20190620_ACH_Gen_II_ARPD_14-01C_Amendment_1.pdf

INCH-POUND

AR/PD 14-01 Rev C Amendment 1

20 JUN 2019

Supersedes AR/PD 14-01 Rev C

29 MAR 2019

PURCHASE DESCRIPTION

HELMET, ADVANCED COMBAT, SECOND GENERATION (ACH GEN II)

1. SCOPE

Scope. This document covers the performance and verification requirements for the Second Generation Advanced Combat Helmet (ACH Gen II), a ballistic shell, suspension system, and Retention System with chinstrap and nape strap. The ACH Gen II is a Critical Safety Item (CSI).

Classification. The helmet assembly will be of the following types and classes as specified (see 6.2).

Types.

Type I - One (1) hole for Night Vision Device (NVD) mount Type II - No hole for NVD mount

Classes.

Class 1 - X-Back Retention System Class 1A - Right-Handed X-Back Retention System Class 1B - Left-Handed X-Back Retention System

Class 2 - H-Back Retention System Class 2A - Right-Handed H-Back Retention System Class 2B - Left-Handed H-Back Retention System

DISTRIBUTION STATEMENT C. Authorized distribution is to U.S. Government Agencies and their Contractors for official use or for administrative and operational use as determined on 11 February 2019. Other requests for this document shall be referred to Product Manager Soldier Protective Equipment, Program Executive Office Soldier, US Army, 10170 Beach Road, Building 328T, Fort Belvoir, Virginia 22060

Beneficial comments (recommendations, additions, deletions) and 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.

AMSC N/A FSC 8470

AR/PD 14-01 Rev C Amendment 1

UNCLASSIFIED // FOR OFFICIAL USE ONLY

Schedule of sizes. The helmet assembly is constructed in the following sizes:

SCHEDULE OF SIZES

Extra-Small (XS)

Small (SM) Medium (MD)

Large (LG) Extra-Large (XL)

Double Extra-Large (2X)

NOTE: Due to low tariff, the Extra-Small (XS) and Double Extra-Large (2X) First Article Test (FAT) will be handled on a case-by-case basis. Direct all XS and 2X FAT inquiries to the Contracting Officer (KO).

Helmet sizing. Soldier head size distribution for the 5th to the 95th percentile for the ACH Gen II is Small (6%), Medium (48%), Large (42%), and Extra-Large (4%).

2. APPLICABLE DOCUMENTS

General. The Sections 3 and 4 specify the documents listed in this section. 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, 4, and 5 of this specification, whether or not they are listed.

Government documents.

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.

COMMERCIAL ITEM DESCRIPTIONS

A-A-55301 Webbing, Textile, Textured or Multifilament Nylon A-A-59826 Thread, Nylon

UNCLASSIFIED // FOR OFFICIAL USE ONLY

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-32075 dated October 17, 2000

- Label: For Clothing, Equipage, and Tentage (General Use)

MIL-DTL-46593B

w/Amendment 1

- Projectile, Calibers .22, .30, .50, and 20mm Fragment-Simulating

MIL-DTL-64159B - Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant

MIL-DTL-83133H w/ Amendment 2

- Turbine Fuel, Aviation, Kerosene Types JP-8 (NATO F-34), NATO F- 35, and JP-8 + 100 (NATO F-37)

MIL-PRF-2104J - Lubricating Oil, Internal Combustion Engine, Combat/Tactical Service

MIL-PRF-372E w/ Amendment 2

- Cleaning Compound, Solvent (For Bore of Weapons)

MIL-PRF-46170E - Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic Hydrocarbon Base, NATO Code No. H-544

MIL-PRF-6083G - Hydraulic Fluid, Petroleum Base, for Preservation and Operation

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-662F V50 Ballistic Test for Armor MIL-STD-810 w/ Amendment 1

Environmental Engineering Considerations and Laboratory Tests

MIL-STD-1916 Notice 2 DoD Preferred Method for Acceptance of Product MIL-STD-3004D Quality Assurance/Surveillance for Fuels, Lubricants, and Related

Products MIL-STD-3027 Testing of Body Armor

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

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

DRAWINGS

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

SOLDIER CENTER

2-1-2515 Helmet Shell, Advanced Combat, Small 2-1-2516 Helmet Shell, Advanced Combat, Medium 2-1-2517 Helmet Shell, Advanced Combat, Large 2-1-2518 Helmet Shell, Advanced Combat, Extra-Large 2-1-2576 Helmet Shell, Advanced Combat, Extra, Extra-Large 2-1-2566 Suspension System http://quicksearch.dla.mil/

UNCLASSIFIED // FOR OFFICIAL USE ONLY

U.S. ARMY PRODUCT MANAGER SOLDIER PROTECTIVE EQUIPMENT, FORT BELVOIR,

VA

53-032-001 Drawing - Enhanced Night Vision Goggle (ENVG) III Hot Shoe, Female 53-031-001 Drawing - ENVG III Quick Release, Female 53-025-001 Drawing - ENVG III Hot Shoe, Male 53-030-001 Drawing - ENVG III Quick Release, Male

SPE-HPT-19150-6310-003 IHPS Retention System S/M SPE-HPT-19150-6310-004 IHPS Retention System L/XL SPE-HPT-19150-6310-006 IHPS Retention System, Left Handed, S/M SPE-HPT-19150-6310-005 IHPS Retention System, Left Handed, L/XL SPE-HPT-19150-6310-007 IHPS Retention System, S-M H-Back SPE-HPT-19150-6310-008 IHPS Retention System, L/XL, H-Back

Soldier Protection System (SPS) Interface Control Document (ICD) Version 1.3 ENVG III Helmet Mount Assembly (ICD) Version 1.0.0

PURCHASE DESCRIPTIONS

AR/PD 17-06 Purchase Description for the Integrated Head Protection System

Helmet Retention System

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

OTHER GOVERNMENT DOCUMENTS AND PUBLICATIONS

DEPARTMENT OF TRANSPORTATION FEDERAL MOTOR VEHICLE SAFETY

DOT FMVSS 218

Department of Transportation Federal Motor Vehicle Safety Standard No.218 Motorcycle Helmets

(Copies of documents are available online at http://www.nhtsa.dot.gov/cars/rules/standards.)

FEDERAL ACQUISITION REGULATION

FAR 52.209-3 First Article Approval—Contractor Testing

(Copies of documents are available online at https://www.acquisition.gov/content/52209-3-first-article-approval-contractor-testing)

NATIONAL INSTITUTE FOR OCCUPATIONAL SAFETY AND HEALTH (NIOSH)

NRR Calculation Methods for Calculating and Using Reduction Ratings

(Copies of documents are available online at http://www2a.cdc.gov/hp-devices/hp_srchpg01.asp) http://www.nhtsa.dot.gov/cars/rules/standards

NATIONAL INSTITUTE OF JUSTICE (NIJ)

NIJ Standard 0106.01 Ballistic Helmets

(Copies of documents are available online at https://www.ncjrs.gov/pdffiles1/nij/077182.pdf and http://www.ojp.usdoj.gov/nij/pubs-sum/223054.htm)

TECHNICAL MANUALS

TM 10-8470-204-10 Technical Operators Manual for the Advanced Combat Helmet

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

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

ITOP 04-2-805 FR/GE/UK/US Projectile Velocity and Time-Of-Flight Measurement

(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)

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

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

AATCC Evaluation Procedure 1 - Gray Scale for Color Change AATCC Evaluation Procedure 2 - Gray Scale for Staining AATCC Evaluation Procedure 8 - AATCC 9-Step Chromatic Transference Scale AATCC Evaluation Procedure 9 - Visual Assessment of Color Difference of Textiles AATCC Test Method 8 - Colorfastness to Crocking: Crockmeter Method AATCC Test Method 15 - Colorfastness to Perspiration AATCC Test Method 61 - Colorfastness to Laundering: Accelerated AATCC Test Method 107 - Colorfastness to Water AATCC Test Method 143 - Appearance of Apparel and Other Textile End

Products after Repeated Home Laundering AATCC Test Method 169 - Weather Resistance of Textiles: Xenon Lamp

Exposure AATCC Test Method 195 - Liquid Moisture Management Properties of Textile

Fabrics

(Copies are available online at http://www.aatcc.org.)

AMERICAN NATIONAL STANDARDS INSTITUTE

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

(Copies are available online at http://webstore.ansi.org/ansidocstore.)

https://www.ncjrs.gov/pdffiles1/nij/077182.pdf http://www.ojp.usdoj.gov/nij/pubs-sum/223054.htm http://www.aatcc.org/ http://webstore.ansi.org/ansidocstore

ASTM INTERNATIONAL

ASTM D76 - Standard Specification for Tensile Testing Machines for Textiles ASTM D523 - Standard Test Method for Specular Gloss ASTM D910 - Standard Specification for Aviation Gasolines ASTM D975 - Standard Specification for Diesel Fuel Oils ASTM D1149 - Standard Test Methods for Rubber Deterioration ASTM D1655 - Standard Specification for Aviation Turbine Fuels ASTM D1776 - Standard Practice for Conditioning and Testing Textiles ASTM D1777 - Standard Test Method for Thickness of Textile Materials ASTM D3359 - Standard Test Methods for Measuring Adhesion by Tape Test ASTM D6413 - Standard Test Method for Flame Resistance of Textiles (Vertical) ASTM E4 - Practices for Force Verification of Testing Machines ASTM E18 - Standard Test Method for Rockwell Hardness and Rockwell

Superficial Hardness of Metallic Materials ASTM E29 - Standard Practice for Using Significant Digits in Test Data to

Determine Conformance with Specifications ASTM E140 - Standard Harness Relationship Among Brinell Hardness, Vickers

Hardness, Rockwell Hardness, Superficial Hardness, Knoop Hardness, and Scleroscope Hardness

ASTM E384 - Standard Test Method for Knoop and Vickers Hardness of Materials

ASTM F1358 - Standard Test Method for effects of Flame Impingement on Materials Used in Protective Clothing Not Designated Primarily for Flame Resistance

(Copies of documents are available online at https://www.astm.org/.)

OTHER PUBLICATIONS

INFORMA HEALTHCARE

Repeat Insult Patch Test - Modified Draize Procedure – Principles and Methods of Toxicology, A Wallace Hayes (editor).

(Copies are available online at https://www.crcpress.com/,)

Visual Guide of Colors Used in Military Items Color Card

(Copies of document are available from the Contracting Activity.)

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, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

https://www.astm.org/ https://www.crcpress.com/

UNCLASSIFIED // FOR OFFICIAL USE ONLY

3. REQUIREMENTS

First Article Testing (FAT) and Lot Acceptance Testing (LAT) conformance inspections.

FAT. All authorized production of CSI Personal Protective Equipment (PPE) such as the ACH Gen II shall be preceded by FAT that is inspected and approved under the appropriate provisions of FAR 52.209-3. FAT samples shall be subjected to first article inspection in accordance with 4.3 and 6.3. All requirements are listed singularly (i.e., by themselves). In some cases, verification is performed on a test item that has been previously subjected to another verification test.

LAT. Lots shall only be produced in a single size and type, and all Lots shall be subjected to LAT. LAT samples representing full production quality shall be subjected to LAT in accordance with 4.4. Samples will be examined for the defects specified in 4.10.1 and subjected to the tests indicated in 4.9, TABLE VIII. Acceptance criteria for each inspection is stated herein. Unless noted otherwise, all LAT will be conducted under ambient conditions.

Unfinished shell, finished shell, and finished helmet. The following definitions shall apply in this document.

a. Unfinished shell. An unfinished shell shall include the raw shell with the hole for attachment of the NVD for the Type I (shell with one hole), while the unfinished shell for Type II shall consist of the raw shell only. The unfinished shell for both Type I and Type II shall include benchmarks in accordance with 3.3.5.1 and 3.3.5.3.

b. Finished shell. A finished shell shall include the shell, any primer, coating, and texturing aggregate, any attachment hole (Type I), and any edging and adhesive to hold the edging on.

c. Finished helmet. A finished helmet includes the finished shell plus all suspension system attachment material (i.e., hook disks or hook tape), any bracket integration components (not including the bracket itself or the bracket bolt), a complete suspension system, and a complete retention system (see 6.10 for Integrated Head Protection System (IHPS) Retention System (RS) sizing and associated National Stock Numbers (NSN)).

Shell design and shape. The ACH Gen II shall consist of a ballistic protective shell, suspension system, and boltless retention system.

Area of coverage and Shape.

3.3.1.1 Area of coverage. The projected coverage area of a finished helmet shall be equal to or greater than the ACH per drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, and 2- 1-2576 and all subsidiary drawings and parts lists. The presented area at five locations from a three-dimensional scan of the exterior of a finished helmet shall be used to confirm the area of coverage equal to or greater than the ACH area of coverage at the same five locations. Testing shall be in accordance with 4.10.2.

3.3.1.2 Shell shape. The measurements to establish shell shape shall be taken on the inside of an unfinished shell surface only and compared against the Contractor supplied Computer Aided Design (CAD) file (*.sldprt). Contractor submitted and approved drawings become contract reference and shall not be changed without prior Government review and written approval. The outside surface is defined by the inside surface plus the thickness as

UNCLASSIFIED // FOR OFFICIAL USE ONLY

specified in 3.3.4.1. The helmet system shall work in conjunction with the currently used National Institute of Justice (NIJ) 0106.01 headform as well as the U.S. Department of Transportation Federal Motor Vehicle Safety Standard (DOT FMVSS) 218 headform sizes B, C, and D. Testing shall be in accordance with 4.10.3.

Shell construction. Upon removal from the mold, the outer and inner surfaces of the unfinished shell, excluding the bottom edge, shall be finished smooth and even. Both the inside and outside surfaces of the shell shall be free from any hole, void, delamination of ballistic material, blister, cracking, crazing, dry spot, area of non-resin flow, and any pit greater than 0.125-inch diameter or the depth of one ply of the ballistic material, whichever is less, in order to provide a smooth continuous surface. If fabric construction is used, there shall be no exposed ends of the fabric fiber showing. There shall be no raised fibers, raised pleats, raised wrinkles, or raised creases longer than 1-inch on the interior or exterior surfaces.

Processing procedures. The Contractor shall use processing procedures and methods capable of providing uniform properties. Patching or repair of any ballistic material shall not be performed after the material has been molded without documented Government approval. Remolding of helmet shells made with materials other than thermoplastic composites is not permitted. Plans to remold thermoplastic materials or correct cosmetic imperfections, which fall within the acceptable criteria detailed in this specification, shall be submitted to the Government for written approval prior to implementation; plans submitted for approval shall include a detailed description of all tools, materials, and methods necessary to produce the helmet shell. All submitted and approved manufacturing production plans, and other required contracting documents and processes (i.e., Technical Data Package (TDP), Dry Layup, Production Process Package, etc.) shall not be altered by the Contractor without additional written approval from the Government. Such plans that receive written Government approval shall become part of the documented production process. Cosmetic improvements shall not degrade ballistic material properties. More than one material (hybrid construction) may be used to achieve best combination performance requirements listed in the document. Inspection shall be in accordance with 4.10.1.

Shell thickness and uniformity.

3.3.4.1 Shell thickness. The maximum thickness for the helmet shell shall not exceed 0.500-inch regardless of the nominal thickness of the shell. Thickness variations in the shell shall be gradual. For Type I helmets, shell thickness in the area of the NVD bracket shall be of a thickness to accommodate and assure appropriate function of the NVD Front Bracket Kit (see 6.7). Shell thickness in this localized area for Type I helmets may have non-gradual variations as needed to accommodate the NVD hardware, when required by type and class. Testing shall be in accordance with 4.10.4.

3.3.4.2 Shell uniformity. The shell thickness shall not vary by more than 0.100-inch over the entire surface of the shell. For Type I helmets, shell thickness may vary by greater than 0.100-inch in the area of the NVD bracket as needed to meet requirements in 3.3.4.1 and

3.12.1. Testing shall be in accordance with 4.10.4.

Helmet benchmarks. The unfinished and finished shell shall have benchmarks located at the front, crown, left side, right side, and rear locations on the interior and exterior of the shell as shown on drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, and 2-1-2576.

Benchmarks of any shape or type are acceptable on unfinished shells and shall be clearly visible. Inspection shall be in accordance with 4.10.5.

UNCLASSIFIED // FOR OFFICIAL USE ONLY

3.3.5.1 Benchmarks – unfinished shell. Benchmarks on an unfinished shell are required for FAT. Benchmarks on unfinished shells are for non-ballistic testing only; benchmark types used on unfinished shells may differ from those used on finished shells and finished helmets (e.g., using drilled holes as benchmarks). Testing shall be in accordance with 4.10.5.

3.3.5.2 Benchmarks - finished shell, periphery. Benchmarks on a finished shell are required for FAT and LAT. Contractors may place benchmarks on the helmet shell, integrally molded edge trim, or on a one-piece molded construction. The benchmarks must be clearly visible. If an integrally molded edging is used (as defined in 3.3.6) and the edging covers any portion of previous benchmarks from an unfinished shell, periphery benchmarks may be located on the integrally molded edging and shall be at least 0.200 (+0.05 /-0.00) inch long. If a bonded one-piece molded edging is used, and the edging covers any portion of previous benchmarks from an unfinished shell, periphery benchmarks may be located on the bonded one-piece molded edging and shall be at least 0.200 (+0.05 / -0.00) inch long. If a bonded one-piece cut to length edging is used, and the benchmarks are located at the periphery of the shell, the benchmark length shall extend a distance of 0.500 (+0.250 / -0.375) inch up beyond the top edge of the edging. Inspection shall be in accordance with 4.10.1 and 4.10.5.

3.3.5.3 Benchmark, crown. The crown benchmark shall only reside on the interior of the unfinished shell, finished shell, and the finished helmet, and shall be a “+” with each leg measured from the intersection of the “+” being 0.250-inches (± 0.125-inches) long with one leg of the “+” pointing toward the front of the helmet, one to the rear, and one each to the left and right sides of the helmet. The center point of the “+” shall be located at the intersection of the sagittal and coronal planes. Inspection shall be in accordance with 4.10.5.1.

Benchmarks - integrally molded edging. If integrally molded edging is used, periphery benchmarks may be located on the lower or outer surface of the integrally molded edging. There shall not be a length requirement for benchmarks but the benchmarks shall be visible. The shape of benchmarks on finished helmets will be at the discretion of the Contractor and acceptable as long as they are visible. Inspection shall be in accordance with 4.10.1 and 4.10.5.

Benchmarks - bonded edging. If a bonded edging is used, the benchmarks shall be 0.500-inches (± 0.250-inches) long extending upward from the finished shell edge on the outer surface. Inspection shall be in accordance with 4.10.1 and 4.10.5.

Integration and compatibility.

Integration and compatibility for NVD interface. The Type I helmet shall provide a means to attach and allow proper functionality of NVDs that utilize the A3297317 and A3297318 (the PM SPE NVD bolt and nut) and 51-1979-005 and 51-1982-005 (the PM SMS universal hardware). One-hole perforation is acceptable, without additional perforations of the helmet shell Inspection shall be in accordance with 4.10.1, 4.10.8.3, 4.10.9.1, and 4.10.14.

NVD attachment hole (Type I helmet). For the Type I helmet, the Contractor shall bear the responsibility for the hole placement. The Contractor shall develop a template for the hole placement using NVD Bracket Kits cited in 3.12. The diameter of the hole shall be 0.200 (±0.010) inch. The hole shall be drilled orthogonal to the shell surface (± 1°), and the location of the hole shall be 0° (± 1°) relative to the front of the helmet using the coordinate system defined in drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, and 2-1-2576. The application of coating and aggregate shall not impact this hole diameter and tolerance requirement. When required by type and class, there shall be no delamination greater than 0.125-inch from the edge of the hole or other damage of the shell material as a result of making the hole. Any

UNCLASSIFIED // FOR OFFICIAL USE ONLY

fraying (i.e., uncut material attached at the edge of the hole) as a result of making the hole shall not be at a length of more than 0.125-inch. Additionally, when required by type and class, the hardware shall pass through the hole freely and not be impeded or obstructed by any frayed material. Finished helmets shall be examined for conformance in accordance with 4.10.1,

4.10.3 and 4.10.4.

NVD hardware. The NVD attachment hole serves as an attachment point for optical devices on the helmet. The NVD bracket shall attach to the helmet shell via this attachment hole, and no more than one size of attachment hardware shall be required to ensure a secure mount for all listed NVD brackets to all helmet sizes. All NVD hardware delivered with or separate from helmet production Lots shall meet the 9mm Full Metal Jacket (FMJ) Round Nose Projectile (RNP) Resistance to Penetration (RTP) hardware ballistic testing requirements as specified in 3.4.3.1 and 3.4.3.2. All Type I ACH Gen II production Lots delivered without NVD hardware must be preceded by a successful FAT demonstrating that the produced design is ballistically compatible with existing, ballistically qualified hardware. The hardware or in the case of Type I helmet only deliveries the helmet in conjunction with Government furnished NVD hardware must meet the RTP criteria set forth for Production Verification Testing (PVT) and for Lot Verification Testing (LVT) as outlined in Appendix A.

3.4.3.1 NVD hardware PVT. During PVT, the NVD hardware (or the helmet with Government furnished NVD hardware in the case of helmet only FAT) shall have a Lower Confidence Level (LCL) of 90 percent (90%) for a 90% Probability of No Penetration (P(nP)) when impacted with a 124-grain, 9mm FMJ RNP. The 9mm FMJ RNP shall impact at 1,400 feet per second (ft/sec) (+50 ft/sec, -0 ft/sec) at zero degrees plus or minus five degrees (0° (± 5°)) obliquity. The LCL for P(nP) is calculated using the Clopper-Pearson method and combines all shots under standard ambient environment condition. Testing shall be in accordance with 3.7.2, 3.11.9, and 4.10.1.1, and 4.10.10.1.2.2.

3.4.3.2 NVD hardware LVT. NVD hardware may be qualified as hardware Lots, separate from helmet Lots. For LVT of NVD hardware Lots or helmet Lots, the NVD hardware shall resist penetration from a 124-grain, 9mm FMJ RNP at 1,400 ft/sec (+50 ft/sec, -0 ft/sec) at 0° (± 5°) obliquity under standard ambient environment conditions. Testing shall be in accordance with 4.10.10.3.

Edging. The finished shell shall have a firmly bonded, structural, or an integrally molded edging that protects the periphery of the finished shell from delamination, wear, cuts, tear, and infiltration of environmental elements and fluids. An integrally molded edging is co-molded at the time of shell molding, not applied in an operation subsequent to shell molding.

The edging itself shall not be susceptible to cutting, wear, or tear. The edging shall completely cover the bottom edge of the shell and extend up the sides a minimum of 0.500-inch of the finished shell. If the edging is a non-integral component of the molded shell, then the edging shall consist of a one-piece molded construction or one piece cut to length. If the edging is cut to length, the cut end shall be placed at the rear center of the shell, the butt ends shall not overlap, and any gap between the ends shall not exceed 0.060-inch. The edging shall be firmly and completely attached to the finished shell (i.e., there shall be no unbounded areas). The edging shall be rounded at the corners with a minimum radius of .0625-inch. A corner shall be defined as the transition between the edge of the shell and the inside of the shell and the edge of the shell and the exterior of the shell (i.e., the “lower” part of the edging). The standoff of the applied edging from the shell (the sides as opposed to the edge or rim) shall be a maximum of 0.130-inch, for both inside and outside surfaces. The edging shall be the same color as the exterior of the finished shell (see 3.4.5). The edging shall be the same color as the exterior of the finished shell. Testing shall be in accordance with 4.10.1 and 4.10.6.1.

UNCLASSIFIED // FOR OFFICIAL USE ONLY

3.4.4.1 Edging adhesion. The edging shall remain firmly attached to the finished shell when tested as specified in 4.10.4.

3.4.4.2 Edging adhesion after heat aging. The edging shall not peel back more than 0.25-inch. For structural or integrally molded edging, the edging shall not move down more than 0.125-inch. Testing shall be in accordance with 4.10.6.2.

Coating. Coating shall be applied to the exterior of the helmet shell including the outside of the edging. The coating helmets shall conform to MIL-DTL-64159 (either Type is permissible), color Foliage Green 504. The coating shall completely and uniformly cover the shell surface and the outside of the edging. After drying, no cracks, scuffed areas, blemishes (such as peeling, blistering, or flaking), or foreign matter appearing on or embedded in the finish shall be visible in the coating. The coating shall be applied in accordance with the manufacturer’s instructions previously reviewed and Government approved prior to production.

The bottom and inside edges of the edging are not required to be coated. The outside of the edging requires coating. After drying, no cracks, scuffed areas, blemishes (such as peeling, blistering or flaking), or foreign matter embedding in or appearing on the finish shall be visible on the coating. While coating is not required for the interior helmet shell, if applied, it shall be Foliage Green 504. If the interior of the helmet is not fully painted and if the line between the painted and unpainted surface is not covered by the edging or occurs on the edging, the line between the unpainted surface and the painted surface must be uniform from helmet to helmet with a clean smooth edge without bleed over or other observable workmanship flaws. The coating shall be completely cured (not be wet or tacky to the touch) at time of final packaging.

When required by type and class, hardware exposed on the exterior and interior of the shell (e.g., screw heads) shall not be coated. Testing shall be in accordance with 4.10.1.

3.4.5.1 Shell surface preparation. Prior to the application of any coating to the surface of the unfinished shell, the unfinished shell shall be appropriately prepared in order to meet the requirements for finish provided by the coating manufacturer. Permissible surface gaps and pits on the outside surface (and inside surface if painted) of the finished shell (see 3.3.2) may be filled with suitable materials (such as Acryl-Green Spot Putty) to provide a smooth and continuous surface. The rework of defects affecting ballistic material, such as filling blisters of any size, is not permitted. If surface preparation includes abrading, then the ballistic material shall show no signs of being visibly cut, gouged, or raised. Before application of the final coating, the surface shall be free of any contaminants including dust, oil, grease, or any other foreign matter. Testing shall be in accordance with 4.10.1, TABLE IX.

3.4.5.2 Adhesion of coating. The coating, when cut into squares, shall not lift more than 50% of the coverage of any square. A slight unevenness of the edges of any square shall not be considered cause for test failure. Testing shall be in accordance with 4.10.7.

3.4.5.3 Infrared reflectance. The texturing and Foliage Green 504 color coating (for the finished shell) shall meet the spectral reflectance requirements of TABLE I. The infrared reflectance requirement is replicated from MIL-DTL-64159 for Foliage Green 504. Testing shall be in accordance with 4.10.7.1.

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TABLE I. Spectral reflectance limits for Foliage Green 504.

Wavelength Nanometers (nm)

% Reflectance

Min Max

600 8 18

620 8 18

640 8 20

660 10 26

680 10 26

700 12 28

720 16 30

740 16 30

760 18 32

780 18 34

800 20 36

820 22 38

840 24 40

860 26 42

3.4.5.4 Specular gloss. The outer surface of the finished shell shall have a specular gloss as specified in TABLE II. The specular gloss requirement is replicated from MIL-DTL-64159 for Foliage Green 504. Testing shall be in accordance with 4.10.7.2.

TABLE II. Specular gloss for Foliage Green 504.

Specular gloss for Foliage Green 504 Minimum Maximum

60 degree - 1.0 85 degree - 3.5

Retention system operating requirements. The Government shall evaluate the retention systems during FAT and LAT per AR/PD 17-06. The helmet retention system shall be in accordance with all requirements specified in the Product Manager Soldier Protective Equipment (PM SPE) Purchase Description AR/PD 17-06. The design shall be the same as the IHPS RS. The retention system shall not be attached to the outer surface of the helmet. The Government will provide the retention system specifications.

Retention system intended use. The retention system shall allow the user to easily don and doff the helmet and provide adjustment to allow for proper fit of the helmet. The retention system shall be compatible with male and female Soldier hair styles authorized in AR 670-1, Wear and Appearance of Army Uniforms and Insignia. Testing shall be in accordance with 4.10.8.

Retention system adjustment. The retention system shall allow for quick and convenient adjustment of its size and level of tightness with one or both hands, with and without Army Combat Gloves. When using one hand, the desired objective is that it takes less than two seconds per strap, and while using two hands, the desired objective is that it takes less than five seconds to properly adjust all four helmet straps. This capability must be inherent to all webbing straps that ultimately attach to the finished shell and while wearing Army Combat Gloves. The

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straps of the retention system shall be capable of being adjusted while wearing the helmet.

Testing shall be in accordance with 4.10.8.

Static pull Strength. No component of the retention system shall fail; the retention system closure device shall not release (open), and the webbings shall not slip when subjected to a load of 150 pound-force (lbf) when tested in accordance with 4.10.8.1.

Dynamic pull strength. No component of the retention system installed in a helmet shall fail when subjected to a 25 ft/sec drop when tested in accordance with 4.10.8.2.

Helmet stability. The retention system shall keep the helmet in the proper “as worn” condition throughout operational use. This includes activities like running, jumping, prone shooting, and airborne free-fall. The helmet must maintain proper positioning when used with NVDs and other situational awareness improvement equipment, which adds weight in certain regions of the helmet. Testing shall be in accordance with 4.10.8.3.

Suspension system.

Suspension system design. The helmet shall utilize a modular pad suspension system consisting of a series of pads that act as the suspension system between the Soldier (wearer’s) head and the helmet shell. The pad suspension system shall attach, remove, and reattach to the helmet shell via hook tape disks permanently adhered to the inside of the helmet shell. The pads shall remain firmly in place when attached. The ease of attachment of the pads and the ability to attach the pads where the wearer desires (i.e., in a variety of locations) shall permit accommodations among different sized and shaped heads. There are three (3) different pad shapes that form the suspension system: round, trapezoidal, and oblong. A complete pad suspension kit shall consist of seven (7) pads as follows: one (1) round pad (crown), two (2) trapezoidal pads (front and back), and four (4) oblong pads (distributed around the perimeter to achieve comfort and stability). Samples shall be examined for the defects specified in 4.10.1.

Mandatory source for this component shall be in accordance with 6.12. All helmet types and classes specified in 1.2 shall use this mandatory source.

Suspension system compatibility. The suspension system must be compatible with the NVD and retention system designs, tactical headset and communication system components (see 6.7). Testing shall be in accordance with 4.10.9.1.

Pad construction. The pad shall have at least three basic layers or be designed in such a way as to function in three ways: an inner layer shall contact the wearer’s head, a padding layer shall provide the standoff, comfort, protection and stability, and an outer material layer which attaches the pad to the hook disk inside the helmet shell. The three (3) layers shall be permanently joined around the perimeter to prevent disassembly. The shapes of the pads shall meet the shapes shown in Drawing 2-1-2566 with a tolerance of ± 0.125-inch. The 3/4-inch thick pad set shall be made up of all 3/4-inch thick pads and shall be within 0.0625-inch of the nominal thickness. Testing shall be in accordance with 4.10.9.1 and 4.10.9.2.

3.6.3.1 Inner layer material. The inner material that contacts the wearer’s head shall wick moisture away from the wearer’s head and absorb it. The color of the inner material shall be Foliage Green 504 for all helmet classes. Testing shall be in accordance with 4.10.9.3 and 4.10.9.7.

3.6.3.2 Padding layer material. The padding material shall provide standoff, comfort, protection, and stability. The padding material shall not increase in weight by more than 3.0 percent when immersed in salt water. The pad may consist of multiple layers. Thickness of this

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layer shall provide for the bulk of the overall pad thickness required. Testing shall be in accordance with 4.10.9.4.

3.6.3.3 Outer layer material. The outer material shall be made of a loop-type material and allow the pad to be attached to the inside of the helmet shell. The material shall have an average peel strength no less than 2.8 pounds per inch of width when tested in accordance with

4.10.1 and 4.10.9.5. It is desirable that the outer material interface with the currently fielded hook disk (see 6.11). The color shall be Foliage Green 504 for all helmet classes. The outer material shall interface with hook disk. Testing shall be in accordance with 4.10.1, 4.10.9.5, and 4.10.9.7.

3.6.3.4 Pad compression durability. The pads shall be constructed such that they can withstand multiple compressions without failing. Each pad shape and thickness shall be subjected to repeated 1/4-inch compressions and show no signs of degradation. Degradation includes, but is not limited to, the structure of the pad losing its resiliency, not returning to its original shape, and thickness. There shall be no physical damage to any of the pad components. Physical damage includes, but it is not limited to, breakage of threads (if used), seams, or closures, damage to any of the components such that they do not return to their original shape and thickness. Testing shall be in accordance with 4.10.9.6.

Suspension system attachment material.

3.6.4.1 Suspension system attachment. The attachment material shall possess means of easy attachment, removal, and reattachment of the suspension system to the finished shell with no special tools required. The suspension system shall remain firmly in place when attached. Testing shall be in accordance with 4.10.1.

3.6.4.2 Attachment material shape. Attachment material shape is at the discretion of the Contractor. Shape uniformity is required. Testing shall be in accordance with 4.10.1.

3.6.4.3 Attachment material coverage. Any means to attach a suspension system component to the inside of the shell shall be applied to the inner surface of the shell and shall interface with the outer material of the suspension system. No attachment material shall be installed in the ear dome area of the finished shell. Additionally, no attachment material shall cover any molded-in markings. An adequate amount of attachment material shall be installed on the interior of the finished helmet to allow movement of the suspension system components into any position and to allow securing of the helmet cover and retention system. At a minimum, enough attachment material shall be installed to allow the smallest pad to be placed anywhere inside the shell and have at least 50% of the pad’s surface in contact with the attachment material. Alternate plans for attachment material coverage that achieve the above criteria shall be submitted for Government written approval prior to implementation. Such plans that receive written Government approval shall become part of the documented suspension system design.

Testing shall be in accordance with 4.10.1 and 4.10.9.8.1.

3.6.4.4 Attachment material durability. Attachment material for the affixing of suspension systems to the interior surface of the helmet must be durable. If an adhesive mechanism is used, no attachment material should have air bubbles or gaps between the affixed surface and the finished shell. At no time shall removal of any suspension system component of the finished helmet cause the attachment material to become separated from the finished helmet. The attachment mechanism shall firmly affix the attachment interface to the inner surface of the finished helmets with no lifting of attachment material on any contours within the finished helmets. The adhesion between the hook disk and the outer material on the pad shall be a minimum of 2.0 pounds per inch. The attachment material shall remain affixed to the

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helmet shell after twenty-two (22) cycles of installation and removal of suspension system components. At no time shall removal of any suspension system component cause the attachment material to become separated from the finished shell. Testing shall be in accordance with 4.10.9.8.2.

Colorfastness. The inner layer material, outer layer material, and attachment material shall exhibit colorfastness to laundering, crocking, perspiration (acid and alkaline), and water. The materials shall meet or exceed the requirements listed in

TABLE III. Testing shall be in accordance with 4.10.9.9.

TABLE III. Inner and outer material colorfastness.

Characteristic Requirement

Colorfastness to Laundering (1 cycle) (minimum) Color Change Staining 1/

Colorfastness to Crocking (minimum) Dry Wet

Colorfastness to Perspiration (acid and alkaline , minimum)

Colorfastness to Water (minimum)

1/ Polyester, Nylon.

Ballistic protection. The finished helmet shall provide ballistic protection (fragmentation and 9mm projectiles). Protection shall meet the requirements set forth in this document throughout the entire surface area of the finished helmet unless specified otherwise in this document.

Fragmentation protection – minimum V50 Ballistic Protection Limits (V50 BL(P)).

The finished helmet shall be capable of providing the minimum V50 BL(P)s listed in

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TABLE IV at 0o (±5o) obliquity against the specified Right Circular Cylinder (RCC) and Fragment Simulating Projectile (FSP) projectiles when tested in accordance with 4.10.10.1, 4.10.10.2, and 4.10.10.3 under the following conditions:

a. Ambient (see 4.6 and 4.10.10.6.1)

b. Extreme hot (see 4.10.10.6.1)

c. Extreme cold (see 4.10.10.6.1)

d. After immersion in seawater (see 4.10.10.6.2), tested at ambient temperature

e. After exposure in weatherometer (see 4.10.10.6.3), tested at ambient temperature

f. After accelerated aging (see 4.10.13.13), tested at ambient temperature

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TABLE IV. Minimum V50 BL (P)s.

Projectile 1/ Minimum V50 BL(P) at 0° (±5°) Obliquity (ft/sec)

2-grain RCC 2/ 4200

4-grain RCC 3475

16-grain RCC 2475

64-grain RCC 1750

17-grain FSP 3/ 2200

1/ V50 ballistic limit testing shall be performed in accordance with 4.10.10.3.

2/ Right Circular Cylinders shall be in accordance with FIGURE 1.

3/ Fragment Simulating Projectile – MIL-DTL-46593 with the exception of Hardness Testing per ANSI/ASQ Z1.4, Special Inspection Level S-3.

RTP – 9mm. The finished helmet, including any NVD hardware, when required by type and class, exposed on the outside of the shell, shall be resistant to penetration from a 9mm FMJ RNP bullet with a nominal mass of 124 grains in accordance with NIJ 0106.01, Ballistic Helmets, at 1400 (+50, -0) feet per second (ft/sec) at 0o (±5o) obliquity when tested in accordance with 4.10.10.1, 4.10.10.1.2, and 4.10.10.4 under the following environmental conditions.

a. Ambient (see 4.6 and 4.10.10.6)

b. Extreme hot (see 4.10.10.6.1)

c. Extreme cold (see 4.10.10.6.1)

d. After immersion in seawater (see 4.10.10.6.2), tested at ambient temperature

3.7.3.1 FAT 9mm RTP helmet requirement.

3.7.3.1.1 FAT part A: There shall be no complete penetrations in the first twenty-two impacts (helmet shell, eleven helmets required). At least four impacts shall be in each of the four environmental conditions. The three remaining helmets will be subjected to each condition specified (high temperature, low temperature, and seawater). Testing shall stop if one complete penetration occurs in the first twenty-two impacts and the design does not meet the 9mm RTP requirement for the finished helmet.

3.7.3.1.2 FAT part B: If there have been no complete penetrations in the first twenty-two impacts as specified in Part A, then testing will continue in accordance with the FAT matrix as specified in APPENDIX A.

3.7.3.1.3 RTP testing on the helmet shall meet a P(nP) with 90% LCL for 9mm RTP testing in accordance with TABLE V when the LCL is calculated using the Clopper-Pearson method. The aggregate condition will be determined by combining all shots including the first twenty-two (22) impacts. Other conditions will be determined by combining all shots that include the stated condition (i.e. all front, all ambient medium, etc.). Testing shall be in accordance to 4.10.10.1.2.1.

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TABLE V. RTP Lower Confidence Levels (LCL).

Conditions

LCL

(P(nP) / Confidence) Allowable complete penetrations

Aggregate 96 / 90 3

Size 89 / 90 2

Environment 89 / 90 2

Location 89 / 90 2

Size by Location 71 / 90 1

Environment by Location 71 / 90 1

Size by Environment 71 / 90 1

3.7.3.2 FAT, RTP NVD hardware requirement. For Type I helmets, NVD hardware RTP testing on the helmet will be calculated separately from the helmet RTP. 9mm RTP hardware testing shall meet a 90% P(nP) with 90% LCL when the LCL is calculated using the Clopper- Pearson method. Testing shall be in accordance with 4.10.10.1.2.2.

3.7.3.3 LAT, RTP requirement.

3.7.3.3.1 LAT part A: There shall be no complete penetrations in the first five impacts.

Testing shall stop if one complete penetration occurs in the first twenty-two impacts and the design does not meet the 9mm RTP requirement for the finished helmet.

3.7.3.3.2 LAT Part B: If there have been no complete penetrations in the first five (5) impacts as specified in Part A, then testing will continue in accordance with the LAT matrix specified in APPENDIX A. The RTP requirement will then be based on the accept/reject criterion specified in the LAT section of APPENDIX A. Testing shall be in accordance to 4.10.10.4.

Ballistic transient deformation (BTD). BTD shall be used for Government reference.

3.7.4.1 Ballistic transient deformation - FAT. BTD shall be measured during RTP testing for Government reference under the environmental conditions specified in 3.10 at 1400 (+50, -0) feet per second at 0° (±5°) obliquity. An Upper Tolerance Limit (UTL) for BTD shall be calculated and used for Government reference as described in APPENDIX B. The Government reserves the right to purchase additional helmets for use in additional BTD evaluation. Testing shall be in accordance with 4.10.10.1.3 and 4.10.10.5.

3.7.4.2 Ballistic transient deformation – LAT. During LAT, BTD shall be measured during RTP testing for Government reference. Testing shall be in accordance with 4.10.10.1.3 and 4.10.10.5.

Weight. The maximum weight of the finished helmet system, as described in 3.2c, shall not exceed the weights listed in TABLE VI. This requirement applies to all helmet Types as defined in 1.2. Each helmet system size, Small (SM), Medium (MD), Large (LG), Extra- Large, (XL), and Double Extra-Large (2X), shall have its own category of weight as shown on TABLE VI. During FAT, a minimum of five (5) finished helmets of each size (SM through XL) shall be tested. During LAT, all sample-finished helmets shall be tested. Testing shall be in accordance with 4.10.11.

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TABLE VI. Weights.

Helmet system size

Finished helmet maximum weight (lbs.)

SM 2.49

MD 2.60

LG 2.81

XL 3.29

2X 3.40

Blunt impact protection. The finished helmet shall provide non-ballistic impact protection to the wearer by reducing acceleration of the head during low velocity blunt impact events at various temperatures and impact sites. Blunt impact protection testing on the helmet shall meet a Probability of under Limit (P(uL)) with 90% LCL for blunt impact testing in accordance with

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TABLE VII when the LCL is calculated using the Clopper-Pearson method. A measurement shall be considered under the limit if it is not in excess of 150g, where g is gravitational acceleration due to earth’s gravity at sea level. Greater impact protection (i.e., lower g) is desired as an objective. Following blunt impact testing, there shall be no damage to any part of the retention system or suspension system. Also, there shall be no physical damage to the helmet shell that degrades ballistic performance such as delamination of ballistic material, ply separation, or shell fracture. If the finished shell has a cosmetic inner or outer layer, separation of the ballistic material from the cosmetic layer because of blunt impact testing shall not be considered a defect. If physical damage such as the previously detailed criteria is evident on the inside surface of any finished helmet, additional testing shall be conducted. The Government will conduct a 9mm RTP test approximately at the center of the damage on the mirrored location of the finished helmet exterior of each damaged location and in accordance with 4.10.10.4. An impact that is off the center of the damage shall be considered a fair shot with a result of a complete or partial penetration. Additionally, there shall be no indentation on the exterior of the helmet shell in excess of 0.20-inch present after blunt impact testing. If deemed necessary (excluding the 0.20-inch indentation requirement), the Government will analyze the damage and conduct a non-invasive imaging scan (i.e., Computed tomography (CT) Scan) of the sample to confirm the damage. Each affected area with damage (visually obvious damage or visually borderline damage confirmed by non-invasive imaging scan) will be impacted with a 9mm projectile and a partial or complete penetration will be documented as described in 6.5.2 and 6.5.3.1. Only the front, crown, right side, left side, and rear locations shall be included in the analysis. The Government reserves the right to impact the nape location after all locations on a helmet have been tested. BTD may be measured for Government reference. If more than twenty-two impacts are required, RTP testing on the helmets shall meet a minimum of 90% P(nP) with 90% LCL for 9mm RTP testing when the LCL is calculated using the Clopper-Pearson method. If twenty-two (22) impacts or less are required, 100% of the impacts must result in partial penetrations to meet the requirement.