Attachment_0004_-_General_Specification_for_Non_Standard_Ammunition.pdf

Distribution Statement A. Approved for public release; distribution is unlimited.

Project Manager – Maneuver Ammunition Systems

Product Director – Non Standard Ammunition

GENERAL SPECIFICATION FOR

NON-STANDARD AMMUNITION

02 November 2015

1. SCOPE

1.1 Scope. This general specification describes the requirements and verification procedures for

Non Standard Ammunition excluding Non Standard Small Caliber, Mortar, and Spin Stabilized/Rocket

Propelled Grenade ammunition (see family specifications for these items).

2. APPLICABLE DOCUMENTS

2.1 General. In addition to documents listed in this section, there are documents specified in section 5 of this specification.

2.2 Government documents. Not Applicable.

2.3 Non-Government publications.

a) United Nations Recommendations on the Transport of Dangerous Goods Model

Regulations, 13th Edition, 2003.

b) International Civil Aviation Organization (ICAO) Technical Instructions for the Safe

Transport of Dangerous Goods by Air, 2015-2016 Edition.

c) International Maritime Organization (IMO) International Maritime Dangerous Goods

Code (IMDG), Amendment 34-08.

2.4 Acquisition requirements. Acquisition documents must specify the following:

a. Title and date of this specification.

b. Requirements for certificates of conformance for each lot or shipment of product.

c. Requirements for age of ammunition.

d. Requirements and provisions for submission of data as required.

e. Requirements for acceptance criteria if different than those stated in specification.

f. Requirements for reduction or elimination of verification procedures.

g. Requirements and provisions for contractor and Government verification.

h. Requirements and provisions for packaging of ammunition.

i. Requirements and provisions for transportation of ammunition.

General Specification for Non-Standard Ammunition – 02 November 2015

2.5 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. Requirements specified in the contract or delivery order precede the text of this document. Nothing in this document or the contract, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 Technical requirements. Ammunition shall meet the requirements and verifications of this specification for the non-standard ammunition listed in ANNEX A. All non-standard ammunition shall be accompanied with technical data (see APPENDIX) that meets or exceeds the requirements of this specification.

3.1.1 Compliance to technical requirements and storage history records. A Technical Data

Package (TDP) as well as Lot history reports shall be provided to ensure ammunition is in compliance with this specification. Additionally, documented storage history of the ammunition shall be provided.

3.2 Conformance Testing and Inspection. A sample of the ammunition shall be subjected to conformance testing and inspection in accordance with TABLE I.

3.2.1 Stock ammunition. All ammunition must be less than 5 years old and meet the verification procedures in TABLE I of this specification. Any lot that has not been adequately tested to comply with all requirements of TABLE I shall be subjected to conformance testing and inspection in accordance with this specification.

3.3. Serviceability. Ammunition shall be serviceable and issuable, in good condition and without visible signs of degradation.

3.3.1 Identification of defects. Visual defects shall be identified within the technical data and include a defined method for acceptance/rejection of the ammunition.

3.4 Weapon interface and interoperability. The ammunition shall be functionally compatible with the weapons identified in ANNEX A or as otherwise specified in the contract or delivery order.

3.5 Operating requirements. Each round shall provide the following functional, operational, and performance capabilities when fired from the weapons listed in ANNEX A, regardless of weather conditions (i.e. rain, snow, mud, wind, fog).

3.5.1 Operating temperatures. The ammunition shall demonstrate safety and reliability throughout exposure to ambient and extreme temperatures.

3.5.2 Muzzle velocity. The average velocity obtained at ambient temperature shall meet the requirement listed in the TDP.

3.5.3 Chamber pressure. The individual maximum and average pressure of the ammunition shall meet the requirements specified in the TDP.

3.5.4 Maximum effective range. Each lot of ammunition shall be tested to determine maximum range as listed in the TDP.

3.5.5 Dispersion. The ammunition shall demonstrate dispersion characteristics as specified in the TDP.

3.5.6 Function and casualty. The ammunition shall function without casualty or cause damage to the weapon, and shall exhibit a ballistic performance free of misfires, duds, premature bursts, short rounds, and metal parts separation. The ammunition shall cause no hazard or unsafe condition to the gunner during storage, transportation or use.

3.5.7 Performance. The ammunition shall function according to its specific purpose and as defined in the TDP. Specific performance requirements may include but are not limited to fragmentation, illumination, penetration, smoke and flare.

3.6 Fuze identification and description. When applicable, the fuze shall be identified within each

TDP with a drawing/figure of the internal fuze design with components categorized and a functional description of the fuze that includes, at a minimum, a detailed description of the fuze arming sequence, operating temperatures, in-process tests (ie. jolt/jumble, sensitivity, safe arming/non-arming etc.), and safe separation distances. Test records shall be available to the US Government for verification.

3.7 Environmental Requirements.

3.7.1 Sequential rough handling. Ammunition shall be capable of withstanding the rigors of the sequential rough handling and transportation throughout extreme temperature ranges and meet all performance and safety requirements.

3.7.2 Shelf life. The ammunition shall meet all requirements of this specification within its operating temperature range at a minimum of ten (10) years of storage.

4. VERIFICATION

4.1 Technical verification. The ammunition shall be subjected to verification of all requirements cited in section 3 in this specification, in accordance with the TABLE I. Noncompliance to any requirements shall be cause to withhold acceptance of the lot or batch in which the noncompliance was found.

TABLE I – Requirements/Verification Cross-Reference Matrix

4.1.1 Lot formation. The ammunition shall be assembled into identifiable lots, sublots, or batches, or in such other manner as may be prescribed. Each lot or batch shall, as far as practicable, consist of units of product of a single type, grade, class, size, and composition, manufactured under essentially the same conditions, and at essentially the same time. Lot quantities shall be determined by the total quantity for shipment and include the additional rounds from the same lot to be consumed during lot acceptance testing along with contingency rounds for potential retesting. The lots or batches shall be identified by the contractor and shall be kept intact in adequate and suitable storage space. All ammunition in a given lot must be manufactured prior to lot acceptance testing.

4.1.2 Conformance verification. The ammunition shall be subjected to verification in accordance with TABLE I of this specification.

4.1.3 Conformance acceptance. Acceptance of ammunition shall be based on compliance with the requirements in TABLE I of this specification. Failure to meet requirements of TABLE I shall be cause to withhold acceptance of the lot or batch for which verification was performed. A Request for

Variance (RFV) may be submitted for special consideration of a lot that does not comply with all requirements of the TDP. The US Government may approve or disapprove RFVs on a case by case basis.

Section 3

Requirements Requirement

Section 4

Verification

Procedures

Sample Size

3.1 Technical requirements 4.1 -

3.3 Serviceability 4.3 Note 1

3.3.1 Identification of defects 4.3 Note 1

3.4 Weapon interface 4.4 Annex A

3.5.1 Operating temperatures 4.5.1 Annex A

3.5.2 Muzzle velocity 4.5.2 Annex A

3.5.3 Individual/Average max.

pressure

4.5.3 Annex A

3.5.4 Maximum effective range 4.5.4 Annex A

3.5.5 Dispersion 4.5.5 Annex A

3.5.6 Function and casualty 4.5.6 Annex A

3.5.7 Performance 4.5.7 Annex A

- Packing - Note 1

- Marking - Note 1

Note 1) To be performed using a defined sampling procedure for inspection determined by the ammunition lot sizes.

4.1.4 Retest criteria. A ballistic retest is authorized upon initial failure of ammunition to meet test requirements as long as the failure is not considered critical. Retest procedures must be clearly defined in the technical data and results must be combined with data from the first test unless a failure analysis confirms that the failure was caused by something other than the ammunition (i.e. weapon failure or faulty test set up).

4.2 Verification of evidence of compliance. Evidence shall include, but is not limited to, the following;

a. Identification of technical requirements to which the grenades is/was produced.

b. Producer, date of manufacture and original acceptance documentation.

c. Initial acceptance reports, including type, lot or batch identification, quantity and method of acceptance (e.g. sample size, verification method, acceptance criteria, results).

d. Surveillance reports, including lot or batch identification, quantity and method of surveillance

(e.g. sample size, verification method, criteria for action to be taken on lot or batch, results).

e. Storage history, including duration and storage condition (e.g. controlled, uncontrolled).

4.3 Serviceability. A random sample shall be selected from each lot of ammunition using a defined sampling procedure for inspection. The ammunition shall be visually inspected for signs of degradation and the identification of defects according to the producer’s technical data. Re-inspection of a lot that fails for non-ballistic reasons is authorized as long as the criteria for re-inspection is clearly outlined in the technical data package.

4.4 Weapon interface and interoperability. A random sample shall be selected from each lot of ammunition to be delivered and inserted into a weapon chamber or chamber gage that conforms to the identified weapon system to check for profile and alignment. Inability to interface properly with weapon system shall be considered a failure to show compliance and constitute a single reliability failure.

4.5 Operating verification.

4.5.1 Operating temperatures. All ammunition shall operate reliably and safely when conditioned and fired throughout the extreme operating temperature range. Temperature testing shall be conducted on a skip-lot basis (see APPENDIX) either in-process or during LAT. A single safety failure will result in lot rejection and there shall be no retest. Functional testing parameters must be defined in the technical data and meet manufacturer requirements.

4.5.2 Muzzle velocity. Velocity tests shall be conducted in accordance with the producers test procedures to verify that a sample representative of the lot meets the minimum velocity requirements specified in the TDP.

4.5.3 Maximum pressure. Pressure tests shall be conducted in accordance with the producers test procedures to verify that a sample representative of the lot does not exceed the average or individual pressure requirements listed in the TDP, regardless of in-process testing. Any single round that exceeds the maximum individual pressure requirement will result in lot rejection.

4.5.4 Maximum Effective Range. Maximum effective range shall be verified during lot acceptance testing to ensure compliance with the TDP (does not apply to medium caliber ammunition).

4.5.5 Dispersion. Dispersion tests shall be conducted to verify that each lot of ammunition meets the specified requirements in the TDP.

4.5.6 Function and casualty. A random sample shall be selected from the cartridges in accordance with ANNEX A to be delivered and functioned from the identified weapon system to check for function, casualty and metal parts security. The ammunition shall function across the entire operating temperature range without casualty or damage to the weapon, and shall exhibit a ballistic performance free of misfires, duds, premature bursts, short rounds and metal parts separation. The ammunition shall cause no hazard or unsafe condition to the gunner during storage, transportation or use. Any round which detonates prior to impact of intended target, or which detonates in the weapon is considered a safety critical failure and will result in immediate lot rejection.

4.5.7 Performance. Proper functioning for each ammunition type is defined below. Any round which does not function properly according to the below definitions and the requirements in the TDP is considered a function failure:

a. Fragmentation: High-order detonation of the warhead upon initial impact with the specified target.

b. Illumination: The ammunition shall provide candlepower illumination and the parachute suspended burn time as identified in the TDP.

c. Smoke: The ammunition shall produce smoke upon impact with the target as specified in

d. Penetration: The ammunition shall meet the armor penetration characteristics as specified in

e. Flare: The ammunition shall deploy from the launcher and produce its intended effect for a minimum amount of time as per the TDP.

5. PACKAGING

5.1 Preservation, packaging, packing, unitization, and marking shall provide protection for multiple handling, redistribution, and shipment by any transportation mode and meet or exceed the following requirements.

5.1.1 Packaging containers for hazardous materials, ammunition and explosives shall meet or exceed the requirements found in part 6 of the "United Nations Recommendations on the Transport of

Dangerous Goods Model Regulations" and in a manner acceptable to the competent authority of the nation of origin and in accordance with the regulations of all applicable carriers.

5.1.2 Cleanliness - Items and packaging shall be free of dirt and other contaminants which would contribute to the deterioration of the item or which would require cleaning by the customer prior to use.

Coatings and preservatives applied to the item for protection are not considered contaminants.

5.1.3 Preservation - Items susceptible to corrosion or deterioration shall be provided protection against external environmental effects.

5.1.4 Cushioning - Items requiring protection from physical and mechanical damage (e.g. fragile, sensitive, critical material) or which could cause physical damage to other items, shall be protected by wrapping, cushioning, pack compartmentalization, or other means to mitigate shock and vibration and prevent damage during handling and shipment.

5.1.5 All natural wood packing material shall be constructed from heat treated lumber and certified by an accredited recognized agency in accordance with International Standards for

Phytosanitary Measures (ISPM-15) regardless of origin or destination. All natural wood packing materials must include certification markings that are readily visible to inspectors and on at least two sides of every container when palletized.

5.2. Unit Package

5.2.1 Unit package shall be so designed and constructed that it will contain the contents with no damage to the item(s), and with minimal damage to the unit pack during shipment and storage in the shipping container, and will allow subsequent handling. The outermost component of the unit package shall be a container such as a sealed bag, carton, or box.

5.3. Packing

5.3.1 Unit packages must be packed in shipping containers. All shipping containers shall be the most cost effective and shall be of the minimum cube to contain and protect the items.

5.3.2 Shipping Containers - the shipping container (including any necessary blocking, bracing, cushioning, or waterproofing) shall comply with the regulations of the carrier used and shall provide safe delivery to the destination at the lowest tariff cost. The shipping container shall be capable of multiple handling, stacking at least ten feet high, and storage under favorable conditions and meet the requirements of the “United Nations Recommendations on the Transport of Dangerous Goods”.

5.4. Unitization

5.4.1 Shipments of identical items going to the same destination shall be palletized if they have a total cubic displacement of 20 cubic feet or more unless skids or other forklift handling features are included on the containers. Pallet loads must be stable, and to the greatest extent possible, provide a level top for ease of stacking. The weight capacity of the pallet must be adequate for the load. A pallet load shall not exceed 4,000 pounds and should not exceed 52 inches in length or width, or 54 inches in height. The load shall be contained in a manner that will permit safe handling during shipment and storage.

5.4.2 Banding - metal banding shall be used to secure load. Straps shall be applied to each column or layer of boxes. Tie down straps shall be applied to each column of boxes at 90 degrees to the load straps. Edge protectors shall be used when securing fiberboard boxes.

5.5. Marking

5.5.1 Packaging marking shall be visible, clear, and remain legible during normal life cycle handling.

5.5.2 All unit packages, intermediate packs, exterior shipping containers, and, as applicable, unitized loads shall be marked with item description, quantity, lot number, or serial number. The outer shipping container and unitized load shall indicate load weight, UN dangerous goods proper shipping name, UN number and UN POP marking.

5.5.3 Each package shipping container shall show the United Nations packaging symbol and applicable codes in accordance with the construction requirements and testing of packaging as expressed in part 6 of the " United Nations Recommendations on the Transport of Dangerous Goods Model

Regulations, 13th Edition, 2003".

5.6. Additional Requirements for Hazardous Materials

5.6.1 The shipment shall be prepared in accordance with the "United Nations Recommendations on the Transport of Dangerous Goods Model Regulations, 13th Edition, 2003" and other applicable regulations effective at the time of shipment in a manner acceptable to the competent authority of the nation of origin and in accordance with the regulations of all applicable carriers.

5.6.2 Packaging and marking for hazardous material shall comply with the requirements for the mode of transport and the applicable performance packaging contained in the following documents:

a. International air transport: International Civil Aviation Organization (ICAO)

Technical Instructions for the Safe Transport of Dangerous Goods by Air, 2015-2016

Edition.

b. International vessel transport: International Maritime Organization (IMO)

International Maritime Dangerous Goods Code (IMDG), Amendment 34-08.

Lawrence W. Dring III

LTC, AC

Product Director Non-Standard Ammunition Picatinny Arsenal, NJ

Annex A: Weapon Interface and Sample Size Requirements

APPENDIX - Definitions

General Specification for Non-Standard Ammunition - 02 November 2015

ANNEX A - Weapon Interface and Sample Size Requirements

Medium Caliber

Item Weapon Interface Function and Casualty/Safety

Sample Size2-Accept-Reject & Retest (cumulative)

14.5 x 114mm Ball KPV Machine Gun

Ambient: 32-0-1 or 60-1-2

14.5 x 114mm Tracer

23 x 115mm (All Types) GSh-23

23 x 152mm (All Types) ZU-23

30 x 165mm HEI

2A42 or Gsh-30

30 x 165mm HE-T

30 x 165mm APT

Note 1: Any non-standard medium caliber ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show function and casualty at ambient temperature. 32 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: Each lot of cartridges shall demonstrate its ability to perform its intended function, for example, AP cartridges shall penetrate armor, incendiary ammunition shall ignite fuel, tracers shall ignite and provide trajectory of the projectile, etc.

ANNEX A - Weapon Interface and Sample Size Requirements (continued)

Artillery Ammunition

Item Weapon Interface Function and Casualty/Safety

Sample Size2-Accept-Reject & Retest (cumulative)

122mm HE Frag Full Charge

D-30 Towed

Howitzer

Ambient: 15-0-1 or 29-1-2

122mm HE Frag Partial

Charge

122mm HEAT

122mm WP Smoke

122mm Illum

152mm Frag-HE D-20 Towed Howitzer

122mm Artillery Rockets BM-21 Grad Multiple

Rocket System (MRS)

Note 1: Any non-standard artillery ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: A function failure shall be defined as

a) A cartridge that will not load into the weapon

b) A misfire

c) A cartridge that does not detonate (HE and Practice cartridges only)

d) A cartridge that does not produce smoke (Smoke cartridges only)

e) A cartridge that does not have a parachute suspended burn time as identified in the TDP. (Illum cartridges only)

The following safety failures shall result in the immediate rejection of the lot, there shall be no retest;

a) Detonation of an HE, Practice or Smoke cartridge within the weapon or before impact with the ground.

b) Any in-bore or early functions of the fuze (Illumination cartridges)

c) Metal parts separation.

d) Short rounds; a cartridge impacts the ground at a range 80% or less of the range average or its respective temperature/charge/group; excluding the cartridge(s) in question.

e) A cartridge that damages the weapon or renders the weapon inoperable without special tools.

Aircraft Ammunition

Item Weapon Interface Function and Casualty/Safety

Sample Size2-Accept-Reject & Retest (cumulative)

57mm S-5KO Aviation Rocket

UB-16-57UM /UB-32

Rocket Pod

Ambient: 15-0-1 or 29-1-2

57mm S-5KO Practice Aviation

Rocket

57mm S-5KP Aviation Rocket

80mm S-8 Aviation Rocket B-8M1/B8V20

Rocket Pod

PP3

PP9

PPL YaKB

EKSR-46 Flare Mi-17/35

PPI-26 Flare ASO-2/ASO-2V

Note 1: Any non-standard aircraft ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: The following safety failures shall result in the immediate rejection of the lot, there shall be no retest;

a) Detonation of ammunition within the weapon or before impact with the target.

b) Metal parts separation.

c) A cartridge that damages the weapon or renders it inoperable without special tools.

Tank, Gun and ATGM Ammunition

Item Weapon

Function and Casualty/Safety

Sample Size2-Accept-Reject & Retest

(cumulative)

100mm HE T-55 Tank

Ambient: 15-0-1 or 29-1-2

115mm APFDS-T

T-62 Tank 115mm HE

115mm HEAT

125mm HE-Frag

T-64/T-72 Tank 125mm APFSDS

125mm HEAT

73mm HE 2A28 Grom

73mm HEAT

AT-3 ATGM HE, (Sagger) a.k.a. 9M14 Malyutka

BMP-1, launcher 9P111, BRDM Vehicle

AT-5 ATGM HE (Spandrel) a.k.a. 9M113 BMP-2/BRDM-2

Note 1: Any non-standard tank, gun and ATGM ammunition not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 15 rounds shall be tested for function and safety at the operating temperature extremes. A minimum of 10 data points is required to evaluate all other test parameters.

Note 3: The following safety failures shall result in the immediate rejection of the lot, there shall be no retest;

a) Detonation of ammunition within the weapon or before impact with the target.

b) Metal parts separation.

c) A cartridge that damages the weapon or renders it inoperable without special tools.

Hand Grenades

Item / Requirement Weapon Function and Casualty/Safety

Sample Size2-Accept-Reject & Retest (cumulative)

RKG-3 / Armor penetration >=150mm5

Ambient: 32-0-1 or 60-1-2 Grenade, Rubber Buckshot3

Grenade, Flash & Bang4

Grenade, HE, HE Frag. or Thermobaric3

Grenade, Smoke Ambient: 15-0-1 or 29-1-2

Grenade, Tear Gas

Note 1: Any non-standard hand grenades not listed in this table are still required to meet sample size-accept-reject criteria listed in this table.

Note 2: These samples sizes shall be used to show performance and function and casualty at ambient temperature. 32/15 rounds shall be tested for function and safety at the operating temperature extremes. A single safety failure will result in lot rejection and there shall be no retest.

Note 3: These grenades must be tested at hot/cold/ambient for each lot (skip lot testing does not apply). Any lot that exhibits a delay of less than 3 seconds shall be rejected, there shall be no retest.

Note 4: These grenades must be tested at hot/cold/ambient for each lot (skip lot testing does not apply). Any lot that exhibits a delay of less than 1 second shall be rejected, there shall be no retest.

Note 5: These grenades must be tested at hot/cold/ambient for each lot (skip lot testing does not apply). Detonation prior to impact shall result in lot rejection, no retest.

APPENDIX

1. DEFINITIONS

1.1 Non standard ammunition. Non standard ammunition are those munitions that have not been safety tested and type classified for Army use, and cannot be procured through the Army supply.

Munitions and explosives that are not managed by National Inventory Control Points, have not been safety tested nor type classified for Army use, do not have a national stock number (NSN) and cannot be procured or requisitioned through the Army or other Department of Defense supply system.

1.2 Technical data. Technical data, otherwise known as the technical data package (TDP) is the product specific technical drawings and Quality Assurance (QA) requirements to which ammunition and associated packaging is produced and accepted for each applicable Contract Line Item Number (CLIN).

For the purpose of this specification, the TDP, as a minimum, must contain the following: Government contract number and delivery order; top assembly, fuze and key component drawings with revision number, revision date, document control signature, key interface dimensions, and a list of component assemblies with drawing numbers and revision dates; packaging and marking drawings with revision number, revision date, document control signature and markings; and product specification with final assembly, fuze and key component in-process acceptance test methods with sample size, and accept/reject criteria. Within the TDP there shall also be a clear cut-away and/or exploded drawing(s) to show all of the inner parts and workings of the fuze. Additionally, there shall be paragraphs which describe the fuze arming sequence and events leading to function.

1.3 Degradation. Ammunition with gross nonconformance to identified technical requirements, corrosion, cracks, deformation, and spillage.

1.4 Deterioration. Packaging ripped, broken, perforated, with water damage, crushed.

1.5 Skip-Lot Temperature Testing. Except for the hand grenades identified in ANNEX A which require temperature testing on all lots, testing at the operational temperature limits shall be conducted on the first lot of every delivery order and every 5th lot thereafter. The ammunition must pass the requirements defined in ANNEX A. If a lot is rejected for any reason, the following two lots must pass temperature testing before resuming the skip lot procedures.