Purchase_Description.pdf

CUI

INCH-POUND

PD19WRWNSEV04

CAGE 98752

01 May 2020

Distribution Statement D. Distribution authorized to the Department of Defense (DoD) and U.S.

DoD Contractors only; Critical Technology; Export Controlled; 01 May 2020. Other requests shall be referred to AFLCMC/WNZEA.

DESTRUCTION NOTICE—Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

AMSC N/A FSC 5410

EXPORT CONTROLLED INFORMATION

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

Comments, suggestions, or questions on this document should be addressed to:

AFLCMC/WNZEA, 235 BYRON ST STE 19A, Robins AFB GA 31098-1813.

Controlled by: USAF/AFMC Controlled by AFLCMC/WNZE CUI Category: CTI/EXPT Distribution Statement D

POC: Chief Engineer, 478-222-1762

PURCHASE DESCRIPTION

Shelter System, Small, Energy Efficient

1. SCOPE

1.1 Scope. This document describes the Energy Efficient Small Shelter System (EESSS) required by the United States Air Force. The EESSS will provide an energy efficient, modular and durable solution to the military’s need for a quickly deployable expeditionary shelter system. Once fielded, the EESSS will be used primarily as office and billeting space for bases in austere locations.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 or 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-A-8625 Anodic Coatings For Aluminum And Aluminum Alloy

MIL-PRF-24712 Coatings, Powder (Metric)

MIL-PRF-5541

MIL-DTL-81706

Chemical Conversion Coatings on Aluminum and Aluminum Alloys

Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys

TT-C-490 Chemical Conversion Coatings and Pretreatments for

Metallic Substrates

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-810 Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-882 System Safety

MIL-STD-889 Dissimilar Metals

MIL-STD-1366 Transportability Criteria

MIL-STD-1472

MIL-STD-1791

Human Engineering

Designing for Internal Aerial Delivery in Fixed Wing

Aircraft

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-310

Global Climactic Data for Developing Military Interface

(Copies of these documents are available online at http://quicksearch.dla.mil/ or from the

Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia PA

19111-5094.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein.

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AIR FORCE INSTRUCTION (AFI)

AFI 32-7086 Hazardous Materials Management

(Copies of this document are available online at http://www.e-publishing.af.mil/.)

U.S. ARMY NATICK RESEARCH, DEVELOPMENT AND ENGINEERING CENTER

(NRDEC)

TEST OPERATIONS PROCEDURE (TOP)

TOP 1-2-621 Outdoor Sand and Dust Testing

TOP 10-2-175 Tents and Shelters

(Copies of these documents are available online at https://vdls.atc.army.mil/.)

U.S. DEPARTMENT OF JUSTICE

NIJ Guide-0101.06, Selection & Application Guide to Ballistic-Resistant Body Armor-

0101.06

(Copies of this publication are available online at http://www.nij.gov/ or Office of Justice

Programs, 810 Seventh St. N.W., Washington, DC 20531)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

http://quicksearch.dla.mil/ http://www.e-publishing.af.mil/ https://vdls.atc.army.mil/ http://www.nij.gov/

AATCC 30 Antifungal Activity, Assessment on Textile Materials:

Mildew and Rot Resistance of Textile Materials

(Copies of this document are available online at http://www.aatcc.org/ or from AATCC, PO Box

12215, Research Triangle Park, NC 27709-2215.)

ASTM INTERNATIONAL (ASTM)

ASTM D2136 Standard Test Method for Coated Fabrics—Low-

Temperature Bend Test

ASTM D6413-08 Standard Test Method for Flame Resistance of Textiles

(Vertical Test)

(Copies of this document are available online at http://www.astm.org . Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, PO Box C700, West

Conshohocken, PA 19428-2959.)

INDUSTRIAL FABRICS ASSOCIATION INTERNATIONAL (IFAI)

USIFI-PRF-44103 Performance Specification, Cloth, Fire, Water and Weather

Resistant

(Copies may be purchased on-line from the IFAI Store at: www.ifai.com, or by contacting

USIFI Headquarters, Specification Committee, 1801 County Road B W, Roseville, MN 55113-

4061, Phone 651-222-2508)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

WD 6 2016 Wiring Devices-Dimensional Specifications

(Application for copies should be addressed to NEMA, 1300 North 17th Street, Suite 1847, Rosslyn

VA 22209, www.nema.org.)

NATIONAL FIRE PROTECTION ASSOCIATION

NFPA 70 2020 National Electrical Code http://www.aatcc.org/ http://www.astm.org/ http://www.ifai.com/ http://www.nema.org/

(Application for copies should be addressed to NFPA, 11 Tracy Drive, Avon, MA 02322, www.nfpa.org.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

AMS-STD-595 Colors used in Government Procurement

(Application for copies should be addressed to SAE International Customer Service, 400

Commonwealth Drive, Warrendale PA 15096, http://www.sae.org/.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), four samples shall be subjected to first article inspection in accordance with 4.2.

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3.2 Energy Efficient Small Shelter description. The EESSS is intended to be a lightweight, energy efficient expeditionary shelter system, to be used by the United States Air Force (USAF) for the purposes of billeting, storage, and work space. The EESSS shall be a fabric structure, measuring approximately 20.0 feet in width, by 32.0 feet in length, configurable to allow multiple shelters to be connected and shall meet all requirements specified henceforth.

3.3 System size.

3.3.1 Useable floor space. Useable floor space for the shelter system is defined as the unencumbered floor space of the shelter (no center poles allowed) measured at the floor level. The usable interior floor space for the shelter system shall be a minimum of 600.0 square feet.

3.3.2 Interior peak height. The minimal interior (liner) peak height shall be no less than 8.0 feet measured along the centerline of the shelter in an operating configuration.

3.3.3 Width. The distance between any two opposite interior (liner) walls of the shelter shall be a minimum of 18.0 feet at floor level.

http://www.nfpa.org/ http://www.sae.org/

3.3.4 Shelter system sidewalls. The shelter shall have sidewalls that are a minimum 7.0 feet high. The sidewalls shall not slope more than a maximum of 16.0 inches from the base to the top of the sidewall.

3.3.5 System weight. The EESSS system weight shall not exceed 1,100 pounds. The EESSS system weight shall encompass the shelter along with all supplied components, including, but not limited to: fabric skin, support structure, interior insulating liner, solar shade fly, electrical system, lighting, flooring, plenums, vestibule, wind lines, anchoring system, repair kit, manual, supplied tools (such as lift poles, etc.) and any other additional gear needed to complete the shelter system.

All components required to meet energy efficiency performance requirements shall be considered part of the shelter system. Individual shelter components shall not exceed crew size lifting limits as prescribed in Mil-STD-1472.

3.3.6 Modular design. The EESSS shall be designed to allow personnel in the field to connect multiple shelters in an end-to-end configuration.

3.4 Deployment and recovery time.

3.4.1 Erect time. The EESSS shall be fully erectable within 40 minutes with a maximum of six personnel. Erect Time is defined as the time it takes to set up the shelter system beginning with the system on the ground in its storage container and ending when it achieves Full Operational

Capability (FOC). FOC is defined as the point in time when the shelter is completely set up, is providing shelter, and is meeting all of the minimum requirements set forth in this document.

3.4.2 Strike time. The shelter system shall achieve Strike Time within 40 minutes with a maximum of six personnel wearing individual protective equipment (i.e. helmet and individual body armor) in the full range of operating temperatures described in 3.5.6. Strike Time is defined as the time it takes to break down and stow a shelter system in its storage container setting on the ground and ready for transport, beginning with the shelter system at FOC as defined in 3.4.1.

3.5 Environmental conditions.

3.5.1 Wind load. The shelter system shall withstand a steady wind speed of at least 80 miles per hour (mph) for a 30 minute duration with three gusts of 90 mph for a duration of two minutes per gust.

3.5.2 Rain intrusion. The EESSS shall prevent water intrusion during exposure to steady rain, wind driven rain, and water spray testing in accordance with TOP 10-2-175.

3.5.3 Snow load. The EESSS, deployed without the solar fly (unless the solar fly is an integral part of the shelter system), shall withstand a snow load of 10 pounds per 1.0 square foot for a period of 12 hours without damage when fully erected. Damage is defined as the permanent deflection that requires any support items to be replaced in order to complete the mission.

3.5.4 Salt fog. The EESSS shall be capable of storage and operation in high temperature, high humidity, salt laden, and sea coast environments without damage or deterioration of performance.

3.5.5 Sand and dust. The EESSS shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance.

3.5.6 Operating temperature range. The shelter system shall be operational and serviceable (to include under canopy, erect and strike) from -25°F to +125 °F. The shelter exterior fabrics and solar shade fly shall resist formation of “cold crack” at -25°F in accordance with ASTM D2136.

Shelter fabrics shall remain sufficiently pliable at -25°F to accomplish strike/erect function without external heating.

3.5.7 Solar radiation. The EESSS shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments and high altitudes.

3.6 System design parameters.

3.6.1 EESSS fabric skin. The EESSS’s fabric skin shall be Class 2, Tan 686A, in accordance with

USIFI-PRF-44103. When requested by the Government, the fabric skin shall also be available in

Class 1, Camouflage Green 483, in accordance with USIFI-PRF-44103. (see 6.2)

3.6.2 Floor. The shelter system shall be equipped with a detachable/replaceable fabric floor. The floor shall be durable and resistant to puncture, tearing, and resist the penetration of ground water.

The fabric floor shall comply with the flame resistance requirement. The EESSS’s floor shall comply with the performance characteristics of USIFI-PRF-44103, Class 3 and Class 4. The floor shall be replaceable without striking the shelter. An energy efficient hard flooring system shall be offered as an available option. The hard flooring with a minimum energy efficiency of R-3 shall be installed without striking the shelter by two people in a maximum of 1 hour. All components of the hard flooring shall comply with a 2-man lift.

3.6.3 Shelter frame. The EESSS shelter frame system shall be designed to support an additional weight of 600 pounds (i.e. Photovoltaic (PV) system, solar fly). If the EESSS shelter frame requires a separate exoskeleton frame to support this additional weight, the external supports shall be the same color as the shelter and shall be considered part of the EESSS.

3.6.4 Energy efficiency. When connected to a single 5-Ton British Thermal Unit/hour (BTU)/hr

Environmental Control Unit ECU, two EESSSs (including solar shade flys and liners) shall provide an inside temperature at least 45 °F cooler than outside ambient temperature throughout the entire operating temperature while in cooling mode. When connected to a single 130K BTU/hr fuel fired heater, two EESSSs (including solar shade flys and liners) shall provide an inside temperature no less than 80 °F warmer than outside ambient temperature throughout the system’s operational temperature range.

3.6.4.1 Solar shade fly. The EESSS shall be capable of supporting the use of a solar shade fly that is designed to decrease solar irradiance on the shelter during use. The solar shade fly will be considered part of the shelter if it provided with the shelter to meet environmental requirements.

3.6.4.2 Insulating liner. The shelter system shall include an interior insulating liner, white in color, on the interior side.

3.6.5 Doors. The EESSS shall be supplied with both hard and soft doors. All doors shall be designed to interface with the vestibule system.

3.6.5.1 End wall soft door. The soft door shall be zippered material and located on opposite end of hard door for emergency egress. The soft door shall have ties to allow the door to be stowed above, or to the side, out of the way when desired.

3.6.5.2 Hard doors. The hard doors shall have a height of at least 80.0 inches, 32.0 inches in width and be framed with fabric skin and insulated. The hard doors shall be supplied with spring loaded slide door latch type hardware with webbing pull handle attached to resist jamming on uneven terrain. The hard doors shall have simple provisions (spring hinges, bungee chains, etc.) designed to ensure automatic closure when not in use. The hard doors shall each have a small window

(approx. 5.0 inches W X 10.0 inches H, +/-1.0 inch) with a curtain located at eye level.

3.6.5.3 Vestibule. The EESSS vestibule shall have interior dimensions of 6.0 feet wide, 6.0 feet long and 7.0 feet height with a hard door.

3.6.6 Heating ventilation and air conditioning (HVAC) ports. The EESSS shall have two sets (a set is one supply and one return port) of ports to allow for the entry of spiral frame flexible insulated ducting into the shelter. One set of ports shall be located on each side wall at the rear of the shelter.

The EESSS heating ventilation and HVAC ports shall accommodate and seal around flexible ducting ranging in outside diameter up to 18.0 inches. HVAC ports shall be sealable when not in use.

3.6.7 HVAC duct adapters. No ducts, adapters, or Ys are required.

3.6.8 Internal plenums. The EESSS shall include a collapsible air sock type internal plenum designed to uniformly distribute air over the shelter’s interior. This plenum shall connect to HVAC ducting ranging in outside diameter from 12.0 to 18.0 inches at or near the HVAC entry ports. The

EESSS plenum shall impose the least impedance possible on the shelter’s usable interior space.

3.6.9 Ventilation. The shelter system shall be designed to promote the natural ventilation of fumes, smoke, steam, or heat without the aid of powered ventilating systems.

3.6.10 Electrical system. The EESSS electrical system shall be capable of connecting to Base

Expeditionary Airfield Resources (BEAR) 25kW Power Distribution Panels (PDPs) via a NEMA

L5-20P twist lock male connector. The EESSS electrical system shall provide a minimum of eight cable drops (four evenly spaced along each shelter side wall). Each cable drop shall have three (3)

120 volt alternating current (VAC), single phase, 20 amp NEMA 5-20R T-slot triplex receptacles evenly spaced along the interior side walls of the shelter. Plugs and receptacles used in the EESSS electrical system shall be in accordance with NEMA WD 6. All cables between the EESSS electrical panel and the cable drops shall be run overhead, closely following the shelter ceiling to minimize snagging and interference. The shelter electrical system shall have a dedicated ground conductor through the electrical power input cable back to the power source ground. All wiring, fixtures, switches, etc. shall meet the requirements of NFPA 7 National Electric Code (NEC). A preliminary wiring diagram shall be supplied with all EESSS proposals.

3.6.11 Interior lighting. The EESSS shall be supplied with a ruggedized overhead energy efficient screw-in style light emitting diode (LED) lighting system. The EESSS lighting system shall provide a minimum of 30 foot-candles at 3.0 feet above the floor over the entire usable shelter space (shelter area where liner height is 5.0 feet or more). The EESSS lighting system shall interface with and draw power from the EESSS electrical system. The EESSS interior lighting system shall be operated by an illuminated rocker switch located near the shelter’s front/hard door entrance.

3.6.12 Utility ports. Each EESSS shall have two utility ports to allow for the passage of cable bundles, up to 6.0 inches in diameter, into the shelter without damage or alteration of the shelter fabric. One utility port shall be located with each set of HVAC ports, no more than 12.0 inches above the ground. Utility ports shall be sealable, when not in use.

3.6.13 Interior support fasteners. The EESSS shall have interior support fasteners distributed throughout the shelter to facilitate the suspension of electrical system wiring and shelter lighting.

Outlet drops shall have Velcro type channels/holders to attach to interior walls.

3.6.14 Non-reflective hardware. All hardware (to include but not limited to bindings, plastic components, fastener tape, webbing, grommets, straps, slips and guy lines, etc.) visible from the shelter exterior, shall be the color of the shelter exterior or shall be flat black.

3.6.15 Repair kit. The shelter system shall include a user level field expedient (operator) repair kit as part of its shelter system. The identified repair kit shall be supplied with enough corresponding components to support erect/strike cycle testing as noted in section 3.4. The repair kit shall be capable of completing repairs to return the shelter system back into operation within

30 minutes with minimum training required and shall include no hazardous materials.

3.6.16 Anchoring system. The shelter system shall include a general purpose anchoring system and a means to insert the anchoring system to ensure proper anchoring in all applicable soil types

(sand, hard packed soil, or rocky soil). The anchoring devices shall be designed for installation by one person without requiring the use of powered equipment.

3.6.17 Hazardous environment protection. The shelter shall accommodate specific ballistic splinter protection kits to protect occupants/contents against small arms and small fragmenting munitions as defined in National Institute of Justice (NIJ) Guide 0101.06, Type IIA. This protection kit shall provide complete surround and overhead protection and be emplaced within one hour by two persons.

3.6.18 Vestibule interface. The shelter system shall have a means to interface with the standard vestibule on each doorway end location.

3.6.19 Flame resistance. All fabric materials (exterior, floor, insulating liner, plenums, solar shade fly, etc.) used in the shelter system shall be flame resistant in accordance with procedures of ASTM

D6413-08 both initially and throughout the shelter service life.

3.6.20 Fungus resistance. All textiles and fabric materials used in the EESSS system shall be resistant to the deteriorating effects of rot, fungus, mildew or corrosion under both operational and storage conditions, wet or dry. All materials shall allow for shelter striking for storage with minimal drying time to preclude mildew. This capability shall be in compliance with AATCC 30.

The interior lining shall be made from a material that is easily cleaned.

3.6.21 Vector intrusion. The EESSS shall be designed to prevent intrusion by flying or crawling insects/animals. The shelter system shall include screens for the windows (as defined in 3.6.5.2) with a mesh size to minimize vector intrusion. All HVAC and utility ports on the shelter shall have cinch-able external boots to allow for tight fit to HVAC ducts and cable bundles and port closure when not in use.

3.6.22 Uneven terrain. The shelter system shall allow erect and use without damage or permanent distortion to the shelter and components on terrain that varies in slope as much as 6.0 inches per

9.8 feet of linear distance.

3.6.23 Quick reference instructions. The shelter system shall include quick reference instructions for conducting Erect and Strike actions. Those instructions shall be permanently attached to each shelter system at or near an inside doorway opening and they shall also be permanently attached to all transport container(s).

3.6.24 Protective coating and finishes.

3.6.24.1 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the EESSS shall not be used or shall have means of protection against such deterioration. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used.

Small commercially procured items, such as miscellaneous handles, brackets, linkages, cables, etc., used as components of the EESSS may be prepared and coated in accordance with the manufacturer’s standard practice, provided it is compatible with the exterior finish color. However, larger procured items shall have the protective coatings required herein in accordance with the respective material substrates.

3.6.24.2 Fungus and moisture resistance. Any electrical circuitry, including all components and connections shall be protected from the effects of fungus growth and moisture. Hermetically sealed components may not be treated for fungus growth and moisture.

3.6.24.3 Surface preparation and pretreatment for aluminum material. Structures shall be cleaned, degreased, and prepped prior to application of any pretreatment. Aluminum surfaces used in construction of the EESSS shall be treated with a suitable conversion coating prior to application of any other corrosion prevention coating. Anodizing or a MIL-DTL-81706 conversion coating process may be utilized, at the discretion of the manufacturer. Any anodizing shall be applied in accordance with MIL-A-8625, Type II, Class 1; no further conversion coating is required on anodized aluminum surfaces. Aluminum surfaces shall have MIL-DTL-81706, Type I, Class 1A, Form I, Method C chemical conversion coating applied in accordance with MIL-PRF-5541, Type

I, Class 1A. Alternatively, in areas and locals where use of hexavalent chrome is not permitted by regulatory authority, aluminum surfaces shall have MIL-DTL-81706, Type II, Class 1A, Form I, Method C chemical conversion coating applied in accordance with MIL-PRF-5541, Type II, Class

1A. Surface preparation and pretreatment shall be applied prior to application of respective powder coat used as a topcoat.

3.6.24.4 Surface preparation and pretreatment for ferrous material. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications.

Structures shall be cleaned, degreased, and scuffed or blasted prior to priming; blasting media shall be free of all oil/grease, fines, and materials not allowable in the manufacturer of the blasting media’s specification. Ferrous surfaces (other than stainless steel, mill-galvanized steel, electro-zinc coated or mill-aluminized) shall be treated with a TT-C-490,Type IV zinc phosphate pretreatment applied in accordance with the manufacturer’s directions prior to the application of any primer. Primer shall be applied before any oxidation or rusting occurs; raw metal edges, to include fastener and drain holes, shall be coated with primer before applying topcoat.

3.6.24.5 Ferrous material primer. Type II Epoxy Resin, Zinc Rich Powder coating, Class 1 Exterior

Primer of a 2-Coat System per MIL-PRF-24712 shall be utilized for ferrous based material. This exterior primer of the 2-coat system shall yield a Dry Film Thickness (DFT) of 8 to 10 mils.

Manufacturer specifications to accomplish application of the coating system shall be utilized.

3.6.24.6 Topcoat. All EESSS components, except for small commercially purchased components, plastic, rubber, shall be top coated with powder coat. Type III, Class 3 powder per MIL-PRF-

24712 shall be applied and cured at temperatures specified by powder vendor. When fully cured, the topcoat shall yield a DFT of 3 to 4 mils free from runs, sags, orange peel, or other defects. The

Contractor shall utilize manufacturer specifications to accomplish application of the coating system. Chemical Agent Resistant Coating (CARC) shall not be used.

3.6.24.7 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotive compatible abutting surfaces is acceptable. The use of dissimilar metals when separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

3.6.24.8 Finish. The finish color of all the non-fabric exterior(to include but not limited to bindings, plastic components, fastener tape, webbing, grommets, straps, slips and guy lines, etc.) items shall be same color of shelter exterior fabric or flat black.

3.6.24.9 Placard. Regardless of priming system used, a placard shall be permanently affixed (i.e., riveted) to the EESSS, in a conspicuous area adjacent to the identification placard, to denote type(s) of primer and topcoat applied to the non-fabric items.

3.6.25 Human engineering. The EESSS shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of MOPP Level 2 protective equipment, individual protective equipment (i.e., helmet and individual body armor) and arctic mittens.

3.6.26 Welders and welding. Welding procedures shall be in accordance with a nationally recognized welding code. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings. Cast components, structural steel components with an ultimate tensile strength greater than 100,000 pounds per square inch (psi), and threaded fasteners (except for weld studs and weld nuts) shall not be welded. Heat treated components shall be in the annealed, normalized condition when welded.

3.6.27 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins, lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial components. Tapped threads shall have a minimum thread engagement in accordance with Table I.

TABLE I. Minimum thread engagement.

Material

Minimum Thread Engagement

Steel 1.0 times the nominal fastener diameter

Cast iron, brass, or bronze 1.5 times the nominal fastener diameter

Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.6.28 Fluid traps and faying surfaces. There shall be no fluid traps on the EESSS. Faying surfaces of all structural joints, except welded joints, shall be sealed to preclude fluid intrusion.

3.6.29 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130. Markings shall be applied with decals and shall be

1.0 inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than 0.5 inch high. Markings, Information/Caution shall be color Black International, Number 37038 of SAE AMSSTD-595,] and Markings, Warning/Danger shall be color Red International, Number 31136 of SAE AMS-

STD-595.

3.6.30 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the EESSS in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). The EESSS and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as

Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a bar code and human readable markings. The “CE” marking shall be affixed in accordance with EU requirements on or adjacent to the identification plate.

3.7 Useful life.

3.7.1 Erect/strike cycles. The EESSS system shall be able to be erected 20 times, struck 20 times and packed into container 20 times without any system failure. System failure is defined as any failure that reduces FOC as defined in section 3.4.1, and which cannot be corrected within 30 minutes by employing the use of the shelter system repair kit.

3.7.2 Service life. The EESSS shall have a minimum field service life of three years with no significant degradation due to weathering effects and with no visible effects of dry rot, mildew and petroleum degradation due to exposure at -25 °F to 125 °F temperature range. The definition of damage includes visual evidence of permanent discoloration, or material breakdown including pitting, shredding, softening, or weakening of the fabric material.

3.7.3 Shelf life. The EESSS shall have a minimum shelf life of twenty years when stored in ship/store International Standards Organization (ISO) containers in temperatures ranging from -65

°F to 180 °F. The stored EESSS shall be resistant to the deteriorating effects of rot, fungus, or mildew. The shelter system components shall not lose strength or show evidence of increased water permeability as a result of storage and/or transportation. The EESSS setup after storage shall show no evidence of damage, degradation, or loss of operational use.

3.8 Safety.

3.8.1 System safety. The design of the EESSS shall not contain any system safety mishap risk categories greater than medium as defined in MIL-STD-882.

3.8.2 Hazardous material. The design shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials and the generation of toxic or noxious gases. The

EESSS shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. Class I ODS and hazardous materials shall not be used in any system, component, or process. The EESSS shall not contain or use either hexavalent chromium or cadmium without written approval by the procuring activity. Hazardous materials are defined in AFI 32-7086; Class I and Class II ODS are defined in 40CFR82.

3.8.3 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard. All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located so as to provide adequate clearance from moving parts and high operational temperatures.

Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

3.9 Transportability.

3.9.1 Transportation containers. The EESSS shall be designed to be transported and stored in a

Internal Airlift/Helicopter Slingable-Container Unit (ISU-90) or International Organization

Standardization (ISO) Tricon/Bicon type containers. When in packed configuration, the EESSS shall not have any member or dimension exceeding 90 inches. Three shelter systems in packed configuration (including support equipment) shall fit into one ISU-90 type container.

3.9.2 Surface transportability. The EESSS shall be transportable via all modes of surface shipment

(highway, rail, and water) in accordance with MIL-STD-1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport, except that design for rail impact testing (see 5.2.5 of MIL-STD-1366) is not required.

3.9.3 Air transportability. The EESSS shall be transportable on C-130, C-17, and C-5 aircraft in accordance with MIL-STD-1791. In all air transport configurations, the EESSS shall be capable of being restrained and withstanding, without loss of serviceability, 2.0 G up and 4.5 G down accelerations, and shall be capable of being restrained and withstanding, without loss of structural integrity, 3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations. The EESSS shall be equipped with pressure relief devices or configured for air transport to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure.

3.10 Maintenance.

3.10.1 Durability. The design of the EESSS shall consist of components determined to perform without failure for a minimum of 365 days under normal operating conditions.

3.10.2 Preventive maintenance. The contractor shall provide a list of all recommended preventive maintenance tasks and associated routine preventive maintenance intervals required to maintain the EESSS while in storage and/or operational configuration. No identified maintenance task shall be required more often than 7 days.

3.10.3 Relative accessibility. EESSS components shall be selected and located for maximum ease of operation, maintenance, and cleaning Critical items that require rapid maintenance shall be most accessible. When relative criticality is not a factor, items that require the most frequent access shall be most accessible. High failure rate items shall be accessible for replacement without moving non-failed items.

3.10.4 Error-proof design. The design of the EESSS shall incorporate error-proofing in equipment mounting, installing, interchanging, connecting, and operating.

a. Equipment shall include physical features (for example, supports, guides, size, or shape differences, fastener locations, and alignment pins) that prevent improper mounting. In the absence of physical features, equipment shall be labeled or coded to identify proper mounting and alignment.

b. Equipment that has the same form and function shall be interchangeable throughout a system and related systems. If equipment is not interchangeable functionally, it shall not be interchangeable physically.

c. Connectors serving the same or similar functions shall be designed to preclude mismating or misalignment.

d. Design, location, procedural guidance, and suitable warning labels shall be provided to prevent damage to equipment while it is being handled, installed, operated, or maintained.

3.10.5 Special tools. The design of the EESSS shall not require any special tools as defined in

6.3.1.

3.10.6 Corrective maintenance. The time to repair/replace any component shall not exceed 30 minutes by trained personnel.

3.11 Workmanship.

3.11.1 General workmanship. The EESSS, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.11.2 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred.

Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.11.3 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.11.4 Cleaning. The EESSS shall be thoroughly cleaned. Loose, spattered, or excess solder;

welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; loose threads and fabric portions and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Operational inspection (see 4.3).

c. Conformance inspection (see 4.4).

Requirements shall be verified in accordance with Table II.

TABLE II. Requirement verification matrix.

Section 3 Requirement Verification

Method

Section 4 Verification

3.3.1 Useable floor space. Examination 4.6.1 Examination of product.

3.3.2 Interior peak height. Examination 4.6.1 Examination of product.

3.3.3 Width. Examination 4.6.1 Examination of product.

3.3.4 Shelter system sidewalls. Examination 4.6.1 Examination of product.

3.3.5 System weight. Test 4.6.2 System weight test.

3.3.6 Modular design. Demonstration

4.6.3 Modular design

demonstration.

3.4.1 Erect time. Demonstration 4.6.4.1 Erect time demonstration.

3.4.2 Strike time. Demonstration 4.6.4.2 Strike time demonstration.

3.5.1 Wind load. Test 4.6.4.3 Wind load test.

3.5.2 Rain intrusion. Test 4.6.4.4 Rain intrusion test.

3.5.3 Snow load. Test 4.6.4.5 Snow load test.

3.5.4 Salt fog. Test 4.6.4.6 Salt fog test

3.5.5 Sand and dust. Test 4.6.4.7 Sand and dust test.

3.5.6 Operational temperature range.

Certification

4.6.4.8 Fabric cold crack

certification.

Demonstration

4.6.4.9 Cold weather simulation.

4.6.10.2 Repair kit demonstration.

3.5.7 Solar radiation. Test 4.6.4.10 Solar radiation test.

3.6 System design parameters.

3.6.1 EESSS fabric skin. Certification 4.6.6.1 EESSS fabric skin tests.

3.6.2 Floor.

Examination 4.6.1 Examination of product.

Certification 4.6.6.2 Floor tests.

3.6.3 Shelter frame.

Examination 4.6.1 Examination of product.

Test

4.6.4.3 Wind load test.

4.6.4.5 Snow load test.

3.6.4 Energy efficiency. Test 4.6.6.3 Energy efficiency tests.

3.6.4.1 Solar shade fly. Examination 4.6.1 Examination of product.

3.6.4.2 Insulating liner. Examination 4.6.1 Examination of product.

3.6.5 Doors. Examination 4.6.1 Examination of product.

3.6.5.1 End wall soft door. Examination 4.6.1 Examination of product.

3.6.5.2 Hard doors. Examination 4.6.1 Examination of product.

3.6.5.3 Vestibule. Demonstration 4.6.6.4 Vestibule demonstration.

3.6.6 HVAC ports. Examination 4.6.1 Examination of product.

3.6.8 Internal plenums. Examination 4.6.1 Examination of product.

3.6.9 Ventilation. Examination 4.6.1 Examination of product.

3.6.10 Electrical system. Examination 4.6.1 Examination of product.

3.6.11 Interior lighting. Test 4.6.6.5 Interior lighting test.

3.6.12 Utility ports. Examination 4.6.1 Examination of product.

3.6.13 Interior support fasteners. Examination 4.6.1 Examination of product.

3.6.14 Non-reflective hardware

Examination 4.6.1 Examination of product.

3.6.15 Repair kit. Examination 4.6.1 Examination of product.

3.6.15 Repair kit.

3.6.16 Anchoring system.

Demonstration

4.6.7.1 Erect/strike cycle

demonstration

Demonstration

Examination

4.6.10.2 Repair kit demonstration.

4.6.1 Examination of product.

3.6.17 Hazardous environment

protection.

Certification

4.6.6.9.1 Hazardous environment

protection certification.

3.6.17 Hazardous environment

protection.

3.6.18 Vestibule interface.

Demonstration

4.6.6.9.2 Hazardous protection

demonstration.

Examination 4.6.1 Examination of product.

3.6.19 Flame resistance. Test/Certification

4.6.6.6 Flame resistance test/

certificate.

3.6.20 Fungus resistance. Test 4.6.6.7 Fungus resistance test.

3.6.21 Vector intrusion. Examination 4.6.1 Examination of product.

3.6.22 Uneven terrain. Demonstration 4.6.6.8 Un-even terrain.

3.6.23 Quick reference instructions. Examination 4.6.1 Examination of product.

3.6.24.1 Protective coatings. Examination 4.6.1 Examination of product.

3.6.24.2 Fungus and moisture

resistance.

Examination 4.6.1 Examination of product.

3.6.24.3 Surface preparation and

pretreatment for aluminum material.

Examination 4.6.1 Examination of product.

3.6.24.4 Surface preparation and

pretreatment for ferrous material.

Examination 4.6.1 Examination of product.

3.6.24.5 Ferrous material primer. Examination 4.6.1 Examination of product.

3.6.24.6 Topcoat. Examination 4.6.1 Examination of product

3.6.24.7 Dissimilar metals. Examination 4.6.1 Examination of product

3.6.24.8 Finish. Examination 4.6.1 Examination of product

3.6.24.9 Placard. Examination 4.6.1 Examination of product.

3.6.25 Human engineering. Examination 4.6.1 Examination of product.

3.6.25 Human engineering.

3.6.26 Welders and welding.

Demonstration

4.6.7.1 Erect/strike cycle

demonstration.

Demonstration

Examination

4.6.10.1 Preventive maintenance

demonstration

4.6.10.2 Repair kit demonstration.

4.6.1 Examination of product.

3.6.27 Fastening devices. Examination 4.6.1 Examination of product.

3.6.28 Fluid traps and faying

surfaces.

Examination 4.6.1 Examination of product.

3.6.29 Markings. Examination 4.6.1 Examination of product.

3.6.30 Identification plate. Examination 4.6.1 Examination of product.

3.7.1 Erect/strike cycles. Demonstration

4.6.7.1 Erect/strike cycle

demonstration.

3.7.2 Service life. Certification

4.6.7.2 Service/shelf life

certification.

3.7.3 Shelf life. Certification

4.6.7.2 Service/shelf life

certification.

3.8.1 System safety. Analysis

4.6.8.1 System safety hazard

analysis.

3.8.2 Hazardous material. Examination 4.6.1 Examination of product.

3.8.3 Component protection. Examination 4.6.1 Examination of product.

3.8.3 Component protection.

3.9.1 Transportation containers.

Examination

Demonstration

4.6.10.1 Preventive maintenance

demonstration.

4.6.9.1 Transportation containers.

3.9.2 Surface transportability. Analysis 4.6.9.1 Transportation containers.

3.9.3 Air transportability. Analysis 4.6.9.1 Transportation containers.

3.10.1 Durability. Certification 4.6.10.3 Durability Certification

3.10.2 Preventive maintenance. Demonstration

4.6.10.1 Preventive maintenance

demonstration.

3.10.3 Relative accessibility. Demonstration

4.6.10.1 Preventive maintenance

demonstration.

3.10.3 Relative accessibility. Demonstration 4.6.10.2 Repair kit demonstration.

3.10.4 Error-proof design. Demonstration 4.6.10.1 Preventive maintenance demonstration.

3.10.4 Error-proof design.

3.10.5 Special tools.

Demonstration

Demonstration

4.6.10.2 Repair kit demonstration.

4.6.10.1 Preventive maintenance

demonstration

3.10.5 Special tools.

3.10.6 Corrective maintenance.

Demonstration

Demonstration

4.6.10.2 Repair kit demonstration.

4.6.10.1 Preventive maintenance

demonstration.

3.11.1 General Workmanship. Examination 4.6.1 Examination of product.

3.11.2 Bolted connections. Examination 4.6.1 Examination of product.

3.11.3 Riveted connections. Examination 4.6.1 Examination of product.

3.11.4 Cleaning. Examination 4.6.1 Examination of product.

4.2 First article inspection. Four first article EESSS systems shall be subjected to the analyses, demonstrations, examinations, and tests described in 4.6. The contractor shall provide or arrange for all test equipment and facilities. Unless otherwise approved by the procuring activity, changes shall not be made to the first article EESSS systems’ configurations during the first article inspection. All components of the base EESSS supplied during production shall be of the exact same configuration and design as the components of the base EESSS supplied for first article inspection.

4.3 Operational inspection. All operational inspections shall be satisfactorily completed and approved prior to final first article acceptance.

4.4 Conformance inspection. Each production EESSS shall be subjected to the examination described in 4.6.1.

4.5 Inspection requirements.

4.5.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

4.5.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data or shorter intervals shall be provided as appropriate for any specific test.

a. Date.

b. Time started.

c. Time finished.

d. Ambient temperature.

e. Ambient humidity.

4.5.3 Test rejection criteria. Throughout all tests specified herein, the EESSS shall be closely observed for the following conditions, which shall be cause for rejection.

a. Failure to conform to design or performance requirements specified herein or in the contractor's technical proposal.

b. Structural failure of any component, including permanent deformation, or evidence of impending failure.

c. Evidence of excessive wear. If excessive wear is suspected, the original equipment manufacturer’s (OEM’s) specifications or tolerances shall be utilized for making a determination.

d. Evidence of corrosion or deterioration.

e. Misalignment of components.

f. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

4.5.4 Failure reporting, analysis, and corrective action system (FRACAS). A closed loop system shall be used to collect data, analyze, and record timely corrective action for all potential failures that occur during the first article and operational tests. The contractor's existing FRACAS shall be utilized with the minimum changes necessary to conform to this specification. The system shall cover all test samples, interfaces between test samples, test instrumentation, test facilities, test procedures, test personnel, and the handling and operating instructions. The contractor shall establish and maintain a FRACAS database; all information shall be entered into the database.

Authorized procuring activity personnel shall have read-only access to the FRACAS database.

4.5.4.1 Problem and failure action. At the occurrence of a problem or potential failure that affects satisfactory operation of a test sample, entries shall be made in the appropriate data logs and the failed test sample shall be removed from test, with minimum interruption to the other test samples continuing on test.

4.5.4.1.1 Problem and failure reporting. A failure report shall be initiated at the occurrence of each problem or potential failure of the contractor hardware or software or Government furnished equipment (GFE). The report shall contain the information required to permit determination of the origin and correction of the failure. The contractor’s existing failure report form may be used with minimum changes necessary to conform to the requirements of this specification. The failure report form shall include the information specified in a through c:

a. Descriptions of failure symptoms, conditions surrounding the failure, failed hardware identification, and operating time (or cycles) at the time of failure.

b. Information on each independent and dependent failure and the extent of confirmation of the failure symptoms, the identification of failure modes, and a description of all repair actions taken to return the test sample to operational readiness.

c. Information describing the results of the investigation, the analysis of all part failures, an analysis of the system design, and the corrective action taken to prevent failure recurrence. If no corrective action is taken, the rationale for this decision shall be recorded.

4.5.4.1.2 Identification and control of failed items. A failure tag shall be affixed to the failed part immediately upon the detection of any failure or suspected failure. The failure tag shall provide space for the failure report serial number and for other pertinent entries from the test sample failure record. All failed parts shall be marked conspicuously or tagged and controlled to ensure disposal in accordance with contract requirements. Failed parts shall not be handled in any manner which may obliterate facts which might be pertinent to the analysis. Failed parts shall be stored pending disposition by the authorized approval agency of the failure analysis.

4.5.4.