Attachment_0005_-_General_Specification_for_Non_Standard_Mortar_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 MORTAR AMMUNITION

02 November 2015

1. SCOPE

1.1 SCOPE: This specification prescribes the performance requirements and identifies the verification procedures for the Non Standard Mortar Cartridges including, but not limited to; 60mm, 82mm, 120mm HE/Illumination/Smoke/Practice.

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) International Maritime Organization (IMO) International Maritime Dangerous Goods

Code (IMDG), Amendment 34-08.

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

Regulations 13th Edition, 2003.

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

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

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 Mortar 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. Mortar cartridges shall meet the requirements and verifications of this specification for the non-standard mortar cartridges listed in ANNEX A. Any non-standard ammunition that is categorized as a mortar cartridge but is not specifically identified in ANNEX A must still adhere to the testing parameters of this specification. All non-standard mortar cartridges shall be accompanied with technical data (see APPENDIX) and meet or exceed the requirements outlined in 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 mortar cartridges presented for acceptance shall be subjected to conformance inspection in accordance with Table I.

3.2.1 Stock Ammunition. All stock mortar 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. Mortar ammunition shall be serviceable/issuable, in good condition and without visible signs of degradation. All parts and assemblies shall be fabricated and finished in a thorough matter and shall be free of burrs, chips, dirt, grease, rust, corrosion and other foreign material that adversely affect fit or function. Coatings and protective finishes shall be uniform and shall provide complete coverage of designated surfaces. The painting and marking shall be restored by the assembling facility on any components that have been marred or obliterated.

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

3.4 Interface and interoperability with Weapon. The mortar cartridges shall conform to weapon interface as identified in ANNEX A or as otherwise specified in contract or delivery order.

3.5 Operating requirements. Each cartridge shall provide the following functional, operational and performance capabilities when fired from the weapon systems listed in ANNEX A.

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

3.5.2 Average muzzle velocity. The average velocity obtained at ambient temperature testing shall meet the specified characteristics listed in ANNEX B.

3.5.3 Chamber pressure. The cartridges shall meet the chamber pressure characteristics specified in ANNEX B.

3.5.4 Maximum range. The maximum range of the mortar cartridges shall meet or exceed the specified requirement listed in ANNEX B.

3.5.5 Dispersion. The mortar cartridges shall demonstrate dispersion as specified by the manufacturer.

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

3.5.7 Fragmentation. The cartridge shall provide the lethal fragmentations at the desired radius for each item as identified in ANNEX B (High Explosive cartridges only).

3.5.8 Illumination. The cartridge shall provide the candlepower illumination intensity and parachute suspended burn time as identified in ANNEX B. (Illumination cartridges only)

3.5.9 Smoke. The cartridge shall produce smoke upon impact with the target as specified in technical data. (Smoke cartridges only)

3.6 Fuze identification and description. Within the technical data, the fuze shall be identified 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 Shelf life. The cartridge shall meet all requirements of this specification within its operating temperature range at a minimum of ten (10) years of storage.

3.7.2 Sequential rough handling. Cartridges 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.

4. VERIFICATION

4.1 Technical verification. The cartridges shall be subjected to verification of all requirements cited in section 3 in this specification, in accordance with 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. Requirement/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 quantity shall be determined by the total quantity for shipment and include the additional rounds from that same lot to be consumed during lot acceptance testing along with contingency rounds for potential re-testing. The lots or batches shall be identified by the contractor and shall be kept intact in adequate and suitable storage space. All cartridges in a given lot must be manufactured prior to lot acceptance testing.

4.1.2 Conformance verification. The mortar cartridges 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 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 the RFV 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 4.4.1 Annex A

3.5.1 Operating temperatures 4.4.2 Annex A

3.5.2 Muzzle velocity 4.4.3 Annex B

3.5.3 Individual/Average max.

pressure

4.4.4 Annex B

3.5.4 Maximum effective range 4.4.5 Annex B

3.5.5 Dispersion 4.4.6 Annex B

3.5.6 Function and casualty 4.4.7 Annex A

3.5.7 Fragmentation 4.4.8 Annex A

3.5.8 Illumination 4.4.8 Annex A

3.5.9 Smoke 4.4.8 Annex A

- Packing - Note 1

- Marking - Note 1

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

4.1.4 Retest criteria. A ballistic retest is authorized upon initial failure of mortars to meet test requirements as long as the failure is not considered critical. Retest procedures must be clearly defined in the TDP 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 mortar cartridges is/was produced.

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

c. In-Process 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 and identification of defects. A random sample shall be selected from the lot of mortar cartridges using a defined sampling procedure for inspection. The mortars shall be visually inspected for signs of degradation and the identification of defects according to the producer’s technical data. Any sign of degradation shall constitute failure to show compliance. 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 TDP.

4.4 Operating verification.

4.4.1 Weapon interface and interoperability. A random sample shall be selected from each lot of mortar cartridges 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.

4.4.2 Operating temperatures. The cartridges 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.

4.4.3 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 ANNEX B.

4.4.4 Chamber Pressure. Individual and average chamber pressure shall be measured during each LAT to verify compliance with the requirements in ANNEX B, regardless of prior in process testing. Any single round that exhibits a pressure above the maximum allowable individual pressure requirement will result in lot rejection and there shall be no retest. Pressure tests shall be conduction using

4.4.5 Maximum Range. Maximum effective range shall be verified during lot acceptance testing to ensure compliance with ANNEX B.

4.4.6 Dispersion. Dispersion tests shall be conducted to verify that a representative sample of the lot meets the requirements identified within the technical data.

4.4.7 Function and casualty. A random sample, in accordance with ANNEX A, shall be selected from the mortar cartridges to be delivered and functioned from the identified weapon system to check for function, casualty and metal parts security. The cartridges shall function across the entire operating temperature range (extreme hot, cold, ambient) 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 cartridges shall cause no hazard or unsafe condition to the gunner during storage, transportation or use. Any rounds 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.

4.4.8 Performance. Proper functioning for each mortar cartridge type is defined below. Any round which does not function properly according to the requirements of the producer’s test procedures and the below definitions is considered a function failure.

a. HE Frag: High-order detonation of the warhead upon initial impact with the target.

b. Smoke: The cartridge shall produce the manufacturer’s specified volume of smoke.

c. Illumination: Each cartridge shall have a parachute suspended burn time that meets the specified candlepower requirement.

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 Unit Package – The unit package shall be so designed and constructed so 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 tube, carton or box.

5.1.3 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.

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

5.1.5 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.

5.1.6 Wood Packing Material – All 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.

5.2. Packing

5.2.1 All shipping containers shall be the most cost effective and shall be of the minimum cube to contain and protect the items.

5.2.2 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”.

5.3. Unitization

5.3.1 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 1321mm in length or width, or 1372mm in height. The load shall be contained in a manner that will permit safe handling during shipment and storage.

5.3.2 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.

5.4. Marking

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

5.4.2 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.

5.4.3 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".

5.5. Additional Requirements for Hazardous Materials

5.5.1 The shipment shall be prepared in accordance with the "United Nations

Recommendations on the Transport of Dangerous Goods" 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.

5.5.2 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

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

Lawrence W. Dring III

LTC, AC

Product Director Non Standard Ammunition Picatinny Arsenal, NJ

Annex A: Weapon Interface

Annex B: Operating Requirements

APPENDIX - Definitions

ANNEX A – Weapon Interface

High Explosive

Cannon Compatibility Item Ambient Testing

Sample Size-Accept-Reject & Retest (cumulative)

M57, M6-211LR

60mm High Explosive 15-0-1, Retest 29-1-2 (Cumulative)

60mm Illumination 15-2-3, Retest 29-4-5 (Cumulative)

60mm Smoke 15-0-1, Retest 29-1-2 (Cumulative)

2B14, M69A

82mm High Explosive 15-0-1, Retest 29-1-2 (Cumulative)

82mm Illumination 15-2-3, Retest 29-4-5 (Cumulative)

82mm Smoke 15-0-1, Retest 29-1-2 (Cumulative)

2B11, 2S12, M75

120mm High Explosive 15-0-1, Retest 29-1-2 (Cumulative)

120mm Illumination 15-2-3, Retest 29-4-5 (Cumulative)

120mm Smoke 15-0-1, Retest 29-1-2 (Cumulative)

Note 1) These sample sizes shall be used to show performance and function and casualty at ambient temperature. If a lot fails, the contractor may propose a plan to repair/rework the entire lot and, if acceptable to the USG, the lot may be resubmitted for full visual/dimensional and ballistic

LAT.

Note 2) 15 rounds shall be tested for function and safety at each of the operating temperature extremes (15 at extreme hot, 15 at extreme cold). A single safety failure will result in lot rejection, there shall be no retest. Safety failures are defined below. Functionality must be in accordance with the TDP.

A function failure shall be defined as;

a) A cartridge that will not properly 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 ANNEX B. (Illumination 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

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

ANNEX B – Operating Requirements

High Explosive Mortar Ammunition

Item Average

Velocity (m/s)

Ave. Chamber

Pressure

(kgf/cm2)

Max

Range

(m)

Lethal

Fragmentation

Radius2 (m)

60mm ≥190 ≤515 ≥ 1500 ≥ 10

82mm ≥205 ≤ 665 ≥ 3000 ≥ 15

120mm ≥270 ≤ 985 ≥ 6000 ≥ 18

Note 1) A minimum of 10 data points shall be required for velocity, pressure, and dispersion.

Smoke Mortar Ammunition

Average

Velocity (m/s)

Ave. chamber

Pressure

(kgf/cm2)

Maximum Range

(m)

60mm ≥ 190 ≤ 515 ≥ 1500

82mm ≥ 203 ≤ 650 ≥ 2835

120mm ≥ 270 ≤ 950 ≥ 6000

Note 1) A minimum of 10 data points shall be required for velocity, pressure, and dispersion.

ANNEX B – Operating Requirements (continued)

Illumination Mortar Ammunition

Average

Velocity (m/s)

Ave. Chamber

Pressure

(kgf/cm2)

Max Range

(m)

Candlepower

(Cd)

60mm ≥ 210 ≤ 430 ≥ 1500 ≥ 150,000

82mm ≥ 240 ≤ 500 ≥ 3000 ≥ 500,000

120mm ≥ 300 ≤ 660 ≥ 5500 ≥ 1,000,000

Note 1) A minimum of 10 data points shall be required for velocity, pressure, and dispersion.

Practice Mortar Ammunition

Average

Velocity (m/s) Ave. Chamber

Pressure

(kgf/cm2)

Max

Range

(m)

60mm ≥190 ≤515 ≥ 1500

82mm ≥205 ≤ 665 ≥ 3000

120mm ≥270 ≤ 985 ≥ 6000

Note 1) A minimum of 10 data points shall be required for velocity, pressure, and dispersion.

APPENDIX

1. Definitions.

1.1 Non standard Mortar ammunition. Non standard mortar ammunition are munitions that have not been safety tested and type classified for Army use, and cannot be procured through the US Army supply. Munitions and explosives that are not managed by National Inventory Control Points, have not been safety tested nor type classified for US 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 drawing 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:

The Government Contract Number and Deliver 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 and drawings and revision dates; packaging and marking drawings with revision number, revision date, and markings; and product specification with visual, dimensional and ballistic acceptance test methods, including in-process testing, with sample size, accept/reject criteria, and retest procedures. Within the TDP there shall also be a clear cut-away drawing of the fuze to show all the inner parts and workings along with a paragraph to 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 that is ripped, broken, perforated, water damaged, or crushed.

1.5 Skip-Lot Temperature Testing. 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.