Attachment_0033__Transportability_Approval_Buffalo_A2_MPCV.pdf

Date: 29 April 2011

Subject: Transportability Approval for the Mine Resistant Ambush Protected (MRAP) Force Protection Industries (FPI) Buffalo Mine Protection Clearance Vehicle (MPCV) A2

File Number: DP 04-11

Requestor: MRAP Joint Program Office (JPO), Mr. Paul Mann

Reference Documents:

a. DoD Instruction 4540.07, "Operation of the DoD Engineering for Transportability and Deployability Program,” dated 11 September 2007

b. Capability Production Document (CPD) for Mine Protected Clearance Vehicle, Buffalo MPCV, Version 3.2, dated December 2006.

c. Developmental Test (DT) Buffalo Mine Protection Clearance Vehicle (MPCV) A2 Configuration, Explosively Formed Penetrator (EFP) ATEC Project No. 2010-DT-ATC- RCVMP-E3138, Report No. AT-10213, dated June 2010

d. Final Report for the Route Clearance Vehicle Buffalo Mine Protected Vehicle, ATEC Project No. 2008-DT-YPG-RCVMP-D7519, YPG No. 08-0008-L-5, March 2011

e. Internal Air Transport Certification for Buffalo Mine Protection Clearance Vehicle A0, Bumper Numbers 10 through 64 with Upgrade Front Axle, file no. 2001-10-26-02, dated 16 October 2009

f. Maintenance Advisory Notice (MAN) Gross Vehicle Weight Advisory, MAN B0006, Force Protection Industries, dated 19 May 2010

g. Memorandum, Subject: Front Axle Overload Condition on the MPCV when Operating with Explosively-Formed Projectile (EFP) Up-Armor Installed, Mr. Ken Wojcik, Project Manager, Assured Mobility Systems, 12 April 2011.

General: In accordance with reference a, and based on the reference documents listed above, SDDCTEA grants transportability approval to the FPI Buffalo MPCV A2 subject to the restrictions provided herein. SDDCTEA also concurs with full materiel release and type classification standard.

TRANSPORTABILITY APPROVAL

DEPARTMENT OF THE ARMY

MILITARY SURFACE DEPLOYMENT AND DISTRIBUTION COMMAND

TRANSPORTATION ENGINEERING AGENCY

1 SOLDIER WAY, BUILDING 1900W

SCOTT AIR FORCE BASE, ILLINOIS 62225-5006

SDTE-DPE

SUBJECT: Transportability Approval for the Mine Resistant Ambush Protected (MRAP) Force Protection Industries (FPI) Buffalo Mine Protection Clearance Vehicle (MPCV) A2

Item Description: The Buffalo Mine Protected Clearance Vehicle (MPCV) is a wheeled, heavily armored personnel carrier with a one-piece body (V-hulled) designed to provide crew survivability against anti-tank mines, improvised explosive devices (IEDs), and small-arms fire (SAF). The Buffalo A2 has an articulated hydraulic arm which is mounted on the right front bumper and can be used to investigate suspected mine locations and to unearth and move mines and other items. The arm is stowed high along the truck’s right (curb) side. The vehicle can accommodate a combat engineer squad and countermine mission equipment. The vehicle crew enters and exits through a single rear door. The Buffalo A2 can be fitted with aluminum bar armor to protect against rocket-propelled grenades (RPGs), and with Explosively-Formed Projectile (EFP) armor to protect against certain threats in theater. Using the vehicle's onboard systems and interrogator arm, it can be confirmed that a mine or IED is present before bringing in an explosive ordnance disposal team onto the scene. The FPI Buffalo MPCV A2 is shown in figures 1 through 4 and the physical characteristics of the vehicle are listed in Table 1. The maximum dimensions with the exterior armor installed will depend on the type of armor package utilized. The maximum weight (Gross Vehicle Weight Rating, GVWR) with any armor package (including ECP) is 66,000 pounds (see Enclosure 1).

Figure 1. Buffalo MPCV A2 Explosively-Formed Projectile (EFP) Up-Armor Installed

Figure 2. Buffalo MPCV A2 with Bar Armor

Vehicle Data:

Figure 3. Buffalo MPCV A2, Side View (without Bar Armor) (in inches)

Figure 4. Buffalo MPCV A2, Front View (without Bar Armor) (in inches)

Table 1. Physical Characteristics of the FPI Buffalo MPCV

Operational Reduced

Length 330 – 348 inches 330 inches Width 105 – 116 inches 105 inches Operational Height 156 inches 146 inches

Gross Vehicle Weight Rating (GVWR) 66,000 pounds Front Axle Load Limit 30,000 pounds Front Axle Load Measured at GVW 35,740 pounds* Rear Tandem Axle Load Limit 46,000 pounds Rear Tandem Axle Measured at GVW 29,970 pounds

* Overloaded Front Axle (see Enclosure 2)

Requirements: From reference b, the transportability requirements for the Buffalo MPCV are as follows:

The Buffalo MPCV will be transported by highway, rail, air and sea. Highway will be transported by truck and trailer (M870). The Buffalo MPCV will be air transportable by C-5 or C-17 aircraft without shoring requirements (i.e., approach, sleeper, parking).

Conditions of Certification: Our analysis shows that the FPI Buffalo MPCV A2 does not completely meet all of its transportability requirements. A summary of our analysis follows:

a. Highway. The FPI Buffalo MPCV does not meet the dimensional and weight limits in the United States and NATO countries for unrestricted highway transport due to the width (over 96” wide) and axle loads of the vehicle. For self-deployment on US highways, state Department of Transportation (DOT) permits must be obtained. As a commercial or military trailer load, state DOT permits will still need to be obtained. For all highway movements (CONUS and OCONUS), coordinate with the Installation Transportation Officer (ITO) to obtain any required permits. Pictures of the Buffalo A2 tied down on an M870 trailer can be found in figures 5 and 6.

Based on the vehicle manufacturer’s information, the front axle and rear tandem are rated at 30,000 and 46,000 lbs respectively. The actual measured axle loads at GVW (65,710 lbs) were 35,740 and 29,970 lbs respectively. The front axle was overloaded by 5,740 lbs and the Program Executive Office (PEO) provided a memorandum (Enclosure 2) accepting the overload and its associated risks. Regular inspections and maintenance will need to be performed to prevent damage to the front axle.

Figure 5. Buffalo A2 Tied Down on an M870 Trailer Towed by an M916 Tractor

Figure 6. Buffalo A2 Tied Down on an M870 Trailer, Front of Trailer (left), Rear of Trailer (right)

Tiedown procedures suitable for highway transport are included in TEA Pamphlet 55-20, Tiedown Handbook for Truck Movements, Fourth Edition. An electronic copy of this pamphlet can be downloaded from our website:

www.tea.army.mil

Hard copies of any of our pamphlets can be ordered from the following location:

www.tea.army.mil/pubs/pubs_order.htm

b. Rail. The Buffalo A2 is capable of restricted rail transport in the United States and NATO countries. It successfully passed a MIL-STD-810 rail impact test conducted by the Army Developmental Test Command at the Aberdeen Test Center (ATC) in spring 2010. For tiedown of the vehicle on a railcar, refer to figures 7 and 9. Due to the size of the Buffalo A2, rail route clearances must be checked before moving the Buffalo A2 by rail.

During preparations for rail impact testing, ATC discovered that the tie-down provisions would not allow the securing chain hooks to engage properly. The front and rear tie-down provisions were slightly chamfered on the inside of the hole; therefore, the railroad hook and chain assembly would not fully rotate through the tie-downs, and the hooks would only partially fit in the provision. The Chemical Agent Resistant Coating (CARC) paint was removed from the area surrounding the front and rear tie-down locations, and the tie-downs were ground down to allow the chains to fit properly (see figure 8). This modification will be made to all fielded vehicles.

Tiedown procedures suitable for rail transport can be found in TEA Pamphlet 55-19, Tiedown Handbook for Rail Movements, Sixth Edition.

Figure 7. Buffalo A2 MPCV Tied Down on a Railcar, Front View

Figure 8. Buffalo A2 Modified Tiedown Provision

Figure 9. Buffalo A2 MPCV Tied Down on a Railcar, Rear View

c. Marine. The FPI Buffalo A2 MPCV meets the dimensional and weight limits for transport on breakbulk, roll-on/roll-off (RORO), sea barge (SEABEE), Lighter Aboard Ship (LASH) and all Army, USMC and Navy lighterage. Vehicle size may restrict stowage in some holds/decks.

Tiedown and lifting procedures for marine transport can be found in TEA Pamphlet 55-22, Marine Lifting and Lashing Handbook, Third Edition.

d. Fixed-Wing Air. The Aeronautical System Center’s (ASC) Air Transportability Test Loading Activity (ATTLA) certified the FPI Buffalo A2 MPCV for air transport on board C-17 and C-5 aircraft. If vehicle axle weights are exceeded, rolling, parking, and/or sleeper shoring may be required. Use of this shoring is against the requirements as stated on page 5.

However, due to the size of the Buffalo A2 and the limitations of the aircraft, movement will require the use of this shoring. The vehicle can still be air transported in C-17 and C-5 aircraft.

Refer to Enclosure 3 for further guidance on internal air transport and shoring requirements.

Air transport and preparation procedures can be found in TEA Pamphlet 55-24, Vehicle and Equipment Preparation Handbook for Fixed-Wing Air Movements, Third Edition.

e. Lifting and Tiedown Provisions. The FPI Buffalo A2 MPCV successfully passed MIL- STD-209K tiedown provision testing at Yuma Proving Grounds, Arizona in March 2010. The tiedown provision loads can be found in Table 2 and the lifting provision loads in Table 3. The FPI Buffalo A2 MPCV’s tiedown points can be seen in figure 10. Lift tests of the Buffalo A2 were performed at Aberdeen Test Center (ATC) in June 2010. Loads were applied in accordance with MIL-STD-209K at a GVWR of 66,000 lbs. The FPI Buffalo A2 MPCV was visually inspected for any deformation or damage after each load application, to include measurement of relevant dimensions and separation of the provisions for comparison with pretest measurements. No adverse effects or visible permanent deformation was evident in the equipment tiedown provisions or supporting structure. A picture of the lifting provisions can be found in figure 11.

Table 2: Applied Load for Tiedown Provision Testing (lbs)

Provision Location

Longitudinal Load

Lateral Load Vertical Load

Front Right 212,515 62,454 55,807

Front Left 104,605 61,521 27,503

Rear Right 199,977 53,858 44,466

Rear Left 115,123 53,993 26,689

Table 3: Applied Load for Lift Provision Testing (lbs)

Provision Location

Average Load Duration

(in seconds) Measured Angle

Front Right 67,245.2 98.0 25.5 degrees

Front Left 36,636.8 104.6 26.1 degrees

Rear Right 49,156.1 100.7 42.5 degrees

Rear Left 34,107.3 98.9 40.5 degrees

Figure 10. Front and Rear Tiedown Provisions

3 Enclosures:

1. Maintenance Advisory Notice, FPI Inc., Reducing the Gross Vehicle Weight Rating from 76,000 lbs to 66,000 lbs, 19 May 2010

2. Front Axle Overload Condition on the MPCV, Program Executive Office, Mr. Ken Wojcik, 12 April 2011

3. Air Transport Certification, Buffalo Mine Protection Clearance Vehicle A1/A2, Hull Numbers 65+, File Number: 2001.10.26.01, Revision 4, dated 8 August 2008

Required Distribution:

Deputy Chief of Staff G-3, ATTN: DAMO-FDZ/FDL, 400 Army Pentagon, Washington, DC 20310-0400

Deputy Chief of Staff G-4, ATTN: DALO-SM, 500 Army Pentagon, Washington, DC 20310-

Deputy Chief of Staff G-8, ATTN: DAPR-FD/FDL/FDA, 700 Army Pentagon, Washington, DC 20310-0700

Assistant Secretary of the Army, Acquisition, Logistics and Technology, ATTN: SAAL-ZS/ZL, 103 Army Pentagon, Washington, DC 20310-0103

Commander, U.S. Army Evaluation Command, ATTN: CSTE-AEC-ILS, 4120 Susquehanna Ave, Aberdeen Proving Ground, MD 21005-3013

Commander, U.S. Army Evaluation Command, ATTN: CSTE-AEC-OP, Park Center IV, 4501 Ford Avenue, Alexandria, VA 22302-1458

Commander, U.S. Army Training and Doctrine Command, ATTN: ATFC-O, Fort Monroe, VA 23651-5000

Commander, U.S. Army Forces Command, ATTN: FCJ4-TRM, Fort McPherson, GA 30330-

MRAP Joint Program Office (JPO), Mr. Paul Mann, MRAP JPO, PEO CS&CSS, SFAE-GCS- MRAP, 6501 E. Eleven Mile Rd., Warren, MI 48397-5000

GROSS VEHICLE WEIGHT RATING ADVISORY

FPII CONFIDENTIAL & PROPRIETARY 1 CONTAINS U.S. EXPORT-CONTROLLED TECHNICAL DATA

MAINTENANCE ADVISORY NOTICE

Force Protection Industries, Inc., 9801 Highway 78, Bldg. 1, Ladson, SC 29456

19 May 2010

MAN B0006

Purpose: This Maintenance Advisory Notice (MAN) is to inform that certain Buffalo A2 vehicles have Gross Vehicle Weight Rating (GVWR) of 66,000 lb and not 76,000 lb.

Scope: Buffalo hull numbers 300 to 431 and US FAT vehicles listed in Table 1 on page 2

Application: Informational

General: Certain Buffalo A2 vehicle information plates incorrectly stated GVWR to be 76,000 lb. Be advised that GVWR is 66,000 lb and cannot be exceeded.

Data plates reflecting this change will be installed CONUS at a later date.

WARNING

Do not exceed GVWR of 66,000 lb Failure to comply can result in serious injury or death.

A. VEHICLE INFORMATION PLATE MODIFICATION

1. Park vehicle on level ground and chock wheels.

PROPRIETARY INFORMATION STATEMENT

This material contains confidential and proprietary information of Force Protection, Inc. and its subsidiaries.

Copying this material or disclosing such information to others without the Company's prior consent is prohibited.

EXPORT-CONTROL STATEMENT

This material contains technical data that is restricted by U.S. Export Control Laws, including without limitation the International Traffic in Arms Regulations (22 CFR Parts 120 - 130) and the Export Administration Regulations (15 CFR Parts 730 - 744). Appropriate export control licenses or authorizations are required before it is either sent outside of the United States or made available to non-US persons either within the United States or abroad. THE

TRANSFER OR DISCLOSURE OF THIS TECHNICAL DATA TO ANY NON-U.S. PERSON OR COMPANY

WITHOUT AN EXPORT LICENSE OR OTHER APPROPRIATE U.S. GOVERNMENT AUTHORIZATION IS

STRICTLY PROHIBITED. FURTHER, THIS DATA SHALL NOT BE PROVIDED TO ANY PERSON OR ENTITY LISTED ON ANY "DENIED PARTIES/ENTITIES" LIST AND RECIPIENT CERTIFIES THAT HE/SHE IS A U.S.

PERSON AS DEFINED BY 22 CFR 120.15 OR 15 CFR PART 772, AS APPLICABLE, AND IS NOT ON ANY

SUCH LIST.

Enclosure 1

MAN B0006

FPII CONFIDENTIAL & PROPRIETARY 2 CONTAINS U.S. EXPORT-CONTROLLED TECHNICAL DATA

2. Use pen and tape, label maker, or other means to modify vehicle information plate to show correct GVWR of 66,000 lb.

3. Fill out Corrective Action Report (CAR).

B. AFFECTED VEHICLES

The following vehicles are affected by this informational update:

Table 1. List of Affected Vehicles

Vehicle Category

Nomenclature D.O./Contract

GRN/

AFN

OEM

VIN

FPII Hull Number FPII SN TLPN

BUFFALO

ARMY A2

0028 105428 FPIMPCVA2H300 5ZSB6EAD29A105428 B6EAD

BUFFALO

ARMY A2

0028 105429 FPIMPCVA2H301 5ZSB6EAD49A105429 B6EAD

BUFFALO

ARMY A2

0028 105654 FPIMPCVA2H302 5ZSB6EAD09A105654 B6EAD

BUFFALO

ARMY A2

0028 105655 FPIMPCVA2H303 5ZSB6EAD29A105655 B6EAD

BUFFALO

ARMY A2

0028 105656 FPIMPCVA2H304 5ZSB6EAD49A105656 B6EAD

MODIFY TO SHOW

66,000 LB.

MODIFY TO SHOW

66,000 LBS.

MODIFY TO SHOW

66,000 LBS.

Enclosure 1

Enclosure 2

Internal Air Transport Certification

ASC/ENFC

2530 Loop Road West

WPAFB, OH 45433-7101

https://afkm.wpafb.af.mil/ATTLA (direct) https://wwwd.my.af.mil/afknprod/ATTLA (AF Portal)

Date: 21 May 2009 Item Nomenclature: Buffalo Mine Protection Clearance Vehicle A1/A2, Hull Numbers 65+ File Number: 2001.10.26.01 Revision 4 Requestor: TARDEC, PM Assured Mobility Systems (Mr. Wilson)

Superseded Certification Date: 8 August 2008

New Information Summary: This revision incorporates an upgraded bar armor configuration and air digger attachment along with other upgrades which result in increased vehicle width and length dimensions. Vehicles with these improvements comprise the new A2 series and will transport at greater weight (approximately 50,500 lbs). The new L-Rod bar armor and air digger attachment will be configured on hull numbers 300+.

Reference Documents:

1. AMSAA Bar Armor Kit Analysis, April 2009, Buffalo A2 MPCV.

2. PM Assured Mobility Systems Vehicle Dimensions Data, May 2009, Buffalo A2 MPCV.

3. Tank-Automotive & Armaments Div. Safety Confirmation, September 2008, Buffalo MPCV.

4. Approved Capabilities & Limitations Report, received September 2008, Buffalo MPCV.

5. ATC Mobility Test Report, September 2007, Buffalo MPCV.

Item Description: The Buffalo is identified to be a three axle armored personnel transport vehicle equipped with mine sweeper components. The Buffalo may be equipped without add-on armor. It may also be configured with bar armor or expedient armor or both. Buffalo dimensions are 330” – 348” L X 101.5” – 116” W X 146” H. Height with air digger reel and camera installed is 151 inches. Gross vehicle weight rating is 80,000 lbs. Gross vehicle weight is restricted to 66,000 lbs for air transport due to combined restraint provision capability. Front, intermediate and rear axle rated capacities are 30,000 lbs, 25,000 lbs and 25,000 lbs respectively. Individual axle weights shall not exceed rated capacities.

Exceptions: The expedient armor configured Buffalo vehicle front axle is permitted to weigh 30,500 lbs for air transport. Buffalos configured with both expedient and bar armor are permitted to have maximum front axle weight of 32,000 lbs. Transport will require rolling, parking and sleeper shoring for excepted vehicles.

Expedient Armor Bar Armor Figure 1 Figure 2

Enclosure 3

File Number 2001.10.26.01

Certified Aircraft: USAF C-5 and C-17

Conditions of Certification:

1. Maximum Weight for Air Transport:

a. Gross Vehicle Weight:

1) 66,000 lbs (based on tiedown capability)

b. Axle Limits:

1) Front axle – No Armor – 30,000 lbs

Expedient or Bar Armor – 30,500 lbs Expedient and Bar Armor – 32,000 lbs

2) Intermediate and aft axles: 25,000 lbs (each axle)

2. Item Preparation:

a. C-17: Mine sweeper arm top mounted camera (applicable to all Buffalo’s) and air digger reel (applicable to A2 variant) shall be removed for air transport to reduce maximum vehicle height to 146 inches when either of these vehicle components will be positioned under or forward of wing box area. See figure 2.2 for illustration of camera and air digger reel components.

b. Maximum air transport weight and allowable axle weights shall not exceed paragraph 1 limitations.

c. Normally, tire inflation pressure shall not exceed 100 psi. Vehicles equipped with both expedient and bar armor require front axle tires to be inflated to 110 psi.

d. All hazardous materials (to include fuel level, batteries, etc.) must be prepared and certified for airlift in accordance with TM 38-250/AFMAN 24-204(I). Do not consider this air

Figure 2.2 – Air digger reel and camera will be removed for C-17 transport when these two components are to be positioned under or forward of wing box.

Figure 2.1 – A2 Bar armor upgrade kit example.

transport certification as approval for hazardous materials. Authorization for airlifting hazardous material is the responsibility of 401 SCMS/GUMAA (DSN 787-4503 or COM

(937) 257-4503).

3. Loading Instructions:

a. C-17: Axles parked off-centerline forward of FS 578 and aft of FS 1074 must be less than or equal to 22,000 lbs. Front axle weight prohibits off-centerline parking in D, F & G compartments. If vehicles are parked off-centerline in D, F & G compartments, vehicle shall be positioned so the heavy front axle is positioned in E compartment. The front axle weight must be less than or equal to 27,000 lbs to park vehicle off-centerline. When front axle weight is greater than 27,000 lbs, vehicle will be loaded within 8 inches of aircraft centerline with front axle located in E compartment.

b. C-5: Buffalo shall be aligned between BL 75 L & R when loaded through either forward or aft end of aircraft. CAUTION: Do not load over aft ramp in aft kneel configuration.

c. Rolling shoring is required when any individual axle exceeds 28,800 lbs. See paragraph 5.b for shoring dimensions. Length dimension shall be sufficient for timely load/off-load operations.

d. Parking shoring is required under both tires of individual axles that are equal to or greater than 18,300 lbs. NOTE: When sleeper shoring is used and in contact (snug) with frame structure, parking shoring is not required. See paragraph 5.c.

e. Sleeper shoring is required for the front end of Buffalo vehicles configured with expedient armor or expedient and bar armor any time front axle weight exceeds 30,000 lbs. Shoring shall be stacked to within ½” of locations indicated in the pictorial representation below in figure 6/7. Shoring stacks will be secured with cargo straps. See paragraph 5.a

4. Restraint requirements: The Buffalo and all accompanying cargo must be restrained to meet MIL-HDBK-1791 requirements of 3G forward, 1.5G aft and lateral, and 2G up. In addition, stored or installed equipment must meet these requirements and be capable of withstanding a 4.5G down load. Restraint will be applied using the vehicle’s four 50,000 lb tie-down provisions. The lower two holes of each provision shall be used as locations to apply restraint. The lower two holes combined give each provision a rated capacity of 50,000 lbs in all directions. CAUTION: Do not apply aircraft tie-down chains to upper provision hole.

Upper provision hole is rated for towing purposes only. See photos below. All items mounted or stowed on or within the Buffalo to include armor must meet the above restraint requirements in addition to a potential 4.5G download force. NOTE: Expedient and bar armor is mounted to withstand above G Forces, additional restraint for expedient and bar armor is not required.

5. Required Shoring Dimensions & Diagrams:

a. Sleeper Shoring: Minimum base dimensions shall be 24” L X 22” W each stack.

Sleeper shoring must be stacked to within ½” of chassis/frame area and secured with cargo straps. When sleeper shoring is snug under frame, parking shoring is not required.

C-17 CAUTION: When parking shoring is used under tires positioned below wingbox, loadmasters will ensure there is a minimum of 3 inches vertical clearance between vehicle arm and wingbox.

NOTE: Center sleeper shoring stacks under the leaf spring tiedown cross-car members as indicated by the red arrows for Buffalo MPCV equipped with expedient armor or both expedient armor and bar armor when front axle exceeds 30,000 lbs.

b. Rolling Shoring: Two rows 24” W X 1” H when applicable. See paragraph 3.c.

c. Parking Shoring: See paragraph 3.d.

1) C-5: Front axle tires – 24” L x 24” W x 2.75” H. Intermediate and aft axle tires – 24” L x 24” W x 1” H

2) C-17: Front axle tires – 24” L x 24” W x 4.25” H. Intermediate and aft axle tires – 24” L x 24” W x 2.25” H.

Rear Tiedowns (Lower 2 Holes Only) Front Tiedowns (Lower 2 Holes Only)

Figure 6 Figure 7

Figure 4 Figure 5

Required Distribution:

1. Shipper shall give a copy of this certification to the ATOC representative when the item is presented for airlift. This memo shall be part of the official cargo manifest documentation package and shall be briefed to the aircraft loadmaster prior to loading these items.

2. AMC/A3V.

3. SDDCTEA.

Point of Contact: Douglas.Simpson@wpafb.af.mil, DSN 785-2547 or Commercial (937) 255- 2547. Refer to file number 2001.10.26.01 to reference this item.

Reviewed by: MELVIN C.J. SANTIAGO Aerial Delivery Technical Expert Crew Systems Branch

Approved by: MARTIN J. ANDRIES Acting Technical Advisor Crew Systems Branch