A07_Attachment_1_ACH_Gen_II_ARPD_14-01_Rev_A.pdf

Summary of Changes to ACH Gen II Purchase Description AR/PD 14-01

Rev # Change Paragraph Rationale

A

1 ACH Cover NSNs 3.11 NSNs were previously for covers with commo flaps. Army only procures covers without commo flaps.

Added “(to include Material Safety Data Sheets)”

4.10.17 MSDSs are necessary to complete Safety Assessment Report

Clarified first five (5) impacts (not five or ten) in LAT Part A

3.7.2.3

Removed ten (10) impact wording left over from LATs of various sample sizes (ACH Gen II LATs are 8 helmets for any size lot)

4 Changed ASTM F1358 to ASTM D6413 2.3

ASTM D6413 is referenced in the FR requirement and verification section.

ASTM F1358 is not referenced elsewhere in the PD.

HPI specified with ACH values from ATC

IOP

4.10.13(12) Ensures consistent HPIs that match ACH geometry

6 Various cross reference corrections Various Ensures consistency in referencing and linkage between requirements and verifications

7 Corrected TM number 4.10.13 TM 10-8400-304-10 was incorrect;

correct TM is 10-8400-204-10

Added NVG bracket integration components to finished helmet definition; Specifically stated inclusion of NVG bracket integration components are included in the finished helmet weight

3.2.c, 3.11.1

NVG bracket integration solutions are considered part of the helmet weight

Clarified wording on number of sizes of helmets used for weight verification

3.8 Additional clarification

Added description of ballistic pad configuration (wording taken from LW

ACH PD)

4.10.11.4 Ballistic pad configuration was not previously described

Clarified allowance of benchmarks on bonded one-piece molded edging

3.3.3.2 Clear benchmarks are required regardless of vendor construction technique

Moved IRS drawings from under Natick heading to under Ops-Core heading

2.2.2 IRS drawings are Ops-Core generated drawings, not Natick drawings

Added Type III (No hole for Night Vision Device Mount, No Holes for Retention System).

Multiple, Appendix C

Incorporated wording to account for unique requirements of a potential future boltless retention system configuration

INCH-POUND

AR/PD 14-01 Rev A 16 August 2016

SUPERSEDING

AR/PD 14-01

31 March 2016

Purchase Description

HELMET, ADVANCED COMBAT, SECOND GENERATION (ACH GEN II)

Record of Revisions

REV CHANGED

BY

REVISED

PAGE(S)

DESCRIPTION DATE

(M/D/Y)

Approval

- PM SPE -

Purchase Description for the acquisition of a

Second Generation Advanced Combat Helmet

(ACH Gen II)

03/31/16 AWM

A PM SPE Multiple

Incorporates changes made during the solicitation and adds a Type III helmet (no holes for retention system, one hole for NVD mount)

08/16/16 AWM

MILITARY INTERESTS:

Custodians: Preparing activity:

Army – PM SPE Army – PM SPE

NOTE: The activities listed above were interested in this document as of the date of this document. Since organizations and responsibilities can change, you should verify the currency of the information above using ASSIST online database at:

https://assist.daps.dla.mil/quicksearch/

1.0 SCOPE

1.1 Scope. This document covers the performance and verification requirements for the

Second Generation Advanced Combat Helmet (ACH Gen II), a ballistic shell, suspension system, and retention system with chinstrap and nape strap. The ACH Gen II is a Critical Safety

Item (CSI).

1.2 Classification. The helmet assembly will be of the following Types and Classes as specified (see 6.2).

Type I – Advanced Combat Helmet Gen II (No Hole for Night Vision Device (NVD)

Mount, Four holes for retention system)

Class 1 – Retention System, Suspension system, Foliage Green 504

Type II – Advanced Combat Helmet Gen II (One Hole for NVD Mount, Four holes for retention system)

Class 1 – Retention System, Suspension system, Foliage Green 504

Type III – Advanced Combat Helmet Gen II (One Hole for NVD Mount, No Holes for

Retention System)

Class 1 – Retention System, Suspension system, Foliage Green

Beneficial comments (recommendations, additions, deletions) and any pertinent data, which may be used in improving this document, should be addressed to Product Manager – Soldier

Protective Equipment, Program Executive Office – Soldier, US Army, 10170 Beach Road, Building 328T, Fort Belvoir, Virginia 22060.

AMSC N/A FSC 8470

1.3 Schedule of Sizes. The helmet assembly is constructed in the following sizes:

SCHEDULE OF SIZES

Extra-Small (XS)

Small (S)

Medium (M)

Large (L)

Extra-Large (XL)

Double Extra-Large (XXL)

Note: Due to low tariff, the Extra-Small and Double Extra-Large (XXL) First Article Test

(FAT) will be handled on a case-by-case basis. Direct all XS and XXL FAT inquiries to the

Contracting Officer.

Helmet Sizing. The size Small through Extra-Large must fit the 5th to the 95th percentile of all Soldiers. Soldier head size distribution for the 5th to the 95th percentile for the

Army combat helmet is Small two percent (2%), Medium (40%), Large (50%), and Extra-Large

(8%). Soldier head size distribution for the ACH Gen II must not increase the use of larger sized helmets. Increased use of smaller sized helmets is desirable. This requirement will be examined through user evaluations and must be in accordance with 4.10.1.

2.0 APPLICABLE DOCUMENTS

2.1 General. This section lists documents specified in sections 3.0, 4.0 and 5.0 of this purchase description. This section does not include documents cited in other sections of this purchase description or recommended for additional information or as examples. Document users are cautioned that they must meet all specified requirements in the documents cited in sections 3.0, 4.0, and 5.0 of this purchase description, whether or not they are listed.

2.2 Government Documents.

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 solicitation and at the time of contract award.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-32075 - Label: For Clothing, Equipage, and Tentage (General Use)

MIL-DTL-46593B

W / Amendment 1 - Projectile, Calibers .22, .30, .50, and 20mm Fragment-Simulating

MIL-DTL-64159B - Camouflage Coating, Water Dispersible Aliphatic Polyurethane, Chemical Agent Resistant

MIL-DTL-83133H W/ Amendment 2-Turbine Fuel, Aviation, Kerosene Types JP-8 (NATO

F-34), NATO F-35, and JP-8 + 100(NATO F-37)

MIL-PRF-372E W/ Amendment 2-Cleaning Compound, Solvent (For Bore of Weapons)

MIL-PRF-2104J - Lubricating Oil, Internal Combustion Engine, Combat/Tactical

Service

MIL-PRF-6083G - Hydraulic Fluid, Petroleum Base, for Preservation and Operation

MIL-PRF-46170E - Hydraulic Fluid, Rust Inhibited, Fire Resistant, Synthetic

Hydrocarbon Base, NATO Code No. H-544

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-662F - V50 Ballistic Test for Armor

MIL-STD-810G W/Amendment 1 - Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-1916 Notice 2 - DoD Preferred Method for Acceptance of Product

MIL-STD-3004D - Quality Assurance/Surveillance for Fuels, Lubricants, and Related Products

(Copies of documents are available online at https://assist.daps.dla.mil or from the

Standardization Documents Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA

19111-5094.)

Other Government Documents, Drawings, and Publications. The following

Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation or contract.

DRAWINGS

U.S. ARMY RESEARCH, DEVELOPMENT AND ENGINEERING COMMAND, NATICK

SOLDIER CENTER

2-1-2515 - Helmet Shell, Advanced Combat, Small

2-1-2516 - Helmet Shell, Advanced Combat, Medium

2-1-2517 - Helmet Shell, Advanced Combat, Large

2-1-2518 - Helmet Shell, Advanced Combat, Extra Large

2-1-2576 - Helmet Shell, Advanced Combat, Extra, Extra Large

2-1-2566 - Suspension System

OPS-CORE, INC., BOSTON, MA

07-99-121 - Improved Retention System (XS), Advanced Combat Helmet

07-99-101 - Improved Retention System (S-XL), Advanced Combat Helmet

U.S. ARMY PRODUCT MANAGER SOLDIER PROTECTIVE EQUIPMENT, FORT

BELVOIR, VA

SPE-HP-15-216-A - Improved Retention System (S-XL), Left Handed, Advanced

Combat Helmet

(Copies of drawings, publications, and other Government documents required by contractors in connection with specific acquisition functions should be obtained from the contracting activity.)

PURCHASE DESCRIPTIONS

AR/PD 12-01 - Improved Retention System

(Copies of this document are available by contacting the Contracting Officer.)

DEPARTMENT OF TRANSPORTATION FEDERAL MOTOR VEHICLE SAFETY

DOT FMVSS 218 - Department of Transportation Federal Motor Vehicle Safety

Standard No.218 Motorcycle Helmets

(Copies of documents are available on line at http://www.nhtsa.dot.gov/cars/rules/standards. The complete text of all Federal Motor Vehicle Safety Standards and other NHTSA regulations can be found in Title 49 of the Code of Federal Regulations (CFR). Title 49 of the CFR is published in seven volumes; the fifth volume (Parts 400-999) is where these regulations can be found.

Copies of this volume can be obtained for a cost from the U. S. Government Printing Office, Superintendent of Documents, Mail Stop: SSOP, Washington, DC 20402-9328.

NATIONAL INSTITUTE OF JUSTICE (NIJ)

NIJ Standard 0106.01 - Ballistic Helmets

NIJ Standard 0101.06 - Ballistic Resistance of Body Armor

(Copies of documents are available online at https://www.ncjrs.gov/pdffiles1/nij/077182.pdf and http://www.ojp.usdoj.gov/nij/pubs-sum/223054.htm or from the National Institute of Justice, 810

Seventh St. NW, Washington, DC 20531

U.S. ARMY DEVELOPMENTAL TEST COMMAND, ABERDEEN PROVING GROUND,

MD

ITOP 04-2-805 - FR/GE/UK/US Projectile Velocity and Time-Of-Flight Measurement

(Copies of documents are available by sending to Commander, US Army Test and Evaluation

Command, ATTN: AMSTE-TM-T, Aberdeen Proving Ground, MD 21105-5055)

2.3 Non-Government Standards and Other Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents are those cited in the solicitation or contract.

http://www.nhtsa.dot.gov/cars/rules/standards https://www.ncjrs.gov/pdffiles1/nij/077182.pdf http://www.ojp.usdoj.gov/nij/pubs-sum/223054.htm

AMERICAN ASSOCIATION OF TEXTILE CHEMISTS AND COLORISTS (AATCC)

AATCC Test Method 8 - Colorfastness to Crocking: Crock meter Method

AATCC Test Method 15 - Colorfastness to Perspiration

AATCC Test Method 61 - Colorfastness to Laundering: Accelerated

AATCC Test Method 107 - Colorfastness to Water

AATCC Test Method 143 - Appearance of Apparel and Other Textile End Products after Repeated Home Laundering

AATCC Test Method 169 - Weather Resistance of Textiles: Xenon Lamp Exposure

AATCC Test Method 195 - Liquid Moisture Management Properties of

Textile Fabrics

AATCC Evaluation Procedure 1 - Gray Scale for Color Change

AATCC Evaluation Procedure 2 - Gray Scale for Staining

AATCC Evaluation Procedure 8 - AATCC 9-Step Chromatic Transference Scale

AATCC Evaluation Procedure 9 - Visual Assessment of Color Difference of Textiles

(Copies of documents are available on line at www.aatcc.org or from the American

Association of Textile Chemists and Colorists, P.O. Box 12215, Research Triangle Park, NC

27709-2215.)

AMERICAN NATIONAL STANDARDS INSTITUTE

ANSI/ASQ Z1.4 - Sampling Procedures and Tables for Inspection by Attributes

(Copies of documents are available online at http://www.ansi.org/ or from the American National

Standards Institute, 1819 L Street, 6th floor, Washington, DC or at http://asq.org/index.aspx or from the American Society for Quality, 600 North Plankinton Avenue, Milwaukee, WI

53203.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D76 - Standard Specification for Tensile Testing Machines for Textiles

ASTM D910 - Standard Specification for Aviation Gasolines

ASTM D975 - Standard Specification for Diesel Fuel Oils

ASTM E29 - Using Significant Digits in Test Data to Determine Conformance with Specifications

ASTM D6413 - Standard Test Method for Flame Resistance of Textiles (Vertical)

ASTM D1777 - Standard Test Method for Thickness of Textile Materials

ASTM D523-89 - Standard Test Method for Specular Gloss

(Copies of documents are available on line at www.astm.org or from the ASTM

INTERNATIONAL, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19426-

2959.)

http://www.ansi.org/ http://asq.org/index.aspx

(Non-Government standards and other publications are normally available from the organizations that prepare or distribute the documents. These documents also may be available in or through libraries or other informational services.)

OTHER PUBLICATIONS

Repeat Insult Patch Test - Modified Draize Procedure

Principles & Methods of Toxicology (4th Edition), A Wallace Hayes (editor) p.1057-1060, 2001

(Copies are available at http://www.taylorandfrancis.co.uk/ or from Taylor and Francis, 325

Chestnut Street, Philadelphia, PA 19106.)

2.4 Order of Precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 First Article/Lot Acceptance.

First Article. Sample(s) shall be subjected to FAT as specified in 4.3 and 6.3. All requirements are listed singularly (i.e., by themselves). In some cases, verification is performed on a test item that has been previously subjected to another verification test.

Lot Acceptance. Single size lots shall be subjected to Lot Acceptance Testing (LAT).

Samples will be examined for the defects specified in 4.10.1 and subjected to the tests indicated in 4.9, Table VIII. Acceptance criteria shall be specified in the contract. Unless noted otherwise, all LAT will be conducted under ambient conditions.

3.2 Unfinished Shell, Finished Shell, and Finished Helmet. The following definitions shall apply in this document.

a. Unfinished Shell. An unfinished shell shall include the raw shell and attachment holes.

The shell shall not include primer, paint [coating], edging, edging adhesive, and suspension system attachment material. The unfinished shell shall include benchmarks.

b. Finished Shell. A finished shell shall include the shell, any primer, coating, and texturing aggregate, all attachment holes, and any edging and adhesive to hold the edging on.

c. Finished Helmet. A finished helmet includes the finished shell plus all suspension system attachment material (i.e., hook disks or hook tape), any Night Vision Goggles

(NVG) bracket integration components (not including the bracket itself or the bracket bolt), a complete suspension system, and a complete retention system including any attaching hardware or hardware spacers, assembled in the standard configuration.

3.3 Shell Design and Shape. The shape of the finished shell when measured without surface finish and edging, shall have the same shape as shown on drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, 2-1-2576, and all subsidiary drawings and parts lists. These Government drawings are for guidance only. Once the Offeror submitted drawings are approved; they become a part of the contract and no deviation will be allowed without documented Government approval. The measurements for the shape of the helmet shall be taken to the inside surface only. The outside surface is defined by the inside surface plus the thickness as specified in

3.3.2.1. Testing shall be conducted in accordance with 4.10.2.

Shell Construction. Upon removal from the mold, the outer and inner surfaces of the unfinished shell, excluding the bottom edge, shall be finished smooth and even. Both the inside and outside surfaces of the shell shall be free from any hole, void, delamination, blister, cracking, crazing, dry spot, area of non-resin flow, and any pit greater than 0.125-inch diameter or the depth of one ply of the ballistic material, whichever is less, in order to provide a smooth continuous surface. If fabric construction is used, there shall be no exposed ends of the fabric fiber showing. There shall be no raised fibers, raised pleats, raised wrinkles, or raised creases longer than 1 inch on the interior or exterior surfaces. Processing procedures and methods capable of providing uniform properties shall be used. Patching or repair of any ballistic material shall not be performed after the material has been molded without documented

Government approval. Remolding of helmet shells made with thermoplastic materials is permitted. Remolding of helmet shells made with materials other than thermoplastic composites is not authorized. Plans to correct cosmetic imperfections, which fall within the acceptable criteria detailed above, shall be submitted for Government written approval prior to implementation; plans submitted for approval shall include a detailed description of all tools, materials, and methods necessary to produce the helmet shell. All submitted and approved manufacturing, production plans, and other required contracting documents and processes (i.e., Technical Data Package, Dry Layup, Production Process Package, etc.) shall not be altered by the contractor without additional written approval. Such plans that achieve written Government approval shall become part of the documented production process. Cosmetic improvements shall not degrade ballistic material properties. More than one material (hybrid construction) may be used to achieve best combination performance requirements listed in the document. Testing shall be conducted in accordance with 4.10.1.

Shell Thickness and Uniformity. The following dimensional criteria are based on an unfinished shell. Testing shall be conducted as required in 3.10 in accordance with 4.10.3.

3.3.2.1 Shell Thickness. The maximum thickness for the helmet shell shall not exceed 0.400-inch regardless of the nominal thickness of the shell. Thickness variations in the shell shall be gradual. For Type II helmets, shell thickness in the area of the NVG bracket shall be of a thickness to accommodate and assure appropriate function of the NVG Front Bracket Kit (NSN

5340-01-509-1467). Shell thickness in this localized area for Type II helmets may have non-gradual variations as needed to accommodate the NVG hardware.

3.3.2.2 Shell Uniformity. The shell thickness shall not vary by more than 0.100-inch over the entire surface of the shell. For Type II helmets, shell thickness may vary by greater than 0.100-inch in the area of the NVG bracket as needed to meet requirements in 3.3.2.1 and 3.11.1.

Benchmarks. The unfinished and finished shell shall have benchmarks located at the front, crown, left side, right side, and rear locations on the interior and exterior of the shell as shown on drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, and 2-1-2576. The benchmarks shall be clearly visible. Testing shall be conducted in accordance with 4.10.4.

3.3.3.1 Benchmarks – Unfinished Shell. Benchmarks on an unfinished shell are required for

FAT. Benchmarks shall be located on both the inside and outside periphery of the shell. The periphery benchmarks shall extend 0.500 (+ 0.250 / -0.00) - inch upward from the shell edge. A benchmark shall be located on the inside crown of the unfinished shell. The crown benchmark shall be a “+” with each leg measured 0.250 (± 0.125) - inch long from the intersection of the

“+” with one leg of the “+” pointing toward the front of the shell, one to the rear, and one each to the left and right sides of the shell.

3.3.3.2 Benchmarks - Finished Shell. Benchmarks on a finished shell are required for FAT.

Vendors may place benchmarks on the helmet shell, integrally molded edge trim, or on a one-piece molded construction. The benchmarks must be clearly visible. If an integrally molded edging is used (as defined in 3.3.5) and the edging covers any portion of previous benchmarks from an unfinished shell, periphery benchmarks may be located on the integrally molded edging and shall be at least 0.200 (+0.05 / -0.00) – inch long. If a bonded one-piece molded edging is used, and the edging covers any portion of previous benchmarks from an unfinished shell, periphery benchmarks may be located on the bonded one-piece molded edging and shall be at least 0.200 (+0.05 / -0.00) inches long. If a bonded one-piece cut to length edging is used, and the benchmarks are located at the periphery of the shell, the benchmark length shall extend a distance of 0.500 (+0.250 / -0.375) of an inch up beyond the top edge of the edging. The crown benchmark shall only reside on the interior of the finished shell. The crown benchmark shall be an “+” with each leg measured 0.250 (± 0.125) of an inch long from the intersection of the “+” with one leg of the “+” pointing toward the front of the shell, one to the rear, and one each to the left and right sides of the shell. The benchmarks shall be clearly visible on a coated shell.

Attachment Holes. There shall be no delamination greater than 0.125-inch from the edge of the hole or other damage of the shell material as a result of making the hole. Any fraying (i.e., uncut material attached at the edge of the hole) as a result of making the hole shall not be at a length of more than 0.125-inch. Additionally, the hardware shall pass through the hole freely and not be impeded or obstructed by any frayed material. Finished helmets shall be examined for conformance in accordance with 4.10.1, 4.10.1.1, and 4.10.2.

3.3.4.1 Retention System Holes. For Type I and Type II helmets, holes for the retention system, after application of the coating, shall be of the diameter as shown on drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, and 2-1-2576. The retention system hardware must pass through the holes freely without obstruction, by hand. Testing shall be in accordance with 4.10.1, 4.10.1.1, and 4.10.2. For Type III helmets, there shall be no holes for the retention system.

3.3.4.2 Night Vision Device (NVD) Hole. For the Type II and Type III helmets, the

Contractor shall bear the responsibility of the hole placement. The Contractor shall develop a template for the hole placement using NVD Bracket Kits cited in 3.11. The diameter of the hole shall be 0.200 (±0.010) of an inch. The application of coating and aggregate shall not impact this hole diameter and tolerance requirement. Testing shall be conducted in accordance with 4.10.1, 4.10.1.1, and 4.10.2.

Edging. The finished shell shall have a firmly bonded, structural, or an integrally molded edging that protects the periphery of the finished shell from delamination, wear, cuts, tear, and infiltration of environmental elements and fluids. An integrally molded edging is co-molded at the time of shell molding, not applied in an operation subsequent to shell molding.

The edging itself shall not be susceptible to cutting, wear, or tear. The edging shall completely cover the bottom edge of the shell and extend up the sides a minimum of 0.30-inch of the finished shell. If the edging is a non-integral component of the molded shell, then the edging shall consist of a one-piece molded construction or one piece cut to length. If the edging is cut to length, the cut end shall be placed at the rear center of the shell and the butt ends shall not overlap and any gap between the ends shall not exceed 0.060-inch. The edging shall be firmly and completely attached to the finished shell, i.e., there shall be no unbounded areas. The edging shall be rounded at the corners with a minimum radius of 1/16-inch. A corner shall be defined as the transition between the edge of the shell and the inside of the shell and the edge of the shell and the exterior of the shell, i.e., the “lower” part of the edging. The standoff of the applied edging from the shell (the sides as opposed to the edge or rim) shall be a maximum of 0.125-inch, for both inside and outside surfaces. The edging shall be the same color as the exterior of the finished shell (see 3.3.6). Testing shall be conducted in accordance with 4.10.1 and 4.10.5.1.

3.3.5.1 Edging Adhesion. The edging shall remain firmly attached to the finished shell when tested as specified in 4.10.5.2.

3.3.5.2 Edging Adhesion After Heat Aging. The edging shall not peel back more than 0.25-inch. For structural and/or integrally molded edging, the edging shall not move down more than

0.125-inch. Testing shall be conducted in accordance with 4.10.5.3.

Coating. Coating shall be applied to the exterior of the helmet shell including the outside of the edging. The coating for Foliage Green 504 helmets shall conform to MIL-DTL-

64159B (either Type is permissible), color Foliage Green 504. The coating shall completely and uniformly cover the shell surface and the outside of the edging. After drying, no cracks, scuffed areas, blemishes such as peeling, blistering or flaking, foreign matter appearing on or embedded in the finish shall be visible in the coating. The coating shall be applied in accordance with the manufacturer’s instructions that has been reviewed and Government approved prior to production. The bottom and inside edges of the edging are not required to be coated. The outside of the edging requires coating. After drying, no cracks, scuffed areas, blemishes (such as peeling, blistering or flaking), foreign matter embedding in or appearing on the finish shall be visible on the coating. While coating is not required for the interior helmet shell, if applied, it shall be Foliage Green 504. If the interior of the helmet is not fully painted and if the line between the painted and unpainted surface is not covered by the edging or occurs on the edging, the line between the unpainted surface and the painted surface must be uniform from helmet to helmet with a clean smooth edge without bleed over or other observable workmanship flaws.

The coating shall be completely cured (not be wet or tacky to the touch) at time of final packaging. Hardware exposed on the exterior and interior of the shell (e.g., screw heads) shall not be coated. Testing shall be conducted in accordance with 4.10.1.

3.3.6.1 Shell Surface Preparation. Prior to the application of any coating to the surface of the unfinished shell, the unfinished shell shall be appropriately prepared in order to meet the requirements for finish provided by the coating manufacturer. Permissible surface gaps and pits on the outside surface (and inside surface if painted) of the finished shell (see 3.3.1) may be filled with suitable materials (such as Acryl-Green Spot Putty) to provide a smooth and continuous surface. The rework of defects affecting ballistic material, such as filling blisters of any size, is not permitted. If surface preparation includes abrading, then the ballistic material shall show no signs of being visibly cut, gouged, or raised. Before application of the final coating the surface shall be free of any contaminants including dust, oil, grease, or any other foreign matter. Testing shall be conducted in accordance with 4.10.1.

3.3.6.2 Adhesion of Coating. The coating, when cut into squares, shall not lift more than 50 percent of the coverage of any square. A slight unevenness of the edges of any square shall not be considered cause for test failure. Testing shall be in accordance with 4.10.6.

3.3.6.3 Infrared Reflectance. The texturing and Foliage Green 504 color coating (for the finished shell) shall meet the spectral reflectance requirements of Table I. The infrared reflectance requirement is replicated from MIL-DTL-64159B for Foliage Green 504. Testing shall be in accordance with 4.10.6.1.

Table I. Spectral Reflectance Limits for Foliage Green 504.

Wavelength

Nanometers

(nm)

% Reflectance

Min Max

600 8 18

620 8 18

640 8 20

660 10 26

680 10 26

700 12 28

720 16 30

740 16 30

760 18 32

780 18 34

800 20 36

820 22 38

840 24 40

860 26 42

3.3.6.4 Specular Gloss. The outer surface of the finished shell shall have a specular gloss as specified in Table II. The specular gloss requirement is replicated from MIL-DTL-641529B for

Foliage Green 504. Testing shall be in accordance with 4.10.6.2.

Table II. Specular Gloss for Foliage Green 504.

Specular gloss for Foliage Green 504 Minimum Maximum

60 degree - 1.0

85 degree - 3.5

3.4 Retention System and Attaching Hardware. For Type I and Type II helmets, the helmet retention system and attaching hardware shall be in accordance with all requirements specified in the Product Manager Soldier Protective Equipment (PM SPE) Purchase Description

(PD), AR/PD 12-01, and drawings 07-99-121, 07-99-101, and SPE-HP-15-216-A. For Type III helmets, the retention system shall be a boltless retention system as specified in APPENDIX C.

Retention System Attachment Points. For Type I and Type II helmets, four (4) attaching points shall be used for the chinstrap/nape strap, two on the front half of the helmet and two on the rear half, each symmetric about the helmet mid-sagittal centerline. The attaching points shall use the holes referenced in 3.3.4.1. The attaching points shall be in accordance with drawings 2-1-2515, 2-1-2516, 2-1-2517, 2-1-2518, and 2-1-2576. Testing shall be in accordance with 4.10.7.1 and 4.10.7.2. For Type III helmets, the boltless retention system shall attach to the interior surface of the shell. The boltless retention system shall not attach to the outside of the shell or the edging. Testing shall be in accordance with APPENDIX C, paragraphs C.4.3 and

C.4.4.

Static Pull Strength. Type I and Type II helmets shall meet the requirements in accordance with AR/PD 12-01. Testing shall be in accordance with 4.10.7.1. Type III helmets shall meet the requirement in accordance with APPENDIX C, paragraph C.3.4.2.1. Testing shall be in accordance with APPENDIX C, paragraph C.4.3.

Dynamic Pull Strength. Type I and Type II helmets shall meet the requirements in accordance with AR/PD 12-01. Testing shall be in accordance with 4.10.7.2. Type III helmets shall meet the requirement in accordance with APPENDIX C, paragraph C.3.4.2.2. Testing shall be in accordance with APPENDIX C, paragraph C.4.4.

3.5 Suspension System. The helmet shall utilize a modular pad suspension system consisting of a series of pads that act as the suspension system between the wearer’s head and the helmet shell. The pads shall possess means of easy attachment, removal, and reattachment to the inside helmet shell. The pad suspension system shall attach, remove, and reattach to the helmet shell via hook tape disks permanently adhered to the inside of the helmet shell. The pads shall remain firmly in place when attached. The ease of attachment of the pads and the ability to attach the pads where the wearer desires (i.e., in a variety of locations) shall permit accommodations among different sized and shaped heads. There are three (3) different pad shapes that form the suspension system: round, trapezoidal, and oblong. A complete pad suspension kit shall consist of seven (7) pads as follows: one (1) round pad (crown), two (2) trapezoidal pads (front and back), and four (4) oblong pads (distributed around the perimeter to achieve comfort and stability). Drawing 2-1-2566 shows the shapes and dimensions of the pads.

The shape of the pad shall meet the shapes shown in Drawing 2-1-2566 with a tolerance of (± 1/8 inch). The 3/4-inch thick pad set shall be made up of all 3/4-inch thick pads and shall be within

0.0625 inch of the nominal thickness. Testing shall be conducted in accordance with 4.10.8.1.

Samples shall be examined for the defects specified in 4.10.1. Mandatory source for this component shall be in accordance with 6.8. All helmet Types specified in 1.2 shall use this mandatory source.

Pad Construction. The pad shall have at least three basic layers or be designed in such a way as to function in three ways: an inner layer shall contact the wearer’s head, a padding layer shall provide the standoff, comfort, protection and stability, and an outer material layer which attaches the pad to the hook disk inside the helmet shell. The three layers shall be permanently joined around the perimeter to prevent disassembly. Testing shall be conducted in accordance with 4.10.8.2.

3.5.1.1 Inner Layer Material. The inner material that contacts the wearer’s head shall wick moisture away from the wearer’s head and absorb it. The color of the inner material shall be

Foliage Green 504 for all helmet classes. Testing shall be conducted in accordance with

4.10.8.1, 4.10.8.2, 4.10.8.5, and 4.10.10.1.

3.5.1.2 Padding Layer Material. The padding material shall provide standoff, comfort, protection, and stability. The padding material shall not absorb or hold moisture when tested in accordance with 4.10.8.4. If the pad has increased in weight more than 3 percent (3%) then the result shall constitute test failure. The pad may consist of multiple layers. Thickness of this layer shall provide for the bulk of the overall pad thickness required. Testing shall be in accordance with 4.10.8.2.

3.5.1.3 Outer Layer Material. The outer material shall be made of a loop-type material and allow the pad to be attached to the inside of the helmet shell. The material shall have an average peel strength no less than 2.8 pounds per inch of width when tested in accordance with 4.10.8.6.

It is desirable that the outer material interface with the currently fielded hook disk (3M p/n

SJ3572). The color shall be Foliage Green 504 for all helmet classes. The outer material shall interface with hook disk. Testing shall be conducted in accordance with 4.10.8.1, 4.10.8.2, and

4.10.10.1.

Pad Compression Durability. The pads shall be constructed such that they can withstand multiple compressions without failing. Each pad shape and thickness shall be subjected to repeated 1/4-inch compressions and show no signs of degradation. Degradation includes, but is not limited to, the structure of the pad losing its resiliency, not returning to its original shape, and thickness. There shall be no physical damage to any of the pad components.

Physical damage includes, but it is not limited to, breakage of threads (if used), seams, or closures, damage to any of the components such that they do not return to its original shape and thickness. Testing shall be in accordance with 4.10.8.3.

3.6 Suspension System Attachment Material.

Suspension System Attachment. The attachment material shall possess means of easy attachment, removal, and reattachment of the suspension system to the finished shell with no special tools required. The suspension system shall remain firmly in place when attached.

Testing shall be in accordance with 4.10.1.

Attachment Material Shape. Attachment material shape is at the discretion of the contractor. Shape uniformity is required. Testing shall be in accordance with 4.10.1.

Attachment Material Coverage. Any means to attach a suspension system component to the inside of the shell shall be applied to the inner surface of the shell and shall interface with the outer material of the suspension system. No attachment material shall be installed in the ear dome area of the finished shell. Additionally, no attachment material shall cover any molded-in markings. An adequate amount of attachment material shall be installed on the interior of the finished helmet to allow movement of the suspension system components into any position and to allow securing of the helmet cover and retention system. Testing shall be conducted in accordance with 4.10.1 and 4.10.9.1.

Attachment Material Durability. Attachment material for the affixing of suspension systems to the interior surface of the helmet must be durable. If an adhesive mechanism is used, no attachment material should have air bubbles, or gaps between the affixed surface and the finished shell. At no time shall removal of any suspension system component off the finished helmet cause the attachment material to become separated from the finished helmet. The attachment mechanism shall firmly affix the attachment interface to the inner surface of the finished helmets with no lifting of attachment material on any contours within the finished helmets. The attachment material shall remain affixed to the helmet shell after twenty-two (22) cycles of installation and removal of suspension system components. At no time shall removal of any suspension system component cause the attachment material to become separated from the finished shell. Testing shall be in accordance with 4.10.9.2.

Colorfastness. Attachment material shall exhibit colorfastness to laundering, crocking, perspiration, and water. The materials shall meet or exceed the requirements listed in

Table III. Testing shall be conducted in accordance with 4.10.10.

Table III. Inner and Outer Material Colorfastness.

Colorfastness to Laundering (1 cycle) Color Change Staining Polyester, Nylon

Grade 3 or better

Grade 3 or better

Colorfastness to Crocking Dry Wet

Colorfastness to Perspiration Color Change

Grade 3 or better

Colorfastness to Water Color Change

Grade 3 or better

3.7 Ballistic Protection. The finished helmet shall provide ballistic protection

(fragmentation and 9mm projectiles). Protection shall meet the requirements set forth in this document throughout the entire surface area of the finished helmet unless specified otherwise in this document.

Fragmentation Protection – Minimum V50 Ballistic Protection Limits (V50 BL(P)).

The finished helmet shall be capable of providing the minimum V50 BL(P)s listed in Table IV at

0o (±5o) obliquity against the specified right circular cylinder (RCC) and Fragment Simulating

Projectile (FSP) projectiles when tested in accordance with 4.10.11.1, 4.10.11.2, and, 4.10.11.3 under the following conditions:

a. Ambient (see section 4.6 and 4.10.11.6.1)

b. Extreme hot (see section 4.10.11.6.1)

c. Extreme cold (see section 4.10.11.6.1)

d. After immersion in seawater (see section 4.10.11.6.2), tested at ambient temperature

e. After exposure in weatherometer (see section 4.10.11.6.3), tested at ambient temperature

f. After accelerated aging (see section 4.10.14.13), tested at ambient temperature

Table IV. Minimum V50 BL (P)s.

Projectile Minimum V50 BL(P) at 0° (±5°) Obliquity (ft/sec)

2-grain RCC 1/ 4200

4-grain RCC 3475

16-grain RCC 2475

64-grain RCC 1750

17-grain FSP 2/ 2200 1/ Right Circular Cylinders shall be in accordance with Figure 1.

2/ Fragment Simulating Projectile – MIL-DTL-46593B with Amendment 1, 11 August 2008, with the exception of

Hardness Testing per ANSI/ASQ Z1.4, Special Inspection Level S-3.

V50 ballistic limit testing shall be performed in accordance with 4.10.11.3.

Resistance to Penetration (RTP) – 9mm. The finished helmet, including any hardware exposed on the outside of the shell, shall be resistant to penetration from a 9mm Full Metal

Jacketed Round Nose (FMJ RN) bullet with a nominal mass of 124 grains in accordance with

National Institute of Justice (NIJ) 0106.01, Ballistic Resistance of Body Armor, at 1400 (+50, -0) feet per second (ft/sec) at 0o (±5o) obliquity when tested in accordance with 4.10.11.1, 4.10.11.1.2, and 4.10.11.4 under the following environmental conditions.

a. Ambient (see section 4.6)

b. Extreme hot (see section 4.10.11.6.1)

c. Extreme cold (see section 4.10.11.6.1)

d. After immersion in seawater (see section 4.10.11.6.2), tested at ambient temperature

3.7.2.1 First Article Testing (FAT), 9mm Resistance to Penetration (RTP) Helmet

Requirement.

3.7.2.1.1 FAT Part A: There shall be no complete penetrations in the first twenty-two (22) impacts (helmet shell, eleven (11) helmets required). At least four (4) impacts shall be in each of the four (4) environmental conditions. The three (3) remaining helmets will be subjected to each condition specified (high temperature, low temperature, and seawater). Should there be at least one (1) complete penetration in the first twenty-two (22) impacts then testing will be stopped and the design does not meet the 9mm RTP requirement for the finished helmet.

3.7.2.1.2. FAT Part B: If there have been no complete penetrations in the first twenty-two

(22) impacts as specified in Part A, then testing will continue in accordance with the FAT matrix as specified in.

3.7.2.1.3 RTP testing on the helmet shall meet a Probability of no Penetration (P(nP)) with

90% Lower Confidence Level (LCL) for 9mm RTP testing in accordance with Table V when the LCL is calculated using the Clopper-Pearson method. The aggregate condition will be determined by combining all shots including the first twenty-two (22) impacts. Other conditions will be determined by combining all shots that include the stated condition (i.e. all front, all ambient medium, etc.). Testing shall be in accordance to 4.10.11.1.2.1.

Table V. RTP Lower Confidence Levels

Conditions

LCL

(P(nP) / Confidence)

Allowable Complete

Penetrations

Aggregate 96 / 90 3

Size 89 / 90 2

Environment 89 / 90 2

Location 89 / 90 2

Size by Location 71 / 90 1

Environment by Location 71 / 90 1

Size by Environment 71 / 90 1

3.7.2.2 First Article Testing (FAT), Resistance to Penetration (RTP) Hardware Requirement.

For Type I and Type II helmets, hardware RTP testing on the helmet will be calculated separately from the helmet RTP. 9mm RTP hardware testing shall meet a 90% Probability of no

Penetration (P(nP)) with 90% Lower Confidence Level (LCL) when the LCL is calculated using the Clopper-Pearson method. Testing shall be in accordance with 4.10.11.1.2.2.

3.7.2.3 Lot Acceptance Testing (LAT), RTP Requirement.

3.7.2.3.1 LAT Part A: There shall be no complete penetrations in the first five (5) impacts.

Should there be ≥ one (1) complete penetration in the first five (5) impacts then testing will be stopped and the lot does not meet the 9mm RTP requirement for the finished helmet.

3.7.2.3.2 LAT Part B: If there have been no complete penetrations in the first five (5) impacts as specified in Part A, then testing will continue in accordance with the LAT matrix specified in APPENDIX A. The RTP requirement will then be based on the accept/reject criterion specified in the LAT section of APPENDIX A. Testing shall be in accordance to 4.10.11.4.

Ballistic Transient Deformation (BTD). BTD shall be used for Government reference.

3.7.3.1 Ballistic Transient Deformation - FAT. BTD shall be measured during RTP testing for Government reference under the environmental conditions specified in 3.7.2 at 1400 (+50, -0) feet per second at 0° (±5°) obliquity. An Upper Tolerance Limit (UTL) for BTD shall be calculated and used for Government reference as described in APPENDIX B. The Government reserves the right to purchase additional helmets for use in additional BTD evaluation. Testing shall be conducted in accordance with 4.10.11.1.3 and 4.10.11.5.

3.7.3.2 Ballistic Transient Deformation – LAT. During LAT, BTD shall be measured during

RTP testing for Government reference. Testing shall be conducted in accordance with

4.10.11.1.3 and 4.10.11.5.

3.8 Weight. The maximum weight of the finished helmet system, as described in section

3.2.0, shall not exceed the weights listed in Table VI. This requirement applies to all helmet

Types as defined in 1.2. Table VI displays weights for each size corresponding to a 15% weight reduction from the legacy ACH. Upon contract award, the weight requirement for each size shall be changed to match the maximum weight for each size as proposed in the winning proposal via Engineering Change Proposal (ECP). These proposed weights shall not exceed the weights in Table VI. All FAT and LAT finished helmets shall be equal to or below the new maximum weight requirement as adjusted via this ECP. Each helmet system size, Small (S), Medium (M), Large (L), Extra Large, (XL), and Double Extra Large (XXL), shall have its own category of weight as seen below in Table VI. Five (5) finished helmets of each size (S through

XL) shall be tested. Testing shall be conducted in accordance with 4.10.12.

Table VI. Weights.

Helmet

System Size

Finished Helmet

Maximum Weight (lbs)

S 2.499

M 2.601

L 2.813

XL 3.298

XXL 3.400

3.9 Blunt Impact Protection. The finished helmet shall provide non-ballistic impact protection to the wearer by reducing acceleration of the head during low velocity blunt impact events at various temperatures and impact sites. Blunt impact protection testing on the helmet shall meet a Probability of Under Limit (P(uL)) with 90% Lower Confidence Level (LCL) for blunt impact testing in accordance with Table VII when the LCL is calculated using the Clopper-

Pearson method. A measurement shall be considered under the limit if it is not in excess of

150g, where g is gravitational acceleration due to earth’s gravity at sea level. Greater impact protection (i.e., lower g) is desired as an objective. Following blunt impact testing, there should be no damage to any part of the retention system or pad system. Also, there shall be no physical damage to the helmet shell that degrades ballistic performance such as delamination, ply separation, or shell fracture. If physical damage such as the above criteria is evident on the inside surface of any finished helmet, additional testing shall be conducted. The Government will conduct a 9mm RTP test approximately at the center of the damage on the mirrored location of the finished helmet exterior of each damaged location and in accordance with section

4.10.11.4. An impact that is off the center of the damage shall be considered a fair shot with a result of a complete or partial penetration. Additionally, there shall be no indentation on the exterior of the helmet shell in excess of 0.20-inch present after blunt impact testing. If deemed necessary (excluding the 0.20-inch indentation requirement), the Government will analyze the damage and conduct a non-invasive imaging scan (i.e., CT Scan) of the sample to confirm the damage. Each affected area with damage (visually obvious damage or visually borderline damage confirmed by non-invasive imaging scan) will be impacted with a 9mm projectile and a partial or complete penetration will be documented as described in sections 6.5.2 and 6.5.3.1.

Only the front, crown, right side, left side, and rear locations shall be included in the analysis.

The Government reserves the right to impact the nape location after all locations on a helmet have been tested. BTD may be measured for Government reference. If more than twenty-two

(22) impacts are required, RTP testing on the helmets shall meet a minimum of 90% Probability of no Penetration (P(nP)) with 90% Lower Confidence Level (LCL) for 9mm RTP testing when the LCL is calculated using the Clopper-Pearson method. If twenty-two (22) impacts or less are required, 100% of the impacts must result in partial penetrations to meet the requirement. The helmet will fail the blunt impact test if the ballistic data does not meet a 90% P(nP) with 90%

LCL or if there is one or more complete penetrations as described previously. Testing shall be in accordance with 4.10.13.

Table VII. Blunt Impact Protection Lower Confidence Levels

Conditions LCL (P(uL) / Confidence)

1st Impact | 2nd Impact

Impacts Over 150g Allowed

1st Impact | 2nd Impact

Aggregate 90/90 | 80/90 11 | 26

Size 81/90 | 73/90 4 | 7

Environment 81/90 | 75/90 6 | 9

Location 79/90 | 69/90 2 | 4

3.10 Operating Environment. All helmet components shall be constructed such that they can withstand various environmental extremes without degradation.

Seawater Resistance. There shall be no structural, visible or operational degradation to the finished shell when subjected to immersion in seawater. The finished shell shall show no evidence of softening, peeling, blistering, cracking, delamination, or increase in weight of greater than three (3) percent over dry weight or increase in thickness greater than 6.0 percent when tested in accordance with 4.10.3, 4.10.12, and 4.10.14.1.

Weatherometer Resistance. The finished shell shall experience no structural, visible, or operational degradation to include evidence of cracking, blistering, delamination, ply separation, separation of edging, increase in thickness greater than 6.0 percent, finish defects, or ballistic degradation when tested in accordance with 4.10.3 and 4.10.14.2. Additionally, the requirements of 3.7.1 (e) shall be met after weatherometer exposure (see 3.7.1).

Field Agent Resistance. The finished shell, when exposed or subjected to the following agents shall show no evidence of softening, peeling, delamination, ply separation, or tackiness. Testing shall be in accordance with 4.10.14.3.

a. DEET insect repellent, Personal Application, NSN 6840-01-284-3982, O-I-503 Type

II, Concentration A

b. Gasoline, ASTM D910

c. Motor Oil, MIL-PRF-2104J

d. Hydraulic fluid, petroleum base, MIL-PRF-6083G

e. Fire resistant hydraulic fluid, MIL-PRF-46170E

f. Fuel Oil, Diesel, ASTM D975

g. Turbine Fuel, Aviation, F-24, NSN 9310-00-359-2026, MIL-STD-3004D, ASTM D1655-11b

h. Rifle Bore Cleaning Compound, NSN 6850-00-224-6656, MIL-PRF-372E(2)

i. Lubricating Oil, Semifluid, Weapons (LSA), NSN 9150-00-935-6597

j. Lubricating Oil, Arctic, Weapons, NSN 9150-00-292-9689

k. Face paint, Camouflage, NSN 6850-01-493-7309

Flame Resistance. The finished shell shall be self-extinguishing with no after-flame greater than 2.0 seconds (Threshold), 0.5 seconds (Objective). Flaming before the withdrawal of the flame source is permitted according to ASTM D 6413. There shall be no melting or dripping. It is desired, however, that the finished shell be ignition resistant. Testing shall be conducted in accordance with 4.10.14.4.

High Temperature Storage and Use. The finished shell shall exhibit no structural, visible, or operational degradation or physical damage when subjected to elevated temperature exposure. The finished shell shall exhibit no cracking, delamination, separation of plies, distortion, softening, change in thickness greater than 6.0 percent, or other deterioration. The paint (coating) shall suffer no degradation or deterioration. Testing shall be in accordance with

4.10.3 and 4.10.14.5.

Cold Temperature Storage and Use. The finished shell shall exhibit no structural, visible, or operational degradation or physical damage when subjected to low temperature exposure.