Att_1_FY16_EOD_MERC_Specification_07Mar2016_-_DRAFT_FOR_RFI.doc

FY16 EOD MERC Specification 07 March 2016

NAVAL EXPEDITIONARY COMBAT COMMAND

EXPLOSIVE ORDINANCE DISPOSAL (EOD)

MULTI-USE EOD RESPONSE CRAFT (MERC)

SPECIFICATION

REV. -

07 March 2016

REVISION HISTORY

TABLE OF CONTENTS

2REVISION HISTORY

3TABLE OF CONTENTS

9SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

9040 INTRODUCTION AND GENERAL DESCRIPTION

9040-1 Background

9040-2 Variants

10040-3 Threshold and Objective Requirements

10042 GENERAL ADMINISTRATIVE REQUIREMENTS

10042-1 General Requirements

10042-2 Referenced Documents

12042-3 Builder's Warranty

12042-4 Hull Warranty

12042-5 Alternate Items

13070 GENERAL REQUIREMENTS FOR DESIGN AND CONSTRUCTION

13070-1 Vessel Characteristics

14070-2 Builder Submitted Drawings

14070-3 Environmental Conditions

15070-4 Load Conditions

16070-5 Configuration Management

16070-6 American Boat and Yacht Council (ABYC) Standards

16070-7 Alterations

16070-8 Equipment Installation

17071 ACCESS

17071-1 Accessibility

17071-2 Bilge Access

17075 FASTENERS

17075-1 Stainless Steel Fasteners

18078 MATERIALS

18078-1 Non-Metallic Materials

18078-2 Structural Material/FRP

18078-3 Non-Biodegradable Materials

18078-4 Fabric Material

19079 STABILITY

19079-1 Stability

19079-2 Flotation

19079-3 Flotation Foam

19080 INTEGRATED LOGISTIC SUPPORT

19080-1 Packaging

19083 SPARES

19083-1 Initial Spares List

20084 TRANSPORTATION AND HANDLING

20084-1 Air Transport

20084-2 Road Transport

20084-3 Marine Transport, Launch and Recovery

21084-4 Boat Tiedowns

21084-5 Tiedown Straps

22084-6 Rough Terrain Trailer (RTT)

23085 TECHNICAL DATA PACKAGE (TDP)

24085-1 Technical Design Analyses

25085-2 Drawings

29085-3 Bill of Materials (BOM)

30085-4 Commercial Off The Shelf (COTS) Technical Manuals and Documentation

30085-5 Boat Technical Manual

30085-6 OEM Certification Letters

30085-7 OEM Warranties Booklet

30085-8 Tests and Trials Reports

30085-9 Master Data Index (MDI)

31085-10 TDP Format

31085-11 TDP Submittal

31085-12 TDP Acceptance

31092 TESTING

31092-1 Test Certifications

33094 TRIALS

33094-1 Builder's Trials (BT)

33094-2 Pre-Delivery Inspection and Boat Trials (PDIT)

34SECTION 1: HULL STRUCTURE

34100 GENERAL REQUIREMENTS FOR HULL STRUCTURE

34100-1 General Structural Requirements

35100-2 Limber Holes

35110 SHELL AND SUPPORTING STRUCTURE

35110-1 Beaching Shoe

35130 HULL DECKS

35130-1 Aft Deck Interior Beam

36130-2 Deck Drains

36150 DECK HOUSE STRUCTURES

36150-1OCC Hull Style/Center Console/T-Top (OCC Variant)

37150-1CAB Hull Style/Cabin (Cabin Variant)

38150-2 Ergonomics

38166 COLLAR

38166-1 Air/Foam Hybrid Collar

39166-2 Bow Collar Cover

39167 HULL STRUCTURAL CLOSURES

39167-1 Doors and Hatches

39169 SPECIAL PURPOSE CLOSURES AND STRUCTURES

39169-1 Outboard Motor Bracket

39169-2 Engine Guard

39169-3 Aft Deck Canopy

40169-4 Weather Curtain Set

40169-5OCC Aft Arch (OCC Variant)

40SECTION 2: PROPULSION

40236 OUTBOARD ENGINES

40236-1 Outboard Engines

41236-2 Outboard Engine Break-In

41236-3 Diagnostic Laptop

41252 PROPULSION CONTROL SYSTEM

41252-1 Propulsion Instrument Marine Package

41252-2 Propulsion Controls and Joystick Piloting System

41252-3 Power Steering

42252-4 Dynamic Positioning System

42SECTION 3: ELECTRIC PLANT

42300 GENERAL REQUIREMENTS FOR ELECTRIC PLANT

42300-1 Suitable for Marine Environment

42300-2 Panel Covers

42300-3 Switches

42300-4 Bonding System

42303 PROTECTIVE DEVICES

42303-1 DC Overcurrent Protection

43303-2 AC Overcurrent Protection

43304 ELECTRICAL CABLE, WIRING, AND CONNECTIONS

43304-1 Watertight Connections

43304-2 Cable Supports

44304-3 Marine Multi-Conductor Cable

44304-4 Electrical Connections

44304-5 Weatherproofed Connectors

44304-6 Watertight Cable Penetrations

44304-7 Cableways

45304-8 Ignition Protection

45310 GENERATORS

45310-1 Generator (120 Vac / Single Phase)

45313 BATTERIES

45313-1 Batteries

46313-2 Battery Charging

46313-3 Battery Voltmeter

46313-4 Plug-In Battery Charger

46320 POWER DISTRIBUTION SYSTEMS

46320-1 DC Power Distribution System

46320-2 AC Power Distribution System

47320-3 Outlets (12 Vdc)

47320-4 Outlets (120 Vac GFCI)

47324 SWITCHGEAR AND PANELS

47324-1 Electrical Circuit Breaker Panels

47330 LIGHTING

47330-1 Electronic Dimmer

48330-2 Blackout Switch

48330-3 Overhead LED Lighting

48330-4 Deck Work Lights

48330-5 Special Operations Light

48330-6OCC Handheld Spotlight (OCC Variant)

48330-6CAB Fixed Spotlight (Cabin Variant)

49SECTION 4: COMMAND AND CONTROL

49405 ANTENNA REQUIREMENTS

49405-1 Antenna Reservations

49405-2 Antenna Installations

49421 NON-ELECTRICAL/ELECTRONIC NAVIGATION AIDS

49421-1 Magnetic Compass

49422 ELECTRICAL NAVIGATION AIDS

49422-1 Navigation Lights

50422-2 Integrated Electronic Navigation System

50422-3 Defense Advanced GPS Receiver (DAGR)

51422-4 Day Shape Mast

51436 ALARM, SAFETY, AND WARNING SYSTEMS

51436-1CAB CO Monitor (Cabin Variant)

51441 RADIO SYSTEMS

51441-1 VHF Radio (Standard Horizon GX2000)

51441-2 Communications Shelves

51441-3 Tactical Radio System

52443 VISUAL AND AUDIBLE COMMUNICATION SYSTEMS

52443-1 Navigation Horn

52443-2 Law Enforcement Hailer/Siren System

52443-3 Infrared (IR) Strobelight

53SECTION 5: AUXILIARY SYSTEMS

53500 GENERAL REQUIREMENTS FOR AUXILIARY SYSTEMS

53500-1 Mechanical Components

53500-2 Through-Hull Fittings and Valves

53500-3 Fluid Systems Connections

53505 HOSES

53505-1 Hoses

53505-2 Hose Installation

54505-3 Hose Clamps

54512 HEATING, VENTILATION, AND AIR CONDITIONING (HVAC)

54512-1 Bilge Blower

54512-2CAB Defogging/Defrosting System (Cabin Variant)

54512-3CAB Cabin Fans (Cabin Variant)

54512-4CAB Cabin Heating, Ventilation, and Air Conditioning (HVAC) (Cabin Variant)

55523 WASHDOWN SYSTEM

55523-1 Raw Water Deck Washdown System

55529 BILGE/DRAINAGE SYSTEM

55529-1 Fixed Manual Bilge Pump

55529-2 Electric Bilge Pump

55529-3 Hull Drains

55541 FUEL SYSTEM

55541-1 Fuel Tank (Non-Integral)

56541-2 Fuel Sounding

56541-3 Fuel Level Gauge

56541-4 Fuel Valves

56541-5 Fuel/Water Separator and Filter

56555 FIRE FIGHTING

56555-1 Portable Fire Extinguishers

57555-2 Fire Port

57561 STEERING CONTROL SYSTEMS

57561-1 Power Hydraulic Steering

57561-2 Emergency Steering System

57565 TRIM AND HEEL CONTROL SYSTEMS

57565-1 Trim Tabs

57581 ANCHOR HANDLING

57581-1 Fortress Anchor

58582 MOORING and TOWING

58582-1 Forward and Aft Tow Provisions

58582-2 Bow Eye

58582-3 Cleats

58589 SPECIAL PURPOSE SYSTEMS

58589-1 Davit Foundations

59589-2 Davit

59592 DIVER SUPPORT SYSTEMS

59592-1 Dive Ladder

59592-2 SCUBA Tank Stowage

59SECTION 6: OUTFIT AND FURNISHINGS

59600 OUTFIT

59600-1 Boat Hook

59600-2 Ring Buoy

60600-3 U.S. Flag

60600-4 Mooring Lines

60600-5 Collar Pump

60600-6 First Aid Kit

60600-7 Emergency Positioning Indicating Radio Beacon (EPIRB)

60600-8 Paddles

60600-9 Dive Flags

60600-10 Collar Repair Kit

61602 LABELING

61602-1 Hull Registry Number (HRN)

61602-2 Label Plates (General)

61602-3 Piping System Label Plates

62602-4 Valve Label Plates

62602-5 Instruction Label Plates

62602-6 Hoisting Label Plates

62602-7 Boat Information Label Plate

62602-8 Boat Alteration Label Plate

62602-9 Shipping Data Label Plate

63602-10 In-Service Label Plate

63602-11 Systems Label Plates

63602-12 Stowage Label Plates

63602-13 Unique Item Identification (UID)

63611 HULL FITTINGS

63611-1 Deck Cargo Tiedowns

64611-2 Hoisting Fittings

64611-3 Hoisting Sling

65611-4 Hoisting Hardware

65612 RAILS, STANCHIONS, AND LIFELINES

65612-1 Grab Rails

65625 WINDOWS

65625-1 Windshield Wiper/Washer System

66630 PRESERVATIVES AND COVERINGS

66630-1 Paint and Gel Coat

66630-2 Anodes

66630-3 Exterior Non-Skid

66630-4 Anti-Fatigue Matting

66644 SANITARY SPACES AND FIXTURES

66644-1CAB Head (Cabin Variant)

67662 WORKING SPACES AND SEATING

67662-1OCC Bolster – Coxswain (OCC Variant)

67662-1CAB Seating (Cabin Variant)

67670 STOWAGE SPACES

67670-1 Stowage (General)

68670-2 Stowage Compartment

68SECTION 7: ARMAMENT

68700 ARMAMENT

68700-1 Machine Gun Foundations

SECTION 0: GENERAL GUIDANCE AND ADMINISTRATION

040 INTRODUCTION AND GENERAL DESCRIPTION

040-1 Background

The MERC will be used in the Navy EOD forces, including Mobile Diving and Salvage Units (MDSU), provide diving/demolition services in the maritime environment up to 330 feet of seawater (FSW). Joint and Naval commanders require EOD platoons and MDSU companies to conduct underwater operations to locate, render safe and/or recover submerged objects and ordnance; harbor clearance/search; and expeditionary salvage operations. These operations have unique small-craft requirements. This capability will support:

· Diving missions during limpet response

· Mine countermeasures (MCM) operations

· Unmanned systems operations

· Harbor clearance

· Expeditionary salvage

· Casualty evacuation (CASEVAC)

· Passenger transport The described missions will be conducted worldwide in permissive and non-permissive environments.

040-2 Variants

This Specification describes two variants of the MERC; the Open Center Console (OCC) variant and the Cabin variant.

Specification sections specific to the Open Center Console variant only are identified with a section number suffix of “OCC” and sections specific to the Cabin variant are identified with a section number suffix of “CAB” for convenience. The below table summarizes the differences between the two variants throughout this Specification. Commonality between the variants shall be maintained for all major components such as engines, trailers, hoisting slings, and tie down straps. In other respects, commonality shall be maintained as much as practical.

040-3 Threshold and Objective Requirements

In this Specification all Sections are threshold requirements unless otherwise stated. A threshold requirement is defined as a minimum acceptable operational value below which the utility of the system becomes questionable.

An objective requirement is designated by (OBJECTIVE). An objective requirement is defined as the desired operational goal associated with a performance attribute beyond which any gain in utility does not warrant additional expenditure.

The following Sections have objective requirements.

· Section 084-2: Gross Vehicle Weight (GVW)

· Section 130-1: Aft Deck Interior Beam

042 GENERAL ADMINISTRATIVE REQUIREMENTS

042-1 General Requirements This Specification is for a nominal (9) meter long, Fiberglass Reinforced Plastic (FRP), U.S. Navy EOD Rigid Inflatable Boat.

The mission duration is for up to twelve (12) hours.

The expected service life for the boat delivered under this Specification is ten (10) years. The service life may be extended for up to fifteen (15) years with major overhauls including replacement of propulsion systems (engines, outdrives), mechanical systems (fuel, bilge), electrical systems, collars, and cosmetic hull repair.

Offeror’s shall adhere to best marine practices. Specifications identified in this section provide the minimum required general system characteristics and requirements for the selection; installation; onboard performance; onboard inspection of machinery, equipment, and outfit; and pre-installation handling and inspections of materials for construction.

042-2 Referenced Documents

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

· 49 CFR Part 393.102, Securement Systems

· 49 CFR Part 571, Federal Motor Vehicles Safety Standards

· ABYC, Standards and Technical Information Reports for Small Craft, July 2013

· ASME Y14.100, Engineering Drawing Packages, 2013

· ASTM B33, Standard Specification for Tin-Coated Soft or Annealed Copper Wire for Electrical Purposes, 2010

· ASTM B928, Standard Specification for High Magnesium Aluminum-Alloy Sheet and Plate for Marine Service and Similar Environments, November 2009

· ASTM F593, Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and Studs, February 2008

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

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

· Core Material Selection Guidance for Navy Boatbuilders, GFI, 16 May 2011

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

· 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) which are contained in “Navigation Rules, International Inland”, U.S. Coast Guard publication COMDTINST M166672.2 (U.S. Department of Transportation, United States Coast Guard, 2100 2nd Street S.W., Washington D.C. 20593-0001)

· ISO 6185-4:2014, Inflatable Boats – Part 4: Boats with a Hull Length of Between 8m and 24m with a Motor Power Rating of 15 kW and Greater

· ISO 11812:2002, Small Craft – Watertight Cockpits and Quick-Draining Cockpits

· ISO 12215-6:2008 Small Craft – Hull Construction and Scantlings – Part 6: Structural Arrangements and Details

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

· MIL-STD-1366E, Interface Standard for Transportability Criteria, 31 October 2006

· MIL-STD-1791A, Designing for Internal Aerial Delivery In Fixed Wing Aircraft, 19 November 2012

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

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

· NSWCCD-23-TM-2009/33 Rev B, Hoisting System Design and Certification Process Guidance, October 2009

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

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

· NSWCCD-23-TM-2009/63 Rev D, Small Craft Crew Served Weapons Integration Guidance and Certification Process, October 2014

· NSWCCD-23-TM-2009/64 Rev C, Transportability Design and Certification Process Guidance, November 2009

· NSWCCD-23-TM-2009/65 Rev C, Towing Fitting Design and Certification Process Guidance, November 2009

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

· NSWCCD-23-TM-2011/38 Rev A, Mooring Fitting Design and Verification Process Guidance, 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

· S6430-AE-TED-010, Piping Devices, Flexible Hose Assemblies, 20 January 2012

· 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, 01 February 2013

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

· UL 1077, Standard for Supplementary Protectors for Use in Electrical Equipment, 25 June 2015

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

· WSTDA-T-1, Recommended Standard Specification for Synthetic Web Tie Downs, 2015 042-3 Builder's Warranty

The Builder shall provide a Builder'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 builder by the United States (U.S.) Navy Boat Inventory Manager.

042-4 Hull Warranty

The Builder shall provide a minimum ten (10) year limited Hull Warranty starting from the date the boat enters service with the Navy's end-user. Notification of official in-service date will be provided to the builder by the U.S. Navy Boat Inventory Manager.

042-5 Alternate Items Where boat components and 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 Builder may propose the use of other products which are equal to the specified make and model products. The following general requirements shall form the basis for determining the equality of alternate products unless additional specific or alternate requirements are designated within the applicable sections of these Specifications.

· 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 (i.e., 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 Builder 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 Builder 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 Builder's expense.

· An alternate item shall conform to the same industry or Government 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 Builder.

· 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 Builder 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): xx.xx feet (ft)

· Length with collar deflated: xx.xx ft

· Hull Length (Lhull): xx.xx ft

· Beam Overall (BOA): xx.x ft

· Beam with collar deflated: xx.x ft

· Chine Beam: xx.x ft

· Height, Keel to Fixed Structure: xx.x ft

· Height, Keel to Moveable Structure: xx.x ft

· Length on trailer when rigged for transport: xx.x ft

· Height on trailer when rigged for transport: xx.x ft

· Width on trailer when rigged for transport: xx.x ft

· Deadrise: xx degrees (state if constant or variable)

· Total Installed Fuel Capacity: xxx gallons

· Full Load Weight:

· OCC Variant (as defined in Section 070-4): x,xxx pounds (lbs) incl x% construction margin

· Cabin Variant (as defined in Section 070-4): x,xxx lbs incl x% construction margin

· Longitudinal Center of Gravity (LCG) in Full Load:

· OCC Variant: xx.x ft forward of transom/keel intersect

· Cabin Variant: xx.x ft forward of transom/keel intersect

· Draft: x.x ft at Full Load

· *Cruise Speed (at x,xxx engine RPM): xx knots at Full Load in calm water

· Sprint Speed (at wide open throttle): xx knots at Full Load in calm water

*Cruise Speed shall be minimum 30 knots at Full Load in calm water.

Builders shall provide all parameters above in Attachment 2.

070-2 Builder Submitted Drawings

Builders shall provide a list of the submitted drawings describing the OCC and Cabin variants of the proposed boat in Attachment 2.

070-3 Environmental Conditions

The boat shall be capable of operating in ambient air temperatures between five (5) degrees Fahrenheit and one hundred and twenty-five (125) degrees Fahrenheit and water temperatures between twenty-eight (28) degrees Fahrenheit and ninety-five (95) degrees Fahrenheit.

The boat shall be capable of full operation in up to Sea State 2 (2.9 foot significant wave height) and reduced operations in up to Sea State 3 (4.6 foot significant wave height). The boat shall survive up to Sea State 4 conditions (6.9 foot significant wave height) at minimum headway speed.

070-4 Load Conditions The following load conditions are defined for reference throughout this Specification for the OCC and Cabin Variants. These definitions apply to the engineering design values for weight and moments of the vessel in the described condition. The heavier of the OCC or Cabin Variant in each applicable condition shall be used for design calculations. 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 300 lbs.

· Minimum Payload (OCC Variant): The boat shall be capable of supporting a minimum of 4,995 lbs total payload, including personnel and mission gear. The notional breakdown of payload is seven (7) personnel (two (2) crew + five (5) divers @ 285 lbs each) and 3,000 lbs of mission gear. Mission gear is defined as a combination of weapons, ammunition, miscellaneous mission gear, and cargo tied down on the deck.

· Minimum Payload (Cabin Variant): The boat shall be capable of supporting a minimum of 3,995 lbs total payload, including personnel and mission gear. The notional breakdown of payload is seven (7) personnel (two (2) crew + five (5) divers @ 285 lbs each) and 2,000 lbs of mission gear. Mission gear is defined as a combination of weapons, ammunition, miscellaneous mission gear, and cargo tied down on the deck.

· Light Ship: The boat is complete in all respects including outfit (defined in Section 670-1), and ready for service with liquids in machinery at operating levels but no personnel, fuel, or other variable loads.

· Boat Scale Weight Condition: Light Ship plus full fuel. If simulated fuel weight shall be calculated using a density of 6.1 lbs/gallon.

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

· Builder’s Trials (BT) Load Condition: Lightship 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): Full Load minus personnel (-7 x 220 lbs = -1540 lbs).

· 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 Only Design Hoisting: Full Load Condition.

· Trailer Design Hoisting: Trailer Curb Weight.

· Combined (Boat and Trailer) Design Hoisting: Boat OTR (weight and moment) plus Trailer Design Hoisting (weight and moment), including any additional material needed for hoisting trailer beneath boat (e.g. additional tie-down straps, ballast (if necessary) and deck tie-downs, etc.).

· Internal Air Transport (IAT): Boat OTR, reduced to have no more than 25% fuel plus Trailer Curb Weight, rounded up to the neared 1,000 pounds (minimum).

070-5 Configuration Management The Builder shall practice configuration management of each of the boat variants per the Statement of Work (SOW).

070-6 American Boat and Yacht Council (ABYC) Standards

As a minimum, the boat in all respects shall meet ABYC standards and recommended practices.

070-7 Alterations

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

070-8 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.

Galvanically dissimilar metals (copper compounds or stainless steels, aluminum) 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 140 oF . Protective guards, insulation, or caution signs shall be installed to prevent contact with equipment where surface temperatures exceed 120 oF , up to 140 oF .

Protective guards shall also 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 radiused to avoid injury to personnel.

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 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.

071-2 Bilge Access

All bilges and voids shall have removable plates or hatches for bilge access/inspection. The access and inspection openings shall be of sufficient size and location to allow personnel visual access to the entire bilge and void area.

075 FASTENERS

075-1 Stainless Steel Fasteners

Fasteners shall be Stainless Steel. Fasteners used for structural applications shall be ASTM F593, type 316 throughout for structural applications. Self locking hardware shall be used unless otherwise specified.

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

Fasteners may be threaded into structural or non-structural materials only with Government approval. Any pins used for folding, removable, or stowable features shall be secured with stainless steel lanyard to prevent loss.

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.

078 MATERIALS

078-1 Non-Metallic Materials

The use of non-metallic materials and metals with low magnetic properties are desired where practical to reduce the boat’s overall magnetic signature.

078-2 Structural Material/FRP

The hull and deck shall be FRP using an infusion lamination process (or similar Government approved process). Fire retardant vinylester resin shall be used throughout. Polyvinyl Chloride (PVC) or polyurethane core shall be utilized for all cored structure. High density PVC or polyurethane foam core inserts shall be used in all high strength connections in cored areas. See “Core Material Selection Guidance for Navy Boatbuilders” for guidance on core materials.

Fabricated structural metal components of the boat shall conform to the following specifications:

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

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

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

078-3 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 UltraViolet (UV) exposure.

078-4 Fabric Material

All boat fabric shall be marine grade as well as fade, stain and mildew resistant and as near a match in color as possible to the surface it is mounted to 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.

079 STABILITY

079-1 Stability

The boat shall meet the static stability standards of ISO 6185-4:2014, Inflatable Boats Part 4: Boats with a Hull Length of Between 8m and 24m with a Motor Power Rating of 15 kW and Greater. Calculation assumptions shall be:

· The boat shall be Type X with a design category of B, option 3 in the full load condition as defined in Section 070-4.

· The payload shall be assumed to have a Vertical Center of Gravity (VCG) of 24 inches above the deck and a Longitudinal Center of Gravity (LCG) equal to the Lightship plus fuel LCG.

· A crew limit of seven (7) at 220 lbs each shall be used for the offset load calculations.

The tops of the collar and transom shall be used as the downflooding points.

See Section 085 for technical analysis requirements.

079-2 Flotation Flotation characteristics shall be incorporated (e.g. foam, tubes/collars and/or proven watertight compartmentalization) to meet the flotation requirements of ISO 6185-4:2014 Section 7.6 using the calculation methods, not the physical testing methods.

See Section 085 for technical analysis requirements.

079-3 Flotation Foam

If flotation foam is required and used to obtain the proper floating characteristics, foam in place solutions (pour in foam) shall not be used. Flotation Foam installed shall meet ISO 6185-4:2014 requirements.

080 INTEGRATED LOGISTIC SUPPORT

080-1 Packaging

Packaging/Shrink Wrap shall be used to protect the boat during delivery.

083 SPARES

083-1 Initial Spares List

Where specified by the Delivery Order, the builder shall provide initial spares in accordance with Attachment 3.

Builders shall provide a quote for spares listed in Attachment 3: submit in Vol II (Price).

084 TRANSPORTATION AND HANDLING

084-1 Air Transport

Boat and trailer combination shall meet all requirements (size, weight, tiedown) for air transportability in a C-130, C-17, and C-5 including personnel safety aisle criteria. C-17 and C-5 transport should not require equipment removal. Tiedowns shall be provided on the trailer and boat to provide a restraint independent of each other of 3-Gs fwd, 2-Gs up and 1.5-Gs aft and laterally, engineering certification/ratings included for tiedowns. Preliminary profile and general arrangement drawings shall be provided 60 days after receipt of order (ARO) to verify boat system will fit into C-130 envelope.

Not-to-exceed parameters for C-130:

· Height - 102 inches

· Width - 107 inches

Height and width parameters are per MIL-STD-1366E (Table 24; additional guidance in MIL-STD-1791A, Sec 4.2.1.5 and Appendix B, Fig. 42). Items may exceed the height or width envelope if hinged or removable and are provided with proper securing for stowage during transport.

See Section 085 for technical analysis requirements.

084-2 Road Transport

Boat and trailer combination shall meet all requirements for wide load without escort vehicle road transport on Continental United States (CONUS) Highways per MIL-STD-1366E.

Boat/trailer combination shall not exceed the following dimensions:

· Height - 162 inches

· Width (collars inflated) - 120 inches (10 ft)

Items may exceed the height or width envelope if hinged or are otherwise collapsible for transport. Trailer components (except goal posts) shall not be removed to meet this requirement.

See Section 085 for technical analysis requirements.

(OBJECTIVE) GVW: The GVW (for the OCC and Cabin Variants) shall be 13,000 lbs or less to be within Light Service Support Vehicle (LSSV) prime mover maximum towing capacity.

084-3 Marine Transport, Launch and Recovery The boat shall be designed for marine transport, to include onboard stowage and at sea underway (manned) launch and recovery from U.S. Navy ships. Launch and recovery shall be from ship’s crane with the single point hoisting configuration (see Sections 611-2 and 611-3) or from a specialized launch and recovery system on the well deck’s stern gate of a U.S. Navy amphibious ship. See Sections 084-6 and 582-2 for trailer and boat provisions to interface with the launch and recovery system.

084-4 Boat Tiedowns

Boat shall have aluminum or stainless steel tiedown provisions including two (2) transom tiedowns, bow eye, and side tiedowns. Labeling of the tiedowns shall include load ratings in lbs. Tiedown provision and adjacent structure shall be sized for maximum applicable load, as follows:

1.) Air Transport: Restraint of boat and trailer using IAT load condition weights (Section 070-4), shall provide a minimum safety factor of 1.5 on yield strength for accelerations of 3g Forward, 1.5g Aft, 1.5g Transverse, 2g Up and 4.5g Down (shoring permitted), or

2.) OTR Transport: Restraint of boat to trailer using Boat OTR load condition weight (Section 070-4), shall be designed per MIL-STD-1366E and 49CFR393.102, to provide a minimum safety factor of 1.5 on yield strength, or

3.) Marine Transport: Restraint of boat and trailer using GVW load condition weight (Section 070-4), per MIL-STD-1366E section 5.1.6 shall provide a minimum safety factor of 1.5 on yield strength. Fittings design limit loads are as follows: 0.5 times the load in the longitudinal direction and 1.0 times the load in the lateral direction. For calculations, bunk loads can be assumed to restrain the boat in the lateral direction, or 4.) Trailer Hoisting: Trailer Design Hoisting condition with a minimum safety factor of five (5) on ultimate strength for hoisting trailer with boat.

Notes:

a) A common tiedown system shall be designed for all variants using the highest load cases of all the variants.

b) If aluminum (preferred) or stainless steel trailer tiedowns are not available, hot-dipped galvanized components may be used.

c) Boat and trailer may be considered separately (each at their own IAT weight) to assist in IAT restraint calculations.

d) Trailer winch cable shall not be considered in restraint calculations for IAT or hoisting, but may be considered for OTR loads.

e) See Transportability Design and Certification Process Guidance NSWCCD-23-TM-2009/64 for additional details.

See Sections 085 and 092 for testing requirements.

084-5 Tiedown Straps

Tiedown straps shall be provided 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 completed trailer weight beneath boat.

· The trailer tiedown strap arrangement shall provide 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.

084-6 Rough Terrain Trailer (RTT) A Boatmaster RTT shall be provided for the boat. The boat and RTT will be towed by Light Service Support Vehicle (LSSV) or similar prime mover for off-road operations on unimproved roads. Unimproved roads are defined as one lane trails or roads with seldom maintained loose surfaces intended for low-density traffic. The trailer shall be air transportable in a C-130 with the boat. The trailer shall be capable of supporting the boat in the OTR condition and negotiating ramp angles up to 16 degrees. The trailer shall be capable of being used for Stern Gate Launch and Recovery (SGLR) of the boat from the well deck of a U.S. Navy amphibious ship. Adapter plates for easy installation of a SGLR kit (not procured) shall be integrated into the trailer design. SGLR design details available upon request. The trailer shall have the following characteristics:

· Gross Vehicle Weight Rating (GVWR) shall not be less than the GVW defined in Section 070-4.

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

· Axle Rating: The trailer shall be two axle. The axle ratings shall be chosen such that the total provides 115-120% of the GVW due to high loads seen during rough terrain transit and SGLR operations.

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

· Tire Rating: The combined tire ratings per axel 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: LT All-Terrain 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: Surge 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 (two inch (2") min. radius). Flex hoses, where necessary, shall be stainless or Kevlar, and have a minimum rating of 3,000 psi.

· 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-TightTM) 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 w/ 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.

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

· Winch: Manual winch with cable 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: Interchangeable hitch with three inch (3") lunette ring and two and five-sixteenths inch (2 5/16") ball receiver (both shall be provided when appropriate for trailer GVWR).

· 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 084-4). Tiedowns shall be labeled per MIL-STD-209K.

· SGLR Kit Provisions: Adapter plates and components for future install of a removable SGLR kit shall be integrated into the trailer.

· 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.

Builders shall provide specific trailer specification sheet in Attachment 2.

085 TECHNICAL DATA PACKAGE (TDP)

A TDP for each boat variant [OCC, Cabin] shall be provided and shall comply with the requirements of this section.

The TDP shall include all information essential for acceptance, operation/training, maintenance, repair, modification and supply support for the delivered boat and trailer (where provided). The TDP shall include but not be limited to:

1. Technical Design Analyses

2. As-built boat drawings including or cross referenced to:

3. Bill Of Materials (BOM) to the Line Replaceable Unit (LRU) level

4. COTS manuals

5. Boat Technical Manual

6. OEM certifications

7. OEM warranty durations for major systems

8. Test and Trials Reports

9. A Master Data Index.

085-1 Technical Design Analyses

Technical Design Analyses shall be clear and complete. No steps shall be skipped or presumed. Any descriptive information needed to completely describe the calculations and their methods shall be included. For repetitive calculations, a full example calculation describing methodology, assumptions and any additional descriptive information shall be provided. Subsequent repetitive calculations may be placed in a matrix or tabular form that includes all inputs and outputs to these calculations.

Calculations shall be clear and complete and include the following:

· Clear, complete and concise assumptions presented in a neat, legible manner.

· Any necessary diagrams to fully describe the design situation and its associated calculations.

· Pertinent information from all references, standards and guidelines cited including appropriate excerpts.

· All symbols and acronyms fully defined.

A sample calculation is included as an Appendix to NSWCCD-23-TM-2009/33, Hoisting System Design and Certification Process Guidance, October 2009, US Navy Boats Hoisting Guidance document.

The Builder shall provide the following Technical Design Analyses:

a) Boat Stability and Flotation: The analysis shall demonstrate that the integration of static stability and flotation standards in the boat design meets the required criteria in Sections 079-1 and 079-2.

b) Air Transport Design: The report meeting the requirements of Section 084-1 for air transportability shall include general arrangement drawings proving the boat on trailer can be loaded into the C-130, C-17, and C-5 aircraft, boat and trailer to airdeck tiedown arrangement drawings, and restraint calculations.

a) Transportability Report: A report shall be provided for over-the-road transport, maritime shipping, and internal air transport in C-130/C-17/C-5 aircraft, in accordance with the format and content of Data Item Description, DI-PACK 80880 per Sections 084-1, 084-2, and 084-3.

b) Tiedown Provision Design: The analysis shall demonstrate that the design of the tiedowns/restraints, fittings, and straps have the appropriate minimum factor of safety based on the weight and design loads in Section 084-4.

c) Forward and Aft Tow Provision Design: The analysis shall demonstrate that the design of the tow provisions and supporting structure meets the required criteria in Section 582-1.

d) Bow Eye Design: The analysis shall demonstrate that the design of the bow eye and supporting structure meets the required criteria in Section 582-2.

e) Davit Design: The analysis shall demonstrate that the design of the davit system and supporting structure meets the required criteria in Section 589-2.

f) Hoisting System Design: The analysis shall demonstrate that the design of the hoisting system and supporting structure meets the required criteria in Section 611-2.

g) Weapon Foundation Design: The analysis shall demonstrate that the weapon foundation and supporting structure is designed to meet the required criteria in Section 700-1.

Analysis documentation for Items in Section 085-1 shall be provided in electronic format per Section 085-10. Analyses are for the first boat of the contract. As a minimum, final analyses shall be presented with the Preliminary TDP thirty (30) days prior to PDITs of the first Delivery Order. Initial submission of specific analyses shall also be accomplished in accordance with the applicable Specification sections prior to installation.

085-2 Drawings

Drawings and drawing revisions shall be prepared in accordance with the guidance of ASME Y14.100 and all referenced documents. Drawing level of detail shall be sufficient for acceptance, operation/training, maintenance, repair, modification and supply support for the delivered boat. The Builder shall validate the construction drawings during the construction process by building all boats to the drawings. Drawings shall first be validated against the initial boat. The original drawings shall be revised to show the actual construction if discrepancies are found. Subsequent boats shall be checked against the revised drawings to validate the revision. The drawings shall be revised so that they are maintained up to date. The latest revision shall accurately reflect all boats as constructed and the current status of changes, deviations and waivers. Drawings shall include a list above the title block of the applicable hull numbers for the given contract. All drawings shall be marked as ‘Rev –‘ during the draft process through final approval. Any changes made after final approval will receive a ‘Rev A’, ‘Rev B’, etc marking with revision history.

Drawings shall include, but are not limited to:

a) Boat Drawing Index

A boat drawing index shall be developed. This drawing shall list, in tabular form, all final construction drawings by drawing number, revision and title.