SOW - SSETI Validation Testing Phase 1A final.docx

Statement of Work for Blast Simulator Testing To Investigate Silicone Glazed Curtain Wall Systems Utilizing Aluminum Panels as Surrogate Glazing Systems (SSETI Validation Testing Phase 1A)

The U.S. State Department’s Bureau of Diplomatic Security, Research and Development Branch (DS/PSD/RD, aka RD) is executing a program aimed at providing analytical tools for design and evaluation of structural silicone glazed – uncaptured bite window systems. The overarching program is Structural Silicone Evaluation Tool Initiative (SSETI). The scope of work outlined below entails blast simulator (e.g. “shock tube”) testing performed for the purpose of tuning and validation of the analytical models being developed as part of the SSETI program. The overall validation testing will entail a multiphase test program. This phase (Phase 1A) involves shock tube testing of two-edge supported aluminum panels that serve as surrogates for laminated glass layups that are of interest to the Department of State. Multiple test articles will be evaluated with variation in surrogate dimensions, load, and silicone bond dimensions.

OUTLINE OF THE SCOPE OF WORK REQUIRED BY THIS SOLICITATION

1. The contractor will ultimately be responsible for the assembly, fabrication and testing of the silicone glazed curtain wall surrogate specimens. RD has arranged for partial supply of test materials and for silicone manufactures to provide the required silicone application. The contractor is responsible for coordinating these aspects of the overall testing program. Specifics follow.

2. Most of the aluminum required for this testing program is available to the contractor as government provided equipment (GPE). This aluminum is located at a commercial ballistic test firm (Newtec) located in South Carolina. Details of the available aluminum can be found in this SOW in the Section entitled GPE ALUMINUM INFORMATION. The contractor is responsible for procuring any additional aluminum material required for this test program as well as all preparation and shipping costs associated with adapting GPE aluminum for the testing program.

3. RD is engaged with manufacturers of structural silicone in an ongoing research effort. Three silicone manufacturers have agreed to apply the silicone required to produce all test specimens for this work. The contractor is responsible for all other aspects of curtain wall glazing surrogate fabrication. This specifically means ensuring that test specimens are fabricated to accommodate testing in a shock tube. The contractor is responsible for all shipping costs associated with having the three silicone manufacturers prepare test specimens. Details of this aspect of the SOW can be found in the section entitled SILICONE APPLICATION SUPPORT FROM MANUFACTURER.

4. Specifics of test specimen and shock tube test parameters and documentation of test results can be found in the SOW sections TESTING and POST-TEST SILICONE CONNECTION EVALUATION.

BACKGROUND INFORMATION

Phase 1A testing includes two-edge supported aluminum surrogate panels conducted in a shock tube.

· Two-edged support captures the effects at the middle of long edges of glazing units without the added complexity of two-way action and corner effects. The panel geometry is a natural extension of that for static connection tests previously executed on behalf of RD as part of a material characterization program.

· Aluminum panels are used as surrogates for glazing units since they have stiffness and mass that are similar to selected glass make-ups of interest to RD.

· Shock tubes are well equipped to provide positive phase loading comparable to open blast tests. They most often offer relatively poor negative phase pressure signatures. Accordingly, they are most useful for positive phase response (and maybe rebound). The greatest advantage is repeatability, cost per shot, and turnaround time for the low end RD loads conditions. It is also the case that reasonably good correlation is often seen with simple triangular waveforms for the pressure curves. Simple triangular waveforms are useful for some classical analysis methods and for general load comparison.

TESTING

The primary purpose of Phase 1A testing is to provide results that support the tuning and validation of structural silicone connection models for positive phase blast loading. The test results will also provide fundamental mathematical validation for the more general SETTI glazing system evaluation tool.

All testing for this effort will be conducted in a shock tube.

Test Set Up:

Figure 1 provides a conceptual sketch of the target end of the shock tube where the test articles are to be mounted. Three articles shall be mounted for each shot. As shown in the sketch, the panels shall be supported by a non-responding frame and shall be separated by covers that mitigate shock wave interference or clearing effects between panels.

Figure 1. Target Elevation View

Figure 2 shows the section view through an assembled panel as installed in the shock tube target wall. The sketch is for concept only. The actual design of the non-responsive panel support frame and bolted connections are the responsibility of the performer (test facility). While installation tolerances should be considered and accounted for, the bolted connections shall not slip during the test.

Figure 2. Target Cross Section

Tools, lifting equipment, replacement bolts, and labor required for installation and removal of the test articles are the responsibility of the performer.

Test Instrumentation:

In general terms, refer to BLAST TESTING SOP FOR DS/PSD/RD, May 5, 2020 as applicable for guidance on test plan, test setup, instrumentation, data processing and report information. Specific to this test program, instrumentation shall include displacement gauges (laser) at the middle of each panel and at a minimum of four interface bars as shown in Figure 1. Reflective pressures shall be measured at locations shown in Figure 1. Additional gauges or other documentation shall be provided to quantify the variation in pressure from left to right on each panel. This additional instrumentation or documentation shall be included in the test plan and submitted to RD for approval prior to testing. Temperature of the silicone on both ends of each panel shall be recorded immediately before each shot.

High speed video shall be captured from two view points for each shot as shown in Figure 3. One view shall capture global response while the second shall be focused on a connection or connections. The specific views shall be coordinated with RD before each shot.

Figure 3. High Speed Video Camera Placement

RD will have Digital Image Correlation (DIC) data taken and analyzed by a third party to support the interpretation of test results and to facilitate the numerical validation. The DIC analysis results shall provide detailed information regarding the movement of the panels relative to the interface bars. The relative movement will be used to characterize the strains (joint movement) within the silicone. The DIC data shall be taken for up to ten (10) shots. In each case, the focus shall be on one end of one of the three panels included in each shot. As indicated in Figure 4, the DIC cameras may be offset vertically or horizontally or both (approximately 25 Degree separation). The performer shall coordinate with the third party DIC test group and provide access for testing. The performer shall also accommodate the DIC testing in terms of incidental tools, supplies and labor required to support set up of the equipment. The actual capture and processing of DIC information is not part of the scope of this effort.

Figure 4. Digital Image Correlation

The performer shall document pre-test test setup and post-test results including photographs, dimensional information, displacements, silicone connection evaluations, and general observations.

Shock Tube Test Loads:

Table 1 lists the load cases to be used for this test series. Pressure (P) and impulse (Im) are to be considered primary and shall be within +/- 10% of the targeted values. The equivalent triangular duration (Td) is for reference only. Reported peak pressure shall be obtained from a Friedlander curve fit to the positive phase pressure test data. Reported impulse shall be obtained by direct integration of the positive phase of the pressure test data. Note that prior to the test and as the test series progresses, the targeted values for P and Im for load cases P1, P2, P3, and P4 may be adjusted by RD. The adjustments shall be limited by the performance of the shock tube and shall not impose a significant additional cost for the test facility.

(psi-msec) Td (msec)

Table 1. Load Cases

Test Matrix:

The test matrix is shown in Table 2 will be repeated for each of the three (3) silicone types. Note that there are twelve (12) shock tube shots (runs) per silicone type and three (3) different silicones for a total of 36 shock tube shots. Each shot will have three (3) test articles corresponding to 36 assembled test articles per silicone for a total of 108 test articles. The test number identifier is comprised of five components, example:

· A_0.2500_44_P1_a

· A = Aluminum surrogate panel

· 0.2500 = sample thickness e.g. 0.2500 is ¼" thick

· 44 = DLO e.g. 44 is a 44” DLO

· P1 = Load Case e.g. P1 is 4psi and 28psi-ms per Table 1. Load Cases

· a = test sample identifier e.g. a-f are the individual test samples that are a part of the higher category test sample configuration.

Table 2. Test Matrix Test Articles:

108 test articles are required for this effort. A test article consists of the following components:

· Aluminum panel (thickness varies per test matrix)

· Silicone

· Interface plate

A representative test article showing the three components can be seen in Figure 5.

Figure 5. Representative Test Article

More information regarding test articles is included below.

GPE ALUMINUM INFORMATION

· RD has most of the material required for the aluminum panels in inventory. The inventory is held by Newtec of Edgefield, South Carolina (POC Keith Williams, 803-480-0410). It is the responsibility of the provider to coordinate with Newtec to confirm available stock and to contract with Newtec for any material preparation and shipping that may be required. A material list is provided in Appendix B as a starting place but it is not intended as the final firm total. The provider is responsible for obtaining and processing any additional aluminum that is required to fully populate the test matrix in Table 2.

· The aluminum plates available are in 12” x 144” plate sections. The test articles need to be in 12” x 48” plate dimension:

Table 3: Available GPE Material for Test Articles

The additional twelve (12) 1”x 12” x 48” aluminum panels and nine (9) 2”x 12” x 48” aluminum panel will need to be procured by the vendor. 6061 T6 is an acceptable material for these if 6063 T5 or T6 is not available. Mil certs and actual material properties shall be obtained by the performer provided remaining aluminum. Note this is not specified minimum values but rather tested values (tensile tests) for the actual lots of aluminum plate.

Interface Bars:

· The interface bars are to be obtained and prepared by the performer. Preparation includes cutting to size and drilling bolt holes. The bars are to be fabricated from A36 steel or similar. Preliminary weights for the interface bars (and panels) are shown in Table 4.

· Surface conditions, coatings, etc. for the interface bars (and the aluminum panels) shall be suitable for providing full-adhesive silicone bonding to the substrates. Performer shall seek guidance from the silicone manufacturers so as to simplify the silicone installation process while assuring full adhesion.

Table 4. Component Weights

SILICONE APPLICATION SUPPORT FROM MANUFACTURER

· RD coordinated with silicone manufacturers for their support of this test program. The test articles will be assembled (silicone bonded) by the silicone manufacturers at their respective facilities.

· The performer shall have the aluminum panels and interface bars delivered to the three different silicone manufacturer facilities (Waterford, NY, Lakewood, NJ, and Auburn, MI). All pieces shall be clearly and indelibly marked with a test number and a silicone number before shipment to the silicone manufacturers. The markings should not be in the area of the silicone bond. The performer shall also provide for shipment of the assembled test articles from the silicone manufacture facilities to the performer test facility. All shipping cost to be paid by the testing performer. Provision for shipping includes not only shipping costs but also shipping containers that are sized in accordance with the assembled test articles.

· Scheduling considerations include the requirement that the silicone be allowed to cure no less than 30 days and no more than 90 days before the actual test. Also, while the silicone manufacturers have agreed to provide the silicone installation at no charge, their schedule may be somewhat indefinite. RD will support any coordination that may be required but it is important that the provider be in direct communication with the silicone manufacturers as the project unfolds. The silicone manufacturers will be providing quality control documentation for the silicone installation (application process). This documentation shall be gathered by the performer and included with the final report.

· The individual silicones shall be tested as a contiguous set. There may be allowance for scheduling gaps between the three silicone test sets.

· The performer shall coordinate with the silicone manufacturer to ensure that their interface bars are installed according to the performers plan for mounting them to the end of the shock tube, e.g. the bolt holes still line up.

The specific dimensions of the silicone bond are to be provided by RD prior to silicone assembly of the test articles.

POST-TEST SILICONE CONNECTION EVALUATION

Post-test connection evaluations shall be performed using the grading scheme listed in Table 5 along with the failure type shown in Table 6. A summary of test result similar to Table 7 shall be recorded and reported. The failure characterization shall be based on visual inspection of the failure surfaces. The Adhesion Area is the bonded area on one surface of the silicone. As an example, a complete tear of the silicone would result in 100% in the C column. A partial tear would result in a value less than 100%. The performer may or may not have access to the predictions before the test and therefore may not be required to include the information in the test report.

Table 5. Connection Evaluation

Table 6. Failure Type

Table 7. Test Results

DELIVERABLES

A quick look report shall be provided within 30 days of test completion, with a draft of the full written report due 30 days later. There shall be allowance for at least one review by RD. Provider to deliver final report with RD comments addressed before final approval. Report packages shall include:

· Information listed is sections above.

· Original test plan with documentation of deviations from the original plan.

· Test article dimensional information.

· Raw gauge data and processed gauge data.

· Videos – Overall from protected side (for up to 6 shots).

· Photographs – pre and post. Post to include support for silicone performance characterization.

· Temperature of the silicone at shot time.

· Mechanical property test reports for aluminum panel. Newtec has mill certs and test reports for the aluminum in their possession. Actual material properties shall be obtained by the performer provided remaining aluminum. Note this is not specified minimum values but rather tested values (tensile tests) for the actual lots of aluminum plate.

· QC reports for the silicone including cure time (from silicone installer).

· Requirements listed in BLAST TESTING SOP FOR DS/PSD/RD, May 5, 2020 as applicable.

All final reports, photos, and full testing videos shall be delivered at the completion of all testing on a DVD delivered via FedEx or UPS to:

Attention: Alec Williamson

A monthly status update on progress, scheduling, delays or other information shall be provided the first of the month. Status updates shall be in the format of an email with subject “SSETI Validation Testing Phase 1A – Month”. An example monthly status update template is provided in Appendix A.

Appendix A: Example Monthly Status Report DS/C/PSP/PSD/RD – Project Name Task Manager: TBD Developer PI: (Fill in name, phone number once contract is awarded) Contract Number: (fill in)

MONTHLY STATUS REPORT

1) TASK TITLE: ((fill in)

2) DESCRIPTION/REQUIREMENT: (fill in)

3) DEVELOPER(S): (add any significant subcontractors)

4) TECHNICAL APPROACH: (In five or six sentences, summarize the project’s technical approach.)

5) MILESTONES: (fill in relevant milestones)

Project Plan

Kickoff Meeting

Preliminary Design Review

Operations and Maintenance Manual

Critical Design Review

Test Plan

Test Report

Etc.

6) FUNDING & COSTS:

Project Funding History

Funding Provided to Date Expenditures (Current Month)

Obligated Funds

Insert graph showing planned expenditures, current funding level, and actual expenditures here. The graph must cover from contract start date to end date. If a revised spend plan becomes necessary, be sure to include the original plan as well. (See sample below):

8) ISSUES: (Identify any issue that affects the progress of the project, funds requirements, payment of invoices, potential schedule problems. Include requirements for resolution of the issue.)

Appendix B: Material List

Material Required for Panels:

6063-T5 or T6

Material Available from Newtec:

12”x144” 6065-T5

12”x144” 6065-T6

Note:

The performer is responsible for the final count on material requirements and availability. It will be necessary to obtain additional panel material. Panel materials shall have mechanical properties similar to those at Newtec (example shown below). Substitutions must be approved by RD, aluminum 6061 T5 or T6 are acceptable substitutes if 6063 T5 or T6 is not available.

Example of Material Properties for Material at Newtec:

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