Attachment 0021 - ETS Container Specifications T2 9-1-1375.pdf

REVISIONS

DESCRIPTION DATELTR APPROVAL

Initial Release 12-May-09- GM

CHECKED BY:

PROJ ENGR APPROVAL:

PROG MGMT APPROVAL:

MFG APPROVAL:

U.S. ARMY, RESEARCH, DEVELOPMENT

AND ENGINEERING COMMAND

NATICK SOLDIER CENTER

KANSAS ST, NATICK, MA, 01760-5056

QA APPROVAL:

DRAWN BY: B SINGLETON

5-12-09

TECHNICAL SPECIFICATION

TRICON CONTAINER (T2),

EXPEDITIONARY TRICON SYSTEM

SIZE

A

SHT 1 OF 10

CAGE

81337 9-1-1375 REV

SCALE: NONE

DISTRIBUTION STATEMENT A

THIS DOCUMENT IS APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

APPLICATION

USED ON NEXT ASSEMBLY

ETS 9-1-1413

ETS 9-1-1410

1 SCOPE

This technical specification covers general and application-specific requirements for 6’ – 5 ½” x 8’ x 8’ high modular shelter TRICON containers with two doors each end that will become a critical component of the U.S. Military Expeditionary TRICON Systems (ETS) and be used in conjunction with other support systems deployed worldwide. This document is to be used in conjunction with the referenced Vendor Item Drawings (See 2.2) to form a complete description of the modular shelter TRICON containers. Vendor part numbers and recommended sources of supply can be found on the applicable Vendor Item Drawings.

2 APPLICABLE DOCUMENTS

2.1 Government Documents

2.1.1 Specifications, Standards, and Handbooks

Unless otherwise specified, the version of the following documents in effect on the date of purchase form a part of this source control drawing. Unless otherwise specified, the issues of these documents are those listed in the Department of Defense Index of Specifications and Standards (DoDISS).

MIL-STD-810F DoD Test Method Standard for Environmental Engineering Considerations and Laboratory Tests

2.2 Other Government Documents

2.3 Non-Government Publications and Documents

ISO 1496-1 International Organization for Standardization, Series 1 Freight Containers – Classification, Dimensions, and Ratings (DoD Adopted)

ISO 6346 International Organization for Standardization, Freight Containers – Coding, Identification, and Marking (DoD Adopted)

2.4 Order of Precedence

In the event of a conflict between the text of this specification and the references cited herein, the text of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

The order of precedence of documents shall be:

• The procurement contract

• The requirements contained in this specification

• The requirements contained in documents referenced in this specification.

3 REQUIREMENTS

3.1 Basic Requirements

3.1.1 Description of Container

This specification describes a 6’-5½”x 8’x 8’ high all steel dry cargo container fitted with eight (8) bottom type ISO corner fittings. The container shall be designed to be lifted individually when laden/empty from the top corner fittings by either spreader/slings, from the bottom corner fittings via slings, or via four-way entry fork pockets in the base frame. When three containers are coupled together with eight (8) approved connectors to form an ISO series 1C 20’x 8’x 8’ module, it shall be designed to be top or bottom lifted laden/empty by the outermost corner fittings by spreader or slings.

SHT 2 OF 10 REV - 9-1-1375

Each individual container shall incorporate two pairs of doors featuring four hinges, one locking bar and one door tieback per door. The design shall feature vertically corrugated side walls incorporating framed apertures for power, water entry/exit, ventilation fans, and/or personnel door, corrugated roof, smooth steel floor with drains and four way entry fork pockets. One ventilator in each side wall, one external manifest holder, and three Duraloc interconnectors, NSN 3040-01-387-4048, or approved equivalent, shall be provided. Fold-out shelter shall be provided at each end. Structural testing shall be in accordance with ISO 1496/1, unless otherwise stated. Design and CSC Approval shall be by Lloyd’s Register North America, Inc.(LRNA) or American Bureau of Shipping (ABS) in accordance with US Coast Guard Regulations and US Dept of Homeland Security Customs Regulations.

Individual TRICON modular containers do not qualify for CSC Approval, CSC Approval only applies to three (3) interlocked TRICON modular containers forming a series 1C 20’x 8’x 8’ container with approved interconnectors.

3.1.2 WEIGHTS AND DIMENSIONS

MGW (R) 4,536 kg 10,000 lb.

Container plus shelter foldouts Laundry/Shower/Latrine 1,682 kg 3,700 lb.

Kitchen 1,727 kg 3,800 lb.

Payload (P—fully secured) Laundry /Shower/Latrine 2,864 kg 6,300 lb.

Kitchen 2,818 kg 6,200 lb

External Dimensions: Length 2438 mm 8’ – 0”

Width 1968 mm 6’ – 5½” Height 2,438 mm 8’ – 0”

Internal Dimensions: Length 2,242 mm 7’ – 4 .25” Width 1,882 mm 6’ – 2.063” Height 2,239 mm 7’ – 4.15”

Door Aperture Width 1,794 mm 5’ – 10.625” Height 2,139 mm 7’ – 0.21”

Fork Pockets (4-way entry) Sides Centers 902 mm 2’ – 11½” Width 356 mm 1’ – 2.02” Height 118 mm 4.66” Door Ends Centers 902 mm 2’ – 11½” Width 356 mm 1’ – 2.02” Height 115 mm 4.53”

Cube Capacity 9.45 cu.m 335.65 cu.ft

Stacking 9 high at 24,000 kg (52,910 lb.) MGW Stacking Test Load 86,400 kg (190,478 lb.) per post Allowable Stack Weight at 1.8g 192,000 kg (423,280 lb.)

MGW of three (3) connected TRICONS 20,320 kg (44,800 lb)

3.1.3 Operational Environment/Approvals

3.1.3.1 Operational temperature range –40°F to 140°F

3.1.3.2 Container, with foldouts attached, shall comply with all applicable requirements of ISO 1496/1, 668, 1161, 6346, 49 CFR Chapter 4, parts 450- 453, and Customs Convention.

SHT 3 OF 10 REV - 9-1-1375

3.1.3.4 Military Environment and Transportability (fully mission capable):

3.1.3.4.1 Transit Drop (transport mode): 6-in. transit drop, test in accordance with MIL-STD-810F, Method 516.5, Procedure IV.

3.1.3.4.2 Rail Impact (transport mode): Test in accordance with MIL-STD-810F, Test Method 516.5, Procedure VII (rail impact) 4, 6, 8 mph forward, 8 mph reverse.

3.1.3.4.3 Ground Mobility (transport mode on PLS truck and trailer): Gravel roads (ATC Munson Test Area) 650 miles; Highways (paved roads) 250 miles; Cross-Country (ATC Perryman 1 Course) 100 miles.

3.1.3.4.4 Blowing Sand and Dust (operational mode): Test in accordance with the guidelines in MIL-STD-810F, Test Method 510.4, Procedures I and II.

3.1.3.4.5 Blowing Rain (operational mode): 40 mph, 4 in/hr, test in accordance with the guidelines in MIL-STD- 810F, Test Method 506.4, Procedures I and II.

3.1.4 Container Construction (Alternate materials, features, and construction may be acceptable, with Government approval.)

3.1.4.1 Materials

Steel - Main Structure SM 50A High Tensile & SPAH (Corten equiv.)

- All Panels, Roof SPAH

- Floor Sheet SPAH

- Tubes SPAH structural tubing

- Corner Fittings SCW 480 cast steel, certified for –40°F operation Door Gaskets EPDM Sealant

- External Chloroprene, colored to match container

- Internal White Polyurethane, USDA approved Rivets Stainless Steel Ventilators ABS plastic Door hinges S25C steel Hinge pin 304 stainless steel Bushing-hinges & /locking gear Nylon 6/6 Locking gear cams/keepers S20C steel Data Plate 304 stainless steel

3.1.4.2 Container Design Features

3.1.4.2.1 Outward facing ‘C’ section bottom side rails 4mm (8 ga.) each rail incorporating 2 fork pocket apertures, twistlock protection ‘V’ plates each end, 2 floor drains, couplings as required and 2 door tieback hooks.

3.1.4.2.2 Floor sheet 5mm (3/16”) flat with drains and other fittings as required.

3.1.4.2.3 Under floor members formed ‘L’ and ‘C’ pressings, 4.5mm (7 ga) configured to form 4-way entry fork pockets. 6mm (¼”) fork pocket straps.

3.1.4.2.4 Sidewalls, 1.6mm (16 ga.) vertically corrugated panels featuring one ventilator each. Framed apertures incorporated as required by individual type specification. Topside rail 50mm square x 3mm (2”square x 0.125”)

3.1.4.2.5 Door sill fabricated welded section incorporating forklift pocket apertures. Lower member 10mm (3/8”), ‘C’ pressings 4.5mm (7ga), gussets and aperture side plates 4mm (8 ga)

SHT 4 OF 10 REV - 9-1-1375

3.1.4.2.6 Door header two-piece pressing with four (4) internal gussets at cam keeper positions two (2) intermediate gussets and two (2) transverse gussets at corner castings. All 4.5mm (7 ga.)

3.1.4.2.7 Doors, 1.6mm (16 ga.) panel horizontally corrugated; vertical framing 100 x 40 x 3mm (4”x 1.5”x 1/8”) tube, horizontal framing 150 x 40 x3mm (6” deep x 1/8” thick) ‘C’ section top and bottom. One

(1) set of weld-on locking gear on each door. EPDM gasket riveted to door edge with stainless steel retaining strips. Each door fitted with nylon rope tieback.

3.1.4.2.8 Corner post inner and outer 6mm (¼”) thick pressings. Additional 3mm (1/8”) corner post plate fitted for attachment of shelter side walls hinges.

3.1.4.2.9 Spreader protection plates 4mm x 300mm (8 ga. x 12”) square at each corner of roof.

3.1.4.2.10 Corrugated roof sheet 1.6mm (16 ga.) cambered 6mm (¼”).

3.1.4.2.11 One manifest box, fitted to outside of RH door at Data plate end.

3.1.4.2.12 Stainless steel consolidated data plate fitted to LH rear door. Matt black cast vinyl decals or stenciled serial numbers and weight panel applied.

3.1.4.2.13 Three (3) interconnectors, corrosion protected, shall be provided.

3.1.4.2.14 The Tricon Kitchen Shelter container shall have a steel personnel door w/polyurethane insulation centered on the right side wall of the container. Clear opening will be a minimum of 815mm (32.09”) wide x 2026mm (79.75”) high. One non-locking door handle shall be provided approximately 1000mm (39.37”) from the floor of the container. A second padlock able mechanism shall be provided to secure door from tampering and prevent opening during transport. Mechanism shall be permanently welded or bolted together to prevent tampering, disassembly, or separation from the container. A door restraint chain shall be supplied with the personnel door.

3.1.4.2.15 Studs for application specific internal lining shall be provided on internal surfaces of side walls and roof.

3.1.4.2.16 One (1) lightweight Tee Bar prop rod shall be supplied with each container to support roof panel of foldout during deployment. Kitchen prop rod shall be attached to inside of personnel door and secured with Velcro strap(s).

3.1.4.2.17 Four (4) floor drains shall be supplied in each container floor. Removable, perforated covers inside and outlet pipe fittings and plugs, outside, shall be provided. Drains shall be cleanable and shall direct water outside the container footprint, through the bottom side rails.

3.1.4.3 Shelter Foldout Design Features

3.1.4.3.1 Each Tricon Shelter container includes two (2) Foldout panel sets as described below:

(1) Right Side Wall panel, (1) BiFold Panel, (1) Roof Panel, (1) Floor Panel

3.1.4.3.2 Materials:

` Panels Aluminum A5052-H32 Extrusions Aluminum A6061-T6/A6063-T5 Panel Internal Reinforcements Aluminum A6063-T5 Pans 304 Stainless Clamps (extended adjustment) 304 Stainless Hinges Aluminum A6061-T6 Gaskets EPDM Steel Reinforcements SPAH

3.1.4.3.3 General panel construction - external aluminum extrusions framing, incorporating gaskets, with pre-painted white aluminum interior sheathing and corrugated aluminum exterior. Overall thickness shall be approximately 28.5mm (1.12”) Panel interior injected with polyurethane foam insulation. Recessed stainless steel pans with either latches or receivers included. Reinforcements included within the panels for attachment of application specific fittings. Hinges (2) and cables (2) for floor panel support shall be provided. Means of securing floor panel upright when folded for transport shall be provided, using captive hardware. Roof panel shall be supplied with interface point for Tee Bar prop rods. BiFold Panels shall be supplied with captive lifting handles.

4.3.4.3.4 The BiFold Panel consists of (1) Left Side Panel and (1) application specific End Wall:

Latrine/Laundry/Shower- Man Door with clear opening of 628mm (24.72”) x1860mm (73.22”) and (1) A/C Opening 495mm (19.5”) wide x 330mm (13.0”) high. Man Door shall be provided with door restraint mechanism and ingress/egress latching mechanism.

Kitchen-

SHT 5 OF 10 REV - 9-1-1375

(End 1) - Framed Serving Window 1235mm (48.62”) wide x 922mm (36.29”) high

(End 2) - Framed A/C Opening 495mm (19.5”) wide X 330mm (13.0”) high

4.3.4.3.5 Stabilizer jacks (4 ea) shall be supplied with each container to prevent tipping of shelters when deployed.

A secure means of attaching the stabilizer jacks to the shelter foldouts, using captive hardware, shall be provided.

4.3.4.3.6 Loads (when deployed): Roof panels shall support minimum uniform static load of 20 lbs/square foot.

Floor panel (and cables) shall support minimum uniform static load of 100 lbs/square foot. All panels shall withstand live and point loading as encountered during intended use.

3.1.5 Metal Preparation & Painting (Alternate preparation and painting may be acceptable, with Government approval.)

3.1.5.1 Metal Preparation:

All steel shall be degreased and abrasive blasted in sheet form and shop primed. After components are formed and welded into sub-assemblies all welds shall be abrasive blasted and all surfaces primed with zinc rich primer.

After weld assembly of the container, all weld areas shall be abrasive blasted and manually cleaned to paint supplier’s recommendations. After post blast clean down all welds shall be inspected and any rectification made prior to application of primer to the weld areas.

3.1.5.2 Painting:

A two coat system shall be applied externally and internally.

Shop Primer – organic zinc rich to 10-15 microns dry film thickness (DFT).

Primer – organic zinc rich to 25-30 microns, total primer 40 microns DFT minimum.

External Topcoat –Urethane on all surfaces including underframe and inside surfaces of doors to 70 microns, to give a total DFT of 110 microns minimum.

Colors to FED-STD-595C – Desert Tan 686A #33446 or Forest Green 383 #34094 (per contract.)

Interior topcoat – Two part epoxy shall be applied to all internal surfaces to 50 microns giving a total internal DFT of 90 microns minimum. Color – White. Weld stud threads shall be free of paint.

3.1.5.3 Foldout Shelter Paint:

Exterior surfaces of the Shelter Foldouts shall be painted with urethane top coat to match the core container color as specified by the customer’s purchase order. Personnel door latches, reinforcement bars, and stabilizer jacks shall be black in color.

3.1.6 Marking

3.1.6.1 Marking of containers shall comply with the requirements of MIL-STD-130, to include UID marking requirements.

3.1.6.2 Container serial numbers shall be stenciled or decaled on the exterior of the containers IAW ISO 6346:1995. Supplier must contact Army Intermodal Distribution Platform Management Office (AIDPMO), Tobyhanna Army Depot, PA, for Army ISO Serial Numbers and Surface Deployment and Distribution Command (SDDC), Scott Air Force Base, IL, for all other service branch ISO Serial numbers.

Service branch shall be specified in the contract.

3.1.7 Warranty

Structure – One (1) year from date of acceptance Paint – 5 years Decals (if provided) – 5 years

SHT 6 OF 10 REV - 9-1-1375

3.2 Application-Specific Requirements

Specific features and dimensions shall be as described in the referenced Vendor Item Drawings (See 2.2).

General Tolerances shall be as follows:

Overall Width +0 and -3 mm Overall Length +0 and -5 mm Overall Height +0 and -5 mm Location of Core Container Modifications - ± 3 mm Size of Core Container Power/Water Panel and Vent Frame Weldments +0 and -1.6 mm Size of Cutouts in Foldout Panels +1 and -0 mm Mounting Studs in Core Container located at true position within .188 inch diameter.

3.2.1 Critical Dimensions and Tolerances

The use of the containers procured to this specification requires that certain internal dimensions be held to closer tolerances than necessary for a standard TRICON II container. The following are considered such critical dimensions. These dimensions shall be held to the tolerances specified below.

3.2.1.1 Side Wall to Side Wall

The internal dimension between the side walls shall be 74 inches with a total cumulative tolerance (length, straightness, squareness, etc.) of ±0.25 inch.

3.2.1.2 Floor to Ceiling

The internal dimension between the floor and ceiling shall be 88 inches with a total cumulative tolerance (length, straightness, squareness, etc.) of ±0.25 inch.

3.2.1.3 Longitudinal Distance between Vertical Corner Posts and Door Headers The internal longitudinal dimension between either two vertical corner posts, measured between the edges of the posts that are welded to the sidewalls, shall be 80 inches with a total cumulative tolerance (length, straightness, squareness, etc.) of ±0.25 inch. The internal longitudinal dimension between the cargo door headers at the ceiling shall be 83 inches with a total cumulative tolerance (length, straightness, squareness, etc.) of ±0.25 inch.

3.2.2 Core Flooring

The core flooring shall be watertight and permanently attached. Floor plates shall be smooth (not diamond plate) high-strength steel, and shall be flat from edge to edge to ± 5mm.

3.2.3 Side Walls

Wall corrugations shall be approximately 1-1/16 inches deep and repeat approximately 11 inches on center. The wall corrugations shall be such that the centerline of an outward corrugation corresponds to the longitudinal centerline of the container.

3.2.4 Foldout Wall Cutouts

All versions of the containers, except the kitchen, shall include end wall personnel doors and air conditioner cutouts as shown on the referenced drawings. The kitchen version of the container shall include one serving window cutout in the front wing end wall, and one air conditioner cutout in the opposite end wall. The front in this container is the left end when facing the personnel door from the exterior.

3.2.5 Mounting Bracket Backing Plates

SHT 7 OF 10 REV - 9-1-1375

To provide strength for mounting the sinks, urinals, and other components within all versions of the containers, backing plates shall be installed under the interior skins of the foldout side walls as shown in Figure 1.

Figure 1 Locations of Mounting Bracket Backer Plates.

3.2.6 Exclusion Areas

3.2.6.1 Foldout Panel Packout Exclusion Volume

When the panels that make up the extension foldouts are folded in their packed (transport) positions, they shall not extend into an exclusion volume extending from core side wall to side wall and in the direction of each container door 37-1/8 inches from the container centerline. This volume extends from the floor to the ceiling above the area specified, and includes an exclusion volume extending downward 6 inches from the ceiling and extending to the container cargo door headers on each end (for ceiling light fixtures). Foldout floor cable brackets may fall within the 6-inch exclusion volume at the ceiling if they are placed within 6 inches of the container walls.

3.2.6.2 Foldout Floor Exclusion Volume

Deleted

3.2.6.3 Core Ceiling and Side Wall Exclusion Areas

The areas of the core ceiling between the cargo door header, and the core side walls extending between the vertical corner posts shall be kept clear of obstructions (excluding stud, slide bolt receivers, and mounting angles, as shown on the referenced drawings) that would interfere with the installation of insulation and sheathing panels

3.2.6.4 Core Floor Drain Exclusion Area

Containers shall include floor drains that drain outside of the container footprint, as shown on the referenced drawings. These floor drains shall be located through the core floor within ± .25 inches of a location 2 inches inboard of the core side wall sills and 33.75 inches from the core container centerline.

3.2.6.5 Curtain Attachments

SHT 8 OF 10 REV - 9-1-1375

The design of the container and its extension foldouts shall not prevent the attachment of curtain hooks in the areas shown in 2. These hooks will extend approximately ¼ inch below the wing ceilings. These hooks will be present in both the deployed and packed (transport) conditions.

Figure 2. Curtain Hook Mounting Areas.

3.2.7 Foldout Panel Packout Spacing

When packed for transport, a minimum space of 0.28 inch shall be provided between the wing panel faces to allow for mounting brackets and other small provisions to be attached.

3.2.8 Container Penetration

The container shelter supplier shall install all necessary external interface penetrations (I/O’s) in accordance with the referenced drawings, for the specific unit type (shower, latrine, self-serve laundry, or kitchen).

3.2.9 Equipment Mounting Provisions

The container shelter supplier shall install all necessary welded equipment mounting provisions (weld studs, brackets, etc.) in accordance with the referenced drawings, for the specific unit type (shower, latrine, self-serve laundry, or kitchen).

4 VERIFICATION/QA PROVISIONS

Unless otherwise specified in the contract, the supplier is responsible for the performance of all tests and analyses required to verify and certify that the requirements in Section 3 are met. The supplier may use any inspection, analysis, and test methods normally employed to verify compliance with his prescribed design, manufacturing workmanship, and statutory requirements (see 6.1). The Government (or its designated representative) reserve the right to review inspection/test records, and to witness and/or perform any of the tests required for certification where such tests are deemed necessary to assure that the container conforms to the specified requirements.

4.1 Certificates of Compliance

Unless otherwise stated in the procurement contract or purchase order, the supplier shall provide a certificate of compliance (CoC) with each ETS container purchased to this document. Each CoC shall indicate the applicable container serial number, and be signed and dated by an authorized supplier representative, including said representative’s title. The supplier shall certify that the delivered container complies with all of the requirements as indicated herein.

4.2 Acceptance Verification

SHT 9 OF 10 REV - 9-1-1375

As a minimum, the Government (or its designated representative) will inspect each container for compliance to the requirements set forth in section 3.2.

SHT 10 OF

REV - 9-1-1375

4.3 Design Change Approval

The supplier shall not change any aspect of the design of this item after First Article acceptance without prior written approval from the Government.

5 PACKAGING/DISPOSITION

No special packaging is required for the container itself. Any loose items that might be shipped with a container shall be packaged and secured such that neither the item nor the container is damaged in transport.

6 NOTES

6.1 Inspection, Test, and Analysis Records

All applicable certifications shall be delivered to the Government (or its designated representative) at the same time as the unit is delivered. Inspection, test, and analysis records shall be retained by the supplier and forwarded to the Government (or its designated representative) for review as required.