OEM instruction.

078 MATERIALS AND CORROSION CONTROL

078-1 Materials Components or parts of equipment and machinery shall be new. When materials are referred to in this Specification without further identification, they shall be as specified in this section. Other materials for specific applications are defined in the specific sections of this Specification, or on the drawings or referenced documents that require their use.

Aluminum (if used) shall be:

· Sand cast (3560 T6)

· Plate and sheet (5086 H116 or 5086-H117 both ASTM B928; for non-welded applications 6061-T6 or 6061-T651 may be substituted.)

· Extrusions (5086-H111; for non-welded applications 6061-T6 or 6061-T52 may be substituted.)

· Drawn tube (5086-H32; for non-welded applications 6061-T6 may be substituted.)

· Non-structural components such as handrails, small component brackets and wire ways may include extruded 6061 material.

Stainless Steel (if used) shall be:

· Cast for general applications (UNS J92800 or J92500; for non-welded applications UNS J92900 or J92600 may be substituted.)

· Cast for underwater applications (UNS J92800; for non-welded applications UNS J92900 may be substituted.)

· Plate/sheet, bars/shapes, tubing, pipe (UNS S31603; for non-welded applications UNS S31600 may be substituted.)

078-2 Corrosion Control All parts and fittings required for disassembly of systems shall be of Monel, stainless steel type 316L (or 316 if not welded), or copper alloy containing no more than 10% zinc (except manganese bronze), whichever is compatible with the basic material of the equipment. Stainless steel, if used where it is likely to be submerged in seawater, shall be type 316L.

Joined components shall be galvanically compatible with each other wherever possible, or shall be isolated to prevent galvanic corrosion. Where it is necessary to join dissimilar metals, ensure complete isolation of faying surfaces of the galvanically dissimilar metals, including fasteners, using non-water absorbent dielectric barrier or sealant materials.

078-3 Bedding Compound Bedding compound shall be either Woolsey 2005N or Sikaflex 241.

078-4 Non-Biodegradable Materials Use of wood and other hygroscopic or biodegradable materials anywhere on the boat is prohibited. All materials shall be marine grade and resistant to corrosion and UV exposure.

078-5 Fabric Material Fabric for covers, canopy and upholstery shall be marine grade fade, stain and mildew resistant and as near a match in color as possible to the surface to which it is mounted or covering unless otherwise noted. Fabrics shall be easy to maintain and waterproof and/or breathable where required. All seams, edges, grommets, fastening points and areas of chafe shall be reinforced. Venting is acceptable to ventilate covers, but must minimize or eliminate the intrusion of water. Seats, seat fabric and foam shall be durable, provide comfort and be flame retardant.

080 INTEGRATED LOGISTIC SUPPORT

080-1 Packaging Packaging/shrink wrap shall be used to protect the boat during delivery.

080-2 Boats Requiring Extended Storage (Long Term Preservation) Where specified by the Delivery Order, the Contractor shall complete long-term engine preservation in accordance with OEM instructions for the specified period of time. Re-activation instructions shall be included in the TDP and a hard copy secured to the helm of each preserved boat.

083 SPARES

083-1 Initial Spares List Where specified by the Delivery Order, the builder shall provide initial spares in accordance with Attachment 3. Comment by Demko, Daniel T CIV NSWCCD Little Creek, 831: Update with correct attachment numbe

084 TRANSPORTATION AND HANDLING

084-1 Applicable Transport Modes The boat shall be compatible with marine transport, over-the-road trailer transport, and initial delivery to the Government via motor freight and stowage on a dedicated shipping cradle (or trailer as applicable per the Delivery Order).

084-2 Marine Transport, Launch and Recovery The boat will be used with marine transport, to include onboard stowage and at sea underway (manned) launch and recovery from U.S. Navy ships. Launch and recovery will be from ship’s crane with the single point hoisting configuration, from ship’s davit with two point hoisting configurations (see Section 611), or from a specialized launch and recovery system in the ship’s well deck or mission bay.

084-3 Boat Tiedowns The boat shall have aluminum or stainless steel tiedown provisions including two (2) transom tiedowns, bow eye, and ten (10) side tiedowns (five tiedowns per side) per the drawings. Labeling of the tiedowns shall include load ratings in lbs. Tiedown provisions will be used for OTR transport, marine transport, and trailer hoisting.

See Section 092 for testing requirements.

084-4 Tiedown Straps Tiedown straps shall be provided for securing the boat to the trailer for OTR and lifting that comply with “Recommended Standard Specification for Synthetic Web Tie Downs”, Web Sling & Tie Down Association WSTDA-T-1, except that:

· Straps are sized for a safety factor of five (5) based on maximum boat-to-trailer design load when suspending trailer design hoisting weight beneath boat.

· The trailer tiedown strap arrangement is designed so that no single strap failure will result in the trailer being ‘dropped’ during the hoist. In addition to marking required by WSTDA-T-1, all straps used in hoisting the trailer shall be permanently marked identifying the testing activity, contract number, date of testing, boat type, rating and intended usage of the strap (and leg to fitting identifier, i.e. 'FWD PORT') and a unique serial number. The optional label from WSTDA-T-1 “not to be used for hoisting” shall not be installed.

See Section 092 for testing requirements.

084-5 Trailer A Boatmaster trailer shall be provided for the boat. The trailer shall have the following characteristics:

· Gross Vehicle Weight Rating (GVWR): GVWR shall not be less than the GVW defined in Section 070,

· Dimensions: Loaded trailer dimensions within acceptable limits for all applicable transport modes,

· Axle Rating: The trailer shall have three axles, each rated at 8,000 lbs (highway),

· Hub Rating: Hubs rated at highway speeds for a minimum of 50% of the axle rating,

· Tire Rating: The combined tire ratings per axle shall meet or exceed the axle rating,

· Component Capacities: Axle, wheel, and tire creep load capacities provided with trailer technical information,

· Frame Material: Aluminum construction,

· Fasteners: ASTM F593, type 316 stainless steel fasteners, flat washers, and ASTM F594 nylon insert lock nuts throughout (No threading of aluminum),

· Component Materials: Aluminum or 316 stainless steel components used where possible (e.g. fenders, brackets, etc.), hot-dipped galvanized steel elsewhere (e.g. axles),

· Tires: Light Truck (LT) series tire and wheel,

· Spare: Matching and mounted spare tire and wheel,

· Suitable For Marine Environment: Actuation components shall be capable of total submersion in salt water for short periods of time,

· Brakes: Full air brakes on each axle using all stainless steel disc brake components (including stainless steel rotors, stainless steel brake caliper assembly with stainless steel cylinder and guide pins). NOTE: no electric brakes,

· Brake Lines: Stainless steel brake lines with smooth regular bends. Flex hoses, where necessary, shall be stainless or Kevlar, and have a minimum rating of 3,000 psi,

· Service air connections (if necessary for brake operation),

· Suspension: Suspension type (e.g. leaf spring, torsional axle, or air with trailing arm) and strength consistent with trailer GVWR,

· Hubs: Positive pressure hub system (Air-Tight) to prevent contamination of hub lubrication,

· Bearings: Bearings shall be U.S. made,

· Electrical System: the trailer shall be equipped for 12 Vdc (with commercial seven (7)-pin round plug with flat connectors) and 24 Vdc (with twelve (12)-pin NATO plug),

· Electrical Materials: Electrical system components shall be marine grade: all connections shall be made using ring terminals sealed with heat shrink at all connections. Electrical cables and conductors shall be secured by stainless steel supports or stainless steel banding with chafing protection (no zip ties),

· Lighting: Lighting shall be submersible Light Emitting Diode (LED),

· Storage: On-trailer stowage for tools and tiedown straps with drain holes,

· Ladder: Removable forward ladder extending to bow of the boat,

· Winch: Manual winch with cable (or Dyneema Rope) and closed end hook. Entire system shall be designed to the same load as the bow eye with a minimum safety factor of one and one-half (1.5) on yield strength of materials,

· Jack Stand: Heavy duty jack stand (foot or roller),

· Bow Stop: Bow stop with rubber pads,

· Hitch: Vertically adjustable hitch with three inch (3") lunette ring,

· Fenders,

· Safety chains,

· Bunks: Bunks shall be sized to support boat under accelerations for applicable transport modes. Bunks shall not be roller style,

· Tiedowns: The trailer shall be equipped with tiedown provisions with rated capacities to suit tiedown requirements (see Section 084). Tiedowns shall be labeled per MIL-STD-209K,

· Standards Compliance: The trailer shall comply with all applicable federal requirements, including CFR title 49 Chapter III Part 393 and Chapter V Part 571, excepting that the CFR exclusion of heavy trailers does not apply for all cited CFR requirements.

084-6 Shipping Cradle A heavy-duty wood shipping/stowage cradle pressure treated and/or coated with wood preservative shall be provided when specified by the Delivery Order.

The cradle shall be designed and fitted to prevent any damage to, and movement of, the boat or cradle during shipment and storage.

The boat’s external tiedown fittings shall be used to secure the boat to the cradle. The hoisting, deck, and underwater fittings shall not be used for tie down points of the boat to…