Proof Load RP DRAFT.pdf
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- MLRS Proof Load Pods
- Solicitation number
- W911RQ26QA017
About this file
This document is a technical instruction manual for constructing a Load Test Pod using an expended practice Rocket Pod (M28A1 or M28A2). The Load Test Pod is designed to simulate the weight and balance of an operational rocket pod for testing lifting and handling equipment, with a target weight range of 6,274.9 to 6,375.0 pounds for HIMARS applications.
The construction process involves four main phases: (1) fabricating and installing a forward end plate using 5/8-inch plywood and 2-inch x 4-inch lumber boards around the six rocket pod tubes; (2) constructing and positioning tube end plugs from plywood and lumber for tubes #2, #3, #4, and #6, with tube #3 receiving a more robust plug assembly measuring approximately 14 inches long; (3) securing the forward end plate to the rocket pod's forward bulkhead using banding material positioned between specific tubes; and (4) filling the tubes with gravel concrete to achieve target weight, with tube #3 filled to approximately 80 percent capacity (14 inches from the aft end) and tubes #2, #4, and #6 filled to within 5/8-inch of their aft ends. The document specifies that the completed pod must be weighed and marked with weight and specification stencils applied in 1-inch and 2-inch heights. Critical safety warnings address structural inspection requirements, securing procedures for elevated pods during concrete curing, and proper concrete pouring techniques to prevent air pockets and ensure balanced loading. Materials required include concrete, steel tubes, plywood, lumber, paint, and banding materials, while tools include standard construction equipment such as drills, saws, and measuring devices.
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Other files
| File | Type | Posted |
|---|---|---|
| SKU-0767 PROOF LOAD.PDF | ||
| SKU 0766.pdf | ||
| SKU 0768 TACTICAL LOAD.pdf | ||
| Combined Synopsis for PODs.pdf |
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Text version
- LOAD TEST POD CONSTRUCTION -
MATERIALS REQUIRED:
Concrete, Gravel 1.5 Cubic Yards
3 Tubes @ 160-Inches Long
1 Tube At 82% Length: 131-Inches
Tube Diameter: 12-Inches Material, Banding and Clips As Required Nails/Wood Screws As Required Paint, Spray (Yellow or Red) 1 CN Plywood, 5/8-Inch x 4 Feet x 8 Feet. 1 SHT Rocket Pod, Practice, M28A1 (13031950) or M28A2 (13540620), Expended 1 EA Wood, 2-Inch x 4-Inch x 8 Feet. 2 EA
TOOLS REQUIRED:
Bit, Hole Saw, 1-Inch 1 EA Bit, Screwdriver, Flat-Tip/Cross Tip (If Wood Screws Used) 1 EA Drill, Electric 1 EA Hammer (If Nails Used) 1 EA Measure, Tape 1 EA Saw, Circular 1 EA Stencils, 1-Inch and 2-Inch 1 Set EA Tool, Banding Material 1 EA
SUPPORT EQUIPMENT:
Wrecker, 5-Ton Capacity (Minimum) 1 EA
- WARNING -
Inspect expended Rocket Pod (RP) for structural damage. Ensure RP is free of structural damage and damage to tubes 2, 3, 4, and 6. Failure to do so could result in personal injury or damage to equipment.
- NOTE -
Expended or used practice Rocket Pods (RP), with transportation/storage skids, are to be locally obtained from
MLRS/HIMARS units or Ammunition Supply/Storage Facilities.
1. CONSTRUCTION OF FORWARD END PLATE.
a. Using 5/8-inch (15.8mm) plywood, cut to fit around six RP tubes at front end of expended RP. Plywood should lay flush and should cover all six tubes as much as possible.
b. Measure top and bottom widths of base plate.
c. Cut two pieces of 2-inch x 4-inch (50mm x 100mm) lumber boards to dimensions measured in step 1b. Secure each 2-inch x 4-inch lumber board to base plate using nails/wood screws.
Figure 1 - LOAD TEST POD FORWARD END PLATE CONSTRUCTION.
2. CONSTRUCTION OF RP TUBE END PLUGS.
a. At forward end of RP, measure inside diameter of tube #3.
b. Cut five circular end plugs from 5/8-inch (15.8mm) plywood 1/8-inch (3mm) smaller than dimension measured in above step (2a.).
c. Cut three 2-inch x 4-inch (50mm x 100mm) lumber boards to a length of 12-3/4 inches (324mm) long.
d. Assemble tube plug for RP tube #3:
Stack three 2-inch x 4-inch (50mm x 100mm) lumber boards side by side and using nails/wood screws, secure three boards together.
Using two circular end plugs of 5/8-inch (15.8mm) plywood cut in step 2b, position plug at each end of 2-inch x 4-inch lumber assembled in above step. While maintaining alignment of end plugs, use nails/wood screws to secure end plugs to 2-inch x 4-inch boards. Outside dimensions of RP tube plug #3 should be approximately 14-inches (350mm) long.
Figure 2 - LOAD TEST POD TUBE END PLUGS CONSTRUCTION.
e. Position 3 circular end plugs of 5/8-inch (15.8mm) plywood into forward ends of RP tube numbers 2, 4 and 6.
End plugs are to be positioned flush with end of each tube. If end plugs are capable of maintaining position within tube on their own, then go to paragraph 3, SECURE END PLATE TO FORWARD END OF EXPENDED RP.
Otherwise continue with instructions below to locate and secure end plugs on base plate:
Locate base plate on forward end of expended RP. Using drill and 1-inch hole saw, drill locator hole through areas of base plate covering RP tube numbers 2, 4 and 6. Remove base plate from RP.
Position 3 circular end plugs of 5/8-inch plywood into forward ends of RP tube numbers 2, 4 and 6. End plugs are to be positioned flush with end of each tube.
Overlay base plate onto forward end of RP. Thru 1-inch locator holes drilled into forward end plate, mark location of locator holes onto each tube end plug located in RP tube numbers 2, 4 and 6. Remove forward end plate and three end plugs from expended RP.
Locate tube end plugs on forward end plate by aligning locator marks of each tube plug to locator holes on base plate. Using wood screws or nails, secure tube plugs to end plate while maintaining alignment of locator marks.
Figure 3 - LOAD TEST POD FORWARD END PLATE ASSEMBLY.
3. SECURE FORWARD END PLATE TO FORWARD END OF EXPENDED RP.
a. Slide RP tube #3 plug into RP tube #3. Position end plug flush with end of tube.
b. Position forward end plate onto forward end of expended RP.
c. Secure forward end plate to forward RP bulkhead using banding material. Banding material is to be positioned around forward bulkhead of RP between RP tubes #3 and #5 and between #3 and #1.
Figure 4 - LOAD TEST POD FORWARD END PLATE ATTACHMENT.
4. FILLING EXPENDED RP WITH CONCRETE.
a. At aft end of expended RP, measure 14-inches (350mm) from end of RP tube #3. Mark inside surface of tube.
Figure 5 - LOAD TEST POD TUBE #3 INTERIOR MARKING.
- WARNING –
RP IS APPROXIMATELY 13 FEET (3900MM) LONG. IF POSITIONED ABOVE GROUND LEVEL, RP MUST BE
SECURED IN PLACE TO PREVENT RP FROM FALLING DURING THE FILL AND CONCRETE DRYING
PROCESS.
b. Raise RP and remove forward transportation/storage skids.
c. Position RP on its forward end and secure RP in place.
- CAUTION -
WHILE POURING CONCRETE INTO EACH TUBE, AIR MUST BE PURGED FROM TUBE IN ORDER TO
MAINTAIN AN EVEN AND CONSISTENT POUR. TO ASSIST IN THIS, POUR CONCRETE SLOWLY WHILE HITTING OUTSIDE SURFACE OF TUBE WITH A RUBBER MALLET. FAILURE TO DO SO COULD RESULT IN
AN UNBALANCED LOAD TEST POD.
d. Using gravel concrete, slowly fill RP tube numbers 2, 4 and 6 until concrete is approximately 5/8-inch (15.8mm) from end of aft tubes.
e. Using gravel concrete, slowly fill RP tube #3 to mark made inside of tube in step 3a (approximately 80% full).
As with tubes 2, 4 and 6, ensure air inside tube is purged during the fill process. Allow concrete to setup and dry.
- WARNING –
LOAD TEST POD WEIGHS APPROXIMATELY 6300.0 lbs. (2863.6 kg). USE EXTREME CAUTION WHEN
LOWERING POD ONTO ITS SKIDS.
e. With concrete dry, raise RP and reinstall forward transportation/storage skids.
f. Lower RP onto ground.
g. Remove forward end plate from load test pod.
- NOTE –
MINIMUM WEIGHT OF LOAD TEST POD IS 6274.9 lbs. (2846.25 kg). FOR HIMARS APPLICATIONS, LOAD
TEST POD MUST NOT EXCEED 6375.0 lbs. (2892.4 kg). IF UNDER WEIGHT, SAND BAGS MAY BE PLACED
ON TOP OF THE RP TO ADD ADDITIONAL WEIGHT. THESE SAND BAGS CAN ALSO BE USED TO
ADJUST RP CENTER OF GRAVITY PROVIDING A LEVEL LIFT DURING LOAD TEST OPERATIONS. WITH SKIDS ATTACHED, RP WEIGHS AN ADDITIONAL 68.0 lbs. (31.0 kg).
h. Weigh load test pod.
i. Apply weight markings to top of load test pod.
Figure 6 - LOAD TEST POD MARKING.
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