PWS_for_RFI_Ballistic_Testing.pdf

PERFORMANCE WORK STATEMENT

C.1 GENERAL.

C.1.1 SCOPE. This is a non-personal services contract to perform ballistic lot acceptance testing of personal body armor that protects the Soldier against a variety of threats. Ballistic lot acceptance testing shall be performed in accordance with U.S. Army Aberdeen Test Center (ATC) Internal Operating Procedures (IOPs) for the following three commodity categories: 1) soft body armor, 2) hard body armor, and 3) helmets.

C.1.2 BACKGROUND. The Army has a requirement for ballistic testing of personal body armor that provides protection against a broad range of ballistic threats. Ballistic threats include handgun and rifle ammunition, right circular cylinders, and fragment simulating projectiles; testing is conducted over a range of environmental conditions. Testing to be performed is part of the ongoing body armor program, which includes various configurations of test items.

C.1.2.1 Soft Body Armor. Soft body armor includes, but is not limited to: the Outer Tactical Vest (OTV), Improved Outer Tactical Vest (IOTV), Soldier Protection System (SPS) Torso and Extremity Protection (TEP), Protective Undergarments (PUGs), Plate Carriers, Concealable Body Armor (CBA), and Nape Pads.

C.1.2.2 Hard Body Armor. Hard body armor includes, but is not limited to: the Small Arms Protective Insert (SAPI), Enhanced Small Arms Protective Insert (ESAPI), X Small Arms Protective Insert (XSAPI), Enhanced Side Ballistic Inserts (ESBIs), X Side Ballistic Inserts (XSBIs), and Groin Armor Protective Inserts (GAPIs).

C.1.2.3 Helmets. Helmets includes, but is not limited to: the Advanced Combat Helmet (ACH), Enhanced Combat Helmet (ECH), Integrated Head Protection System (IHPS), Lightweight Fragmentation Helmet (LWH), ACH/ECH/LWH Universal Retention System, and ACH/ECH/LWH Hardware.

C.1.3 HOURS OF OPERATION. The contractor shall execute the requirements of this Statement of Work during the contractor’s normal work hours. Occasionally, extended work hours or “night shift” work hours may be required to meet testing requirements and schedules.

ATC is currently operating under an alternative work schedule. Currently, the ATC normal hours of operation are 0700 to 1630 Monday through Thursday. The work schedule on Friday is 0700 to 1530 hours, with every second Friday off. ATC may deviate from the normal work schedule to meet test requirements.

C.1.4 PERSONNEL.

C.1.4.1 Training, Education, and Certification Requirements.

C.1.4.1.1 Contractor personnel shall be sufficiently trained to be able to safely and competently perform ballistic lot acceptance testing with at least one year of NIJ ballistic testing experience. In addition, contractor personnel shall be trained to be able to safely and competently operate all equipment associated with ballistic lot acceptance testing (for example, laser scanning back face deformation (BFD) measurement instruments and high speed cameras). A “pilot test” or “dry run” shall be conducted by the contractor prior to a Lot Acceptance Test (LAT) or series of LATs to verify procedures and that contractor test personnel are sufficiently trained. At least one Government representative shall be present for the pilot test.

C.1.4.1.2 FARO Operators.

1. Power User training requirements. Contractor Power User personnel shall meet the following requirements: 1) attend 1 week of formal training in the software used for BFD measurements; this training must be conducted by the vendor; 2) complete 2 days of formal training at ATC in the use of the laser arm, software settings, and scanning techniques; 3) complete 40 hours of on the job training (OJT) at the contractor facility; 4) submit to ATC for verification a random sample of 20 percent of all scans performed during OJT.

2. Standard User training requirements. Contractor personnel shall meet the following requirements: 1) attend 1 week of formal training in the software used for BFD measurements; this training must be conducted by the vendor; 2) complete 40 hours of OJT at the contractor facility under the supervision of a Power User.

C.1.4.1.3 The Government reserves the right to request the laser scan files be sent to ATC for verification of scanning competence and accuracy. ATC must approve all software upgrades and related training requirements. The laser arm calibration shall be verified by measuring the distance between the sphere centers of a certified-length “ball bar” using the laser scan arm and currently approved software to verify the system operation on range according to ATC Materials and Measurements Test Branch (MMTB) Internal Operating Procedure (IOP)-0049.

When it becomes available, a “calibrated ballistic artifact” shall replace the ball bar to calibrate the laser scanner.

C.1.4.2 Hazardous Conditions. Contractor personnel may be exposed to the following hazardous conditions during lot acceptance testing: 1) elevated noise levels; 2) hazards resulting from clay working; 3) hazards during emplacing, changing, or removing the weapon;

4) hazards resulting from handling and loading ammunition; 5) hazards from arming/firing flash bulbs for high speed photography; 6) hazards from firing the weapon; and 7) chronic health hazards resulting from personnel exposure to particulate lead (Pb), other hazardous munitions or energetic compounds, and gasoline/oil/diesel fumes or fluids when conditioning test items. The contractor is responsible for ensuring its personnel wear the appropriate personal protective equipment (PPE) (for example, hearing protection and safety shoes) during testing to mitigate risk. Material Safety Data Sheets (MSDSs) for all hazardous materials shall be on hand at the lab where testing is being performed. All contractor facilities and ranges shall be in compliance with current Occupational Safety and Health Administration (OSHA) Pb industry standards and monitoring requirements specified in 29 Code of Federal Regulations (CFR) 1910 (General Industry Pb Standards).

C.1.4.3 Program Management and Key Personnel. The contractor shall designate a Program Manager (PM) who shall be responsible for the overall management of services provided in accordance with the PWS. The PM shall be the contractor’s primary point of contact and shall have the authority to make decisions on all matters on behalf of the contractor. The PM shall interact primarily with the Contracting Officer’s Representative (COR) or Alternate COR (ACOR). The contractor shall designate an alternate who shall be authorized to make decisions in the absence of the PM 10 calendar days prior to the start of performance. The contractor shall submit to the Government, in writing, the names and telephone numbers of the PM and other key range testing personnel who shall perform work under this PWS.

C.1.5 SAFETY. The contractor shall conduct testing in a safe environment in accordance with applicable commercial standards. If a safety issue is identified prior to testing, then the issue shall be addressed before any lot acceptance testing is performed. If a safety issue is encountered during testing, then the on-site Government representative or any contractor personnel working on the range shall have the authority to shut down lot acceptance testing until the safety issue has been addressed or resolved. Any safety issues shall be brought immediately to the attention of Government personnel. The contractor facilities shall be in compliance with OSHA Pb standards and monitoring requirements as stated in 29 CFR 1910.

C.1.6 SECURITY.

C.1.6.1 Range Security. All lot acceptance testing shall be performed at an indoor firing range at the contractor facility. The contractor shall monitor range access and restrict range access to personnel directly involved in the LAT while testing is ongoing.

C.1.6.2 Security of Test Data. The contractor shall safeguard all test data and shall not release any test data pertaining to any part of this contract or any program related to this contract to anyone outside the contractor’s organization, regardless of medium (e.g., film, tape, or document). All test data from the LAT shall be released by and through the Government unless the Contracting Officer has given prior written approval. Requests for approval shall identify the specific information to be released, the medium to be used, and the purpose for the release. In addition, the contractor shall ensure that all test data from the LAT are stored and segregated between the various vendor representatives. The contractor is responsible for ensuring its personnel shall not disclose test information to unauthorized parties.

C.1.6.3 Security Clearance. All contractor personnel performing body armor lot acceptance testing shall possess a current security clearance (at minimum, a Secret clearance) issued by the Defense Industrial Security Clearance Office (DISCO) or have a favorably completed National Agency Check (NAC) or National Criminal Information Check (NCIC). The clearance level required for lot acceptance testing shall be decided on a case-by-case basis and will be included in the task order for each particular LAT. No foreign nationals shall be used in the execution of this contract. The contractor is responsible for providing eligible individuals who meet the security criteria for a LAT and shall have the appropriate documentation available upon request of Government representatives.

C.2 APPLICABLE DOCUMENTS AND AVAILABILITY. The applicable references required for the performance of this PWS will be posted and maintained by the Government in the Versatile Information Systems Integrated On-Line (VISION) Digital Library System (VDLS). The contractor must maintain personnel and accounts for this system. Also see

Section C.5.3.

C.3 REQUIREMENTS.

C.3.1 General.

C.3.1.1 The contractor shall perform lot acceptance testing in accordance with ATC test protocols as specified in the Detailed Test Plan for one or several of the three commodity categories (soft body armor, hard body armor, and helmets). All ballistic testing shall be conducted in an NIJ-certified laboratory.

C.3.1.1.2 The Government reserves the right to witness and/or participate in the testing.

A Government technical monitor and data collector may be on-site at the contractor facility for all testing. In addition, representatives from the involved Program Manager’s Office, a representative from the Defense Contract Management Agency (DCMA), and a vendor representative for the test item may be on-site at the contractor facility for part or all of a LAT.

C.3.1.2 Computer Network Access. The contractor shall employ at least two individuals who apply for and maintain an Army Knowledge Online (AKO) account, a VDLS account, and the electronic certificates necessary to access both. The electronic certificates are associated with a Common Access Card (CAC) or Department of Defense (DoD)-approved External Certification Authority (ECA)-issued or Federal Bridge Certification Authority (FBCA)-issued user certificates. Should one of the individuals with these accounts and certificates leave the company, the contractor shall replace the individual.

C.3.1.3 Velocity Measurement. The contractor must use an ATC-approved device to measure velocity. The currently approved devices include break screens, laser intervalometers, and Oehler Model 57 screens; both devices are used in a double-base configuration.

C.3.1.4 Facility Requirements Prior to Beginning a Task Order. Labs are expected to add an appropriate amount of range time/labor to allow the ATC representative to perform the range(s) validation prior to test. The validation typically lasts 4 hours. Before firing a task order for the hard body armor, soft body armor, or helmet commodity area, the contractor shall jointly verify with an ATC representative the following range setup requirements set forth in Table 1:

1. The number of the range(s) on which lot acceptance testing shall be performed.

2. That all instruments and equipment to be used have been calibrated, that calibration is current, and the date the calibration expires. The FARO laser scanner’s calibration must be verified daily using the ball bar or the calibrated ballistic artifact (when available).

3. The status of the clay block(s) to be used during lot acceptance testing (Table

1). At a minimum, the contractor shall:

a. Verify the date the clay block(s) was packed.

b. Verify the date the clay block(s) was X-rayed.

c. Verify the results of the technical assessment of the X-ray image(s).

d. Verify tracking/labeling of the clay block(s) to be used during testing.

e. Verify the number of shots on the block(s) and the number of system complete penetrations on the block(s).

f. Provide copies of the X-ray of the clay block(s), if requested.

4. The contractor shall verify the velocity setup measurements. Specifically, the contractor shall verify the following:

a. Velocity measurement system wiring. The contractor shall verify that the velocity measurement system is wired in a double-base configuration, as stated in the applicable Test Operations Procedure (TOP) or IOP.

b. Distance from muzzle to velocity screen 1.

c. Distance from velocity screen 1 to velocity screen 2.

d. Distance from velocity screen 2 to velocity screen 3.

e. Distance from velocity screen 3 to velocity screen 4.

f. Distance from velocity screen 4 to target.

5. Velocity Measurement System Verification. The contractor shall verify that the velocity measured by the velocity measurement system is accurate and consistent using Doppler radar (10-shot minimum with less than a 10-ft/s difference).

6. OSHA Compliance. The contractor shall verify that the test range is in compliance with OSHA Pb standards and monitoring requirements as stated in

29 CFR 1910.

Table 1.

Verification Criterion

Verify date the clay block(s) was packed Packed within 1 year Verify date the clay block(s) was X-rayed X-ray performed within 3 months Verify the number of system completes the block has undergone

X-ray performed after 10 system completes

Verify the number of shots taken on the block X-ray performed after 200 shots

Verify technical assessment of the X-ray image

Free of voids and fragments greater than those allowed by Protective Equipment Division (PED) IOP-005, Clay Monitoring.

Verify tracking/labeling of the clay block Clay blocks must be uniquely identified in the format Block No., Task Order No.

Verify date the clay block(s) and headforms were packed

Helmet clay block and paired headforms packed on the same day and within 1 year

Verify FARO laser scanner calibration

Must be calibrated yearly by FARO or an approved FARO calibration center; FARO laser also shall be calibrated at least once on the day of testing and verified with a ball bar or ballistic artifact (when available)

C.3.1.5 The contractor shall re-verify the facility requirements in C.3.1.4 when a) there are any equipment configuration changes on the test range, or b) if equipment is “changed out” or replaced while a test is ongoing (for example, if a velocity screen fails and is repaired or replaced by another screen). This verification shall be jointly performed by the contractor and a Government representative.

C.3.1.6 The contractor is encouraged to utilize multiple ranges to support testing; however, once a range is verified, the contractor shall not switch ranges while lot acceptance testing is ongoing.

C.3.2 Detailed Test Plan (DTP). The contractor shall use test procedures and guidelines contained in the DTP when conducting lot acceptance testing. The DTP provided by the Government to the contractor at the time of order shall detail the testing to be performed. At a minimum, the DTP shall include all test methods and procedures (for example, shot spacing requirements, clay handling requirements, velocity requirements, obliquity, and instrumentation), applicable quality assurance protocols for the LAT (required sample size, etc.), and test criteria (for example, definitions of what constitutes a complete penetration, partial penetration, “fair hit,” “unfair hit,” and fair and unfair velocity measurements during test execution). The contractor shall review the DTP provided by the Government and shall notify the Government of any concerns or issues with the document within 3 days of receipt.

C.3.3 Soft Body Armor Lot Acceptance Test. The contractor shall perform all testing in accordance with the applicable Detailed Test Plan (DTP) and the soft armor TOP. If documents conflict, the DTP takes precedence.

C.3.4 Hard Body Armor Lot Acceptance Test. The contractor shall perform all testing in accordance with the applicable DTP and the hard armor TOP. If documents conflict, the DTP takes precedence.

C.3.5 Helmet Commodity Area. The contractor shall perform all testing in accordance with the applicable DTP and the helmet TOP. If documents conflict, the DTP takes precedence.

C.4 DELIVERABLES AND DELIVERY SCHEDULE.

C.4.1 Reporting. The contractor shall immediately bring any problems or potential problems affecting lot acceptance testing to the attention of the COR, or on-site ATC government personnel; verbal reports shall be followed up with written reports (e-mail is sufficient).

C.4.2 Test Data Sheet. The contractor shall input all test data into a Government-provided outsourcing data collection spreadsheet (“data sheet”) that shall detail each subtest. The contractor shall input the test data in real time, as each LAT evaluation (i.e., test or subtest) or set of evaluations is being performed. At a minimum, this data sheet shall include:

1. Subtest number.

2. Test item identifier.

3. Striking velocity for every shot fired.

4. Charge weight for every shot fired.

5. Result of each shot fired (partial penetration, complete penetration, or misfire).

6. Date and time for every shot fired.

The contractor shall provide the completed test data sheet to the on-site Government representative immediately after completing each subtest. The contractor shall provide one data sheet for each subtest. The completed data sheet shall then be submitted electronically (i.e., uploaded) by the on-site Government representative to an ATC database. The Government will provide the most current data sheet version; this version must be used by the contractor during all testing.

C.4.3 Photographs. The contractor shall take high resolution digital photographs to document lot acceptance testing. Resolution needs to be sufficient to read the test item serial numbers. The photographs to be taken shall be specified in the DTP. At a minimum, these photographs shall consist of pre-shot photographs of the test setup, test item, and clay block or clay-filled headform, and post-shot photographs of the test setup, test item, clay block, clay-filled headform, witness plate, and projectile. Photographs shall be provided to ATC either immediately after the conclusion of a test or subtest or at the end of the day. Each individual photograph shall include a letter/number board in the photograph containing the following information so that the photograph is traceable to the LAT: 1) test name, 2) subtest number, 3) unique test specimen number, 4) shot number, 5) indication of whether the photograph was taken pre- or post-shot, 6) range or location where test is being conducted, 7) date, and 8) nomenclature of test item.

C.4.4 High Speed and Standard Video. The contractor shall perform high speed video imaging as specified in the approved DTP during lot acceptance testing to more completely validate projectile velocity, obliquity, and accuracy, and to validate test results. The high speed video imaging system must include two synchronized high speed video cameras (80,000 frames per second). The contractor shall also utilize ATC-approved software that shall allow the measurement of high speed offsets if requested. Additionally, standard video imagery must be collected to show the following: 1) the front of the target, 2) an overall range shot, 3) and the clay calibration area. If samples undergo conditioning (for example, soaks or high/low temperature), a view of the conditioning area (temperature chamber, etc.) will be required. For soft armor testing, a view of the back of the target may be required. Audio is required for the range cameras and the clay calibration area. Audio is not required for the conditioning areas.

Original data shall be preserved until it has been delivered to and approved by ATC. If high speed photography is required by the DTP, testing must stop if the photography/video equipment becomes temporarily unavailable. The same applies to standard range video.

C.4.5 Meetings. The contractor shall attend planning/coordination meetings, technical meetings, and In Progress Reviews (IPR) as required. These may be held at the contractor facility or at a Government facility. The contractor shall immediately bring any problems or potential problems affecting lot acceptance testing to the attention of the Government; verbal reports shall be followed up with written reports (e-mail is sufficient). The COR will prepare meeting minutes and a list of action items within 2 days after the meeting.

C.4.6 Re-Shooting of Test Items During a LAT. If a test result must be discarded due to failure to meet the test requirement, the contractor shall re-shoot the test. The criteria in the DTP shall be used to determine whether a test item needs to be re-shot. The Government may pay the cost of all retests that are not a result of lab negligence. However, the lab shall be responsible for the cost of retests that result from lab negligence.

C.5 GOVERNMENT-FURNISHED FACILITIES, EQUIPMENT, AUTOMATION

SYSTEMS, MATERIALS, AND SERVICES.

C.5.1 Threat ammunition for testing. In some instances, the Government may provide ammunition that may not be immediately available to the contractor. The contractor shall perform a receiving inspection and is required to verify that the ammunition received is the correct ammunition for the test. The contractor shall track rounds fired by type. All remaining rounds shall be returned to ATC after the test by the contractor.

C.5.2 Shoot Packs for Hard Armor Testing. The Government shall provide a sufficient number of shoot packs. At the completion of testing, the contractor shall return the remaining shoot packs to ATC.

C.5.3 The Government shall provide necessary Purchase Descriptions (PDs), Specifications, TOPs, IOPs, International Test Operation Procedures (ITOPs), DTPs, and drawings to the contractor. If any requirements are revised, then the Government may provide the updated PDs, Specifications, TOPs, IOPs, ITOPs, DTPs, and drawings to the contractor. All necessary documents shall be provided via VDLS. Also see Section C.2

C.5.4 The Government will provide drag correction tables to the contractor to ensure consistency of velocity calculations. If multiple drag correction tables are available, the Government shall indicate which table to use.

C.5.5 The Government will provide all test items for lot acceptance testing to the contractor.

Test items (including any contingency items) will be shipped from APG, MD, or directly from the manufacturer to the contractor facility for testing. All test items (both tested and contingency items) from lot acceptance testing shall be accounted for and returned to APG by the contractor when testing is complete. Shipment of all test items shall be coordinated with the Government by the contractor prior to shipment. The contractor shall provide an account of the final disposition of all test items and contingency items at the end of every LAT.

C.5.6 The Government will provide a unique identifier for each test item and will provide specific instructions for the tests to be conducted, and will clearly indicate the requirements for the test. The Government will provide unique test numbers for all tests to be conducted.

C.5.7 The Government will provide data sheet templates to the contractor. The data sheet will be provided in electronic format. The contractor shall input the test data in real time as each evaluation (i.e., test or subtest) or set of evaluations is being performed and submitted to the Government.

C.5.8 All items provided to the contractor shall be accounted for by the contractor until final disposition instructions are received from the Government. The return of any residual materials shall be coordinated by the COR.

C.5.9 As needed, the Government may provide a single set of chest molds to the contractor.

The Government may provide the contractor with either a ball bar or a calibrated artifact to verify calibration of the FARO laser equipment.

C.5.10 The Government will provide shipping costs for all test items.

C.6 CONTRACTOR-FURNISHED FACILITIES, EQUIPMENT, AUTOMATION

SYSTEMS, MATERIALS, AND SERVICES.

C.6.1 Except for Government-furnished equipment (GFE), the contractor shall furnish all labor, materials, ammunition, and equipment necessary to perform lot acceptance testing in accordance with the requirements of this PWS. In exceptional cases, the Government may provide ammunition as stated in paragraph C.5.1 of this PWS.

C.6.2 The contractor shall provide access to the Internet for ATC witnesses so they can use Virtual Private Network (VPN) access to connect to ATC’s server from the contractor facility.

C.7 TECHNICAL EXHIBITS.

C.7.1 Sample Data Sheets. Data sheets shall be used to capture test data as stated in paragraph C.4.2 of this PWS. Electronic files for the data sheets shall be provided by the Government to the contractor through VDLS. The contractor shall always use the most current version of the outsourcing data sheet, available from ATC through VDLS.

PERFORMANCE

PERIOD OF PERFORMANCE. The period of performance will be four (4) years from date of award.

PLACE OF PERFORMANCE. The primary place of performance shall be the contractor’s facilities; all ballistic testing performed by the contractor under this contract shall be conducted at an NIJ-certified laboratory. Some travel by contractor personnel to Aberdeen Proving Ground (APG) to attend briefings, training sessions, planning/coordination meetings, technical meetings, and IPRs may be required.