ESAPI_COPD_0419_Rev_J.PDF

DISTRIBUTION STATEMENT C.

Authorized distribution is to U.S. Government Agencies and their Contractors for administrative and operational use as determined on 05 February 2018. Other requests for this document, beneficial comments (recommendations, additions, deletions), or any pertinent data which may be used in improving this document should be addressed to Product Manager-Soldier Protective Equipment, Program Executive Office Soldier, US

Army, 10170 Beach Road, Building 328T, Fort Belvoir, Virginia 22060.

INCH-POUND

CO/PD 04-19REV J

01 October 2018

SUPERSEDING

CO/PD 04-19H

04 March 2013

PURCHASE DESCRIPTION

PERSONAL ARMOR

ENHANCED SMALL ARMS PROTECTIVE INSERT (ESAPI)

This document is approved for use by all Departments and Agencies of the Department of Defense (DOD).

1. SCOPE

1.1 Scope. This purchase description covers the Enhanced Small Arms Protective Insert (ESAPI) worn by ground troops. When placed in the Improved Outer Tactical Vest (IOTV) or Soldier Plate Carrier System (SPCS) (as a component of the Interceptor Body Armor (IBA) system), or Soldier Protection System (SPS), the insert will provide ballistic protection from specific 5.56 mm and 7.62 mm rifle rounds. Product Manager Soldier Protective Equipment (PM SPE) designates the ESAPI a Critical Safety Item (CSI).

1.2 Classification. The ESAPI shall be of one type and in the following sizes (see paragraph 6.9):

ESAPI Sizes Extra-Small (XS) Small (SM) Small-Long (SL) Medium (MD) Large (LG) Extra-Large (XL)

CO/PD 04-19 REV J

FOR OFFICIAL USE ONLY

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this performance requirement. 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 documents cited in sections 3 and 4 of this specification, whether or not they are listed under Section 2, Applicable Documents.

2.2 Government Documents.

2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

2.2.1.1 SPECIFICATIONS:

FEDERAL

MIL-DTL-32075 17, OCT

Label: For Clothing, Equipage, and Tentage

DEPARTMENT OF DEFENSE

MIL-STD-662F V50 Ballistic Test for Armor MIL-STD-810G_CHG-1 Environmental Engineering Considerations and Laboratory Tests MIL-STD-130N_CHG-1 DoD Standard Practice – Identification Marking of US

Military Property

Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available 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 of the exact revision level shown form a part of this document to the extent specified herein.

DEPARTMENT OF DEFENSE TESTING PROTOCOLS

27 April 2010 Hard Body Armor Standard for Ballistic Testing 2 July 2010 Standard for Lot Acceptance Ballistic Testing of Hard Body

Armor

U.S. ARMY PROGRAM EXECUTIVE OFFICE SOLDIER, FORT BELVOIR, VA

CO/PD 00-02I Outer Tactical Vest (OTV) AR/PD 10-04F Soldier Plate Carrier System AR/PD 15-03C Body Armor, Torso and Extremity Protection (TEP), Modular

Scalable Vest (MSV) GEN I AR/PD 15-03D Body Armor, Torso and Extremity Protection (TEP), Modular

Scalable Vest (MSV) GEN II FQ/PD 07-05H Body Armor, Multiple Threat, Improved

DRAWINGS

Drawing Numbers 2-6-0588 Enhanced Small Arms Protective Insert, Size: Extra-Small (XS) 2-6-0589 Enhanced Small Arms Protective Insert, Size: Small (SM) 2-6-0593 Enhanced Small Arms Protective Insert, Size: Small-Long (SL) 2-6-0590 Enhanced Small Arms Protective Insert, Size: Medium (MD) 2-6-0591 Enhanced Small Arms Protective Insert, Size: Large (LG) 2-6-0592 Enhanced Small Arms Protective Insert, Size: Extra-Large (XL)

Copies of drawings, publications, and other Government documents required by vendors in connection with specific acquisition functions should be obtained from the contracting activity.

U.S. ARMY DEVELOPMENTAL TEST COMMAND, ABERDEEN PROVING GROUND, MD

TOP 10-2-210 Ballistic Testing of Hard Body Armor Using Clay Backing

Copies of documents are available by sending to Commander, US Army Test and Evaluation Command, ATTN: AMSTE-TM-T, Aberdeen Proving Ground, MD 21105-5055

2.3 Non-Government Publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Y14.5M Dimensioning and Tolerancing (DoD adopted)

Application for copies should be addressed to the American Society of Mechanical Engineers, 345 East 47th Street, New York, NY 10017-2392.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM E29-13 Standard Practice for Using Significant Digits in Test Data to

Determine Conformance with Specifications

AMERICAN NATIONAL STANDARD/AMERICAN SOCIETY FOR QUALITY (ANSI/ASQ)

ANSI/ASQ Z1.4-2008 Sampling Procedures and Tables for Inspection by Attributes

Application for copies should be addressed to the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959).

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 15415 Information Technology Automatic Identification and Data

Capture Techniques, Barcode Print Quality Test Specification

– Two Dimensional Symbols

ISO 16022 Information Technology Automatic Identification and Data Capture Techniques Data Matrix Barcode Symbology Specification

Address applications for copies to ISO, ISO Central Secretariat, 1, ch. de la Voie-Creuse, CP 56, CH-1211 Geneva 20, Switzerland or by accessing www.iso.org.

SAE AEROSPACE STANDARD (AS)

AS 9132 Data Matrix (2d) Coding Quality Requirements for Parts

Marking

Application for copies should be addressed to the Warrendale, PA, USA, 400 Commonwealth Drive, Warrendale, PA 15096 or https://www.sae.org/standards/content/as9132b/.

2.4 Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence over the cited Test Operations Procedure (TOP), and cited TOP takes precedence over MIL-STD-662F. However, for V50 testing, MIL-STD-662F takes precedence over the cited TOP. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

http://www.iso.org/

3. REQUIREMENTS

3.1 First Article Testing. First Article Testing (FAT) is a requirement for ESAPI. Samples shall be subjected to FAT In Accordance With (IAW) 4.2.1. Lot Acceptance Testing (LAT) is a requirement for ESAPI. Samples shall be subjected to LAT IAW 4.2.2.

3.2 Construction. The materials selected by the Contractor shall be capable of meeting all performance, operational, and environmental requirements specified herein. The ESAPI shall not contain metallic components within the hard armor composite for any reason other than explicit purpose of crack detection technology. ESAPI with crack detection components (regardless of crack detection method or material) shall meet the same base requirements (weight, protection, durability, environmental robustness, ease of use, et cetera) as those ESAPI without crack detection components.

3.2.1 ESAPI Cover. The ESAPI cover materials used shall mitigate frontal spall, increase durability, and decrease environmental deterioration of the underlying components configuration; the ESAPI cover material shall cover the entire front and back outer surface and all side edges. The cover, including all edges, shall be free of the following: cuts, holes, tears, abraded areas, wrinkles, bubbles, creases. The cover shall not exhibit any areas of under adherence. There shall be none of the following: visible peeling, wrinkles, bubbles, creases of the cover before or after any operating environment conditioning.

3.2.2 Assembly of Components by Bonding. The ESAPI shall exhibit no evidence of under adherence between layers or components. The finished ESAPI shall exhibit no smears and or clumps from excess bonding agent visible on the exposed surfaces.

3.3 Production Data and Technical Data Package. The Contractor shall develop, document and maintain production data for the ESAPI and furnish it in accordance with the contract. The production data shall be traceable with the serial number of the ESAPI. The serial number shall be unique to each ESAPI. The serial number shall be traceable to the production information maintained by the contractor. Traceability information shall enable identification of equipment used, the ESAPI manufacturing date and lot information on all materials used.

a. Production data shall include inspection data generated during manufacturing, any process data collected as part of the Contractor’s quality management system and Production Process Package (PPP). This includes, but is not limited to chemistry, weight, thickness, and dimensional measurements. If ceramics are used, grain structure analysis is required (e.g., grain size maximum, minimum, average or histogram plots or both).

b. Supplier lot information and traceability for all component parts shall be identified in the Technical Data Package (TDP) for the finished ESAPI. The TDP shall include test data from an independent test source from each subcontractor and material supplier verifying the conformance of all materials and components.

c. Operational, ownership, and environmental test data generated by the Contractor on the

ESAPI.

d. Ballistic performance test data generated under all first article, conformance, and validation testing as described in 4.9.

e. The ESAPI ceramic component shall be durably marked and traceable from production through to each finished lot. The serial number shall be marked on the outside face within 1 inch (in) (25.4 millimeters (mm)) of the lower edge of the ceramic component before it is fired.

ESAPI shall be marked by inscribing, embossing, or with high temperature resistant inorganic ink, or after firing with permanent marking to a maximum depth of 0.010 in (0.254 mm) so that the serial number is legible when the spall cover is stripped mechanically or by the use of a solvent. The ESAPI serial number shall not be affected by solvents, fuels, and other liquids.

Ceramic cores shall be durably marked to allow radiographic analysis to identify and trace component to a finished end item lot and Supplier Lot. If inscribed, it shall be done on the outer

0.25 in (0.635 mm) of the plate.

3.4 Workmanship. The finished product shall conform to the quality requirements established by the Purchase Description (PD). The Contractor shall verify and validate that all fabrication procedures will yield quality workmanship to meet product specification and contract requirements. The contractor shall control production to minimize and where possible eliminate or avoid defects. Manufacturing practices shall be capable of consistently yielding product that conforms to all requirements in this PD and internal specifications for the product and their components. The contractor shall properly mark and identify component materials and protect them during storage. The contractor shall ensure that all materials produced and integrated into the finished ESAPI be durable and provide consistency in appearance throughout life of the product. The ESAPI material layers shall be free of contaminants such as, but not limited to:

foreign object debris, any media not associated with the TDP, loose fragments of component materials or adhesives or both, operator elements not part of component materials, cleaning residue which may result in delamination between layers. ESAPI material interfaces shall be compatible and ensure ease of use. The Contractor shall ensure that the finished product, all subcomponents and parts are free of foreign objects, scaling, burrs, frayed edges, material tears, torn edges, stains, holes, and other imperfections when visually examined. Products will be subjected to destructive deconstruction examination and visual examination using nondestructive test methods (radiography, microscopic analysis, liquid penetrant inspection, ultrasonic testing, Computerized Tomography (CT) scanning, and other like technologies) to assess product compliance. This section is applicable to all material or components of the product whether furnished by the Prime Contractor or by any of their suppliers or subcontractors. In any case, of material, process, or equipment change desired to be made by the Contractor, the written consent of the Government shall be obtained before making the change. (See paragraph 4.9.1 for verification).

3.5 Operating Requirements. Each ESAPI shall satisfy the following user-oriented requirements (see paragraph 4.6).

3.5.1 Ease of Insertion. The ESAPI shall be able to easily slide into and out of the Body Armor, Multiple Threat: CO/PD 00-02 Outer Tactical Vest (OTV), FQ/PD 07-05H Improved Outer Tactical Vest (IOTV), AR/PD 10-04F Soldier Plate Carrier System (SPCS), AR/PD 15-03C Body Armor, Torso Extremity Protection (TEP) Modular Scalable Vest (MSV) GEN I, and AR/PD 15- 03D Body Armor, Torso Extremity Protection (TEP) Modular Scalable Vest (MSV) GEN II. No obtrusive or abrasive coverings shall be applied to any of the ESAPI surfaces. No special training, equipment or tools will be required to insert the ESAPI into the carrier pouch (see paragraph 4.6.1).

3.5.2 Weight. The finished ESAPI shall not exceed the following weights;

Size Threshold Maximum Weights (lbs)

Extra-Small 3.80 Small 4.75 Small-Long 4.84 Medium 5.45 Large 6.25 Extra-Large 7.10

3.5.3 Dimensional measurements. The ESAPI shall conform to all measurements, tolerances, radius, and edge chamfers cited in drawings from paragraph 2.2.2 (see paragraph 4.6.3 and 4.6.4).

3.5.4 ESAPI Thickness. The ESAPI in finished form shall not exceed the tolerances shown on the drawings listed in 2.2.2 and shall have uniform thickness throughout. The difference between any two thickness measurements shall not exceed 1/8 in (3.175 mm) between any two measurements (4.6.4).

3.5.5 ESAPI Spall Cover Color. All areas of the ESAPI shall be colored Foliage Green 504 as specified in paragraph 4.6.5.

3.5.6 Plate Labels and Markings. All markings shall be colored white and conform to Type IV, Class 9 markings per MIL-DTL-32075 (See paragraph 4.6.6).

3.5.6.1 Orientation Markings. Permanent markings shall be placed on the back-face of the Torso plates clearly displaying the “TOP” orientation. Orientation marking shall be 1.25 in ±

0.25 in (31.75 ± 6.35 mm) from its respective edge. A permanent marking shall be centered on the front of the Torso Plate, 3.0 in ± 0.25 in (76.2 mm ± 6.35 mm) from the top clearly displaying “STRIKE FACE.” All characters shall be 0.50 in (12.7 mm) height (see Figure 1 and 2 below and paragraph 4.6.6).

3.5.6.2 Performance Markings. A permanent label or marking shall be displayed on the back-face clearly displaying “ESAPI - Rev. J” with 0.25 inch (6.35 mm) height characters. The marking shall be displayed on the center of the Torso Plate, 2.5 in ± 0.25 in (63.5 mm ± 6.35

mm) from the top edge (see Figure 1 and 2 below and paragraph 4.6.6).

3.5.6.3 Complete ESAPI Markings. The manufacturer’s contract number and nomenclature shall be permanently and legibly marked on the upper mid-center back face. The letters “U.S.”

shall be applied 4.0 in ± 0.25 in (101.6 mm ± 6.35 mm) below the top edge and centered on the ESAPI plate in characters 1.0 in (25.4 mm) high. The size identification of the ESAPI Plate shall be clearly displayed centered on the front surface 1.5 in (38.1 mm) below the top edge in all capital characters 0.5 in (12.7 mm) high (i.e. MEDIUM). The words “HANDLE WITH CARE” shall be printed in characters 0.5 in (12.7 mm) high at 6.5 in ± 0.25 in (165.1 mm ± 6.35 mm) below the top edge and centered on the front face surface. (See Figures A and B and paragraph 4.6.6).

FIGURE 1: Back Side Label and UID placement with “quiet zone” distances

FIGURE 2: Front Side Label Placement

3.5.6.4 Unique Identification Label. A Unique Identification (UID) label shall conform to the specifications below: The manufacturer is required to comply with the current versions of Military Standard 130 and the Department of Defense Guide to Uniquely Identifying Items, and the following criteria.

a. Color: Label or tag shall be black with white Human Readable Information (HRI) and Machine Readable Information (MRI).

b. HRI shall consist of: Commercial and Government Entity (CAGE) code of activity applying the label or tag, Lot Number, Serial Number, Date of Manufacture (DOM), National Stock Number (NSN), Design Code and Contract Number. HRI shall meet requirements of the latest version of MIL-STD-130N_CHG-1.

c. MRI shall consist of one ECC200 compliant Data Matrix code containing: CAGE code of activity applying the label or tag, Lot Number, Serial Number, DOM, NSN, Design Code and Contract Number. The label or tag shall comply with the latest version of MIL-STD-130N_CHG- 1, ANSI MH10.8.2, and Items #4 and #5 below. To prevent automated read errors, the Government will not allow other 1D or 2D codes to be printed on this label. This does not restrict Contractor from using other HRI and MRI on labels not associated with the UID label or tag.

d. Data Matrix Construct: The Data Matrix shall be encoded per MIL-STD-130N_CHG-1 using only the data identifiers (DI) and criteria shown below. The following DI sequence shall be maintained in the order listed below:

CAGE = 17V followed by CAGE code Lot = 1T followed by lot number Serial number = S followed by serial number Date of Manufacture (DOM) = 16D followed by production date, YYYYMMDD National stock number (NSN) = N followed by the NSN.

Design Code = 1P followed by design code (the design code may be up to 13 alpha-numeric characters (plus only dashes “-” as special characters)) Contract Number = 4Z followed by Contract number including “-“ as special characters.

Construct Example:

[)>RS06GS17V52969GS1TE034GSS328185GS16D20080215GSN8470-01-520-

7370GS1PABC-123GS4ZW91CRB-13-C-1234RSEOT

e. Data Matrix Geometry: Data Matrix codes shall be a square ECC200 matrix per International Organization Standard (ISO) 16022. Individual Cell size (element size) of the code shall be 0.020 in - 0.023 in (0.5080 mm - 0.5842 mm). A quiet zone of 0.50 in (12.7 mm) of Black label or tag material is required around the Data Matrix code.

f. Verification: Data Matrix code quality shall be graded to ISO 15415 with a certified verifier and meet a minimum passing grade per the latest release of MIL-STD-130N_CHG-1. AS9132 and Automatic Identification and Mobility (AIM) Direct Part Mark (DPM) grading platforms will not be allowed for this project. Contractor must provide the Contracting Officer (KO) with at least two verification reports per plate size for each FAT and Lot Acceptance Test (LAT). These reports shall be submitted to Defense Contract Management Agency (DCMA) and included with U.S. Department of Defense Form (DD) DD1222, Request for and Results of Tests, and the ballistic test sample shipment paperwork to the test lab. Verification shall be on the end item, not a standalone label. If using laminates or overcoats the label must be verified after placing the laminate or overcoat on the label or tag. No exceptions are allowed. Proof of verification is subject to inspection at the time of shipment.

g. Validation: Validation checks of the UID must be performed on a routine basis. The contractor is responsible for encoding the UID per above guidelines (3.5.6.4, #4 and #5) and the latest revision of MIL-STD-130N_CHG-1. Proof of validation is subject to inspection at the time of shipment.

h. Placement of the UID label or tag: The center of the Data Matrix code on an x and y axis will hereinafter be referred to as the centerline of the UID label or tag. The UID label or tag shall be placed on the back-side (opposite the strike face) of the item. The centerline of the UID label or tag shall be left-right centered on the item, positioned 2 in (50.8 mm) from the bottom edge.

A tolerance of ± 0.25 in (6.35 mm) in each direction will be allowed. The entire plate area within

3.0 in (76.2 mm) of the bottom of the plate must be clear of any other labels or markings at all times. Additional non-UID information and logos required by this product description must appear above the 3 in (76.2 mm) featureless zone. HRI information on this label may appear above the 3 in (76.2 mm) quiet zone requirement, all of the MRI information must be below and fully within the 3 in (76.2 mm) quiet zone.

3.5.6.4.1 Data Authentication. A data file (spreadsheet, comma delimited, tab delimited, or otherwise common format in accordance with the contract) containing a list of critical information used for each ESAPI production lot shall be furnished as defined in the contract. All data that is on the UID should be a row in the data file with a column or a serial order with delimiters for each field of information. Format should contain at a minimum the CAGE, Lot, Serial Number, NSN, DOM [YYYYMMDD], Design Code and Contract Number for each plate. See 6.2g

3.5.6.5 PMCS and Cleaning Instructions. PMCS and Cleaning instructions, in a font no smaller than Arial size 8, shall be located as on the above drawings and shall read as below:

3.5.6.5.1 Preventative Maintenance Checks and Services (PMCS): The ESAPI is unserviceable if any of the following conditions are present:

a. Outer cover is damaged exposing inner materials.

b. Plate is cracked (e.g., audible rattling when shaken).

c. Cracking is felt or heard when 0.50 in (12.7 mm) perimeter of plate is firmly pinched.

d. Creaking or squeaking is heard when twisted by hand.

e. Composite is delaminating (backing materials are separating).

f. Plate has been hit by a bullet or fragment.

3.5.6.5.2 Cleaning Procedures: CAUTION: Do not machine wash or dry. Failure to follow these instructions may degrade your plate’s performance against ballistic threats.

a. Remove loose dirt and lint from the outer surface using a cloth or soft bristle brush (Never use a stiff bristled brush).

b. Wet the plate using warm, not hot, water.

c. Apply mild detergent to the soiled areas and scrub with a cloth or soft bristle brush. Badly soiled areas may be scrubbed with hand-soap. Scrub only long enough to remove soil.

d. Heavy grease or oil stains may be pre-treated with a dry cleaning solvent and detergent mixture and scrubbed with a soft bristle brush.

e. Rinse the plate with warm water until all suds are completely gone.

f. Let the insert air dry away from heat source or open flame.

3.5.7 Health and Safety. The ESAPI shall be non-hazardous (e.g., have no toxicological or electromagnetic radiation effects, be non-explosive, be non-carcinogenic, etc.) to the individual wearing the ESAPI or to other Soldiers in the surrounding area. The Government will verify conformance in accordance with paragraph 4.6.7.

3.5.7.1 Flammability. Demonstrate that the ESAPI shall not melt, drip, combust, or explode when impacted with defined threats or when subjected to elevated temperatures of 250 degrees Fahrenheit (ºF) for ten (10) minutes (min) (-0/+1min) (see paragraph 4.6.7.1).

3.5.7.2 Personnel Hazard Inspection. Visually inspect that the ESAPI is free of sharp edges, foreign materials, burrs, or any other conditions that may cause an injury to the user.

Demonstrate that the ESAPI shall not cause injury to the user or surrounding troops when ballistically tested (see paragraph 4.9). Any component of the ESAPI that can cause personnel injury will not be acceptable (see paragraph 4.6.7.2). Chemicals recognized by the Environmental Protection Agency (EPA) as human carcinogens shall not be used in applications that may affect the end user.

Hazardous materials that can be exposed to personnel or the environment during any operational (to include fabrication, transportation, setup and teardown) or maintenance procedures, or exposed as a result of damage to the equipment, or requiring special disposal procedures, shall be eliminated to be consistent with operational requirements. Environmentally acceptable substitutes shall be used without degrading operational function and increasing cost.

Hazardous material exposure to personnel shall be controlled to levels below the Occupational Safety and Health Administration (OSHA) Permissible Exposure Limits. The ESAPI shall not present any uncontrolled health hazard throughout the life-cycle of the item. The ESAPI design shall not use materials that cause skin irritation or allergies.

3.5.7.3 Magnetic Influence. There shall be no magnetic influence on a compass at any distance from the ESAPI (see paragraph 4.6.7.3).

3.6 Ownership and Support. (See paragraph 4.7)

3.6.1 Durability. The ESAPI when inserted into a shootpack shall withstand two drops using a moment arm fixture (see Figure 3) at a height of 48.0 in ± 0.5 in (1,219.2 mm ± 12.7 mm) onto a concrete surface without any detrimental effects to ballistic performance, major surface characteristics, or physical properties. A 10.0 lb ± 0.1 lb (4,535.92 gm ± 45.36 gm clay mold shall be attached to the rear surface of the ESAPI with shootpack sample (see para 4.7.1). The weight of the moment arm and straps shall be 8.5 lb ± 0.5 lb (3855.54 gm ± 226.80 gm).

3.7 Operating Environment Requirements. Unless otherwise stated, ballistic validation testing shall be performed with threats “D” and or “E” in paragraph 3.8.3. Ballistic performance shall not be degraded from exposure to the environmental conditions specified in paragraph 4.8.

Spall cover shall maintain conformance to paragraph 3.2.1 even after exposure to environmental conditions.

3.7.1 Weatherometer Resistance. The finished ESAPI after being subjected to the weatherometer resistance testing shall exhibit no evidence of cracking, blistering, color change, separation of edging (if used) or ballistic degradation (see paragraph 4.8.1).

3.7.2 Temperature Extreme. The ESAPI shall provide structural and ballistic protection when exposed to temperatures ranging from -60 ºF to +160 ºF. (See paragraph 4.8.2).

3.7.3 Fluid Resistance. The ESAPI shall maintain structural and ballistic integrity after exposure to common battlefield contaminants or environmental conditions as detailed in paragraph 4.8.3.

3.7.4 Altitude. The ESAPI shall meet all performance requirements from sea level to 15,000 feet (ft) altitude. No structural, visible, operational degradation, or safety hazard shall occur when the ESAPI is exposed to a pressure change equivalent to a change in altitude from 40,000 ft to 15,000 ft (12192 meters (m) to 4572 m) at a rate of 1500 ft/min - 2000 ft/min (457.2 m/min -

609.6 m/min) (see paragraph 4.8.4).

3.7.5 Fungus. The ESAPI shall be resistant to fungal growth. The visual grading shall be less than 2.5. All components shall show only trace or no susceptibility to fungal growth nor experience damage due to the presence of fungus spores or adjacent fungus growth (see paragraph 4.8.5).

3.7.6 Temperature Shock. The ESAPI shall meet all performance requirements after exposure to temperature changes between the high and low operating temperature extremes;

temperature shock should occur within a five minute period (see paragraph 4.8.6).

3.7.7 Vibration. The ESAPI shall not experience any structural, visible, or operational degradation when subjected to vibration. Vibration testing shall be conducted in accordance with 4.8.7.

3.8 Performance Requirements. (See paragraph 4.9)

3.8.1 Areal Density. The ESAPI shall provide uniform areal density (materials coverage) throughout the entire surface area of the ESAPI. The only exception will be when edge materials are used to protect the plate from side impact (e.g., foam) to increase the durability.

Material no thicker than 0.10 in (2.54 mm) can be used for this purpose. Materials must extend from edge to edge to provide uniform thickness throughout the entire surface area of the ESAPI.

“Patches,” “clamps,” and other materials with partial or interrupted coverage of the ESAPI surface area shall not be acceptable. Materials shall not cause interference with Non Destructive Test Equipment (NDTE) (e.g., radiographic inspection). The ESAPI shall not contain any cuts, open gaps, or slits on any materials. If ceramic materials are used, the ceramic shall have uniform edges without “edge breaks” or chamfers. To reduce sharp edges, an abrasive device or other equipment may be used to clean the edges in production. A radius not to exceed 0.151 in (3.8354 mm) is allowed on the back face (i.e., body side) outside edge only. ESAPI shall meet the requirements established for workmanship as identified in Table IV, Defect Classification Table. Any product outside of the tolerance limits of Table IV shall not be accepted. (see paragraph 4.9.1)

3.8.2 Required V50 Ballistic Limit. The ESAPI shall yield the minimum V50 ballistic limit measurements at 0-degree obliquity with the specified test projectiles as per Appendix A.

3.8.3 V0 Ballistic Resistance. The ESAPI, when tested in conjunction with the simulant (see paragraph 4.9.12), will provide ballistic resistance as specified in Appendix A. The Contractor’s design shall demonstrate statistical confidence in results when tested with the Surrogate soft armor shootpack.

3.8.4 Back Face Deformation. The ESAPI back face deformation shall be tested in accordance with and meet the requirements of paragraph 4.9.9.2, 4.9.9.3, and 4.9.9.4.

3.8.5 Spall, Debris, and Residual Penetrator. The ESAPI will be designed to mitigate injury to the wearer or surrounding individuals from frontal spall, penetrator, or armor debris ejecta when tested against the required threats (see paragraph 4.9.11.5)).

3.8.6 Probability of No complete Penetration Analysis. For each valid test shot, the result is determined to have experienced either a system complete penetration or a system partial penetration. The numbers of complete and partial penetrations are the basis for calculating the 90 percent (%) Lower Confidence Level (LCL) for Probability of no complete Penetration P(nP) via the Clopper-Pearson method, with the numerical result truncated by applying the “floor function” to two-decimal place precision. The LCL for P(nP) is calculated for the first and second shots by combining shot locations, plate sizes, and environmental conditions. The LCL must meet or exceed the requirement specified in the respective FAT or LAT table. For example, if the 90% LCL for the P(nP) associated with a set of second shot data from FAT were calculated to be 0.699987, the reported result would be 0.69 and the outcome would be considered to be non-compliant with the prescribed criterion of 0.70. For all instances of statistical testing, a full data set is required to make the calculations to accept or reject the FAT or LAT. In cases where the second shot was determined unfair after a fair first shot, the first shot only shall be used in the analysis for both penetration and BFD. A subsequent plate shall be used to gather data on the second shot in order to fulfill the sample size required in the analysis matrix. Both shots on the subsequent plate shall be counted for record (assuming both fair hits) and included in the analysis.

3.8.7 Back Face Deformation Analysis. For BFD, the metric of merit is a one-sided Upper Tolerance Limit (UTL) based on the assumption of normally distributed BFD data; the UTL to be calculated is specified in the respective FAT or LAT table. The BFD UTLs are calculated for the first and second shots by combining shot locations, plate sizes, and environmental conditions. Validated one-decimal place BFD measurements, for tested hard armor inserts that did not experience complete penetrations, are the basis for any UTL calculation. The UTL is defined as Yu = Ῡ + ks, where Ῡ is the mean of all valid BFD measurements, k is a look-up constant3 (varying with the sample size, UTL percentage, and confidence percentage), and s is the sample standard deviation. The UTL is reported to one decimal place precision after adjusting upwards via the “ceiling function” ensuring that a conservative UTL is reported. For example, calculated results of 38.1349 mm and 38.1999 mm are each reported as 38.2 mm.

Compliance with the BFD requirement is achieved only if the associated UTL is less than or equal to 2.28 in (44.0mm). When calculating the sample average (mean) and standard deviation in order to compute the UTL, calculate both the mean and standard deviation to six significant digits. This is to avoid the rounding of these intermediate quantities affecting the reported UTL. The final result (the UTL) is then reported to one decimal place as specified above.

Note 1: . Where is the upper cut off from an F distribution with v1 and v2 degrees of freedom (Clopper Pearson Formula from Casella, George and Roger Berger: Statistical Inference 2002 Duxbury / Thomson Learning Inc, Pacific Grove, CA p 454.).

Note 2: NIST/SEMATECH e-Handbook of Statistical Methods http://www.itl.nist.gov/div898/handbook/prc/section2/prc263.htm http://www.itl.nist.gov/div898/handbook/prc/section2/prc263.htm

Note 3: k= where a=1- ; b= - , and zutl is the critical value from the standard normal distribution associated with the UTL percentage. zconf is the critical value from the standard normal distribution associated with the Confidence percentage and N is the total sample size for the data of interest.

3.8.8 Submission, Review, Acceptance, and Rejection of FAT and LAT. An appropriate Government representative defined in the contract shall randomly select all test samples in accordance American National Standards Institute (ANSI) /American Society for Quality (ASQ) ANSI/ASQ Z1.4-2008 AQLs. Test samples shall have DD1222 and electronic copies of all COCs as defined in the contract. Upon completion of the required ballistic testing, the results will be provided to the Contractor; the government will review and acceptance or rejection IAW the FAT or LAT criteria defined in this specification. The Contractor shall not ship any production lot until approval by a Government representative as defined in the contract.

3.8.9 Technical Data Package (TDP). For all design variants, to include the following as a minimum (submitted prior to FAT):

a. Product and Safety Data Sheets

b. Design nomenclature

c. Drawing and Pattern by size

d. Material configuration by size

(1) Type of materials used

(2) Build Sheet and Cut Patterns

(3) Dry layup and assembly

(4) Orientation and the sequence of layers of the design (by size if there are changes, if applicable) shall be annotated on each layer

(5) Packaging Instruction documentation e One finished end item by size

f. Standard Temperature and Pressure Range, and Time for Processing.

g. The Contractor shall submit samples to the Government IAW the performance description prior to FAT. The Contractor shall eliminate where possible or minimize the use of proprietary materials and sole source materials in the design. The Contractor shall disclose at the earliest point in the design development and prove-out (and before FAT samples are manufactured) any remaining proprietary materials or sole source materials to enable the Government to maintain effective life cycle planning. Any changes to the TDP or manufacturing process shall be in compliance with the change process defined in the contract.

4. VERIFICATION

4.1 Verification Alternatives. Acceptable alternative verification approaches shall be identified in the contract or modified into the contract as required.

4.2 Classification of Testing. The testing requirements specified herein are categorized as First Article Testing (FAT) and Lot Acceptance Testing (LAT) as specified in Table I. Unless otherwise specified in the contract or purchase order, the ESAPI Contractor is responsible for meeting all FAT and LAT requirements herein.

4.2.1 First Article Testing (FAT). The Government reserves the right to verify performance to requirements set forth in this specification or the contract where such tests are deemed necessary, to ensure supplies and services conform to prescribed requirements. FAT includes the verifications listed in 4.6, 4.7, 4.8, and 4.9 (see Table I) unless otherwise specified in the contract. Inspection criteria will be derived from the ANSI/ASQ Z1.4-2008 sampling procedures and tables for inspection by attributes. First Article Testing may be conducted in any order deemed necessary to meet the Government’s schedule or to highlight operational areas where the ESAPI is not performing at its best. The Contractor shall successfully pass both ballistic protocols in any order.

4.2.2 Lot Acceptance Testing (LAT). LAT of ESAPI shall include examinations and tests from

4.6 and 4.9 as defined in the contract or by the procuring activity (see paragraph 6.2). See Table I “Requirements and Verifications” for requirements and frequencies of inspection. The Government reserves the right to verify performance to requirements set forth in this specification or the contract where such tests are deemed necessary to ensure supplies and services conform to prescribed requirements. Inspection criteria are derived from ANSI/ASQ Z1.4-2008 Sampling Procedures and Tables for Inspection by Attributes. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements; however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

Table I. Requirements and Verifications

CHARACTERISTICS REQUIREMENT

PARAGRAPH

VERIFICATION

PARAGRAPH

FIRST

ARTICLE

TESTING

(FAT)

LOT

ACCEPTANCE

TESTING

(LAT)

Construction, Production Data and Technical Data Package2

3.3, 3.8.9 4.9.2 PM PM

Workmanship 3.4 4.9.1 X X Tap Test3 3.4 4.9.1 X X Torque Test3 3.4 4.9.1 X X Operating Requirements 3.5 4.6 Ease of Insertion 3.5.1 4.6.1 X X1 Weight 3.5.2 4.6.2 X X Dimensional Measurements1 3.5.3 4.6.3 X X Thickness1 3.5.4 4.6.4 X X Color 3.5.5 4.6.5 X CoC Labels and Markings 3.5.6 4.6.6 Orientation Markings 3.5.6.1 4.6.6 X X Performance Markings 3.5.6.2 4.6.6 X X Complete Plate Markings 3.5.6.3 4.6.6 X X Unique Identification Label 3.5.6.4 4.6.6 X X PMCS Instructions 3.5.6.5 4.6.6 X X Health and Safety 3.5.7 4.6.7 Flammability 3.5.7.1 4.6.7.1 X X2 Personnel Hazard 3.5.7.2 4.6.7.2 X X2 Magnetic Influence 3.5.7.3 4.6.7.3 X X2 Ownership and Support 3.6 4.7 Durability 3.6.1 4.7.1 X X2 Operating Environment Requirements 3.7 4.8

Weatherometer Resistance 3.7.1 4.8.1 X X2 Temperature Extreme 3.7.2 4.8.2 X X2 Fluid Resistance 3.7.3 4.8.3 X X2 Altitude 3.7.4 4.8.4 X X2 Fungus 3.7.5 4.8.5 X X2 Temperature Shock 3.7.6 4.8.6 X X2 Vibration 3.7.7 4.8.7 X X2 Performance Requirements 3.8 4.9 Areal Density 3.8.1 4.9.1 X X2 Req. V50 Ballistic Limit 3.8.2 4.9.8 X X2,3

V0 Ballistic Resistance3 3.8.3 4.9.11.1 X X Transient (Back-face) Deformation3

3.8.4 4.9.11.3 X X

Spall, Debris and Residual Penetrator 3.8.5 4.9.11.5 X X

Notes:

PM PM SPE validated X Official testing for record shall occur at Aberdeen Test Center (ATC) and a final report will be provided.

X# Conformance, once ascertained during FAT, is automatically maintained during LAT as long as conformance to related parameters is maintained. Official testing for records shall occur upon Government request or if linked parameters, as annotated by the numerical subscript, do not demonstrate conformance. The Government shall conduct official testing for record at Aberdeen Test

Center (ATC) to validate requirements and values will be included in the final report.

In example: a failure to meet the Thickness1 requirement will trigger the need to test the related parameter of Ease of Insertion as noted by the X1

CoC Certificate of Conformance; all CoCs shall include test data, an electronic copy of all CoC’s shall accompany the DD1222 to the test lab with the LAT samples.

4.3 Order of Testing. Performing the various testing, operating, ownership and support, operating environment, and performance, can occur in any order.

4.4 Verification Methods. The types of verification methods included in this section are visual inspection, dimensional measurements, sample tests, and component properties analyses.

4.4.1 Verification Using Standard Samples. Plate colors shall match to the shades denoted in

4.6.5. Use standard samples to verify colors with visual inspections.

4.5 Responsibility for Compliance. Production items shall meet all requirements specified in Section 3. The Contractor shall establish and maintain documented procedures for inspection and testing activities in order to verify that the specified requirements for the product are met.

The required inspection, testing, and the records to be established shall be detailed in a Process Production Package (PPP) available to the Government as specified in the contract or procuring activity. The inspection set forth in this specification shall become part of the Contractor’s overall inspection procedures or quality system. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of ensuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection as part of the manufacturing operations is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of known defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.6 Operating Requirements. Complete each test in this paragraph.

4.6.1 Insertion. One barehanded person shall demonstrate insertion of the ESAPI into the SPS Torso Extremity Protection, and IOTV Carrier or SPCS front or back pocket without tools or special aids. Perform insertion into Government furnished carrier in a maximum of 30 seconds.

4.6.2 Weight. The ESAPIs shall meet the physical weight measurement requirements as identified in 3.5.2. The finished ESAPIs shall be weighed to the nearest 0.001 pound (0.4536 gm).

4.6.3 End Item Dimensions. Take physical measurements of all ESAPI to show that all measurements conform to dimensions and tolerances in Drawings (2.2.2).

4.6.3.1 ESAPI Plate Measurements. Two length and two width measurements shall be made and conform to the dimensions and tolerances specified in the drawings (2.2.2). The measurements specified herein shall be made for each Torso Plate. The length measurements should be taken at the two chamfered edges. The first width measurement shall be no further than 1.0 in (25.4 mm) away from the bottom edge. The second width measurement shall be no closer than 7.0 in (177.8 mm) from the first measurement location.

4.6.4 ESAPI Thickness. Take thickness measurements of all ESAPI to show that all measurements conform to dimensions and tolerances in Drawings (2.2.2).

4.6.4.1 ESAPI Plate Thickness. Measure thickness in seven locations, near the center (at least

3.5 in (88.9 mm) from any edges) and near each of the six corners (1/4 in - 1 in (6.35 mm – 25.4

mm) from the edge) with a measuring device capable of reaching all required points of measure and record to the nearest 0.01 in (0.254 mm). (see paragraph 2.2.2 and 3.5.4).

4.6.5 ESAPI Color. Visually inspect the ESAPIs matching to the standard sample color of Foliage Green 504 as specified by the contract.

4.6.6 Instruction labels. Visually inspect for legible, permanent markings and labels on the front and back face surfaces. Visually inspect that labels contain written instructions and orientation directions. Ensure labels conform to Type IV, Class 9 markings per MIL-DTL-32075.

4.6.7. Health and safety. Complete the verifications in this paragraph.

4.6.7.1 Flammability. Observe that the ESAPI does not melt, drip, combust, or explode when impacted in ballistic testing. Ballistic testing at the elevated temperature is reserved for first article testing when required.

4.6.7.2 Personnel Hazard. Inspect all material comprising the end item to verify that the ESAPI is non-hazardous (e.g., have no toxicological or electromagnetic effects, be non-explosive, be non-carcinogenic, etc.) to the individual wearing the ESAPI or to other Soldiers in the surrounding area. The Contractor shall provide Material Safety Data Sheets (MSDS) to the Government for all materials comprising the end item.

4.6.7.3 Magnetic Influence. The ESAPI shall be tested for magnetic influence using magnetic and lensatic compasses. The ESAPI shall not cause any deviation of the compass needle.

4.7 Ownership and Support Requirements. Ownership and Support compliance shall include conformance to the criteria specified in this section.

4.7.1 Durability for ESAPI. Demonstrate durability of the ESAPI by performing drop tests. The ESAPI and shootpack will be attached with a strap, belt, or other non-obstructive retaining device to the front surface of a 10.0 lb ± 0.1 lb (4535.92 gm ± 45.36 gm) clay mold. The weight of the moment arm and straps shall be 8.5 lb ± 0.5 lb (3855.53 gm ± 226.80 gm). The clay mold shall be contoured to the back side of the ESAPI and shootpack. The shootpack, as described in 4.9.13 shall be placed in between the ESAPI and weighted object. A fixture similar to that in Figure 3 has shown to provide accurate and reproducible results and should be securely mounted to the floor. The drop height shall be 48.0 in ± 0.5 in (1219.2 mm ± 12.7 mm), (90 degrees from horizontal) (approximately 16 feet per second (ft/s)) from the flat hardened surface (stiffness of at least 3 x 106 pounds per square in (psi) (20684.3 Pascal (Pa)) and a mass much greater than the moving components (e.g. concrete slab)) and with the ESAPI strike face pointing down, insuring the impact zone is clear of debris before each drop, and drop the weighted fixture two (2) times. Impacts shall occur as near as possible to the center of the ESAPI strike face (not an edge). A radiographic image of the ESAPI shall be inspected to identify any cracks, delaminations, or indentations on the ESAPI surface BETWEEN EACH DROP. Perform ballistic testing IAW 3.8.3 with Threat D and E, as specified. The first test shot shall be taken at the most severely damaged area of the ESAPI specimen as identified by the radiographic image but no closer than 1.5 in (38.1 mm) from any edge. If no damage is visible, the first shot shall be taken near the impact location (center or crown of the strike face). The second test shot shall be located 1.5 in + 0.75 in (38.1 mm + 19.05mm) from any edge and 5.0 in - 6.0 in (127 mm – 152.4 mm) from the first impact.

FIGURE 3. Durability Apparatus

4.8 Operating Environment Requirements. Perform each verification in this section and then perform ballistic testing IAW 3.8.3 with Threat D and E, as specified. Any internal component voids, delamination’s, or critically sized foreign objects (see Table IV) observed via radiographic or CT scanning post conditioning will be targeted for the first shot during ballistic testing.

Furthermore, any degradation in spall cover color shade will not be classified as a defect. The number of tests required for this demonstration shall be specified in the contract as a pre-production item.

4.8.1 Weatherometer Resistance. The ESAPI shall be tested for weather resistance IAW American Association of Textiles Chemists & Colorists (AATCC) Test Method #169 with the following modifications. Pre-conditioning and post-conditioning radiographic images shall be taken of the ESAPI. Upon completion of the test, the ESAPI shall be visually examined and failure to meet any of the requirements in 3.7 shall constitutes a test failure.

4.8.1.1 Modifications to AATCC Test Method # 169:

a. The test apparatus shall be either a test chamber type 1A or 1B. Type 1B shall be equipped with a three-tiered inclined specimen rack. The apparatus shall be equipped with an automatic light monitor and shall be capable of automatically controlling irradiance, temperature, and humidity. The apparatus shall be maintained IAW the manufacturer’s recommendations.

b. The weathering test cycle shall be 40 minutes of light, 20 minutes of light with water spray on the specimen, 60 minutes of light, and 60 minutes of darkness with no spray. The test cycle shall be repeated until the total energy exposure is equal to 100 kilojoules per square meter (m2).

c. The irradiance level shall be 0.55 Watts/square meter/nanometer (W/m2/nm) ± 0.01 W/m2/nm bandpass at 340 nm.

d. The glass filter combination shall be quartz inner filter and a borosilicate type “S” outer filter.

e. The relative humidity (RH) shall be 50% ± 5% during the light cycle and not lower than 95% during the dark cycle.

f. The control set points shall be as follows:

Table II: Control Set Points Dark Cycle Light Cycle

Black Panel 100.4 oF (38oC) 170.0 oF (77oC)

Conditioning Water 104.0 oF (40oC) 127.4 oF (53oC)

Wet bulb depression* 32.0 oF (0oC) [95%RH] 50.0 oF (10oC) [50%RH]

* As a guide only; adjust to achieve required relative humidity

g. The ESAPI shall be mounted on the outside of the rack. After the required exposure period, the ESAPI shall be removed from the apparatus and allowed to dry and condition at ambient conditions.

h. After the ESAPI has been conditioned in the weatherometer and after passing visual examination tests following removal from the weatherometer, the ESAPI shall be tested to establish a V0 ballistic resistance at 0 degree obliquity within 24 hours + 0.50 hours after removal from the weatherometer. Testing shall be conducted IAW 3.8.3 for Threat D and E, as specified.

4.8.2 Temperature Extreme. The finished ESAPI shall be heated in an oven operating at 155 + 5 ºF for a minimum of 6 hours (+ 15min) (Ref. MIL-STD-810G_CHG-1).