Description_of_Requirement_FRP_matting.pdf

Description of Requirement

Purchase of Fiber Reinforced Polymer Matting

1. A minimum of twenty (20) fiber reinforced polymer (FRP) matting assemblies will be procured under the terms of this contract. A FRP matting assembly is defined in the attached specification in section 1.2.1.

The quantities of components should include those listed in 1.2.2. Pricing quoted for the FRP matting assemblies shall be on a per unit basis. In addition, replacement materials shall be quoted on a unit basis for complete sets defined in 1.2.3.1 (Set of Upper Joining Bushings) and 1.2.3.2

(Set of Anchor Bushings). Packaging should be the same as defined for bushings in the full matting assembly.

2. Note that this version of FRP is dimensionally different from past contracts.

Interested vendors must meet the new dimensions included in the revised drawings.

3. All FRP matting assemblies purchased under the terms of this contract shall be delivered to the address below by 31 December 2019. A delivery schedule shall be included in the quote. Shipping costs shall be incurred by the vendor.

Hangar 2 Pavement Test Facility

US Army Engineer Research and Development Center

3909 Halls Ferry Road

Vicksburg, MS 39180

4. First article testing may be required prior to delivery of FRP matting assemblies in accordance with section 4.2. Coordination shall be made with the government for any first article testing required so that testing can be performed by the government is a timely manner so that delivery schedule can be met according to item 4 above.

5. Upper joining bushings shall contain anchor bushing lining as described in section 3.3.2.4.

6. The FRP assemblies shall be packaged in accordance with recommendations in section 5.1.1. Bushings shall be packaged in accordance with recommendations in section 5.1.2

Distribution limited to US Government agencies and their contractors; critical technology.

INCH-POUND

DETAILED SPECIFICATION

FIBER-REINFORCED POLYMER (FRP) MAT FOR AIRFIELD DAMAGE REPAIR (ADR)

This specification is approved for use by all Departments and Agencies of the Department of Defense within the distribution limitations noted at the bottom of the page.

1. SCOPE

1.1. Scope. This specification describes the requirements for manufacturing the bolt-together fiber-reinforced polymer (FRP) panels made of layers of glass fiber and aramid fabric impregnated with polyester resin and connected using metal bushings.

The FRP mats function as expedient foreign object debris (FOD) covers for crushed-stone or debris backfill crater repairs as part the airfield damage repair (ADR) program.

1.2. Classification. The FRP panels shall be of the following types as specified.

a. Full Size 208 x 78 inches

b. Half Size 108 x 78 inches

c. Full Anchor 200 x 24 inches

d. Half Anchor 100 x 24 inches

1.2.1. Mat Assembly Definition. A typical FRP mat assembly capable of covering one 25-ft diameter repair (or multiple smaller repairs) is defined as follows: seven (7) full-size panels, six (6) half-size panels, three (3) full-size anchor panels, four (4) half-size anchor panels, one hundred fifty-two (152) lower joining bushings, one hundred seventy-five (175) upper joining bushings, and one hundred twenty-five (125) anchor bushings. The lower joining bushings (3.7.2) shall be adhered (3.3.2.5) to the holes in the underlap edges of full-size panels and half-size panels prior to delivery.

1.2.2. Quantities of Components. The required quantities of components for a typical FRP mat assembly (1.2.1) are as follows:

TABLE I. Typical FRP mat assembly component quantities

Component Quantity Full-size panel 7 Half-size panel 61

Full-size anchor panel 3 Half-size anchor panel 4 Lower joining bushing 1522

Upper joining bushing 175 Anchor bushing 125 1 If requested by Government, First Article testing will require one (1) half-size panel for destructive testing in addition to the quantities defined in the acquisition document.

2 Lower bushings shall be attached at each hole in the underlap region(s) of full-size and half-size panels.

Additional bushings should be accounted for in panels which will be required as part of the First Article testing protocol.

1.2.3 Replacement Materials. Replacement bushings may be required on an as-needed basis. The full set of replacement materials would include options for one of the following options

1.2.3.1 Set of Upper Joining Bushings. This set would include 175 upper joining bushings as defined in Quantities of Components (1.2.2)

1.2.3.2 Set of Anchor Bushings. This set would include 125 upper joining bushings as defined in Quantities of Components (1.2.2)

2. APPLICABLE DOCUMENTS

2.1. General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not they are listed.

2.2. Government Documents.

2.2.1. Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those listed in the issue of the Department of Defense Index of Specifications and Standards (DoDISS) and supplement thereto, cited in the solicitation (see 6.2).

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-M-43248C Mats, Reinforcing, Glass Fiber MIL-Y-1140 Yarn, Cord, Sleeving, Cloth, and Tape-Glass

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-129R Military Marking for Shipment and Storage MIL-STD-1916 DoD Preferred Methods for Acceptance of Product

(Unless otherwise indicated, copies of the above specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094)

2.3. Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DoDISS are the issues of the documents cited in the solicitation (see 6.2).

ASTM INTERNATIONAL

ASTM D123-13a Standard Terminology Relating to Textiles ASTM D696 Standard Test Method for Coefficient of Linear Thermal

Expansion of Plastics between -30°C and 30°C with a Vitreous Silica Dilatometer

ASTM D790 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM C881/M Standard Specification for Epoxy-Resin-Base Bonding Systems for Concrete

ASTM D1929-96 Standard Test Method for Determining Ignition Temperature of Plastics

ASTM D2565 Standard Practice for Xenon-Arc Exposure of Plastics Intended for Outdoor Applications

ASTM D2583 Standard Test Method for Indentation Hardness of Rigid Plastics by Means of a Barcol Impressor

ASTM D3039/M Standard Test Methods for Tensile Properties for Polymer Matrix Composite Materials

ASTM D3953-15 Standard Specification for Strapping, Flat Steel and Seals

ASTM D4389 Standard Specification for Finished Glass Fabrics Woven from Rovings

(Application for copies should be addressed to ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 or obtained at www.astm.org .)

SAE AEROSPACE MATERIAL SPECIFICATIONS

SAE-AMS-QQ-P-416 Plating, Cadmium (Electrodeposited)

(Application for copies should be addressed to the SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001 or obtained at www.sae.org .)

2.4. Order of Precedence. In the event of a conflict between the text of this document and the references cited herein (except for related associated specifications or specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1. First Article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2.

3.2. Mat Description. Four types of FRP panels, full-size, half-size, full-anchor, and half-anchor are described in this specification. Three types of bushings, upper joining, lower joining, and anchor, required to assemble the panels to form a FOD cover, are also described. Installation tools and anchoring systems required for FRP installation will be detailed separately.

3.3. Materials. Materials shall be as specified herein and in applicable specifications and standards, and other reference documents. Materials not specified shall be selected by the contractor and shall be subject to all provisions of this specification. Materials shall be free of defects which adversely affect performance of serviceability of the finished product. Certification that the herein specified materials meet the requirements of this specification shall be made available to the government at any time upon request.

3.3.1. FRP material. The FRP panels shall be fabricated from fiberglass, polyester resin, and high strength aramid fabric using a closed molding process (i.e., Resin Transfer Molding (RTM) or Vacuum Resin Transfer Molding (VRTM)). The FRP panels shall be fabricated as shown in the drawings given in Appendix A. Full-size and half-size panel edges shall be reinforced with one ply of high-strength aramid fabric with a minimum width of 14 inches; anchor panels shall be reinforced with one continuous 24-inch wide layer of high-strength aramid fabric. All FRP panels shall include UV inhibitors to minimize degradation during outdoor use. Panels shall be colored A compatible pigment shall be introduced to the resin prior to molding to achieve the proper color. A gel coat shall not be used to achieve proper color.

3.3.1.1. Polyester resin. The FRP panels shall be fabricated using a polyester resin. The resin shall be polyester, thermosetting, RTM laminating type. A catalyst should be used to achieve appropriate gel times. The resin and catalyst composition shall be designated by a code number. The code number may include a trade name, if desired. Any changes in the resin components or manufacturing process shall necessitate use of a different code number. The cured resin shall not be corrosive to metals. When used in conjunction with the fiberglass reinforcement specified in

3.3.1.2 and tested as per Section 4.5, the resin shall produce a laminate with the required physical properties listed in Table III. Furthermore, the resin and catalyst combination in conjunction with the fiberglass reinforcement (3.3.1.2) shall produce a laminate which retains a minimum of 90 percent of the required flexural strength and tensile strength (Table III) after being exposed to artificial ultra violet (UV) light for 720 hours, as per ASTM 2565 Table 1, Cycle Number 2 and tested as outlined in Section 4.5 of this specification.

3.3.1.2. Fiberglass reinforcement. The fiberglass reinforcement shall produce a laminate with the required physical properties listed in Table III.

3.3.1.2.1. Fiberglass type. The fiberglass reinforcement used for the mat panels shall be a fiberglass fabric mat reinforcement composite Type V, consisting of a multi-axial woven, stitched, or knitted roving that may be stitched or bonded to a Type III, Class I, Grade A chopped strand backing per MIL-M-43248C. Definitions of the textile terms used herein are described in ASTM D123. All fiberglass used in the roving, continuous strand, and chopped fiber mat portions of the reinforcement shall be E-type (MIL-M-43248C). The glass shall be white in color.

3.3.1.2.2. Roving. The roving material shall be constructed by weaving, stitching, or knitting individual rovings in multi-axial (2 or more) directions.

3.3.1.2.3. Chopped strand mat. The chopped strand mat shall consist of randomly oriented strands. The strands shall be treated with a silane sizing compatible with the polyester resin in accordance with ASTM D4389 and shall be bonded together with a compatible bonding agent. Additional thin chopped strand layers may be added as required to promote a proper bond between reinforcement layers.

3.3.1.3. High-strength aramid fabric reinforcement. The high-strength aramid fabric shall be constructed as required so that the tensile strength of resin impregnated strands or equivalent). The high-strength aramid fabric reinforcement shall be, 15 ± 2 ounces per square yard, and be compatible with polyester resin (3.3.1.1). The high-strength aramid fabric shall be approved by the Government prior to use.

3.3.1.4. Continuous strand mat. The continuous strand mat shall be a continuous filament mat consisting of randomly oriented strands in multiple layers held together with a polyester binder and with a silane coupling agent. Continuous strand mat shall be compatible with the polyester resin (3.3.1.1).

3.3.1.5. Color of panels. All surfaces of the FRP panels shall be colored representative of an The selected pigment shall be compatible with the polyester resin (3.3.1.1). Excessive flaking, peeling, or scaling of panel coloring shall be grounds for rejection of the product.

3.3.1.6. Non-skid coating. The top wearing surface of each panel shall be coated, except for the underlap edges, with a non-skid coating. The coating shall be composed of crystalline silica and the polyester resin (3.3.1.1). The crystalline silica shall be RUST-OLEUM 200504 or equivalent and shall be compatible with the polyester resin (3.3.1.1). The dosage rate shall be approximately 1 lb crystalline silica per gallon of polyester resin (3.3.1.1). The non-skid coating shall be applied to the wearing surface of each panel within 24 hrs of removal of the panel from the mold. Panel surfaces shall be clean, dry, and free of dust or other contaminates prior to application of the non-skid coating. Non-uniform application or excessive flaking, peeling, or scaling of the non-skid coating shall be grounds for rejection of the product.

3.3.2. Bushing material.

3.3.2.1. Lower joining bushing. Lower joining bushings shall be made from 303 Stainless Steel.

3.3.2.2. Upper joining bushing. The upper joining bushing shall be made from 1045 Steel and plated per SAE-AMS-QQ-P-416 Rev F, TYP II, Class 2, Gold. The upper joining bushing bolt shall be SAE Grade 5, 5/8-11 Thread. The upper joining bushing bolt shall be plated per AMS QQ-P-416 Rev F, TYP II, Class 2, Gold Hydrogen Embrittlement release baked at 370 degrees F for 23 hours within 4 hours of plating before assembly. The upper joining bushing bolt shall be adhered to the upper joining bushing via a threadlocking material (3.3.2.7).

3.3.2.3. Anchor bushing. Anchor bushings shall be made from 1045 Steel and plated per SAE-AMS-QQ-P-416 Rev F, TYP II, Class 2, Gold.

3.3.2.4. Anchor bushing lining. If required (see Section 6.2) anchor bushings shall be lined on the bottom surface and around the shoulder with an exothermic, rapid curing, elastomeric polyurethane lining system. Lining shall be brand Rhino TuffGrip or equivalent. The lining shall not migrate into the 0.828-inch diameter hole in the underside of the anchor bushing so as not to prevent passage of an anchor bolt through said hole.

3.3.2.5. Adhesive. The adhesive used to bond lower bushings to panel underlap edges shall be in accordance with ASTM C881, Type I, Grade 3, Class B.

3.3.2.6. Rivet. The rivet used to fasten lower bushings to panel underlap edges shall be stainless steel structural blind rivets such as Huck MGL100-U8-8 or equivalent. If a rivet other than the Huck MGL100-U8-8 is selected, it shall be approved by the Government prior to use in lower joining bushings.

3.3.2.7. Threadlocking material. The threadlocking material shall be LOCTITE 263 Red Threadlocker or equivalent and shall be applied at the manufacturer recommended application rate to ensure adhesion of the upper joining bushing bolt to the upper joining bushing (3.3.2.2). If the threadlocking material is other than LOCTITE 263, the material shall be approved by the Government prior to use.

3.4. Panel Dimensions and Weights. All panels of the same classification shall be identical to the extent necessary to ensure interchangeability of component parts, assemblies, accessories, and spare parts.

3.4.1. Full-size panels. Full-size panels shall be finished to dimensions shown in Appendix A, Drawing 142003. Panel edges shall be recessed to 0.25-inch thickness on top edge (overlap) and 0.25-inch thickness on the bottom edge (underlap). Two adjacent edges of a panel shall have the recess at the panel bottom; the other two edges shall be recessed at the panel top. The thickness of the panels at any underlap or overlap edge shall be 0.25 ± 0.05 inches. The thickness of the panels in the center shall be 0.40 +.125/-.000 inches. The 2.25-inch diameter hole pattern along the underlap edges and the 2.50-inch diameter hole pattern along the overlap edges is shown in Appendix A, Drawing 142003. The lower bushings shall be attached to the underlap edges at each hole using adhesive (3.3.2.5) and two rivets

(3.3.2.6). All holes in underlap edges of full-size panels shall contain lower bushings.

3.4.2. Half-size panels. Half-size panels shall be finished to dimensions shown in Appendix A, Drawing 142004. Panel edges shall be recessed to 0.25-inch thickness on top edge (overlap) and 0.25-inch thickness on the bottom edge (underlap). Two adjacent edges of a panel shall have the recess at the panel bottom; the other two edges shall be recessed at the panel top. The thickness of the panels at any underlap or overlap edge shall be 0.25 ± 0.05 inches. The thickness of the panels in the center shall be 0.40 +.125/-.000 inches. The 2.25-inch diameter hole pattern along the underlap edges and the 2.50-inch diameter hole pattern along the overlap edges is shown in Appendix A, Drawing 142004. The lower bushings shall be attached to the underlap edges at each hole using adhesive (3.3.2.5) and two rivets (3.3.2.6). All holes in underlap edges of half-size panels shall contain lower bushings.

3.4.3. Anchor panels. Anchor panels are used to allow a full- -size holed edge for anchoring of the mat without removal of the lower bushings. These panels shall be anchored to the pavement surface using the anchor bushings and appropriate anchor system.

3.4.3.1. Full-size anchor panels. Full-size anchor panels shall be finished to the dimensions shown in Appendix A, Drawing 142005. The thickness of the panel at the overlap edge shall be 0.25 ± 0.05 inches. The thickness of the remaining panel shall be shall be 0.40 +.125/-.000 inches. The 2.50-inch diameter hole pattern along the panel edges is shown in Appendix A, Drawing 142005.

3.4.3.2. Half-size anchor panel. Half-size anchor panels shall be finished to the dimensions shown in Appendix A, Drawing 142005. The thickness of the panel at the overlap edge shall be 0.25 ± 0.05 inches. The thickness of the remaining panel shall be 0.40 +.125/-.000 inches. The 2.50-inch diameter hole pattern along the panel edges is shown in Appendix A, Drawing 142005A.

3.4.4. Weight. Approximate weight of the panels shall be as given in Table II.

TABLE II. Approximate weight of panels

Description Weight, lbs Full-size panel 400 Half-size panel 200 Full-size anchor panel 150 Half-size anchor panel 75

3.5. Fiberglass and Aramid Fabric Reinforcement Laminate Schedule

3.5.1. Full-size and half-size panels. Each full-size and half-size panel shall contain 70-inch wide plies of fiberglass reinforcement (3.3.1.2) that shall run continuous for the full length of each panel. Discontinuities or overlaps in the reinforcement section are not allowed. Each full-size and half-size panel may contain continuous strand mat across the full 70-inch width of the panel. There shall be no more than one discontinuity in continuous strand layers (i.e. 20 inches of material spliced with 50 inches of material to create the full 70-inch wide section of continuous strand mat).

be reinforced with one 14-inch wide minimum ply of high-strength aramid fabric (3.3.1.3). The selected laminate schedule shall be approved by the Government prior to use. An example reinforcement laminate schedule is shown in Appendix A.

3.5.2. Full-size and half-size anchor panels. Each full-size and half-size anchor panel shall be constructed from 24-inch-wide and 16-inch wide plies of fiberglass reinforcement (3.3.1.2) that shall run continuous for the full length of each anchor panel. Each full-size and half-size anchor panel may contain continuous strand mat (3.3.1.4) across the full width of the panel. Each anchor panel shall be reinforced with one 24-inch-wide ply of high-strength aramid fabric (3.3.1.3). Discontinuities or overlaps in the reinforcement, continuous strand mat, or aramid fabric sections are not allowed. The selected laminate schedule shall be approved by the Government prior to use. An example reinforcement laminate schedule is shown in Appendix A.

3.6. Polyester Resin. The panels shall be fabricated using a polyester resin (3.3.1.1) applied at a ratio of fiberglass reinforcement to resin of approximately 60:40 by weight. The exact rate of application shall be adjusted as required to obtain the specified properties and dimensions of the mat. The polyester resin shall thoroughly wet all reinforcement.

3.7. Holes and Bushings.

3.7.1. Holes. Holes shall be cut on the panel overlap, underlap, and anchor panel edges in accordance with the patterns shown in Appendix A. The holes on the underlap edges of the panels shall be 2.25 ± 0.05 inches in diameter. The holes on the overlap and anchor panel edges shall be 2.50 ± 0.05 inches in diameter.

3.7.2. Lower joining bushings. A detailed drawing of the lower joining bushing is shown in Appendix A, Drawing 142010.The lower bushings shall be attached to the underlap edges of the full-size and half-size panels at each hole using adhesive (3.3.2.5) and two rivets (3.3.2.6). The rivet shall have no sharp edges. The bottom of the rivet receiving holes in the lower joining bushing shall be counter bored in accordance with Appendix A, Drawing 142010. The lower bushings shall be threaded to receive the 0.625-inch bolt from the upper joining bushing.

3.7.3. Upper joining bushing. A detailed drawing of the upper joining bushings is shown in Appendix A, Drawing 142010. Upper joining bushings will be connected to lower joining bushings to join panels together to form a cover. The head of the upper joining bushing bolt shall sit flush with the 2.40 inch top shoulder of the upper joining bushing.

3.7.4. Anchor bushings. A detailed drawing of the anchor bushings is shown in Appendix A, Drawing 142011.The anchor bushing is designed to facilitate anchoring the system to a pavement surface through the holes on panel overlap edges and anchor panel edges.

3.8. Mechanical Properties. The cured resin shall produce a laminate having the mechanical properties shown in Table III when tested as specified in Section 4.5

TABLE III. Required properties of FRP panels

Property Requirement Test Method Reference Tensile Strength, x-axis (Min) 32,000 psi ASTM D3039/M Tensile Strength, y-axis (Min) 45,000 psi ASTM D3039/M Flexural Strength, x-axis (Min) 42,000 psi ASTM D790 Flexural Strength, y-axis (Min) 65,000 psi ASTM D790 Thermal Expansion (Max) 1.8 x 10-5 in/in/°C ASTM D696 Ignition Temperature, Flash (Min) 450° F ASTM D1929 Hardness, Top (Min) 45 ASTM D2583 Hardness, Bottom (Min) 45 ASTM D2583 Note: All testing is to be performed on those areas of panels which do not contain the high-strength aramid fabric reinforcement unless reasonable cause for testing other sections is cited (4.2.1). The x-direction is defined as the direction transverse to the intended direction of trafficking. The y-direction is defined as the direction parallel to the intended direction of trafficking which is perpendicular to the direction of anchor panel placement as seen on Drawing 142009 in Appendix A.

3.9. Workmanship. Workmanship for the FRP panels and bushings shall be of the quality prevailing among manufacturers normally producing similar items to those specified.

Quality Control shall be of the quality prevailing among manufacturers normally producing similar items to those specified, and the panels shall be free from the following defects:

a. Incorrect thickness

b. Incorrect hole placement or size

c. Delamination

d. Dry spots

e. Voids

f. Blisters

g. Crazing

h. Cracks or tears

4. VERIFICATION

4.1. Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3)

4.2. First Article Inspection. . If requested, a first article submission consisting of one typical FRP mat assembly (1.2.1) should be delivered to the Government (see 6.2) for inspection and testing. The first article inspection shall be performed on a minimum of one of each type of panel (1.2) ordered. This inspection shall include examination specified in section 4.4 and testing specified in section 4.2.1. The first article may be either a first production item or a standard production item from the suppli specification and is representative of the design, construction, and manufacturing techniques applicable to the remaining items to be furnished under the contract. The Government reserves the right to determine at its discretion whether a current inventory item shall be accepted as a First Article submission. The panels produced under the contract shall be inspected by the manufacturer at their plant under the direction and in the presence of Government representatives. The purpose of this inspection shall be to determine panel conformity with the contract. Acceptance of the First Article inspection shall not constitute a waiver by the Government of its rights under the provisions contract document or relieve the manufacturer from any requirements defined in this specification. Failure to meet inspection criteria shall constitute cause for rejection.

4.2.1. First Article testing. If requested by the Government (see 6.2), First Article testing shall be performed in conjunction with the First Article inspection specified in 4.2.

First Article testing shall be performed on a randomly selected half-size panel submitted with the First Article submission. This randomly selected half-size panel shall be destructively tested and will remain property of the Government. First Article testing shall consist of the testing specified in 4.5.1 through 4.5.7 and shall be conducted by an independent or Government laboratory. Failure to meet test or inspection criteria shall constitute cause for rejection. First Article approval shall not constitute a waiver by the Government of its rights under the provisions of the contract document or relieve the manufacturer of any requirements defined in this specification. Should the Government have reason to suspect that full-size panels, full-size anchor panels, half-size anchor panels, and/or the other half-size panels are not representative of construction of the half-size panel randomly selected for first article testing, the Government reserves the right to destructively test any panel included in the first article submission and reject the product on a case-by-case basis (areas of panels including aramid fabric reinforcement should exhibit approximately a minimum of 80% of the required properties given in Table III). If additional panels are destructively tested, they will remain property of the Government.

4.3. Conformance Inspection. The conformance inspection shall include the specified examination of 4.4 and any selected tests of 4.5 and shall be performed on panels at a rate of no more than two percent of production volume for destructive testing. The manufacturer is required to notify the Government should raw materials change at any time during production. Following this notification the Government may, at its discretion, perform additional conformance inspections as described herein. Failure to comply with the mechanical properties listed in Table III shall be cause for rejection of all panels manufactured using the same methods as the tested panel(s).

4.4. Workmanship Examination. A minimum of one of each panel type (1.2) shall be examined for compliance with the requirements specified in Section 3 of this specification.

comply with specified requirements, or any necessary redesign or modification following failure to meet specified requirements shall receive particular attention for adequacy and suitability. This element of inspection shall encompass all visual examinations and dimensional measurements. Noncompliance with any specified requirements or presence of one or more of the following defects preventing or lessening maximum efficiency shall constitute cause for rejection.

a. Thickness. Verify by measuring each full, half, and anchor panel edge in at least two (2) places (minimum eight measurements per piece).

b. Hole size and placement. Verify specification compliance by measuring at least five (5) holes on each full, half, and anchor panel.

c. Delamination. Not tolerable in the FRP panels. Verify by visual examination when removing the panel from the mold.

d. Dry spots. None are tolerable in excess of 0.5 inches in diameter. More than 10 occurrences in any 1-square foot area are not tolerable. Verify by visual examination when removing the panel from the mold.

e. Blisters and voids. None are tolerable in excess of 0.5 inches in diameter.

More than 10 occurrences in any single panel are not tolerable. Verify by visual examination when removing the panel from the mold.

f. Non-skid coating. Verify that the nonskid coating is the correct particle size and has been applied uniformly across the appropriate panel areas. Non-uniform coating or inappropriate particle size shall not be tolerable.

g. Cracks or tears. None are tolerable that penetrate into the fiberglass reinforcement of the panels. Verify by visual examination and measurement when removing the panel from the mold.

4.5. Testing. Failure to comply with the mechanical properties listed in Table III shall be cause for rejection of all panels manufactured using the same methods as the tested panel(s). All tests shall be performed on specimens without the high-strength aramid fabric (3.3.1.3) with the exception of panels that are suspected of not being uniform across the production lot (4.2.1).

4.5.1. Tensile strength. Tensile strength testing shall be performed in accordance with ASTM D3039/M except as specified herein. Ten tensile tests will be performed on specimens randomly selected from a portion(s) of an FRP panel(s). Five specimens shall be oriented parallel to the x-axis, and five shall be oriented parallel to the y-axis.

Test specimens shall measure 10 inches long (along reference axis) by 1 inch wide by the thickness of the panel (0.4-inch nominal). The rate of crosshead movement shall be 0.1 inches per minute. Failure of the tested average of either the x-direction or y-direction test specimens to meet the requirement specified in Table III shall be cause for rejection of the product.

4.5.2. Flexural strength. Flexural strength testing shall be performed in accordance with ASTM 790, Procedure A, except as specified herein. Ten flexural tests will be performed on specimens randomly selected from a portion(s) of an FRP panel(s).

Five specimens shall be oriented parallel to the x-axis, and five shall be oriented parallel to the y-axis. Test specimens shall measure 10 inches long (along reference axis) by 1 inch wide by the thickness of the mat (0.4- inch nominal). The rate of crosshead movement shall be 0.43 inches per minute. The support span shall be 8.0 inches. The loading nose shall have a radius of 1.0 inch, and the radius of the supports shall be 1/2 inch. Failure of the tested average of either the x-direction or y-direction test specimens to meet the requirement specified in Table III shall be cause for rejection of the product.

4.5.3. Thermal expansion. Thermal expansion testing shall be performed in accordance with ASTM D696 except as specified herein. A minimum of two specimens, one tested in the x-direction and one tested in the y-direction, shall be tested at temperature extremes of -30°C to +30°C. Failure of the tested average to meet the requirements specified in Table III shall be cause for rejection of the product.

4.5.4. Ignition temperature. Ignition temperature testing shall be performed in accordance with ASTM D1929 except as specified herein. Only the flash ignition temperature of the FRP material is required to be determined. A minimum of two determinations shall be made. Failure of any specimen to meet the requirements specified in Table III shall be cause for rejection of the product.

4.5.5. Hardness. The indentation hardness of each selected specimen shall be tested according to ASTM D2583 except as specified herein. The hardness shall be measured at a minimum of ten points on the top surface of the selected panel and ten points on the bottom surface of said panel. The measurements shall be taken at 73.4°F ± 3.6°F after being conditioned at that temperature with 50 ± 10 percent relative humidity for a minimum of 5 hours. Failure of the tested averages to meet the requirements specified in Table III shall be cause for rejection of the product.

4.5.6. Dimensional accuracy. An overall check of the dimensional accuracy shall be made by joining the panels in a random order to form a cover, as shown in Appendix A, Drawing 142009. The joining shall be completed using the upper joining bushings supplied by the manufacturer and the lower joining bushings which shall be fixed to the underlap regions of full- and half-size panels. Binding, misalignment, or the inability to join the panels in this manner to form a cover shall be cause for rejection of the product.

4.5.7. Interchangeability test. When panels pass the test of 4.5.6, disassemble the cover and reassemble the panels in a different sequence. Binding, misalignment, or the inability to join the panels in this manner to form a cover shall be cause for rejection of the product.

5. PACKAGING

5.1. Packaging. For acquisition purposes, the packaging requirements shall be as specified in the contract or order (see 6.2). When actual packaging of material is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging

System Command. Packaging data retrieval is available from the managing Military -ROM products, or by contacting the responsible packaging activity.

5.1.1. Recommended FRP panel packaging requirements. Stacked mat assemblies shall be wrapped in one layer of polyethylene sheeting, 10 mils. The color of the sheeting shall be white, black, or grey. Prior to banding, the exterior of the packaged assembly shall be sealed to help prevent moisture intrusion. The stacked, wrapped, and sealed assemblies shall be banded along the entire approximate 18 foot length of the stacked assembly by flat steel metallic bands conforming to ASTM D3953, Type 1, Regular Duty High-Strength strapping, size 5/8-inch by 0.023-inches thick.

The spacing of the banding shall be no greater than 3 feet. The banding shall use regular duty, organic finished, snap-on seal of 5/8-inch width, as per ASTM D3953. A plastic edge protector of 2.5-inch width and 1.75-inch leg length shall be used to protect the FRP panels from the steel banding at each point of corner contact with the stacked panels (four protectors per band). The plastic edge protector shall be PAC Strapping Products CP-122 or equivalent. From the bottom of the stack upwards, the stacking sequence for a typical FRP assembly shall be as follows:

Full-size panel

Full-size panel

Two (2) half-size panels

Full-size panel

Full-size panel

Two (2) half-size panels

Full-size panel

Full-size panel

Anchor panels

Two (2) half-size panels

Full-size panel.

5.1.2. Recommended FRP bushing packaging requirements. The upper joining bushings and anchor bushings described in this specification shall be packaged in groups of 25 in M2A1 metal ammunition containers. Containers may be acquired from a number of retail outlets or direct from a manufacturer such as the BWAY Corporation. Packaging of more than one type of bushing into a single container shall not be allowed. Bushing packaging containers shall be clearly stenciled in white paint on the exterior of the container to indicate type and quantity of contents.

6. NOTES

6.1. Intended Use. This specification covers FRP panels and bushings for use as an expedient cover for backfilled bomb craters within airfield pavements.

6.2. Acquisition Requirements. Acquisition documents should specify the following:

a. Title, number, and date of this specification

b. Type and number of panels required

c. If reference documents are other than those specified

d. When first article testing is required for inspection and approval

e. If bushings are to be made from different material than what is specified

f. If panels are to be fabricated differently than what is specified

g. If a non-skid coating other than what is specified is to be required

h. If an anchor bushing lining material is required

i. If size of the cover to be assembled to check the overall dimensional accuracy of the panels is different than what it specified

j. Requirements for marking of the panels

k. Level of packing required

6.3. Subject Term (Key Word) Listing.

a. Airfield damage repair

b. Crater repair

c. FOD cover

Preparing Activity

Army