A02 DOR Road Mat 11-2-23.pdf

UNCLASSIFIED

DETAILED SPECIFICATION

FIBER-REINFORCED POLYMER (FRP) MAT FOR TEMPORARY ROADS

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 fiber-reinforced polymer (FRP) panels made of layers of glass fiber impregnated with polyester resin. The FRP mats function as expedient road system.

1.2. Size and Quantity. The FRP panels shall be 80 x 80 inches and produced according to dimensions in the drawings in Appendix A. hundred ( 0) panels are required. First article testing will require one (1) panel for destructive testing in addition to the quantities defined above.

1.3. Delivery Date. The delivery date shall be 120 days after contract award.

1.4. Delivery Location. The delivery location is as follows:

ERDC

CEERD-GMA

3909 Halls Ferry Rd.

Vicksburg, MS 39180

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.

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)

INCH-POUND

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.

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 .)

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. A sample shall be subjected to first article inspection in accordance with 4.2.

3.2. Materials. Materials shall be as specified herein and in applicable specifications and standards, and other reference documents. Materials shall be free of defects which adversely affect performance o 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.

3.2.1. FRP material. The FRP panels shall be fabricated from fiberglass and polyester resin using a closed molding process (i.e., Resin Transfer Molding (RTM) or Vacuum http://www.astm.org/

Resin Transfer Molding (VRTM)). The FRP panels shall be fabricated as shown in the drawings given in Appendix A. 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.

3.2.1.1. 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

3.2.1.2 and tested as per Section 4.5, the resin shall produce a laminate with the required physical properties listed in Table I. Furthermore, the resin and catalyst combination in conjunction with the fiberglass reinforcement (3.2.1.2) shall produce a laminate which retains a minimum of 90 percent of the required flexural strength and tensile strength (Table I) 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.

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

3.2.1.2.1. 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 stitched or bonded to a Type III, Class I, Grade A chopped strand backing per MIL-M-43248C. One ply is defined as the combination of the roving bonded to the chopped fiber layer. 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.

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

3.2.1.2.3. 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.

3.2.1.3. 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 (3.2.1.1).

3.2.1.4. Color of panels. All surfaces of the FRP panels shall be colored representative of The selected pigment shall be compatible with the polyester resin (3.2.1.1). Excessive flaking, peeling, or scaling of panel coloring shall be grounds for rejection of the product.

3.2.1.5. Non-skid. The top wearing surface of each panel shall be embossed with a .125-inch x .125-inch x .125-inch pyramid shape non-skid texture except for the underlap edges.

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

3.3.1. FRP panels. FRP panels shall be finished to dimensions shown in Appendix A, Drawing G-101. Panel edges shall be recessed to 0.18 - 0/+.125 inch thickness on top edge (overlap) and 0.18 - 0/+.125 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 in the center shall be 0.36 - 0/+.125 inches. The 2.50-inch diameter hole pattern along the underlap edges and along the overlap edges is shown in Appendix A, Drawing G- 101.

3.3.2. Weight. Approximate weight of the panels shall be approximately 120 lbs.

3.4. 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 55:45 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.

3.5. Holes. Holes shall be cut on the panel overlap and underlap edges in accordance with the patterns shown in Appendix A. The holes on the underlap and overlap edges of the panels shall be 2.50 +/- 0.06 inches in diameter.

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

TABLE I. Required properties of FRP panels

Property Requirement Test Method Reference

Tensile Strength, x or y-axis (Min) 32,000 psi ASTM D3039/M

Flexural Strength, x or y-axis (Min) 42,000 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: 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

3.7. Workmanship. Workmanship for the FRP panels 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. Insufficient 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. A first article submission consisting of ( ) FRP panel should be delivered to the Government for inspection and testing. 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 of the 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 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. 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 panel submitted with the First Article submission. This 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.

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 I 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 panel shall be examined for compliance with the requirements specified in Section 3 of this specification. Any 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 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 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 I shall be cause for rejection of all panels manufactured using the same methods as the tested panel(s).

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 (0.36-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 I 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 (0.36- 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 I 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 I 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 I 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 I shall be cause for rejection of the product.

4.5.6. Dimensional accuracy. An overall check of the dimensional accuracy shall be made by positioning the panels in a random order to form a 36 ft. x 36 ft. square.

Misalignment, or the inability to join the panels in this manner to form this 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. 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. 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 within the Military Department o 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. Twenty stacked panels 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 80-inch 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.

One band shall be placed on the center line of the 80-inchs side of the stack and one band 28 inches on both sided so the center band. 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.

APPENDIX A

MAT DETAIL DRAWINGS

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