PD1006011A ACE VEST HARNESS PD 04Apr2024.pdf

PD1006011A

04 APRIL 2024

PD1006011-

21 JULY 2023

PURCHASE DESCRIPTION

AIR SOLDIER AIRCREW COMBAT ENSEMBLE (ACE)

VEST/HARNESS ASSEMBLY

Part Name P/N

AIRCREW COMBAT ENSEMBLE

VEST/HARNESS X-SMALL, ASSEMBLY

1081468-N-1

AIRCREW COMBAT ENSEMBLE

VEST/HARNESS SMALL, ASSEMBLY

1081468-N-2

AIRCREW COMBAT ENSEMBLE

VEST/HARNESS MEDIUM, ASSEMBLY

1081468-N-3

AIRCREW COMBAT ENSEMBLE

VEST/HARNESS LARGE, ASSEMBLY

1081468-N-4

AIRCREW COMBAT ENSEMBLE

VEST/HARNESS X-LARGE, ASSEMBLY

1081468-N-5

This document is approved for use by all Departments and Agencies of the Department of Defense (DOD). Recommended improvements, simplifications, or reductions in paperwork are encouraged and should be directed to the preparing activity.

1. Scope This document defines the production requirements for the Air Soldier Aircrew Combat Equipment (ACE) Vest/Harness Assembly, Part Number (P/N) 1081468-N-1, -2, -3, -4, and -5 (where N is a Generic Color indicator which is substituted with a numeric designation for a specific camouflage family color or pattern (see 6.2)), used by helicopter aircrew for survival gear carriage, extraction and retrieval, insertion, flotation, ballistic protection, and crew restraint.

The objective of the Aircrew Combat Equipment (ACE) is to integrate aviation life support and mission equipment into an ensemble that provides combat overmatch and improves combat effectiveness of the Army aircrew member. It is used by Army aircrew members on flight status.

The ACE Assembly includes a Vest/Harness Assembly with extraction strap and locking carabiner and a Pouch Assembly. It interfaces with an integrated Life Preserver Unit and

NOT MEASUREMENT

SENSITIVE

Comments, suggestions, or questions on this document should be addressed to Product Manager (PM) Air Warrior, SFAE-SDR-AW, 6726 Odyssey Drive NW, Huntsville, AL 35806.

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and DoD Contractors only for administrative and operational use, 10 Jan 2023. Other requests shall be referred to: Product Manager (PM) Air Warrior (AW), SFAE-SDR-AW, 6726 Odyssey Drive NW, Huntsville, AL 35806.

PD1006011

Restraint System (comprised of a Quick Release Tether, an Extension Tether, and a locking carabiner).

The ACE Vest/Harness Assembly consists of:

• Front Harness Armor Carrier Assembly

• Back Harness Armor Carrier Assembly

• Cummerbund Assembly

• Leg Strap Assembly

• Side Armor Pouches (qty 2)

The front harness armor carrier assembly has laser-cut Pouch Attachment Ladder System (PALS) on the exterior panel for attachment of a modular set of pouches (Pouch Assembly) used to carry survival gear. The pouches can be positioned to best suit the individual’s body size and the requirements of the mission. It has carriage compartments for soft Modular Scalable Vest (MSV) body armor panels, Enhanced Small Arms Protective Inserts (ESAPI), and 72-Hour survival kits. These components are not included with the ACE Vest/Harness Assembly and are procured separately.

The ACE Pouch Kit consists of:

• Combat Survivor Evader Locator (CSEL) Pouch

• Combo Pouch (holds folding knife and signaling light/flashlight)

• Multipurpose Pouch (holds tourniquet)

• Utility Pouch

• M17 Magazine Pouch (qty 3)

• M4 Magazine Pouch (qty 2)

• Blower Pouch

• Adapter Platform

The pouches can be mounted on the vest front assembly and on the cummerbund.

The ACE Vest/Harness capabilities include ballistic threat protection, extraction by hoist, extraction attached to the fuselage, crew retention, and dragging an incapacitated aircrew.

• With armor installed in the integrated armor carriage compartments, the assembly provides spall and small arms up to 30 caliber threat protection.

• For the safety of conscious and unconscious aircrew retention and extraction, the assembly includes an integrated full-body harness.

• To provide for extraction, the vest front assembly has an integrated strap with sewn loop end and attached carabiner, stowed within the vest. When removed from stowage, the carabiner on the strap enables connection to a helicopter hoist hook for extraction of a downed aircrew.

• For extraction attached to the fuselage, the integrated straps can also be used with an Extraction Strap to secure aircrew located in precarious positions during rescue such as being seated on helicopter landing gear or pylons.

• For helicopter cabin operations, a retention capability is provided by configuring the ACE Vest/Harness with a Quick Release Tether (QRT) that provides a quick release handle on the vest front and emerges through an opening on the Vest/Harness back panel.

Here, the QRT Emergency Release Assembly hardware is connected to the harness straps to create an attachment point for the Extension Tether, which in turn connects to the aircraft Personal Restraint Tether.

• For retrieval of unconscious aircrew, there is a drag handle for rescue at the top of the back panel of the Vest/Harness.

To add overwater flotation capability, the ACE interfaces with the Life Preserver Unit (LPU), type-classified as Underarm Life Preserver, LPU-42/P which is a torso-wrapping device. The casing of the LPU-42/P attaches to the harness straps of the ACE Vest/Harness, resting the lower edge of the flotation device casing near the lower edge of the armor compartment. This provides secure low-profile carriage of the flotation. A beaded handle for bladder inflation is positioned at the center neck edge of the Vest/Harness. Pulling the beaded handle: 1) triggers CO2 to inflate the bladder; and 2) releases the front panel from the left and right sides. Panel release allows the vest front to pivot outward as the LPU-42/P inflates and wraps around the torso. Buoyancy of the device is greater than 65 lb. which is sufficient to keep the equipment-laden aircrew afloat in rough seas.

2. Applicable Documents

2.1. General

The documents listed in this section are specified in sections 3 and 4 of this document. This section does not include documents cited in other sections of this document or recommended for additional information. 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 document, 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 issues shall be those in effect on the date of the solicitation.

COMMERCIAL ITEM DESCRIPTIONS

A-A-59826 Thread, Nylon

DEPARTMENT OF DEFENSE SPECFICATIONS

MIL-DTL-32075 Label: For Clothing, Equipage, and Tentage, (General Use) MIL-L-11075 Loops, Strap Fastener

(Unless otherwise indicated, copies of Federal and Military specifications, standards, descriptions, and handbooks are available from the Standardization Documents Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA, 19111-5094. Many of these are available from the Assist-Quick Search web site: http://quicksearch.dla.mil/).

2.2.2. Other Government Documents, Drawings and Publications

DRAWINGS

Drawing Number

Drawing Name

1005833 Quick Release Adjustable Buckle 1005938 Electrostatic Decay Test Method 1050955 Component Materials and Colors 1081468 Vest/Harness Assembly 1081471 Cummerbund Assembly 1081472 Front Harness Armor Carrier Assembly 1081473 1081474

Back Harness Armor Carrier Assembly Cut Parts, Adapter

1081475 1081476

Buckle, Side Release, 1 ½ Inch Cummerbund Adapter Assembly

1081477 Shoulder Pad Assembly 1081478 Cut Parts, Shoulder Pad 1081479 Leg Strap Assembly 1081482 Front Harness Strap Assembly 1081484 Cable Keeper 1081486 Back Harness Strap Assembly 1081487 Back Handle Strap 1081488 Pocket Grommet Tab 1081489 Right and Left Pocket Assembly 1081491 Front PALS Panel Assembly 1081494 Connector, Circular Snap 1081495 1081496 1081497 1081498 1081499

Cut Parts, X-Small, Front, Harness/Armor Carrier Cut Parts, Small, Front, Harness/Armor Carrier Cut Parts, Medium, Front, Harness/Armor Carrier Cut Parts, Large, Front, Harness/Armor Carrier Cut Parts, X-Large, Front, Harness/Armor Carrier

1081502 Cut Parts, Medium, Back Harness/Armor Carrier 1081503 1081504

Cut Parts, Large, Back Harness/Armor Carrier Cut Parts, X-Large, Back Harness/Armor Carrier

1081505 Cut Parts, X-Small Cummerbund 1081506 Cut Parts, Small Cummerbund http://quicksearch.dla.mil/)

1081507 Cut Parts, Medium Cummerbund 1081508 Cut Parts, Large Cummerbund 1081509 Cut Parts, X-Large Cummerbund 1081510 Front Armor Pocket Assembly 1081511 Front Main Panel Assembly 1081512 Front Mesh Panel Assembly 1081513 PALS Lock Cable Pocket Assembly 1081514 Back PALS Panel Assembly 1081515 Back Plate Pocket Assembly 1081516 Tray Pocket Panel Assembly 1081517 1081518 1081519 1081520 1081521 1081522

Cummerbund Channel Assembly Back Main Panel Assembly Back Mesh Panel Assembly Labels, ACE Vest Fabric, Laminated Nylon PALS and Plate Pocket Assembly

1081529 Composite Laminate Stiffener 1081533 Side Armor Pouch 1081534 Cut Parts, Vest Pockets 1081556 Cut Parts, Side Armor Pouch, 6x6 1081557 Cut Parts, Side Armor Pouch, 6x8 1081558 Cut Parts, Side Armor Pouch, 7x8 1081559 Labels, Side Armor Pouch 1081561 Harness, Center Extension 1081562 Harness, Extension 1081563 Harness, Front Shoulder 1081567 Labels, Cummerbund 1081568 Labels, Leg Strap 1081569 Ethylene Vinyl Acetate (EVA) Closed Cell Foam, Sheet 1081570 Polyolefin Closed Cell Foam, Sheet

(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 documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues shall be those in effect on the date of the solicitation.

AEROSPACE INDUSTRIES ASSOCATION OF AMERICA (AIA)

NASM16491 Grommet, Metallic, General Specification For

(Copies of these documents are available from the Aerospace Industries Association of America – 1000 Wilson Boulevard, Suite 1700 Arlington, VA 22209-3928, or online at www.aia-aerospace.org.)

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

AATCC Evaluation Procedure 9 2017

Visual Assessment of Color Difference of Textiles

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

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/ASQ Z1.4-R2018 American National Standard Sampling Procedures and Tables for Inspection by Attributes

(Copies of these documents are available from the American Society for Quality (ASQ) – 600 North Plankinton Ave, Milwaukee, WI 53203, or online at www.asq.org.)

ASTM INTERNATIONAL

ASTM D 6193 Standard Practices for Stitches and Seams

(Copies of these documents are available from the ASTM International – 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428, or online at www.astm.org.)

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 11664-2:2007/ Colorimetry – Part 2: CIE standard illuminants (Copies of these documents are available from the Commission Internationale de l’Eclairage (International Commission on Illumination) –online at www.cie.co.at/ or International Organization for Standardization – online at www.iso.org.)

PARACHUTE INDUSTRY ASSOCIATION

PIA-C-5040 Cord, Nylon, Fibrous PIA-C-5651 Cord, Elastic, Exerciser and Shock Absorber, for

Aeronautical Use PIA-W-5625 Webbing, Textile, Nylon, Tubular PIA-W-5664 Webbing, Textile, Elastic PIA-W-17337 Webbing, Textile, Woven Nylon

(Copies of these documents are available from the Parachute Industry Association – 3833 West Oakton Street, Skokie, IL 60076, or online at www.pia.com.)

http://www.aia-aerospace.org/ http://www.aatcc.org/ http://www.asq.org/ http://www.astm.org/ http://www.cie.co.at/ http://www.iso.org/

2.4. Order of Precedence

Unless otherwise noted herein or in the contract, in the event of conflicts between the text of this document and the references cited herein, the drawings take precedence, followed by the text of this document, and then the specifications and standards. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. Requirements

3.1. Classification of Inspection and Test

When specified in the contract or order (see 6.2), sample(s) shall be subject to first article (see 3.1.1) and conformance inspection (see 3.1.2).

3.1.1. First Article Inspection and Test

When specified in the contract or order, sample(s) representing full production quality shall be subjected to first article inspection and test in accordance with (IAW) 4.1.1.

3.1.2. Conformance Inspection and Test

Sample(s) representing full production quality shall be subjected to conformance inspection and test IAW 4.1.2.

3.1.2.1. Classification of Defects

Defects identified during conformance inspection and test shall be classified and assigned a defect code (see Table IV).

3.2. Materials and Components

Materials and components shall conform to applicable specifications, standards, and drawings required herein. The FR Textured Cloth, P/N 1050955-70 and Laminated Nylon Fabric, P/N 1081521-N shall meet the Electrostatic Decay requirements IAW drawing 1005938.

3.3. Design

3.3.1. Part Numbers

The end item part number for the ACE Vest Harness shall be 1081468-N-1, -2, -3, -4, or -5, depending on size, where N is a Generic Color indicator which is substituted with a numeric designation for a specific camouflage family color or pattern (see 6.2).

3.3.2. Fabrication

The end items shall be fabricated IAW the requirements specified in the drawings listed below.

Number

Drawing Name

1005833 Quick Release Adjustable Buckle 1005938 Electrostatic Decay Test Method 1050955 Component Materials and Colors 1081468 Vest/Harness Assembly 1081471 Cummerbund Assembly 1081472 Front Harness Armor Carrier Assembly 1081473 1081474

Back Harness Armor Carrier Assembly Cut Parts, Adapter

1081475 1081476

Buckle, Side Release, 1 ½ Inch Cummerbund Adapter Assembly

1081477 Shoulder Pad Assembly 1081478 Cut Parts, Shoulder Pad 1081479 Leg Strap Assembly 1081482 Front Harness Strap Assembly 1081484 Cable Keeper 1081486 Back Harness Strap Assembly 1081487 Back Handle Strap 1081488 Pocket Grommet Tab 1081489 Right and Left Pocket Assembly 1081491 Front PALS Panel Assembly 1081494 Connector, Circular Snap 1081495 1081496 1081497 1081498 1081499

Cut Parts, X-Small, Front, Harness/Armor Carrier Cut Parts, Small, Front, Harness/Armor Carrier Cut Parts, Medium, Front, Harness/Armor Carrier Cut Parts, Large, Front, Harness/Armor Carrier Cut Parts, X-Large, Front, Harness/Armor Carrier

1081500 1081501 1081502

Cut Parts, X-Small, Back, Harness/Armor Carrier Cut Parts, Small, Back, Harness/Armor Carrier Cut Parts, Medium, Back, Harness/Armor Carrier

1081503 1081504

Cut Parts, Large, Back, Harness/Armor Carrier Cut Parts, X-Large, Back, Harness/Armor Carrier

1081505 Cut Parts, X-Small Cummerbund 1081506 Cut Parts, Small Cummerbund 1081507 Cut Parts, Medium Cummerbund 1081508 Cut Parts, Large Cummerbund 1081509 Cut Parts, X-Large Cummerbund 1081510 Front Armor Pocket Assembly 1081511 Front Main Panel Assembly 1081512 Front Mesh Panel Assembly 1081513 PALS Lock Cable Pocket Assembly 1081514 Back PALS Panel Assembly 1081515 Back Plate Pocket Assembly 1081516 Tray Pocket Panel Assembly

1081517 1081518 1081519 1081520 1081521 1081522

Cummerbund Channel Assembly Back Main Panel Assembly Back Mesh Panel Assembly Labels, ACE Vest Fabric, Laminated Nylon PALS and Plate Pocket Assembly

1081529 Composite Laminate Stiffener 1081533 Side Armor Pouch 1081534 Cut Parts, Vest Pockets 1081556 Cut Parts, Side Armor Pouch, 6x6 1081557 Cut Parts, Side Armor Pouch, 6x8 1081558 Cut Parts, Side Armor Pouch, 7x8 1081559 Labels, Side Armor Pouch 1081561 Harness, Center Extension 1081562 Harness, Extension 1081563 Harness, Front Shoulder 1081567 Labels, Cummerbund 1081568 Labels, Leg Strap 1081569 Ethylene Vinyl Acetate (EVA) Closed Cell Foam, Sheet 1081570 Polyolefin Closed Cell Foam, Sheet

3.3.3. Cut Parts

The cut parts used to fabricate the ACE Vest Harness shall be derived from the electronic data supplied by the Government. Electronic data for the pattern or cut part drawings, listed in 3.3.2, will be provided in electronic format in a recent Gerber AccuMark version if requested. For contractors without access to compatible AccuMark CAD and/or plotting capabilities is recommended to utilize a 2nd party Pattern Service for pattern conversion and/or plotting. [Note to open electronic patterns: On the computer that has your CAD software save the file ending in .zip1 to your desktop, rename the file extension to .zip, then import into CAD. The data (geometry and component locations) in the supplied cut part files shall not be modified without written approval from the Government. The manufacturer may add marks to the working cut parts beyond those defined by the electronic data to support the manufacturer's fabrication process.

3.4. Construction

3.4.1. Stitching and Seams

Stitches, seams, and stitching types shall be as specified on the applicable drawings and constructed IAW ASTM D 6193.

3.4.2. Seam Workmanship

Seam workmanship shall be such that no raw edges, run-offs, pleats, puckers, or open seams are present (see 6.5).

3.4.3. Seam Finishing

Seams shall be either turned under by a hem, or held by other stitching, or encased in edge binding stitched as specified on the applicable drawing.

3.4.4. Backstitching

Backstitching and overstitching shall be not less than ½ inch in length, except where the ends are turned under or caught in other seams or stitching.

3.4.5. Stitches Per Inch

Stitches per inch shall be as specified on the drawings.

3.4.6. Thread Breaks, Skips and Run-offs

Thread breaks, skips, and run-offs shall be over-stitched not less than ½ inch.

3.4.7. Straight Stitching

Each line of straight stitching shall be straight and parallel to the seam edge.

3.4.8. Bartacking

Bartacks shall not be loose, misplaced, or missing.

3.4.9. Thread Tension

Thread tension shall be such that seams show no loose stitching or puckering of the material sewn (see 6.5).

3.4.10. Thread Ends

All thread ends shall be trimmed flush (+1/16/-0 inch) with the surface of the finished item.

3.4.11. General Workmanship

End items shall be free from irregularities or defects that could adversely affect performance or durability.

3.4.12. Labeling

3.4.12.1. Item labeling (labels and alternate markings) shall be IAW the applicable drawing requirements.

3.4.12.2. All item labeling shall be easily legible with unaided examination by untrained personnel.

3.4.12.3. All item labeling shall be free of smears or smudging.

3.4.13. Repairs

For non-load bearing components, repairs to ASTM D 6193 Type 301 stitching are allowed.

Loose or excessively tight stitching shall be repaired by removing the defective stitching without damaging the materials and re-stitching as required in the applicable drawing. Stitching shall be restarted and overstitched a minimum of 1/2 inch. Needle holes resulting from removed stitching do not constitute damage to the material. For load-bearing components, the complete removal and replacement of multiple point (Class 7 or WW) stitch patterns is NOT allowed.

Broken stitches shall be reinforced by overlapping the stitching 4 stitches on either end of the break. Three reinforcements are allowed in the harness assembly with no more than 1 reinforcement per stitch formation. All other proposed repairs (rework that results in a configuration not in strict compliance with the drawing requirements) shall be approved by the Government with a Request for Variance (RFV). Stitching specified as three rows of stitching or bartack stitches on the critical load bearing components (listed in 3.5.2.1 and 3.5.2.2) shall not be reworked or repaired.

3.5. Operational Requirements

3.5.1. Color and Spectral Reflectance

3.5.1.1. Visual Shade Comparison

The components identified in Table I, column A, shall match the standard sample for shade and appearance.

3.5.1.2. Visual Shade Matching

The color and appearance of the components identified in Table I, column B, shall match the standard sample when tested as specified in 4.5.1.2.

3.5.1.3. Spectral Reflectance

The spectral reflectance of the components identified in Table I, column C, shall conform to the requirements specified in the applicable drawing, specification, or document unless otherwise amended.

3.5.2. Performance

3.5.2.1. Static Load

The ACE Vest Harness static load path shall withstand a 3,600 lbf minimum load for not less than 60 seconds when tested as specified in 4.5.2.1. The ACE Vest Harness static load path consists of the Front Harness Strap Assembly, P/N 1081482-N-1 through -5, the Back Harness Strap Assembly, P/N 1081486-N-1 through -5, and the Leg Straps, P/N 1081479-N-1 through -5.

The ACE static load path shall not release the test torso, and shall exhibit no tears in webbing, no breakage or permanent deformation of any metallic components, and no webbing slip greater than 1 inch through any adjuster or adapter.

Figure 1: Sternal Load Path (shown from inside view when laid flat)

3.5.2.2. Dynamic Load

The ACE Vest Harness dorsal dynamic load path (see Figure 2) shall withstand a fall of no less than eight feet vertical distance using the dorsal attachment element, and shall retain the rigid torso test fixture weighing 300 +/- 2 lbs for no less than 5 minutes when tested as specified in

4.5.2.2 The rigid torso shall hang at an angle no greater than 50 degrees from vertical after the drop. The ACE Vest Harness dorsal dynamic load path consists of the Front Harness Strap Assembly, P/N 1081482-N-1 through -5, the Back Harness Strap Assembly, P/N 1081486-N-1 through -5, and the Leg Straps, P/N 1081479-N-1 through -5.

Figure 2: Dorsal Load Path (shown from inside view when laid flat)

3.5.2.3. Interface Requirements

The ACE Vest Assembly shall interface, fit, and securely retain

a) the front, back, and side soft armor ballistic inserts,

b) the front and back enhanced small arms protective inserts,

c) the Quick Release Tether (QRT) and allow for the cable routing,

d) the 72-hour survival kit,

e) the ACE LPU-42/P Flotation Device and allow for the cable routing, and

f) the PALS attachments webbings at the loops located at each shoulder.

4. Verifications

4.1. Classifications of Inspections and Tests

The inspection and test requirements specified herein are classified as outlined below. The Government reserves the right to perform any of the inspections and tests set forth where they are deemed necessary to ensure the supplies conform to prescribed requirements.

4.1.1. First Article Inspection and Test

First article inspection and test shall be performed on the items and quantities specified in the contract or order. The required demonstrations, inspections, and tests shall be as identified in Table III. The contractor shall conduct and pass these demonstrations, inspections, and tests prior to submitting end items for Government acceptance. The Government's acceptance of the contractor's end item product will be determined by the requirements validation.

At any point after first article inspection and test has been approved, any material change must be tested IAW the appropriate paragraph(s) of this document and approved by the Government.

4.1.2. Conformance Inspection and Test

Conformance inspection and test shall be performed, on samples (see 4.1.2.1) of completed units randomly selected by the Government from the production lot (see 4.1.2.3), unless otherwise specified. The inspections and tests shall be performed IAW Section 3 and 4 herein prior to submission of items to the Government for acceptance and delivery. This inspection and tests shall include the verifications listed in Table III. The Government's acceptance of the contractor's end item product will be determined by the requirements validation. Responsibility for requirements validation shall be as specified in the contract.

4.1.2.1. Classification of Defects

Verification that defects identified during conformance inspection and tests have been classified and assigned a defect code (see Table IV) shall be by inspection.

4.1.2.2. Sampling of Components

The quantity of items with part numbers listed in 3.3.1 that shall be subjected to conformance inspection and test shall be based on the size of the production lot (see 4.1.2.3) and IAW ANSI/ASQ Z1.4-R2018. The inspection levels shall be as follows:

a) 100% inspection for material certification inspection,

b) 100% inspection for the critical defects as defined in Table IV,

c) General inspection Level II shall be used for visual inspection requirements,

d) Special inspection Level S-3 shall be used for dimensional inspection requirements,

e) Special inspection Level S-3 shall be used for in-process inspection requirements, and

f) Special inspection Level S-1 shall be used for performance verification requirements, other than those listed in a) and b).

4.1.2.3. Production Lot

A production lot is defined as all the units within a single shipment for a contract delivery order plus the units required for performance testing that are made under the same conditions and made from the same materials and components.

4.1.3. Verification Methods

Verification methods shall be as follows:

a) Demonstration. Demonstration shall consist of a functional requirements verification in which the observation of functional operation is the predominant vehicle. Measurement shall not usually be required. Demonstration shall include the actual exercise of component, article, or system characteristics to verify that requirements have been satisfied.

b) Inspection. Inspection shall consist of visual examination, physical manipulation, or measurement (as applicable) of the item under acquisition to verify that requirements have been satisfied.

c) Test. Test shall consist of the collection of data using instrumentation or other special test equipment obtained from the actual exercise of the equipment in either a controlled or an operational environment as appropriate. Analysis of the collected data to compare the tested characteristics with performance and operational requirements shall be the usual means employed to verify that requirements have been satisfied.

4.2. Materials and Components

The materials and components used in the fabrication of the end item shall be subject to demonstration, inspection and/or test to verify conformance to specifications, standards, and drawings and to the requirements of 3.2, if applicable. Certificates of Conformance (COC) for each material shall be inspected to verify that each material meets the requirements of applicable documents. All certifications shall be supported by test reports to ascertain their validity. The certifications and test reports shall be kept on file and available for review for the life of the contract.

4.3. Design

4.3.1. Part Numbers

Verification that the part number on the label attached to the ACE Vest Harness is 1081468-N-1, -2, -3, -4, or -5 (where N is substituted with a numeric designation for a specific camouflage family color or pattern) shall be by inspection.

4.3.2. Fabrication

Verification that the end item conforms to drawing requirements (see 3.3.2) shall be by visual and dimensional inspection. Inspections for conformance to design attributes that cannot be verified on the completed assembly shall be verified during the assembly process. The manufacturer’s build paperwork shall provide evidence that, at a minimum, inspections have been conducted for conformance to the attributes listed in Table V and that any parts not meeting the requirements have been re-worked or removed from the assembly process. Unless otherwise specified, the dimensional inspections shall be performed with the item laid as flat as possible on a tabletop with only enough tension to keep it flat, without any creases or wrinkles that would affect the measurement. The distance between bartacks shall be measured from center to center.

4.3.3. Patterns and Cut Parts

Verification that the ACE Vest Harness cut parts conform to the Government supplied electronic data (see 3.3.3) shall be by inspection.

4.4. Construction

4.4.1. Stitching and Seams

Verification that the stitches, seams, and stitching types are as specified on the applicable drawings and constructed IAW ASTM D 6193 shall be by inspection.

4.4.2. Seam Workmanship

Verification that no raw edges, run-offs, pleats, puckers, or open seams are present shall be by inspection (see 6.5).

4.4.3. Seam Finishing

Verification that seams are either are turned under by a hem, or held by other stitching, or encased in edge binding stitched as specified on the applicable drawing, shall be by inspection.

4.4.4. Backstitching

Verification that backstitching and overstitching are not less than 1/2 inch in length, except where the ends are turned under or caught in other seams or stitching, shall be by inspection.

4.4.5. Stitches Per Inch

Verification that stitches per inch are as specified on the drawing shall be by inspection.

4.4.6. Thread Breaks, Skips and Run-offs

Verification that thread breaks, skips, and run-offs are over-stitched not less than 1/2 inch shall be by inspection.

4.4.7. Straight Stitching

Verification that each line of straight stitching is straight and parallel to the seam edge shall be by inspection.

4.4.8. Bartacking

Verification that bartacks are not loose, misplaced, or missing shall be by inspection.

4.4.9. Thread Tension

Verification that thread tension is such that seams show no loose stitching or puckering of the material sewn shall be by inspection (see 6.5).

4.4.10. Thread Ends

Verification that all thread ends are trimmed flush (+1/16 / -0 inch) with the surface of the finished article shall be by inspection.

4.4.11. General Workmanship

Verification that the ACE Vest Harness is free from irregularities or defects that could adversely affect performance or durability shall be by inspection for the defects listed in Table IV.

4.4.12. Labeling

4.4.12.1. Verification that item labeling (labels and alternate markings) is IAW the applicable drawing requirements shall be by inspection.

4.4.12.2. Verification that item labeling is easily legible with unaided examination by untrained personnel shall be by inspection.

4.4.12.3. Verification that item labeling is free from smears or smudging shall be by inspection.

4.4.13. Repairs

Verification that item repairs have been made IAW 3.4.13 shall be by inspection.

4.5. Operational Requirements

4.5.1. Color and Spectral Reflectance

Each new color lot shall be verified as required per Table I to ensure that the color and spectral reflectance, as applicable, meet requirements.

4.5.1.1. Visual Shade Comparison

Verification that components identified in Table I, column A, are a good match to the standard sample in shade and appearance shall be by inspection. Samples taken from the new color lot shall be compared to the standard sample. If there is a distinct color difference, the design activity shall participate in the determination of acceptability.

4.5.1.2. Visual Shade Matching

Verification of the color and appearance of components identified in Table I, column B shall be by test. The components shall match the standard sample when viewed using the AATCC Evaluation Procedure 9, Option C (see 6.8), with sources simulating artificial daylight D75 illuminant with a color temperature of 7500K (+/- 200), illumination of 100 (+/- 20) foot-candles, and shall match to the standard sample under incandescent A illuminant with a color temperature of 2856K (+/- 200). The color difference between the test and standard samples of less than 3 when determined IAW AATCC Evaluation Procedure 9, Table IV, Color Difference Magnitude Descriptor shall be a failure to match the standard sample. The test shall be performed in a Government directed lab unless otherwise specified in the contract or procuring documents.

4.5.1.3. Spectral Reflectance

Verification that spectral reflectance of the components identified in Table I, column C, conforms to the requirements specified in the applicable drawing, specification, or within this document shall be by test IAW the following procedure:

Spectral reflectance data shall be obtained from 600 to 860 nanometers (nm) at 20 nm intervals on a spectrophotometer relative to the polytetrafluoroethylene (PTFE) family of compounds, the preferred white standard. Other white reference materials may be used provided they are calibrated to absolute white or vitrolite tiles. The spectral band width shall be less than 20 nm at 860 nm. Reflectance measurements shall be made by either the monochromatic or polychromatic mode of operation. When the polychromatic mode of operation is used, the spectrophotometer shall operate with the specimen diffusely illuminated with the full emission of a continuous source that simulates either CIE Source A or CIE Source D65. Measurements shall be taken on a minimum of two (2) different areas and the data averaged. For fabrics, the measured areas should be at least 6-inches away from the selvage. The specimen shall be measured as a single layer backed with four (4) layers of the same fabric and shade. For webbings or tapes, the specimen shall be measured as a single layer backed with two layers of the same webbing and shade. The specimen shall be viewed at an angle no greater than 10° from normal, with the specular component included. Specimens shall be oriented in different directions during testing. When possible, the specimens tested shall not contain the same warp or filling yarns/wales or courses when presented to the sample port. The diameter for standard aperture size used in the color measurement device shall be 1.0 to 1.25 inches for solid colors and 0.3725 inches for camouflage colors. Photometric accuracy of the spectrophotometer shall be within one (1) percent and wavelength accuracy within two (2) nm.

Any color having spectral reflectance values falling outside the limits at four (4) or more of the wavelengths specified shall be considered a test failure.

4.5.2. Performance

The ACE Vest Harness shall be performance tested to verify that it is acceptable and can be shipped to the Government. The performance tests will be witnessed by the Government. The test units shall be randomly selected from the completed units. One-half of the sample units shall be static load tested and the other half shall be dynamic load tested. For odd sample sizes, the remaining unit shall be dynamic tested. Failure of any units tested shall be cause to reject the lot.

4.5.2.1. Static Load

Verification of static load shall be by test and inspection. The ACE Vest Harness shall be installed on a torso-shaped rigid test fixture and the torso fixture shall be mounted into a static test fixture. The load shall be applied to the sternal attachment strap, and the direction of pull shall be in line with the torso. The load application rate shall be no faster than 2,000 lb/min to avoid dynamic effects. A load of no less than 3,600 lbf shall be reached and held for no less than 60 seconds. The ACE Vest Harness shall then be inspected for compliance as follows:

a) Vest Harness shall retain the test torso;

b) Webbing in the load path shall not tear;

c) Hardware and metallic components in the load path shall not break or permanently deform;

d) Webbing shall not slip through any adjuster or adapter more than 1 inch.

4.5.2.2. Dynamic Load

Verification of dynamic load shall be by test and inspection. The ACE Vest Harness sample(s) shall be subjected to a dorsal dynamic load test with a minimum vertical drop distance of 8 feet.

The ACE Vest Harness shall be installed on a torso-shaped rigid test fixture (National Fire Protection Association (NFPA) Test Torso reference AVNS-DTL-10880, para. 6.10) with weight adjusted to 300 ± 2 lbs. A test-house snaplink shall be attached to the dorsal attachment strap.

The drop line shall be attached to the snaplink. ACE Vest Harness shall be inspected for compliance after testing as follows:

a) The harness shall not release the test torso

b) The harness shall retain the test torso for a period of no less than 5 minutes post-fall

c) The harness shall retain the test torso at a post fall at an angle not greater than 40° to vertical

4.5.2.3. Interface Requirements

Verification that, when constructed IAW their respective drawings, the ACE Vest Assembly is capable of integrating, routing, and fitting the items listed in Table II, shall be by demonstration.

When conducting the demonstration, excessive force shall not be required to insert the demonstration item(s) into its respective locations/attachment points. In addition, the demonstration item(s) shall not stress the pouch seams after insertion, nor shall the inserted item(s) be loose enough to be susceptible to falling out of the pouch. If the demonstration item(s) are not available, the ACE Vest Assembly shall be sent to the procuring activity for the demonstration.

5. Packaging For acquisition purposes, the contract or order shall specify the complete packaging requirements. When DOD personnel perform material packaging, those personnel will contact the responsible packaging activity to ascertain requisite packaging requirements. The Inventory Control Point packaging activity within the Military Department of Defense Agency, or within the Military Department's Systems Command, maintains packaging requirements. Packaging data retrieval is available from the managing Military Department or Defense Agency's automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6. Notes (This section contains information of a general or explanatory nature that may be helpful but is not mandatory.)

6.1. Intended Use

This document defines the production requirements for the Air Soldier Aircrew Combat Equipment (ACE) Vest Harness, Part Number 1081468-N-1, -2, -3, -4, or -5, used by helicopter aircrew for survival gear carriage, extraction and retrieval, insertion, flotation, ballistic protection, and cabin crew restraint.

6.2. Acquisition Requirements

Acquisition documents should specify the following:

a) Title, number, and date of this document,

b) Whether first article and pre-production items are required, and the quantity required,

c) Packaging requirements,

d) Acceptable quality levels (AQLs), and

e) Color, pattern, and shade evaluation requirements (The numeric value for “N” in the part numbers is dependent on the camouflage family that is specified in the contract. For example, -1 is the numerical value for “N” for the Operational Camouflage Pattern

(OCP)).

6.3. Standard Sample

For access to standard samples and pattern drawings, contact the procuring activity issuing the invitation for bid.

6.4. Recycled Materials

The use of recycled materials is encouraged when it is practical to do so if it meets the requirements of this document. However, recycled materials shall NOT be used for any webbing in the full body harness portion of the Vest/Harness.

6.5. Definitions

Open Seam An open seam is defined as one or more stitches joining the seam being broken or runoff, or when two or more continuous skipped stitches occur. Double stitched seams are considered open when one or both rows of the stitching are open.

Puckering A rippled appearance noted at the seams.

Raw Edge Any edge not finished as specified including any protruding raw edge on the outside of the finished article.

Tension Proper tension can be determined by visual examination.

When tension is balanced, the thread lock is hidden between the fabric layers. Tension can also be determined by a firm pull with the hands along the line of stitching.

Too Loose Tension If the tension is too loose, the stitching will appear as a series of loops.

Too Tight Tension If the tension is too tight, the stitching will resist stretching, break, or appear tight to the point of breaking.

6.6. Berry Amendment

The Berry Amendment (10 U.S.C. 2533a) may be applicable to the components and end item.

6.7. Visual and Spectral Reflectance Test

U.S. Army Natick Soldier RD&E Center (NSRDEC) is a Government approved test facility that may be used to perform visual and spectral reflectance testing. Suitable spectrophotometers for measuring spectral reflectance in the visible/near spectral include the Diano Hardy, Diano Match Scan, Hunter D54P-IR, and the MacBeth 1500 with IR options.

6.8. Visual Shade Matching

In 2017, Option A of AATCC EP9 was changed to Option C. NOTE: In case of confusion, the viewing geometry should be “The specimen plane and illumination source will be parallel to each other and aligned so that the light flux is incident at the center of the specimen plane, which is set at a 35 (± 5°) angle relative to the horizontal. The observer will view the specimens at a 90° angle, relative to the plane of the specimens”.

7. Tables

Table I – Color Requirements

Component

A. B. C.

Visual (Good Visual Match Only)

Visual (Government

Approved Test Facility)

Spectral Reflectance (Government

Approved Test Facility)

Fabric, Laminated Nylon 1081521 X X PIA-W-5625 Webbing, Textile, Woven, Nylon (all types)

1006032

X

A-A-59826 Thread (all types and classes)

1050955 (ref. -45, -49)

X

MIL-DTL-32075 Labels (all types and classes)

1050955 (ref. -75, -76)

X

PIA-C-5040 Cord, Nylon Fibrous (all types)

1050955 (ref. -54, -98)

X

PIA-C-5651 Cord, Elastic 1050955 (ref. -100)

X

PIA-W-5664 Webbing, Elastic, Type II, Class 1

1050955 (ref. -91)

X

NASM16491 Grommet, Metallic, Plain Type I, Class 3

1050955 (ref. -35, -44, -102)

X

Buckle, Quick Release Adjustable

1005833-31, -33, -35, -37, -39, -41

X

1050955-114 MIL-L-

11075, TY III, Oval Loop, Welded, 1-3/4 x ½, Coyote Tan

1050955 (ref. -114)

X

Buckle, Side Release 1081475-N-1, -N-2 X Connector, Circular Snap 1081494-1, -2 X Carabiner 1081535 X

High Density Polyethylene 1050955 (ref. -93)

X

EVA Foam Sheet 1081569 X Polyolefin Foam Sheet 1081570 X

Table II: Interface Demonstrations

Item No. Demonstration Item Requirement

Ballistic Insert, Front/Back

8470016706426 (XS)

8470016706763 (S) 8470016706776 (M) 8470016706778 (L)

8470016706779 (XL)

The Front and Back Ballistic Insert1 shall fit2 into the pouch and the fastener on the vest assembly shall mate to the opposite side with the demonstration items in the pocket without bunching or overlapping of the ballistic insert.

Side Ballistic Insert 8470016803001 (S) 8470016803011 (M) 8470016803021 (L)

The Side Ballistic Insert1 shall fit2 into the pocket and fastener on the vest assembly shall mate to the opposite side with the demonstration items in the pocket without bunching or overlapping of the side ballistic insert.

Enhanced Small Arms Protective Insert

(ESAPI)

8470015207360 (XS)

8470015207370 (S) 8470015207373 (M) 8470015207382 (L)

8470015207385 (XL)

The ESAPI1 shall fit2 into the pocket and the fastener on the vest assembly shall mate to the opposite side with the demonstration items in the pocket.

Quick Release Tether 1081555-N-1

The QRT1 or dimensionally accurate mock-ups shall integrate3 onto the ACE Vest utilizing the procedure defined in the ACE Training-Main.pptx. The training document may be obtained from the procuring activity.

72-Hour Survival Equipment 1050921-1

The 72-Hour Survival Kit1 or dimensionally accurate mock-ups shall fit2 into the ACE Vest side pocket and the snap fastener on the pocket shall mate to the snap fastener on the main pocket panel with the demonstration items in the pocket. ACE 72HSE- Complete.pptx defines the size and contents for the kit and may be obtained from the procuring activity.

Flotation Unit, Underarm, LPU-42/P 1081668-N-1

The LPU-42/P1 or dimensionally accurate mock-ups shall integrate3 onto the ACE Vest utilizing the procedure defined in the ACE Training-Main.pptx. The training document may be obtained from the procuring activity.

No. Demonstration Item Requirement

Multi-Purpose Pouch 1081525-N-1

The Multi-Purpose Pouch Strap1 or dimensionally accurate mock-ups shall integrate3 onto the ACE Vest utilizing the webbing loops located in three places on each shoulder without excessive force to get the strap to pass through the loops.

Notes:

1 If the demonstration item(s) are not available, the ACE Vest Assembly shall be sent to the procuring activity for the pocket carrying demonstration.

2 When conducting the demonstration, excessive force shall not be required to insert the demonstration item(s) into its respective pocket. In addition, the demonstration item(s) shall not stress the pouch seams after insertion, nor shall the inserted item(s) be loose enough to be susceptible to falling out of the pocket.

3 When conducting the integration of items onto the vest utilize the procedures as defined in the ACE Training- Main.pptx and ACE 72 HSE-Complete.pptx.

Table II – Verification Cross Reference Matrix

Requirement Verification Verification

Paragraph Method1 FA CI

3.1 Classification of Inspection and

Test Inspection X X 4.1

3.1.1 First Article Inspection and Test Inspection X 4.1.1

3.1.2 Conformance Inspection and Test Inspection X 4.1.2

3.1.2.1 Classification of Defects Inspection X 4.1.2.1

3.2 Materials and Components Inspection X X 4.2

3.3 Design 4.3

3.3.1 Part Numbers Inspection X X 4.3.1

3.3.2 Fabrication Inspection X X 4.3.2

3.3.3 Patterns and Cut Parts Inspection X 4.3.3

3.4 Construction 4.4

3.4.1 Stitching and Seams Inspection X X 4.4.1

3.4.2 Seam Workmanship Inspection X X 4.4.2

3.4.3 Seam Finishing Inspection X X 4.4.3

3.4.4 Backstitching Inspection X X 4.4.4

3.4.5 Stitches Per Inch Inspection X X 4.4.5

3.4.6 Thread Breaks, Skips and Run-offs Inspection X X 4.4.6

3.4.7 Straight Stitching Inspection X X 4.4.7

3.4.8 Bartacking Inspection X X 4.4.8

3.4.9 Thread Tension Inspection X X 4.4.9

3.4.10 Thread Ends Inspection X X 4.4.10

3.4.11 General Workmanship Inspection X X 4.4.11

3.4.12 Labeling Inspection X X 4.4.12, 4.4.12.2, 4.4.12.3

3.4.13 Repairs Inspection X X 4.4.13

3.5 Operational Requirements 4.5

Requirement Verification Verification

Paragraph Method1 FA CI

3.5.1 Color and Spectral Reflectance Inspection X X 4.5.1

3.5.1.1 Visual Shade Comparison Inspection X X 4.5.1.1

3.5.1.2 Visual Shade Matching Test X X 4.5.1.2

3.5.1.3 Spectral Reflectance Test X X 4.5.1.3

3.5.2 Performance 4.5.2

3.5.2.1 Static Load Test X X 4.5.2.1

3.5.2.2 Dynamic Load Test X X 4.5.2.2

3.5.2.3 Interface Requirements Demonstration X X 4.5.2.3

1 The methods listed are defined in 4.1.3.

Table IIIV – Defect Classification

No.

Inspection Group Defect

Classification & Code Critical Major Minor

1 General a. Any hole (except necessary drill holes in fabric panels for manufacturing), cut, tear, mend, or burn. [Drill holes, size 1/16 or less, necessary for manufacturing are allowed on fabric panels but are not allowed on load path webbing].

Affects Load Path1:

No affect on Load Path1:

b. Any other weakening defect such as smash, multiple float, loose slub, needle chew, or abraded area.

Affects Load Path1:

No affect on Load Path:

Greater than ⅛ inch:

Less than or equal to ⅛ inch:

Inspection Group Defect

Classification & Code Critical Major Minor

c. Damage to textiles, not already covered by 1.a above.

One cut warp end (Load Path1 or Non-Load Path1):

More than one cut warp end (Load Path1):

More than one cut warp end (Non-Load

Path1):

Damage to warp or filling yarn greater than

3/8 inch long or 1/8 inch wide (Load Path1):

Damage to warp or filling yarn greater than 3/8 inch long or 1/8 inch wide (Non-

Load Path1):

Damage to more than one yarn (Load

Path1):

Damage to more than three filling yarns

(Non-Load Path1):

d. Color of any component not as specified.

e. Shaded parts, shade bar, spot, or stain. 204

f. Any thread ends not trimmed flush

(+1/16/-0 inch) with surface or loose thread ends not removed.

205 One to four:

Five or more:

g. Any cut edge of the nylon cord, webbing, or tape, except for the hook-and-loop fastener tape, not sear cut, with searing over stitches, or any sharp edges formed when sear cut.

Affects Load Path1 :

No affect on Load Path1:

Affects serviceability2:

Affects appearance3:

h. Any cord or webbing not fabricated from one continuous length.

i. Hook or loop flattened from any fastener tape closure area.

Less than or equal to 10% of the hook or loop area:

Over 10% of the hook or loop area:

Inspection Group Defect

Classification & Code Critical Major Minor

j. Not thoroughly cleaned of all thread, lint, or foreign material.

One to four:

Five or more:

k. Any dimension not as specified.

l. Any material not as specified.

m. Any test or demonstration failure, other than electrostatic decay, flame resistance, static load, or dynamic load.

n. Any electrostatic decay or flame resistance failure.

o. Any static or dynamic load test failure. 10

p. Any fabric panel not oriented in the proper warp/fill direction.

2 Metallic and Plastic Parts

a. Any surface rough, misaligned, or contains any crack, nick, burr, sharp edge, dent, or sliver.

b. Any surface unclean or contains embedded foreign matter.

Affects Load Path1 :

No affect on Load Path1:

Affects serviceability2:

Affects appearance3:

c. Any loose, detached, or otherwise not securely retained part.

d. Any malformed, corroded, fractured, broken, chipped, bent, or distorted part.

Inspection Group Defect

Classification & Code Critical Major Minor

e. Any improperly finished part or part with finish missing.

Affects Load Path1:

No affect on Load Path1:

Visible while donned:

Not Visible while donned:

f. Any fastener or grommet not properly clinched resulting in cutting of the cloth, tape, or webbing, as applicable.

Affects Load Path1 or LPU Actuation4:

g. Any fastener not properly mated or functioning properly (i.e., fails to provide a secure closure, or to open freely).

h. Any fastener or grommet clinched loosely permitting the component to rotate freely to the degree that the component can be expected to become detached during use.

i. Any fastener or grommet with splits in the grommet/washer, button/socket, or stud/eyelet portions.

j. Any part of the fastener or grommet assembly bent, broken.

k. Any buckle bent, broken or does not properly attach and detach…