ASTM E1978-18

Standard Specification for Shelter, Tactical, Expandable, Two-Side

ABSTRACT
This specification covers a rigid wall, two-side expandable shelter constructed of aluminum-faced, nonmetallic honeycomb sandwich panels and meeting the International Organization for Standardization (ISO) cargo container specification in the transport mode. Design and construction of the expandable shelter shall conform to the requirements specified. The shelter shall be free of panel delaminations and shall meet all physical and environmental requirements specified. Inspection requirements shall be classified as follows: first article inspection; comparison sample inspection; and quality conformance inspection. The following tests shall be performed to conform to the specified requirements: electrical continuity testing; water leakage and operational testing; performance testing; packaging examination; thermal shock test; panel interchange test; floor loads test-static load; roof load test; step test; airtightness test; low temperature test; high temperature test; humidity and temperature aging test; blackout test; panel watertightness test; insert working load test; rail transportability test; impact resistance test; drop test; towing test; water leakage test (shelter mode); water leakage test (container mode); water leakage test (shelter mode fully loaded); water leakage test (container mode fully loaded); fluorescent light temperature test; solar load test; operational test; lifting test; six-high stacking test; longitudinal restraint test; racking test; lashing test; end wall strength test; sidewall strength test; lifting from fork lift pockets test; heat transfer test; adhesion of paint test; panel delamination test; thickness test; electrical system test; and panel frame airtightness test.
SCOPE
1.1 This specification covers a rigid wall, two-side expandable shelter constructed of aluminum-faced, nonmetallic honeycomb sandwich panels and meeting the International Organization for Standardization (ISO) cargo container specification in the transport mode. Nominal dimensions when closed (container mode) are: height 8 ft, width 8 ft, and length 20 ft (2.4 by 2.4 by 6.1 m). Approximate dimensions when expanded (shelter mode) are: height 8 ft, width 22 ft, and length 20 ft (2.4 by 6.7 by 6.1 m).  
1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

General Information

• Status: Published
• Publication Date: 31-Aug-2018
• ICS: 77.150.10 - Aluminium products
• Technical Committee: E06 - Performance of Buildings
• Drafting Committee: E06.53 - Materials and Processes for Durable Rigidwall Relocatable Structures

Relations

• Replaces: ASTM E1978-11 - Standard Specification for Shelter, Tactical, Expandable, Two-Side
• Effective Date: 01-Sep-2018
• Refers: ASTM E874-19 - Standard Practice for Adhesive Bonding of Aluminum Facings to Nonmetallic Honeycomb Core for Shelter Panels
• Effective Date: 01-Jul-2019
• Refers: ASTM E1925-18 - Specification for Engineering and Design Criteria for Rigid Wall Relocatable Structures
• Effective Date: 01-Oct-2018
• Refers: ASTM E1749-18 - Standard Terminology Relating to Rigid Wall Relocatable Shelters
• Effective Date: 01-Oct-2018
• Refers: ASTM E1773-18 - Standard Practice for Sealing Rigid Wall Tactical Shelters with Polysulfide Based Sealants
• Effective Date: 01-Oct-2018
• Refers: ASTM E874-11 - Standard Practice for Adhesive Bonding of Aluminum Facings to Nonmetallic Honeycomb Core for Shelter Panels
• Effective Date: 01-Sep-2011
• Refers: ASTM E1826-11 - Standard Specification for Low Volatile Organic Compound (VOC) Corrosion-Inhibiting Adhesive Primer for Aluminum Alloys to Be Adhesively Bonded
• Effective Date: 01-May-2011
• Refers: ASTM E866-11 - Standard Specification for Corrosion-Inhibiting Adhesive Primer for Aluminum Alloys to Be Adhesively Bonded in Honeycomb Shelter Panels
• Effective Date: 01-May-2011
• Refers: ASTM E1773-10 - Standard Practice for Sealing Rigid Wall Tactical Shelters with Polysulfide Based Sealants
• Effective Date: 01-Nov-2010
• Refers: ASTM E1749-10 - Standard Terminology Relating to Rigid Wall Relocatable Shelters
• Effective Date: 01-Nov-2010
• Refers: ASTM E874-10a - Standard Practice for Adhesive Bonding of Aluminum Facings to Nonmetallic Honeycomb Core for Shelter Panels
• Effective Date: 01-Nov-2010
• Refers: ASTM E1925-10 - Specifiction for Engineering and Design Criteria for Rigid Wall Relocatable Structures
• Effective Date: 01-Oct-2010
• Refers: ASTM E874-10 - Standard Practice for Adhesive Bonding of Aluminum Facings to Nonmetallic Honeycomb Core for Shelter Panels
• Effective Date: 01-Oct-2010
• Refers: ASTM E990-09 - Standard Specification for Core-Splice Adhesive for Honeycomb Sandwich Shelter Panels
• Effective Date: 01-Nov-2009
• Refers: ASTM E865-08 - Standard Specification for Structural Film Adhesives for Honeycomb Sandwich Panels
• Effective Date: 01-Nov-2008

Overview

ASTM E1978-18 specifies requirements for a rigid wall, two-side expandable tactical shelter. This robust, modular shelter is constructed from aluminum-faced, nonmetallic honeycomb sandwich panels. When closed, the shelter conforms to ISO cargo container standards for ease of transportation. Expanded, it provides increased usable space for field operations. ASTM E1978-18 sets out physical, environmental, and performance criteria to ensure each tactical shelter meets stringent durability and functionality standards required in military and emergency environments.

Key Topics

• Design and Materials: Shelters are constructed from durable honeycomb sandwich panels with aluminum facings. All joints, edges, and corners are sealed to prevent moisture intrusion, ensuring environmental protection and the integrity of the shelter over time.
• ISO Compliance: In its transport or "container mode," the shelter meets International Organization for Standardization (ISO) requirements for freight containers, enabling compatibility with standard shipping and transport systems.
• Expandability: The two-side expandable feature increases the shelter’s width when deployed, providing a larger, secure, and climate-controlled space in field settings.
• Performance Testing: The standard mandates comprehensive performance tests, including:
  • Electrical system safety and continuity
  • Watertightness in various configurations
  • Load-bearing tests (floor, roof, doors)
  • Environmental resistance (temperature extremes, humidity, shock, vibration)
  • Structural integrity (drop, impact, stacking, restraint)
  • Operational testing for opening, expansion, and usability
  • Blackout and airtightness for tactical needs
• Workmanship: Detailed specifications address the quality of welding, riveting, finish, and component assembly, reflecting a focus on durability and field readiness.

Applications

The ASTM E1978-18 tactical expandable shelter is vital wherever mobile, rapidly deployable workspace or accommodation is needed:

• Military Deployments: Mobile command posts, field hospitals, equipment storage, or personnel living quarters.
• Disaster Response: Rapid assembly shelters for emergency operations, medical triage, and logistics coordination.
• Remote Operations: Oil, gas, mining, or scientific expeditions requiring transportable, robust shelters that withstand harsh environments.
• Civil Defense and Homeland Security: Secure facilities for communication, planning, or medical support in times of crisis.

Key advantages include:

• Intermodal Transport: Compliance with ISO container standards allows for easy movement by truck, rail, or sea.
• Scalability: Expandable design meets variable space demands without complex assembly.
• All-weather Reliability: Tested to function in extreme temperatures and high humidity, ensuring mission continuity.

Related Standards

ASTM E1978-18 references and operates in conjunction with several important standards to ensure complete quality and compatibility:

• ASTM Standards:

  • E864: Surface preparation for aluminum adhesives
  • E865, E866, E874, E990, E1091, E1826: Adhesives, panels, primers, bonding, sealing, and core materials for honeycomb panels
  • E1749: Terminology for relocatable shelters
  • E1773: Polysulfide-based sealant application
  • E1925: Engineering criteria for relocatable structures

• ISO Standards:

  • ISO 1161: Corner fittings for freight containers
  • ISO 1496-1: Specifications and testing for freight containers

• ANSI/ASQ Z1.4: Statistical sampling for inspection by attributes

• AWS D17.1/D17.1M, SAE-AMS-STD-1595, SAE-AMS-STD-2219: Welding specifications and qualifications

• MIL-STD-810G: Environmental testing for military equipment

• ISO 9001: Quality management systems

Conclusion

ASTM E1978-18 ensures that two-side expandable tactical shelters meet rigorous demands for technical performance, reliability, and transportability. Their ISO-compliant design, verified workmanship, and multi-environment resilience make them essential for modern military, emergency response, and field operations worldwide, while adherence to related ASTM, ISO, and military standards guarantees lasting value and safety.

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: E1978 −18
Standard Specification for
Shelter, Tactical, Expandable, Two-Side
This standard is issued under the fixed designation E1978; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Scope E866 Specification for Corrosion-Inhibiting Adhesive
Primer forAluminumAlloys to BeAdhesively Bonded in
1.1 This specification covers a rigid wall, two-side expand-
Honeycomb Shelter Panels
able shelter constructed of aluminum-faced, nonmetallic hon-
E874Practice for Adhesive Bonding of Aluminum Facings
eycomb sandwich panels and meeting the International Orga-
to Nonmetallic Honeycomb Core for Shelter Panels
nization for Standardization (ISO) cargo container
E990Specification for Core-Splice Adhesive for Honey-
specification in the transport mode. Nominal dimensions when
comb Sandwich Structural Panels
closed (container mode) are: height 8 ft, width 8 ft, and length
E1091Specification for Nonmetallic Honeycomb Core for
20 ft (2.4 by 2.4 by 6.1 m). Approximate dimensions when
Use in Shelter Panels
expanded (shelter mode) are: height 8 ft, width 22 ft, and
E1749Terminology Relating to Rigid Wall Relocatable
length 20 ft (2.4 by 6.7 by 6.1 m).
Shelters
1.2 Thevaluesstatedininch-poundunitsaretoberegarded
E1773PracticeforSealingRigidWallTacticalShelterswith
as standard. The values given in parentheses are mathematical
Polysulfide Based Sealants
conversions to SI units that are provided for information only
E1826Specification for Low Volatile Organic Compound
and are not considered standard.
(VOC) Corrosion-Inhibiting Adhesive Primer for Alumi-
1.3 This standard does not purport to address all of the num Alloys to Be Adhesively Bonded
safety concerns, if any, associated with its use. It is the
E1925Specification for Engineering and Design Criteria for
responsibility of the user of this standard to establish appro- Rigid Wall Relocatable Structures
priate safety, health, and environmental practices and deter-
2.2 ANSI/ASQ Standard:
mine the applicability of regulatory limitations prior to use. ANSI/ASQ Z1.4-2003 (R2013)Sampling Procedures and
1.4 This international standard was developed in accor-
Tables for Inspection by Attributes
dance with internationally recognized principles on standard-
2.3 AWS Standard:
ization established in the Decision on Principles for the
AWS D17.1/D17.1MSpecification for Fusion Welding of
Development of International Standards, Guides and Recom-
Aerospace Applications
mendations issued by the World Trade Organization Technical
2.4 ISO Standards:
Barriers to Trade (TBT) Committee.
ISO 1161-1980Series 1-Freight Containers-Corner Fittings,
Specification
2. Referenced Documents
ISO 1496/ISeries 1-Freight Containers-Specification and
Testing Part
2.1 ASTM Standards:
ISO9001QualitySystems—ModelforQualityAssurancein
E864Practice for Surface Preparation of Aluminum Alloys
Design, Development, Production, Installation, and Ser-
to Be Adhesively Bonded in Honeycomb Shelter Panels
vicing
E865Specification for Structural Film Adhesives for Hon-
2.5 Military Standard:
eycomb Sandwich Panels
MIL-STD-810GEnvironmental Engineering Considerations
and Laboratory Tests
This specification is under the jurisdiction of ASTM Committee E06 on
Performance of Buildings and is the direct responsibility of Subcommittee E06.53
on Materials and Processes for Durable Rigidwall Relocatable Structures. Available fromAmerican Society for Quality (ASQ), 600 N. PlankintonAve.,
Current edition approved Sept. 1, 2018. Published September 2018. Originally Milwaukee, WI 53203, https://www.asq.org.
approved in 1998. Last previous edition approved in 2011 as E1978–11. DOI: Available from American Welding Society (AWS), 8669 NW 36 St., #130,
10.1520/E1978–18. Miami, FL 33166-6672, http://www.aws.org.
2 5
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM 4th Floor, New York, NY 10036, http://www.ansi.org.
Standards volume information, refer to the standard’s Document Summary page on Available from DLA Document Services, Building 4/D, 700 Robbins Ave.,
the ASTM website. Philadelphia, PA 19111-5094, http://quicksearch.dla.mil.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E1978 − 18
2.6 Drawings: materials.Welds shall have thorough penetration, good fusion,
5-4-3118Shelter, Assembly, Two-Side Expandable-60 amp and shall be free from scabs, blisters, abnormal pock marks,
5-4-3201Shelter,Assembly,Two-SideExpandable-100amp cracks, voids, slag inclusions, and other harmful defects.
Welded assemblies shall be cleaned to remove any scale,
3. General Requirements
oxidation products, and excess flux.Any acid used in cleaning
shall be completely neutralized and removed.Welders shall be
3.1 Alternate Components—When this specification or the
certified in accordance with AWS D17.1/D17.1M. Welding
referenced drawings specify use of a specific component “or
equipment and procedures shall conform to AWS D17.1/
equal,” the contractor may substitute a component equal to the
D17.1M.
specified component provided that the contractor complies
with the following requirements. Prior to manufacture of the
3.7 Finish—Coatings shall level out to an adherent,
first article or, if none is required, prior to commencing
continuous, and uniform film without runs, wrinkles, streaks,
production, the contractor shall submit for the purchaser’s
or areas of no film. Any coating damaged during assembly or
approval, a list identifying each proposed “or equal” compo-
examination shall be touched up. There shall be no areas of
nent together with proof that each listed component is func-
rust.Finishshallbefreefromblistering,peeling,andchipping.
tionally equal to the specified component and is compatible
3.7.1 Adhesion of Paint—The shelter shall be capable of
with the end item covered by this specification.The purchaser,
withstanding, without degradation to the finish, the tests as
at his/her option, may require a physical sample of any “or
specified in 11.37.
equal” component. Approval of the submitted listing and
NOTE 1—After top coat application, the shelter in the deployed mode
supportingdataauthorizesthecommencementoffabricationof
shall be stored for a minimum of 168 h at a minimum of 70°F (21°C)
the first article or of production, as applicable, but does not
prior to performing this test.
relieve the contractor of the responsibility that the “or equal”
3.7.2 Color—The color of the paint film shall be compared
componentsperforminaccordancewithspecifiedrequirements
with an appropriate color chip for the paint specified.
when incorporated into the end item.
3.7.3 Thickness—Thickness of the paint film shall be
3.2 Materials and Components—Materials and components
checked as specified in 11.39.
shall conform to the documents listed in Section 2 and as
3.8 Finish and Color—Surfaces shall be of the color,
specified herein. Any change to the proposed materials or
treatment, and finish as shown on the drawings. Top coat
processes must be approved by the purchaser. It is encouraged
paintingshallbeperformedonthefullyassembledsheltersoas
that recycled material be used when practical as long as it
to prevent mismatch of color shading, unless other control
meets the requirements of this specification.
techniques are approved by the purchaser. After top-coat
3.3 Workmanship—The shelter, including all parts and
application, the shelter in the deployed mode (that is, ex-
accessories,shallbeconstructedandfinishedinaworkmanlike
panded) shall be stored in a 70°F (21°C) minimum tempera-
manner with particular attention given to removal of burrs and
ture indoor facility for a minimum of 36 h to ensure adequate
sharp edges, accuracy of dimensions, thoroughness of
coating(s) cure. During this storage period, the shelter doors
soldering, welding, painting, alignment of parts and
and vents shall be opened to permit air circulation within the
assemblies, and the tightness of screws, bolts, and so forth.
shelter.
Gaskets shall not be torn or split and shall be free of finish.
3.9 Manuals—Unless otherwise specified (see 13.2), tech-
Cloth components shall be clean and free of holes, cuts, or
nical manuals shall be provided with each shelter. Stowage
tears.All latches utilized for erection and closing of the shelter
provision for the manuals shall be located as shown on the
shall be properly adjusted before the shelter is prepared for
applicable drawings.
delivery to the purchaser.
3.10 Terminology related to this specification is defined in
3.4 Riveting—Rivetingjointsshallbetight.Thejoinedparts
Terminology E1749.
shall be undamaged, and the rivet heads shall be properly
seated and tight against the bearing surfaces. All the rivets,
4. Design and Construction Requirements
except those used in panel bonding, shall be dipped in
polysulfide sealant just prior to insertion; however, a dab of
4.1 Design and Construction—Design and construction of
polysulfide sealant shall be applied to the head of each rivet.
the expandable shelter shall conform to the requirements
3.5 Cleaning—After fabrication, parts shall be cleaned in specified on the drawings, all subsidiary drawings and parts
lists, and hereinafter. The shelter shall be free of panel
accordance with the drawings.
delaminations and shall meet all physical and environmental
3.6 Welding—Welded joints shall be such that grinding of
requirements specified herein.
the finished weld shall not be a requirement, except when
specified on the drawing. Spot, stitch, and seam welds shall be 4.2 Container Mode—The shelter in the closed or transport
asindicatedonthedrawings.Allsurfacestobeweldedshallbe
mode shall be referred to as a container, hereinafter, for the
cleaned and free from scale, paint, grease, and other foreign purpose of definition. The shelter, in the container mode, shall
be an article of transport equipment meeting ISO freight
container requirements related to cargo containers. The shelter
Copies of drawings are available from U.S. Army Natick Soldier Research,
shall not show structural damage when tested as specified in
Development, and Engineering Center, ATTN: RDNS-SEE-T, 15 General Greene
Avenue, Natick, MA 01760-5018, https://www.army.mil/info/organization/natick. 11.20, 11.22, 11.23, and 11.28 – 11.35, and shall not show
E1978 − 18
TABLE 1 Container Dimensions
Height Width Length
Type
ft in. tol. in. ft in. tol. in. ft in. tol. in.
IC 8 0 +0 −0.1875 8 0 +0 −0.1875 19 10.5 +0 −0.25
(2.438 m) +0 (−5 mm) (2.438 m) +0 (−5 mm) (6.058 m) +0 (−6 mm)
leakage when tested as specified in 11.24 and 11.24.1 – 4.3.3 Resistance to Thermal Shock—Panels shall be resis-
11.24.3. The contractor shall ensure that the shelter receives tant to thermal shock, when tested as specified in 11.6.
Coast Guard Certification for ISO containers. The container’s 4.3.4 Panel Interchangeability—All panels and panel as-
overall dimensions shall be in accordance with ISO freight semblies bearing same part numbers shall be functionally and
container designated IC and are as shown in Table 1. dimensionally interchangeable without modification or re-
working. Individual assemblies shall not be hand picked for fit
4.3 Panels—The panels used as structural members in the
or performance, when tested as specified in 11.7.
container configuration shall structurally meet all transporta-
4.3.5 Delaminations—Delaminations in shelter panels shall
tion and environmental requirements specified herein. Each
be tested as specified in 10.3.4.
panel shall be fabricated as a net panel with aluminum
4.3.6 Panel Frame Airtightness—Weldedpanelframesshall
extrusions bonded about the panel perimeter during panel
be airtight when tested as specified in 11.41.
bonding.The inner and outer skins on all joints shall be sealed
to provide a water barrier against the entrance of moisture to 4.4 Inserts—When tested as specified in 11.8, the following
the core material and to the interior of the shelter. The water sized inserts, where used, shall withstand the torque and
barrier is to be maintained intact at all panel cross-sectional pullout loads as specified in Table 2, without failure of the
openings.Alljointsandedgesshallbeassembledandsealedin inserts, panel, or potting compound.
a manner to prevent collection and retention of moisture.
4.5 Payload—The unit is designed to carry a maximum
Particularemphasisshallbeplacedonthesealingofallmitered
payload of 8050 lb (3650 kg) during transport.
corners. All of the above sealing procedures shall be accom-
4.6 Corner Fittings—The container shall be equipped with
plished in accordance with Practice E1773. Rivet shafts shall
cornerfittingsatthetopandbottomcornersinaccordancewith
be coated with sealing compound before insertion. The sealer
the dimensional requirements for corner fittings for Series-1
shallbeasindicatedonthedrawings.Thecontractorshallhave
freightcontainersasstipulatedinISO1161-1980requirements
the appropriate equipment and facilities, use the correct pro-
for commercial containers. The upper faces of the top corner
cedures in accordance with Practices E874 and E864, and use
fittings shall protrude above the top of the rest of the container
qualified panel components (that is, structural film and core
by a minimum of ⁄4 in. (6 mm). The lower faces of bottom
splice adhesives, corrosion-inhibiting adhesive primer, struc-
cornerfittingsshallprotrudebelowthebottomofthecontainer
tural nonmetallic honeycomb core, and as specified 5052-H34
by a minimum of ⁄16 in. (11 mm).
or 6061-T6 aluminum skins, FRPbarrier strips, 6061-T6 panel
extrusions). Prior to use, all critical panel component materials 4.7 Shelter Mode—The shelter in the erected mode shall be
must be qualified to Specifications E865, E866, E990, E1091,
referred to as a shelter herein for the purpose of definition.
and E1826. There shall be no skin splices in the panels except Hinged shelter panels shall be attached in a manner to ensure
where noted on the drawings. Unless otherwise specified (see
compliance with the environmental test requirements as speci-
13.2),priortoawardofcontract,thecontractorsshallsubmitto fied in 11.6, 11.13 – 11.17, 11.24, and 11.26.
the purchaser a certified copy of a laboratory test report and a
4.8 Exterior Lighting—One area lighting fixture, as shown
copy of their process specification covering fabrication of the
on the drawings, shall be provided with each shelter.
metallic-faced, nonmetallic honeycomb core sandwich panels
4.9 Shelter Electrical System:
they propose to use in the construction of the end item. Using
4.9.1 General—The system shall have all equipment,
theirprocessspecification,thecontractorsshallfabricatequali-
cabling, and other hardware necessary to receive three-phase
fication test sandwich panels and structural film adhesive
120/208 V, 60 Hz power from the base electrical distribution
floating roller peel test specimens, and shall perform tests in
systems, and distribute it to lighting fixtures and receptacles as
accordance with Specification E865 and Practice E874 (see
indicated on the drawings. The 60 A shelters shall be in
13.2).
accordancewithDrawing5-4-3118andallsubsidiarydrawings
4.3.1 Panel Processing—The shelter panels shall be pro-
and parts lists. The 100Ashelters shall be in accordance with
cessed and inspected as specified in Practices E864 and E874,
Drawing 5-4-3201 and all subsidiary drawings and parts lists.
and Specifications E865, E866,or E1826 depending upon
which primer is being used, Specifications E990, E1091, and
Practice E1773. The shelter panels shall be inspected for
TABLE 2 Insert Strength (Proof Loads)
dimensions and flatness in accordance with the Dimensional
and Flatness Inspection of Panel paragraph of Practice E874 Insert (diameter thread size) Pull-Out, lb (kN) Torque, ft-lb (N·m)
(see 10.2). 10–32 1000 (4.5) 10 (13.6)
⁄4 –28 1000 (4.5) 20 (27.2)
4.3.2 Panel Watertightness—Panel assemblies shall not per-
⁄16 –24 2000 (9.0) 20 (27.2)
mit the entry of water (see 10.3.1) when tested as specified in
⁄8 –24 2000 (9.0) 40 (54.2)
11.18
E1978 − 18
All parts of the electrical system shall operate when tested for connections terminating in four protected terminals inside and
electrical continuity as specified in 11.40. outside the shelter, as indicated on the drawings.
4.9.2 Operating Temperature—The wiring system and all
4.9.11 Tools—Tools provided with the shelter shall be read-
individualhardwareitemsshallbecapableofoperatingattheir
ily accessible to personnel when the shelter is in both the
required capacity within an ambient temperature range from
container and shelter configuration.
−60 to 125°F (−51 to 52°C), except that the fluorescent lights
4.10 Nameplates and Product Marking—All markings shall
shall operate from 0 to 125°F (−18 to 52°C), when tested as
conform to the drawings. Each shelter shall be serially num-
specified in 11.14 and 11.15.
bered and provided with a nameplate in accordance with
4.9.3 Current Rating—Allconductorsandappropriatehard-
applicable drawings (see 13.2).
ware shall be rated for current carrying capacity in accordance
4.10.1 Interior Markings—Interior markings shall be as
with the applicable industry standards as specified on the
shown and in the locations shown on the applicable drawings.
drawings. Derating of components may be necessary for an
4.10.2 Exterior Markings—The shelter shall be provided
operating ambient temperature of 125°F (52°C).
with specific exterior markings as shown on the applicable
4.9.4 Finish—Panel boards and all other exposed metallic
drawings.
itemsshallhavefinishesasindicatedonthedrawings(see3.7).
4.9.5 Panel Board—The panel board used will be as indi-
5. Performance Requirements
catedonthedrawings.Itwillbeofdeadfrontconstructionand
have a solid neutral bus, a ground bus, and a 60 or 100 A
5.1 Floor Loads—The shelter floor shall be capable of
2 2
three-phasemainbreakerasspecified(see13.2).Thepanelwill
supportingauniformloadof65lb/ft (320kg/m ).Theshelter
have a NEMA-1 enclosure with conduit hubs as necessary and
floorshallbecapableofsupportingaconcentratedloadof2000
2 2
at least 18 breaker spaces excluding the main breaker. The
lb (910 kg) overa4ft (0.4 m ) area at the center of the floor.
panel board bus feed will be by rigid conduit and conductors;
The floor shall also be capable of supporting a point load of
2 2
the conductors having a current carrying capacity of at least
125 lb/in (9 kg/cm ) Loads shall not cause any permanent
100 A at 125°F (52°C) ambient temperature. The bus feed
deformationofthefloorsorcauseanydeflectionthatinterferes
cableswillterminateinaconnectormountedontheexteriorof
with proper shelter operation, when tested as specified in 11.9.
the shelter. Conductors running from panel board circuits to
5.2 Roof Loads—The roof assembly of the shelter shall
fixturesorreceptaclesshallbeenclosedinrigidconduitorshall
2 2
withstandasnowloadof40lb/ft (200kg/m )andapersonnel
be specified flexible cable for the expandable portion of the
2 2
load of 660 lb (300 kg) static over 2 ft (0.2 m ) when tested
shelter.Thecurrentcarryingcapacityoftheconductorsshallbe
as specified in 11.10.
20Aminimum, based upon an ambient temperature of 125°F
(52°C)andNECratingprocedures.Allcircuitbreakersusedin
5.3 Door Loads—Container doors shall be tested to with-
the system shall be bolt-on type and have a minimum inter-
stand the following loads without deformation or impairment
rupting capacity of 10 000 A root mean square symmetrical.
of function:
4.9.6 Cabling—Flexible cables shall be used to feed all
5.3.1 Static Door (Hinge) Load—The doors, frames, and
relocatablelightingfixturesandreceptacles.Thesecablesshall
hardwareshallbecapableofsupporting200lb(90kg)applied
be as indicated on the drawings.
to the door at the edge opposite the hinge pivot line with the
4.9.7 Switches—Switches used shall be as indicated on the
door open to approximately 90 when tested as specified in
drawings.
11.11.
4.9.8 Grounding—All noncurrent carrying metal compo-
5.3.2 Wind Gust Door (Stop) Load—The doors, frames, and
nents shall be solidly grounded using the green ground wire
hardware shall withstand a wind gust of 60 mph (100 km/h) in
within the wiring system, as indicated on the drawings.
any direction when the door is secured in its open position by
4.9.9 Receptacles:
its door stop device when tested as specified in 11.11.
4.9.9.1 Electrical Power Service Entrance—The electrical
5.4 Step Assembly—Thecompletelymountedstepassembly
power service entrance shall be as shown on the drawings.
shallwithstandaverticalloadof500lb(225kg)appliedtothe
4.9.9.2 Convenience Outlets—The shelter shall contain du-
outer section without deformation of the assembly or support-
plex convenience outlets as indicated on the drawings. All
ing structure when tested as specified in 11.12.
outlets shall be electrically grounded.
4.9.9.3 Air Conditioning—Power for heating and cooling
5.5 Airtightness—The shelter shall not permit air leakage
equipment shall be provided from the distribution panel in the
beyond specified limits in either container or shelter configu-
shelter to an electrical connector mounted in the service
ration when tested as specified in 11.13.
entrance recessed pan on the outside of the shelter as indicated
5.6 Temperature Range:
on the drawings.
5.6.1 Non-operating Temperature—The container mode
4.9.9.4 External Outlets—Power distribution shall be pro-
configuration shall withstand exposure to a temperature range
vided from the distribution panel box in the shelter to outlets
of −60 to 160°F (−51 to 71°C).
mounted in the service entrance recessed pan on the outside of
the shelter as indicated in the drawings.
5.6.2 Operational Temperature—The shelter shall be de-
4.9.10 Communications—The shelter shall have four (two pendable and operable in an ambient temperature range of
pairs) circuits through the wall telephone and intercom utility −60°F (except electrical (see 4.9.2)) to 125°F (−51 to 52°C)
E1978 − 18
plus a solar load such that the outer skin reaches a temperature 6.3 Inspection Comparison Testing Sample—When speci-
of200°F(93°C),whentestedasspecifiedin11.14,11.15,and fied (see 13.2), the contractor shall furnish a sample for
11.26. comparison inspection and approval (see 8.1 and 13.4).
5.7 Humidity and Temperature Aging (Components)—The 6.4 Manuals—Unless otherwise specified (see 13.2), tech-
shelter components shall be capable of withstanding the nical manuals shall be provided with each shelter. Stowage
conditions of a minimum 95% relative humidity at 200°F provisions for the manuals shall be located as shown on the
(93°C). There shall be no evidence of delamination, cracking, applicable drawings.
corrosion, or deterioration when tested as specified in 11.16.
7. Quality Assurance
5.8 Blackout—There shall be no internal light visible from
7.1 Responsibility for Inspection—Unless otherwise speci-
outside of the unit in the shelter mode when tested as specified
fied in the contract or purchase order, the contractor is
in 11.17.
responsible for the performance of all inspection requirements
5.9 Insert Strength—When tested as specified in 11.19, the
as specified herein. Except as otherwise specified in the
insertsindicatedinTable2shallwithstandloadsequalto80%
contract or purchase order, the contractor may use his/her own
oftheapplicablestrengthsshowninTable2withoutfailureand
or any other facilities suitable for the performance of the
as indicated in Table 3.
inspectionrequirementsspecifiedhereinunlessdisapprovedby
5.10 Rail Transportability—The shelter when tested as
the purchaser. The purchaser reserves the right to perform any
specified (see 11.20) shall be capable of withstanding, without of the inspections set forth in this specification where such
damage, the shocks normally induced by rail transport.
inspections are deemed necessary to ensure supplies and
services conform to prescribed requirements.
5.11 Impact Resistance—The shelter panel shall be impact
7.1.1 Responsibility for Compliance—All items must meet
resistant when tested as specified in 11.21.
all requirements of Sections3–5. The inspections set forth in
5.12 Drop Test—The shelter when tested as specified in
thisspecificationshallbecomeapartofthecontractor’soverall
11.22shallshownoevidenceofdamageasaresultofthedrop
inspection system or quality program. The absence of any
test.
inspectionrequirementinthisspecificationshallnotrelievethe
5.13 Towing—The shelter shall show no evidence of dam- contractor of the responsibility of assuring that all products or
suppliessubmittedtothepurchaserforacceptancecomplywith
age when tested as specified in 11.23.
all requirements of the contract. Sampling in quality confor-
5.14 Water Leakage—Thesheltershallshownoevidenceof
mance does not authorize submission of known defective
leakage when tested as specified in 11.24
material, either indicated or actual, nor does it commit the
5.15 Fluorescent Light Temperature—Shelter fluorescent
purchaser to acceptance of defective material.
light assemblies shall show no failure when tested as specified
7.1.2 Responsibility for Dimensional Requirements—Unless
in 11.25.
otherwise specified in the contract or purchase order, the
5.16 Solar Load—The shelter shall withstand a solar load contractor is responsible for assuring that all specified dimen-
sionshavebeenmet.Whendimensionscannotbeexaminedon
test when tested as specified in 11.26.
theenditem,theinspectionshallbemadeatanypointoratall
5.17 Operational Fitness—The shelter shall prove func-
points in the manufacturing process necessary to assure com-
tional when tested as specified in 11.27.
pliance with all dimensional requirements.
5.18 Heat Transfer—The overall coefficient of heat transfer
7.2 Classification of Inspection—The inspection require-
2 2
of the shelter shall not exceed 0.35 Btu/h/ft /F (2.0 W/(m *
ments specified herein are classified as follows:
°K) (see 11.36).
7.2.1 First Article Inspection—See 8.1.
7.2.2 Comparison Sample Inspection—See 9.1.
6. Other Requirements
7.2.3 Quality Conformance Inspection—See 10.1.
6.1 Requirements and testing for lifting, six high stacking,
longitudinal restraint, racking, lashing, endwall strength, side- 8. First Article Inspection
wallstrength,andliftingfromforkliftpocketsshallconformto
8.1 First Article Inspection—When a first article is required
ISO 1496-1 when tested as specified in 11.28 – 11.35.
(see 13.3), it shall be examined for visual defects in Table 4,
dimensions specified, and tested as specified and in the
6.2 First Article—When specified, a sample shall be sub-
jected to first article inspection (see 8.1, 13.2, and 13.3). sequencespecifiedinTable5.Alltestingshallbeperformedon
the same shelter. The presence of any visual defect, any
dimension not within specified requirements, or failure of any
test shall be cause for rejection of the first article.
TABLE 3 Insert Strength (Working Loads)
8.1.1 First Article Panel Specimen Inspection—Prior to
Insert (diameter thread size) Pull-Out, lb (kg) Torque, ft-lb (J) fabrication of any panels, a panel specimen shall be fabricated
10–32 800 (360) 8 (11) for torque and pullout testing to demonstrate strengths of
⁄4 –28 800 (360) 16 (22)
pottedinserts.Thepanelspecimenshallbefabricatedusingthe
⁄16 –24 1600 (725) 16 (22)
same techniques and materials used to fabricate production
⁄8 –24 1600 (725) 32 (43)
panels, except aluminum facing thickness shall be nominal
E1978 − 18
TABLE 4 End Item Visual Defects
Classification
Examine Defect
Major Minor
Finish not as specified, not finished where required 101
not adherent, for example, blistered, peeled 201
runs, wrinkles, streaks, or areas of no film 202
finish not dry, that is, wet or tacky to touch 203
scratch, gouge, abrasion exposing prime coat or bare metal, in accordance with the drawings 204
any area of rust 205
Design any characteristic not in accordance with specified requirement 102
Construction and Workmanship component or part fractured, split, punctured, dented, or malformed 103
component missing, inoperative, or will not operate as intended 104
component not properly assembled or secured 105
any functioning component which requires abnormal force to operate 206
burr, rough or sharp edges, or sliver which may be injurious to personnel or cargo 106
gaskets torn or split 107
gasket or seals painted 207
visible gaps between aluminum faces and extruded edges or panel cutout edge members 108
Welding and brazing (where required) not type specified, missing where required 109
incomplete, burn through area, pits, crack or fracture, or otherwise not fused 110
slag inclusion, undercut, not smooth and uniform, scale or flux deposit not removed 208
Metal fasteners, bolts, nuts, screws, studs missing, not type specified, broken, stripped, or loose 111
lockwasher missing where required 209
Rivets missing 112
not type specified 113
not sufficiently peened, not drawn tight, excessively peened 210
cloth cut or tear longer than ⁄8 in. 114
hole larger than ⁄8 in. diameter 115
Marking missing, incomplete, not legible, not specified type or size, misplaced
Instruction plate, nameplate missing, incomplete, not legible 116
Instruction manual missing, incomplete, not legible 117
TABLE 5 First Article Test Sequence
0.040in.(1.0mm)andoverallthicknessshallbenominal2in.
Inspection Requirement Test (25 mm) thick. The edges of the specimen are not required to
be sealed. The specimen shall be sized to accept 16 inserts
Panel frame airtightness 4.3.6 11.41
Panel watertightness 4.3.2 11.18
(foureachsizespecifiedinTable2)locatedaminimumof6in.
Panel delamination 4.3.5 11.38
(150mm)frompaneledgesand6in.(150mm)oncenterfrom
Visual defects 8.1 10.4
Thickness 3.7.3 11.39 eachother.Theinsertsshallbeinstalledinaccordancewiththe
Adhesion of paint 3.7.1 11.37
process to be used for production panels. Eight (two of each
Operational (first time) 5.17 11.27
size) inserts shall be installed within the panel in a vertical
Thermal shock 4.3.3 11.6
Panel interchange 4.3.4 11.7 plane and eight (two of each size) inserts shall be installed
Insert proof load 4.4 11.8
within the panel in a horizontal plane and so identified, that is,
Electrical system 4.9 11.40
HorV.Failureofoneormoreinsertstopassthetestsspecified
Floor load, static 5.1 11.9
Roof load 5.2 11.10
in 11.8.1 and 11.8.2 shall be cause for rejection of the
Door load 5.3 11.11
installation process. This test shall be repeated until an insert
Step 5.4 11.12
installation process has been developed to pass the strength
Airtightness 5.5 11.13
Low temperature 5.6 11.14
test.
High temperature 5.6 11.15
Humidity and temperature aging 5.7 11.16
9. Comparison Sample Inspection
Heat transfer 5.18 11.36
Insert working load 5.9 11.19
9.1 Comparison Sample Inspection—When a comparison
Rail transportability 5.10 11.20
sampleisrequired(see13.4),itshallbeinspectedandtestedas
Impact resistance 5.1 11.21
specified in 8.1.
Drop 5.12 11.22
Towing test 5.13 11.23
9.2 Comparison Sample Panel Specimen Inspection—
Fluorescent light temperature 5.15 11.25
Lifting 6.1 11.28 Comparison sample panel specimen inspection shall be per-
Six-high stacking 6.1 11.29
formed in accordance with 8.1.1.
Longitudinal restraint 6.1 11.30
Racking 6.1 11.31
10. Quality Conformance Inspection
Lashing 6.1 11.32
Endwall strength 6.1 11.33
10.1 Quality Conformance Inspection—Unless otherwise
Sidewall strength 6.1 11.34
specified, sampling for inspection shall be performed in accor-
Lifting from forklift pockets 6.1 11.35
Blackout 5.8 11.17 dance with ANSI/ASQ Z1.4-2003 (R2013). The contractor’s
Water leakage 5.14 11.24
quality control system shall conform to ISO 9001.
Solar load 5.16 11.26
10.1.1 Component and Material Inspection—In accordance
Operational test (second time) 5.17 11.27
with 7.1, components and materials shall be inspected in
E1978 − 18
accordance with all the requirements of the referenced docu- failure analysis report shall be prepared with corrective action
mentsunlessotherwiseexcluded,amended,modified,orquali- defined for inserts tested.
fied in this specification or applicable purchase document.
10.3.4 Panel Frame Airtightness Test—After welding, all
welded panel frames shall be tested as specified in 11.41 and
10.2 In-Process Examination—Examination shall be made
reworked, if required, as specified in 11.41.1.
of the following fabrication operations to establish confor-
mance with the specified requirements: 10.4 End Item Visual Examination—The end item shall be
10.2.1 That panel materials are as specified,
examined for the defects listed in Table 4.The lot size shall be
10.2.2 Thatrivetheadsaresealedandtightforconformance expressed in units of one shelter. The sample unit shall be one
with 3.4,
shelter.TheinspectionlevelshallbeIIandtheAQL,expressed
10.2.3 Thatpartsarecleanedandfreeofadhesivesealerand in terms of defects per hundred units, shall be 4.0 for major
other foreign materials for conformance with applicable draw-
defects and 6.5 for total (major and minor combined) defects.
ings.
10.5 End Item Dimensional Examination—The end item
10.2.4 Prior to assembling other components over any
shall be examined for conformance to dimensions specified.
welded area or prior to priming for painting, that welding
Any dimension not within the specified tolerance shall be
processes and welded assemblies conform to referenced docu-
classifiedasadefect.Thelotsizeshallbeexpressedinunitsof
ments when specified on the drawings and to the requirements
one shelter. The sample unit shall be one shelter. The inspec-
of 3.6.
tionlevelshallbeIIandtheAQL,expressedintermsofdefects
10.2.5 That electrical assemblies and wiring are fabricated
per hundred units, shall be 4.0.
inaccordancewithapplicabledrawingsandindustrystandards.
10.2.6 That the primer thickness, topcoat thickness, and
11. Required Tests
topcoat color are as specified in the applicable drawings (see
11.1 Electrical Continuity Testing—Every end item shall be
3.7.2 and 3.7.3), and
tested as specified in 11.40.Any test failure shall be cause for
10.2.7 That the panels are processed, fabricated and in-
rejection of the end item.
spectedinaccordancewiththerequirementsofPracticesE864,
E874, and E1773, and Specifications E865, E866, E990, and
11.2 Water Leakage and Operational Testing—The first ten
E1091 (see 4.3.1).
production units shall be tested as specified in 11.24, 11.24.1,
10.2.8 Whenever nonconformance is noted, correction shall
and 11.24.3. If no failures are experienced five of the next ten
be made to the items affected and the process.
production units shall be tested. If no failures are experienced
on the 50% sample, one of each 25 production units shall be
10.3 In-Process Testing:
tested thereafter. Any failure on sampled units shall be cause
10.3.1 Panel Watertightness Testing—Prior to assembly
forrejectionofthelotandreturnto1008testing,andrepeatthe
(that is, fabrication of cutouts, installation of inserts and
above procedure (starting with the units of that lot).
hardware, and so forth) one panel from every lot of both
11.2.1 Water Leakage (Fully Loaded)—One out of every
weldedframepanelsandunweldedframepanelsshallbetested
fiftyproductionunitsshallbetestedasspecifiedin11.24.2and
for watertightness as specified in 11.18. The lot size shall not
11.24.3. The purchaser shall be notified of any test failure
exceed 100 panels. The panels to be tested shall be 8 by 20 ft
within 72 h. A failure analysis report shall be prepared with
(2.4by6.1m).Failureofthetestshallbecauseforrejectionof
corrective action defined, and one out of the next ten produc-
the panel lot represented.
tion units shall be tested followed by one out of the next fifty
10.3.2 Panel Insert Testing—Each type of shelter panel
if no failures occur.
(roof, end wall, and so forth) shall be tested for insert working
loadbyfirst-pieceinspectionandbysampleinspectionofeach
11.3 Performance Testing—Oneenditemfromeachinspec-
lot of each type roof panel. The inspection lot shall consist of
tionlotshallbetestedasspecifiedin11.13(sheltermodeonly)
all of one type of panels processed at one time.At the start of
and 11.26. After successful completion of these tests, the end
each panel and insert assembly operation, the first panel
itemsampleshallbetestedasspecifiedin11.17.Thesizeofthe
(first-piece) shall have all inserts tested for working load in
inspectionlotshallnotexceed25shelters.Anytestfailureshall
accordance with 11.19 and failure of any insert shall be cause
be cause for rejection of the lot.
for rejection of the panel and the process. Each start-up of
11.4 Paint Adhesion Testing—Oneofeveryfortyproduction
insert fabrication, change in type or formation of adhesive or
units shall be tested as specified in 11.37. This unit in the
potting compound, or any change in the method of insert
deployed mode shall be tested only after storage in a 70°F
bonding shall be cause for necessary changes to the process
(21°C) minimum temperature indoor environment for 168 h
andforrepeatofthefirst-pieceinspection.Inspectionlotsshall
minimum after topcoat painting. The purchaser shall be noti-
be evaluated using inspection Level II and the acceptable
fied of any test failure within 72 h. A failure analysis report
qualitylevel(AQL),expressedintermsofdefectsperhundred
shallbepreparedwithcorrectiveactiondefined,andoneoutof
units, shall be 10.0. Each sample panel shall have all inserts
the next ten production units shall be tested, followed by one
tested for insert working load in accordance with 11.19.
out of the next forty if no failures occur.
10.3.3 Panel Delamination Testing—All panels coming out
ofthepressshallbetestedasspecifiedin11.18.Failuretopass 11.5 Packaging Examination—An examination shall be
thistestshallbecauseforrejectionofthatpanel.Thepurchaser made to determine that preservation and packing comply with
shall be notified within 72 h of any failures. In addition, a the requirements in Section 5. Defects shall be scored in
E1978 − 18
accordance with Table 6. The sample unit shall be one shelter evaluate the inserts using bolts of the applicable thread size.
fully packaged except the mechanical seals on the doors may Loads shall be applied to the insert in a tightening and
be omitted to facilitate inspection. When omitted for internal loosening direction and held at the specified torque for a
inspection, after acceptance of the lot for preservation, me- minimum of 5 s. The test fixtures shall be fashioned to induce
chanicaldoorsealsshallbeappliedtothesheltersandthenthe only a twisting load to the insert for the torque test and,
lot of shelters subsequently inspected for sealing. The lot shall primarily, only on axial tensile load through the centerline of
be the number of shelters offered for inspection at one time. theinsertforthepull-outtest.Applythereactionloadfromthe
The inspection level shall be II and the AQL, expressed in insertpull-outfixtureontothetestspecimenpanel,tothepanel
terms of defects per hundred units, shall be 2.5. outside of a 3 in. (75 mm) radius measured from the centerline
of the insert.
11.6 Thermal Shock Test—Within 30 min after exposure
11.8.1 Insert Torque—To determine compliance with the
cyclingof11.16hasbeencompleted,thepanelspecimensshall
torque requirements of 4.4, two identical inserts of each size
then be subject to a −65°F (−54°C) environment for4hto
(1-H,1-V),pottedinthetestspecimenparedcitedin8.1.1and
evaluate the effects of thermal shock.After thermal shock, the
9.1.Torque load applied shall be equal to torque strength cited
panel specimens shall be inspected for delamination (see
in Table 2 for applicable size. Inability of any insert to meet
11.38),corrosion,andmaterialdegradation.Anydelamination,
specification requirement shall constitute a failure of the test.
corrosion, or material degradation shall constitute a failure of
11.8.2 Insert Pull-Out—To determine compliance with the
the test.
pull-out requirements of 4.4, a tensile pull load equal to the
11.7 Panel Interchange Test—The folding walls with the
pull-out strength cited in Table 2 shall be applied to two
same part number and two fixed walls with the same part
identical inserts of each size (1-H, 1-V) potted into the test
number randomly selected from the first article or production
specimen cited in 8.1.1 and 9.1. Failure of the potting com-
lot of completed shelters, as applicable, shall be interchanged.
pound to hold the insert firmly in the panel shall constitute
The interchange shall be accomplished by removing the hinge
failure of the test.
pins or bolts, as applicable, interchanging walls, and reinstall-
ing the hinge pins or bolts (see 4.3.4).Any wall that cannot be 11.9 Floor Loads Test-Static Load—The floor loads test-
static load shall be as specified in Specification E1925.
fully interchanged shall constitute a failure of the test.
11.8 Insert Proof Load Test—Testfixturesshallbefashioned
11.10 Roof Load Test—The roof load test shall be as
bythecontractorandapprovedbythepurchaserpriortouse,to specified in Specification E1925.
11.11 Door Load Test—The door load test shall be as
TABLE 6 Packing Defects
specified in Specification E1925.
Examine Defect
11.12 Step Test—A 500 lb (225 kg) weight shall be sus-
Workmanship, doors are not closed, latched, and mechanically
exterior sealed.
pendedfromtheouterendofastepassemblyfor5minandthe
exterior electrical connections are not covered and
load removed.Any permanent deformation or local delamina-
covers are not secure (hand pressure).
tion (see 11.38) shall constitute failure of this test.
expandable wall corner post-cam latch handles are
not in locked position with pin in retaining hole
11.13 Airtightness Test—The shelter airtightness test shall
puncture in exterior skin.
damage (such as bend, gouge, or dent) to frame
be as specified in Specification E1925.
ends or to forklift opening.
steps are not folded closed.
11.14 Low Temperature Test—The shelter in its container
any other protruding or not stowed part.
mode, with shelter components and maximum payload pack-
Workmanship, equipment container is not secured in place.
aged within, shall be first cold soaked at −60°F (−51°C)
interior
parts in the equipment container are not in
temperature for a minimum of 24 h in a mechanically refrig-
accordance with the list of the parts.
eratedcoldchamber.Attheendofthe24hperiodandwhileat
the four lift jacks are not secured on the doors.
−60°F (−51°C), erect the shelter. Operate all hardware (for
the two leveling jacks are not secured on the cargo
door.
example, latches, doors, knockout panels, and so forth) and
the support struts are not secured with lock pin in
examinetheshelteranditscomponentsforanydamage.Donot
place.
move lights or electrical receptacles into position at this time.
the removable light fixtures are not secured to the
fixed ceiling by four captive studs with stowage
Return the shelter to closed/container mode and then raise the
bracket plunger locked.
chamber temperature to −25°F (−32°C). Allow the chamber
the movable utility outlets are not secured to the
to stabilize at −25°F (−32°C) for 4 h. Next, erect the shelter
hinged endwalls by their captive screws.
the area light and cable are not secured to the
and hook up the power source to the shelter. Position the
interior of the personnel end panel with the
ceiling fluorescent lights and electrical receptacles on the
retaining wing nuts secured (hand pressure).
expanded shelter section. Operate circuit breakers, blackout
the area light does contain a bulb (bulb should be
packaged and packed in the equipment container).
emergency switch, and emergency incandescent lights. The
any circuit breaker not in the OFF position.
fluorescent ceiling lights shall not be operated at −25°F
the circuit breaker box keys are not inside the box.
air vents are not secured closed. (−32°C) since they are rated for a minimum of 0°F (−18°C)
environmental control units (ECU) panels are not
operation. The shelter shall then be returned to normal operat-
stowed securely on the fixed ceiling.
ing
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: E1978 − 11 E1978 − 18
Standard Specification for
Shelter, Tactical, Expandable, Two-Side
This standard is issued under the fixed designation E1978; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Scope
1.1 This specification covers a rigid wall, two-side expandable shelter constructed of aluminum-faced, nonmetallic honeycomb
sandwich panels and meeting the International Organization for Standardization (ISO) cargo container specification in the transport
mode. Nominal dimensions when closed (container mode) are: height 8 ft, width 8 ft, and length 20 ft (2.4 by 2.4 by 6.1 m).
Approximate dimensions when expanded (shelter mode) are: height 8 ft, width 22 ft, and length 20 ft (2.4 by 6.7 by 6.1 m).
1.2 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical
conversions to SI units that are provided for information only and are not considered standard.
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety safety, health, and healthenvironmental practices and determine the
applicability of regulatory limitations prior to use.
1.4 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 ASTM Standards:
E864 Practice for Surface Preparation of Aluminum Alloys to Be Adhesively Bonded in Honeycomb Shelter Panels
E865 Specification for Structural Film Adhesives for Honeycomb Sandwich Panels
E866 Specification for Corrosion-Inhibiting Adhesive Primer for Aluminum Alloys to Be Adhesively Bonded in Honeycomb
Shelter Panels
E874 Practice for Adhesive Bonding of Aluminum Facings to Nonmetallic Honeycomb Core for Shelter Panels
E990 Specification for Core-Splice Adhesive for Honeycomb Sandwich Structural Panels
E1091 Specification for Nonmetallic Honeycomb Core for Use in Shelter Panels
E1749 Terminology Relating to Rigid Wall Relocatable Shelters
E1773 Practice for Sealing Rigid Wall Tactical Shelters with Polysulfide Based Sealants
E1826 Specification for Low Volatile Organic Compound (VOC) Corrosion-Inhibiting Adhesive Primer for Aluminum Alloys
to Be Adhesively Bonded
E1925 Specification for Engineering and Design Criteria for Rigid Wall Relocatable Structures
2.2 ANSI/ASQ Standard:
ANSI/ASQ Z1.4-2003 (R2013) Sampling Procedures and Tables for Inspection by Attributes
2.3 AWS Standard:
AWS D17.1/D17.1M Specification for Fusion Welding of Aerospace Applications
2.4 ISO Standards:
ISO 1161-1980 Series 1-Freight Containers-Corner Fittings, Specification
ISO 1496/I Series 1-Freight Containers-Specification and Testing Part
This specification is under the jurisdiction of ASTM Committee E06 on Performance of Buildings and is the direct responsibility of Subcommittee E06.53 on Materials
and Processes for Durable Rigidwall Relocatable Structures.
Current edition approved Sept. 1, 2011Sept. 1, 2018. Published October 2011September 2018. Originally approved in 1998. Last previous edition approved in 20052011
as E1978 – 05.E1978–11. DOI: 10.1520/E1978-11.10.1520/E1978–18.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’sstandard’s Document Summary page on the ASTM website.
Available from American National Standards Institute (ANSI), 25 W. 43rd St., 4th Floor, New York, NY 10036, http://www.ansi.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E1978 − 18
ISO 9001 Quality Systems—Model for Quality Assurance in Design, Development, Production, Installation, and Servicing
2.5 Military Standards:Standard:
MIL-STD-810MIL-STD-810G Environmental Engineering Considerations and Laboratory Tests
2.4 ANSI/ASQC Standards:
ANSI/ASQC Z1.4-1993 Sampling Procedures and Tables for Inspection by Attributes
2.6 Drawings:
5-4-3118 Shelter, Assembly, Two-Side Expandable-60 amp
5-4-3201 Shelter, Assembly, Two-Side Expandable-100 amp
2.6 SAE Standards:
SAE-AMS-STD-1595 Qualification of Aircraft, Missiles, and Aerospace Fusion Welders
SAE-AMS-STD-2219 Fusion Welding for Aerospace Application
3. General Requirements
3.1 Alternate Components—When this specification or the referenced drawings specify use of a specific component “or equal,”
the contractor may substitute a component equal to the specified component provided that the contractor complies with the
following requirements. Prior to manufacture of the first article or, if none is required, prior to commencing production, the
contractor shall submit for the purchaser’s approval, a list identifying each proposed “or equal” component together with proof that
each listed component is functionally equal to the specified component and is compatible with the end item covered by this
specification. The purchaser, at his/her option, may require a physical sample of any “or equal” component. Approval of the
submitted listing and supporting data authorizes the commencement of fabrication of the first article or of production, as applicable,
but does not relieve the contractor of the responsibility that the “or equal” components perform in accordance with specified
requirements when incorporated into the end item.
3.2 Materials and Components—Materials and components shall conform to the documents listed in Section 2 and as specified
herein. Any change to the proposed materials or processes must be approved by the purchaser. It is encouraged that recycled
material be used when practical as long as it meets the requirements of this specification.
3.3 Workmanship—The shelter, including all parts and accessories, shall be constructed and finished in a workmanlike manner
with particular attention given to removal of burrs and sharp edges, accuracy of dimensions, thoroughness of soldering, welding,
painting, alignment of parts and assemblies, and the tightness of screws, bolts, and so forth. Gaskets shall not be torn or split and
shall be free of finish. Cloth components shall be clean and free of holes, cuts, or tears. All latches utilized for erection and closing
of the shelter shall be properly adjusted before the shelter is prepared for delivery to the purchaser.
3.4 Riveting—Riveting joints shall be tight. The joined parts shall be undamaged, and the rivet heads shall be properly seated
and tight against the bearing surfaces. All the rivets, except those used in panel bonding, shall be dipped in polysulfide sealant just
prior to insertion; however, a dab of polysulfide sealant shall be applied to the head of each rivet.
3.5 Cleaning—After fabrication, parts shall be cleaned in accordance with the drawings.
3.6 Welding—Welded joints shall be such that grinding of the finished weld shall not be a requirement, except when specified
on the drawing. Spot, stitch, and seam welds shall be as indicated on the drawings. All surfaces to be welded shall be cleaned and
free from scale, paint, grease, and other foreign materials. Welds shall have thorough penetration, good fusion, and shall be free
from scabs, blisters, abnormal pock marks, cracks, voids, slag inclusions, and other harmful defects. Welded assemblies shall be
cleaned to remove any scale, oxidation products, and excess flux. Any acid used in cleaning shall be completely neutralized and
removed. Welders shall be certified in accordance with SAE-AMS-STD-1595. AWS D17.1/D17.1M. Welding equipment and
procedures shall conform to SAE-AMS-STD-2219.AWS D17.1/D17.1M.
3.7 Finish—Coatings shall level out to an adherent, continuous, and uniform film without runs, wrinkles, streaks, or areas of
no film. Any coating damaged during assembly or examination shall be touched up. There shall be no areas of rust. Finish shall
be free from blistering, peeling, and chipping.
3.7.1 Adhesion of Paint—The shelter shall be capable of withstanding, without degradation to the finish, the tests as specified
in 11.37.
NOTE 1—After top coat application, the shelter in the deployed mode shall be stored for a minimum of 168 h at a minimum of 70°F (21°C)70 °F (21 °C)
prior to performing this test.
3.7.2 Color—The color of the paint film shall be compared with an appropriate color chip for the paint specified.
Available from Standardization Documents Order Desk, DODSSP, Bldg. 4, Section D, DLA Document Services, Building 4/D, 700 Robbins Ave., Philadelphia, PA
19111-5098, http://dodssp.daps.dla.mil.19111-5094, http://quicksearch.dla.mil.
Available from American Society for Quality (ASQ), 600 N. Plankinton Ave., Milwaukee, WI 53203, https://www.asq.org.
Copies of drawings are available from U.S. Army Natick Soldier Center, ATTN: AMSRD-NSC-CP-CS, Kansas Street, Research, Development, and Engineering Center,
ATTN: RDNS-SEE-T, 15 General Greene Avenue, Natick, MA 01760-5018, http://www.natick.army.mil.https://www.army.mil/info/organization/natick.
Available from American Welding Society (AWS), 8669 NW 36 St., #130, Miami, FL 33166-6672, http://www.aws.org.
E1978 − 18
3.7.3 Thickness—Thickness of the paint film shall be checked as specified in 11.39.
3.8 Finish and Color—Surfaces shall be of the color, treatment, and finish as shown on the drawings. Top coat painting shall
be performed on the fully assembled shelter so as to prevent mismatch of color shading, unless other control techniques are
approved by the purchaser. After top-coat application, the shelter in the deployed mode (that is, expanded) shall be stored in a 70°F
(21°C)70 °F (21 °C) minimum temperature indoor facility for a minimum of 36 h to ensure adequate coating(s) cure. During this
storage period, the shelter doors and vents shall be opened to permit air circulation within the shelter.
3.9 Manuals—Unless otherwise specified (see 13.2), technical manuals shall be provided with each shelter. Stowage provision
for the manuals shall be located as shown on the applicable drawings.
3.10 Terminology related to this specification is defined in Terminology E1749.
4. Design and Construction Requirements
4.1 Design and Construction—Design and construction of the expandable shelter shall conform to the requirements specified
on the drawings, all subsidiary drawings and parts lists, and hereinafter. The shelter shall be free of panel delaminations and shall
meet all physical and environmental requirements specified herein.
4.2 Container Mode—The shelter in the closed or transport mode shall be referred to as a container, hereinafter, for the purpose
of definition. The shelter, in the container mode, shall be an article of transport equipment meeting ISO freight container
requirements related to cargo containers. The shelter shall not show structural damage when tested as specified in 11.20, 11.22,
11.23, and 11.28 – 11.35, and shall not show leakage when tested as specified in 11.24 and 11.24.1 – 11.24.3. The contractor shall
ensure that the shelter receives Coast Guard Certification for ISO containers. The container’s overall dimensions shall be in
accordance with ISO freight container designated IC and are as shown in Table 1.
4.3 Panels—The panels used as structural members in the container configuration shall structurally meet all transportation and
environmental requirements specified herein. Each panel shall be fabricated as a net panel with aluminum extrusions bonded about
the panel perimeter during panel bonding. The inner and outer skins on all joints shall be sealed to provide a water barrier against
the entrance of moisture to the core material and to the interior of the shelter. The water barrier is to be maintained intact at all
panel cross-sectional openings. All joints and edges shall be assembled and sealed in a manner to prevent collection and retention
of moisture. Particular emphasis shall be placed on the sealing of all mitered corners. All of the above sealing procedures shall be
accomplished in accordance with Practice E1773. Rivet shafts shall be coated with sealing compound before insertion. The sealer
shall be as indicated on the drawings. The contractor shall have the appropriate equipment and facilities, use the correct procedures
in accordance with Practices E874 and E864, and use qualified panel components (that is, structural film and core splice adhesives,
corrosion-inhibiting adhesive primer, structural nonmetallic honeycomb core, and as specified 5052-H34 or 6061-T6 aluminum
skins, FRP barrier strips, 6061-T6 panel extrusions). Prior to use, all critical panel component materials must be qualified to
Specifications E865, E866, E990, E1091, and E1826. There shall be no skin splices in the panels except where noted on the
drawings. Unless otherwise specified (see 13.2), prior to award of contract, the contractors shall submit to the purchaser a certified
copy of a laboratory test report and a copy of their process specification covering fabrication of the metallic-faced, nonmetallic
honeycomb core sandwich panels they propose to use in the construction of the end item. Using their process specification, the
contractors shall fabricate qualification test sandwich panels and structural film adhesive floating roller peel test specimens, and
shall perform tests in accordance with Specification E865 and Practice E874 (see 13.2).
4.3.1 Panel Processing—The shelter panels shall be processed and inspected as specified in Practices E864 and E874, and
Specifications E865, E866, or E1826 depending upon which primer is being used, Specifications E990, E1091, and Practice E1773.
The shelter panels shall be inspected for dimensions and flatness in accordance with the Dimensional and Flatness Inspection of
Panel paragraph of Practice E874 (see 10.2).
4.3.2 Panel Watertightness—Panel assemblies shall not permit the entry of water (see 10.3.1) when tested as specified in 11.18
4.3.3 Resistance to Thermal Shock—Panels shall be resistant to thermal shock, when tested as specified in 11.6.
4.3.4 Panel Interchangeability—All panels and panel assemblies bearing same part numbers shall be functionally and
dimensionally interchangeable without modification or reworking. Individual assemblies shall not be hand picked for fit or
performance, when tested as specified in 11.7.
4.3.5 Delaminations—Delaminations in shelter panels shall be tested as specified in 10.3.4.
4.3.6 Panel Frame Airtightness—Welded panel frames shall be airtight when tested as specified in 11.41.
TABLE 1 Container Dimensions
Height Width Length
Type
ft in. tol. in. ft in. tol. in. ft in. tol. in.
Height Width Length
Type
ft in. tol. in. ft in. tol. in. ft in. tol. in.
IC 8 0 +0 −0.1875 8 0 +0 −0.1875 19 10.5 +0 −0.25
(2.438 m) +0 (−5 mm) (2.438 m) +0 (−5 mm) (6.058 m) +0 (−6 mm)
E1978 − 18
4.4 Inserts—When tested as specified in 11.8, the following sized inserts, where used, shall withstand the torque and pullout
loads as specified in Table 2, without failure of the inserts, panel, or potting compound.
4.5 Payload—The unit is designed to carry a maximum payload of 8050 lb (3650 kg) during transport.
4.6 Corner Fittings—The container shall be equipped with corner fittings at the top and bottom corners in accordance with the
dimensional requirements for corner fittings for Series-1 freight containers as stipulated in ISO 1161-1980 requirements for
commercial containers. The upper faces of the top corner fittings shall protrude above the top of the rest of the container by a
minimum of ⁄4 in. (6 mm). The lower faces of bottom corner fittings shall protrude below the bottom of the container by a
minimum of ⁄16 in. (11 mm).
4.7 Shelter Mode—The shelter in the erected mode shall be referred to as a shelter herein for the purpose of definition. Hinged
shelter panels shall be attached in a manner to ensure compliance with the environmental test requirements as specified in 11.6,
11.13 – 11.17, 11.24, and 11.26.
4.8 Exterior Lighting—One area lighting fixture, as shown on the drawings, shall be provided with each shelter.
4.9 Shelter Electrical System:
4.9.1 General—The system shall have all equipment, cabling, and other hardware necessary to receive three-phase 120/208 V,
60 Hz power from the base electrical distribution systems, and distribute it to lighting fixtures and receptacles as indicated on the
drawings. The 60 A shelters shall be in accordance with Drawing 5-4-3118 and all subsidiary drawings and parts lists. The 100
A shelters shall be in accordance with Drawing 5-4-3201 and all subsidiary drawings and parts lists. All parts of the electrical
system shall operate when tested for electrical continuity as specified in 11.40.
4.9.2 Operating Temperature—The wiring system and all individual hardware items shall be capable of operating at their
required capacity within an ambient temperature range from −60 to 125°F125 °F (−51 to 52°C),52 °C), except that the fluorescent
lights shall operate from 0 to 125°F125 °F (−18 to 52°C),52 °C), when tested as specified in 11.14 and 11.15.
4.9.3 Current Rating—All conductors and appropriate hardware shall be rated for current carrying capacity in accordance with
the applicable industry standards as specified on the drawings. Derating of components may be necessary for an operating ambient
temperature of 125°F (52°C).125 °F (52 °C).
4.9.4 Finish—Panel boards and all other exposed metallic items shall have finishes as indicated on the drawings (see 3.7).
4.9.5 Panel Board—The panel board used will be as indicated on the drawings. It will be of dead front construction and have
a solid neutral bus, a ground bus, and a 60 or 100 A three-phase main breaker as specified (see 13.2). The panel will have a
NEMA-1 enclosure with conduit hubs as necessary and at least 18 breaker spaces excluding the main breaker. The panel board
bus feed will be by rigid conduit and conductors; the conductors having a current carrying capacity of at least 100 A at 125°F
(52°C)125 °F (52 °C) ambient temperature. The bus feed cables will terminate in a connector mounted on the exterior of the
shelter. Conductors running from panel board circuits to fixtures or receptacles shall be enclosed in rigid conduit or shall be
specified flexible cable for the expandable portion of the shelter. The current carrying capacity of the conductors shall be 20 A
minimum, based upon an ambient temperature of 125°F (52°C)125 °F (52 °C) and NEC rating procedures. All circuit breakers
used in the system shall be bolt-on type and have a minimum interrupting capacity of 10 000 A root mean square symmetrical.
4.9.6 Cabling—Flexible cables shall be used to feed all relocatable lighting fixtures and receptacles. These cables shall be as
indicated on the drawings.
4.9.7 Switches—Switches used shall be as indicated on the drawings.
4.9.8 Grounding—All noncurrent carrying metal components shall be solidly grounded using the green ground wire within the
wiring system, as indicated on the drawings.
4.9.9 Receptacles:
4.9.9.1 Electrical Power Service Entrance—The electrical power service entrance shall be as shown on the drawings.
4.9.9.2 Convenience Outlets—The shelter shall contain duplex convenience outlets as indicated on the drawings. All outlets
shall be electrically grounded.
TABLE 2 Insert Strength (Proof Loads)
Insert (diameter thread size) Pull-Out, lb (kN) Torque, ft-lb (N·m)
10-32 1000 (4.5) 10 (13.6)
⁄4-28 1000 (4.5) 20 (27.2)
⁄16-24 2000 (9.0) 20 (27.2)
⁄8-24 2000 (9.0) 40 (54.2)
TABLE 2 Insert Strength (Proof Loads)
Insert (diameter thread size) Pull-Out, lb (kN) Torque, ft-lb (N·m)
10–32 1000 (4.5) 10 (13.6)
⁄4 –28 1000 (4.5) 20 (27.2)
⁄16 –24 2000 (9.0) 20 (27.2)
⁄8 –24 2000 (9.0) 40 (54.2)
E1978 − 18
4.9.9.3 Air Conditioning—Power for heating and cooling equipment shall be provided from the distribution panel in the shelter
to an electrical connector mounted in the service entrance recessed pan on the outside of the shelter as indicated on the drawings.
4.9.9.4 External Outlets—Power distribution shall be provided from the distribution panel box in the shelter to outlets mounted
in the service entrance recessed pan on the outside of the shelter as indicated in the drawings.
4.9.10 Communications—The shelter shall have four (two pairs) circuits through the wall telephone and intercom utility
connections terminating in four protected terminals inside and outside the shelter, as indicated on the drawings.
4.9.11 Tools—Tools provided with the shelter shall be readily accessible to personnel when the shelter is in both the container
and shelter configuration.
4.10 Nameplates and Product Marking—All markings shall conform to the drawings. Each shelter shall be serially numbered
and provided with a nameplate in accordance with applicable drawings (see 13.2).
4.10.1 Interior Markings—Interior markings shall be as shown and in the locations shown on the applicable drawings.
4.10.2 Exterior Markings—The shelter shall be provided with specific exterior markings as shown on the applicable drawings.
5. Performance Requirements
2 2
5.1 Floor Loads—The shelter floor shall be capable of supporting a uniform load of 65 lb/ft (320 kg/m ). The shelter floor shall
2 2
be capable of supporting a concentrated load of 2000 lb (910 kg) over a 4 ft (0.4 m ) area at the center of the floor. The floor
2 2
shall also be capable of supporting a point load of 125 lb/in (9 kg/cm ) Loads shall not cause any permanent deformation of the
floors or cause any deflection that interferes with proper shelter operation, when tested as specified in 11.9.
2 2
5.2 Roof Loads—The roof assembly of the shelter shall withstand a snow load of 40 lb/ft (200 kg/m ) and a personnel load of
2 2
660 lb (300 kg) static over 2 ft (0.2 m ) when tested as specified in 11.10.
5.3 Door Loads—Container doors shall be tested to withstand the following loads without deformation or impairment of
function:
5.3.1 Static Door (Hinge) Load—The doors, frames, and hardware shall be capable of supporting 200 lb (90 kg) applied to the
door at the edge opposite the hinge pivot line with the door open to approximately 90 when tested as specified in 11.11.
5.3.2 Wind Gust Door (Stop) Load—The doors, frames, and hardware shall withstand a wind gust of 60 mph (100 km/h) in any
direction when the door is secured in its open position by its door stop device when tested as specified in 11.11.
5.4 Step Assembly—The completely mounted step assembly shall withstand a vertical load of 500 lb (225 kg) applied to the
outer section without deformation of the assembly or supporting structure when tested as specified in 11.12.
5.5 Airtightness—The shelter shall not permit air leakage beyond specified limits in either container or shelter configuration
when tested as specified in 11.13.
5.6 Temperature Range:
5.6.1 Non-operating Temperature—The container mode configuration shall withstand exposure to a temperature range of −60
to 160°F160 °F (−51 to 71°C).71 °C).
5.6.2 Operational Temperature—The shelter shall be dependable and operable in an ambient temperature range of −60°F−60 °F
(except electrical (see 4.9.2)) to 125°F125 °F (−51 to 52°C)52 °C) plus a solar load such that the outer skin reaches a temperature
of 200°F (93°C),200 °F (93 °C), when tested as specified in 11.14, 11.15, and 11.26.
5.7 Humidity and Temperature Aging (Components)—The shelter components shall be capable of withstanding the conditions
of a minimum 95 % relative humidity at 200°F (93°C).200 °F (93 °C). There shall be no evidence of delamination, cracking,
corrosion, or deterioration when tested as specified in 11.16.
5.8 Blackout—There shall be no internal light visible from outside of the unit in the shelter mode when tested as specified in
11.17.
5.9 Insert Strength—When tested as specified in 11.19, the inserts indicated in Table 2 shall withstand loads equal to 80 % of
the applicable strengths shown in Table 2 without failure and as indicated in Table 3.
5.10 Rail Transportability—The shelter when tested as specified (see 11.20) shall be capable of withstanding, without damage,
the shocks normally induced by rail transport.
5.11 Impact Resistance—The shelter panel shall be impact resistant when tested as specified in 11.21.
5.12 Drop Test—The shelter when tested as specified in 11.22 shall show no evidence of damage as a result of the drop test.
5.13 Towing—The shelter shall show no evidence of damage when tested as specified in 11.23.
5.14 Water Leakage—The shelter shall show no evidence of leakage when tested as specified in 11.24
5.15 Fluorescent Light Temperature—Shelter fluorescent light assemblies shall show no failure when tested as specified in
11.25.
5.16 Solar Load—The shelter shall withstand a solar load test when tested as specified in 11.26.
5.17 Operational Fitness—The shelter shall prove functional when tested as specified in 11.27.
E1978 − 18
TABLE 3 Insert Strength (Working Loads)
Insert (diameter thread size) Pull-Out, lb (kg) Torque, ft-lb (J)
10-32 800 (360) 8 (11)
⁄4-28 800 (360) 16 (22)
⁄16-24 1600 (725) 16 (22)
⁄8-24 1600 (725) 32 (43)
TABLE 3 Insert Strength (Working Loads)
Insert (diameter thread size) Pull-Out, lb (kg) Torque, ft-lb (J)
10–32 800 (360) 8 (11)
⁄4 –28 800 (360) 16 (22)
⁄16 –24 1600 (725) 16 (22)
⁄8 –24 1600 (725) 32 (43)
2 2
5.18 Heat Transfer—The overall coefficient of heat transfer of the shelter shall not exceed 0.35 Btu/h/ft /F (2.0 W/(m * °K)
(see 11.36).
6. Other Requirements
6.1 Requirements and testing for lifting, six high stacking, longitudinal restraint, racking, lashing, endwall strength, sidewall
strength, and lifting from forklift pockets shall conform to ISO 1496-1 when tested as specified in 11.28 – 11.35.
6.2 First Article—When specified, a sample shall be subjected to first article inspection (see 8.1, 13.2, and 13.3).
6.3 Inspection Comparison Testing Sample—When specified (see 13.2), the contractor shall furnish a sample for comparison
inspection and approval (see 8.1 and 13.4).
6.4 Manuals—Unless otherwise specified (see 13.2), technical manuals shall be provided with each shelter. Stowage provisions
for the manuals shall be located as shown on the applicable drawings.
7. Quality Assurance
7.1 Responsibility for Inspection—Unless otherwise specified in the contract or purchase order, the contractor is responsible for
the performance of all inspection requirements as specified herein. Except as otherwise specified in the contract or purchase order,
the contractor may use his/her own or any other facilities suitable for the performance of the inspection requirements specified
herein unless disapproved by the purchaser. The purchaser reserves the right to perform any of the inspections set forth in this
specification where such inspections are deemed necessary to ensure supplies and services conform to prescribed requirements.
7.1.1 Responsibility for Compliance—All items must meet all requirements of Sections 3 – 5. The inspections set forth in this
specification shall become a part of the contractor’s overall inspection system or quality program. The absence of any inspection
requirement in this specification shall not relieve the contractor of the responsibility of assuring that all products or supplies
submitted to the purchaser for acceptance comply with all requirements of the contract. Sampling in quality conformance does not
authorize submission of known defective material, either indicated or actual, nor does it commit the purchaser to acceptance of
defective material.
7.1.2 Responsibility for Dimensional Requirements—Unless otherwise specified in the contract or purchase order, the contractor
is responsible for assuring that all specified dimensions have been met. When dimensions cannot be examined on the end item,
the inspection shall be made at any point or at all points in the manufacturing process necessary to assure compliance with all
dimensional requirements.
7.2 Classification of Inspection—The inspection requirements specified herein are classified as follows:
7.2.1 First Article Inspection—See 8.1.
7.2.2 Comparison Sample Inspection—See 9.1.
7.2.3 Quality Conformance Inspection—See 10.1.
8. First Article Inspection
8.1 First Article Inspection—When a first article is required (see 13.3), it shall be examined for visual defects in Table 4,
dimensions specified, and tested as specified and in the sequence specified in Table 5. All testing shall be performed on the same
shelter. The presence of any visual defect, any dimension not within specified requirements, or failure of any test shall be cause
for rejection of the first article.
8.1.1 First Article Panel Specimen Inspection—Prior to fabrication of any panels, a panel specimen shall be fabricated for torque
and pullout testing to demonstrate strengths of potted inserts. The panel specimen shall be fabricated using the same techniques
and materials used to fabricate production panels, except aluminum facing thickness shall be nominal 0.040 in. (1.0 mm) and
overall thickness shall be nominal 2 in. (25 mm) thick. The edges of the specimen are not required to be sealed. The specimen shall
be sized to accept 16 inserts (four each size specified in Table 2) located a minimum of 6 in. (150 mm) from panel edges and 6
in. (150 mm) on center from each other. The inserts shall be installed in accordance with the process to be used for production
E1978 − 18
TABLE 4 End Item Visual Defects
Classification
Examine Defect
Major Minor
Finish not as specified, not finished where required 101
not adherent, for example, blistered, peeled 201
runs, wrinkles, streaks, or areas of no film 202
finish not dry, that is, wet or tacky to touch 203
scratch, gouge, abrasion exposing prime coat or bare metal, in accordance with the drawings 204
any area of rust 205
Design any characteristic not in accordance with specified requirement 102
Construction and Workmanship component or part fractured, split, punctured, dented, or malformed 103
component missing, inoperative, or will not operate as intended 104
component not properly assembled or secured 105
any functioning component which requires abnormal force to operate 206
burr, rough or sharp edges, or sliver which may be injurious to personnel or cargo 106
gaskets torn or split 107
gasket or seals painted 207
visible gaps between aluminum faces and extruded edges or panel cutout edge members 108
Welding and brazing (where required) not type specified, missing where required 109
incomplete, burn through area, pits, crack or fracture, or otherwise not fused 110
slag inclusion, undercut, not smooth and uniform, scale or flux deposit not removed 208
Metal fasteners, bolts, nuts, screws, studs missing, not type specified, broken, stripped, or loose 111
lockwasher missing where required 209
Rivets missing 112
not type specified 113
not sufficiently peened, not drawn tight, excessively peened 210
cloth cut or tear longer than ⁄8 in. 114
hole larger than ⁄8 in. diameter 115
Marking missing, incomplete, not legible, not specified type or size, misplaced
Instruction plate, nameplate missing, incomplete, not legible 116
Instruction manual missing, incomplete, not legible 117
TABLE 5 First Article Test Sequence
Inspection Requirement Test
Panel frame airtightness 4.3.6 11.41
Panel watertightness 4.3.2 11.18
Panel delamination 4.3.5 11.38
Visual defects 8.1 10.4
Thickness 3.7.3 11.39
Adhesion of paint 3.7.1 11.37
Operational (first time) 5.17 11.27
Thermal shock 4.3.3 11.6
Panel interchange 4.3.4 11.7
Insert proof load 4.4 11.8
Electrical system 4.9 11.40
Floor load, static 5.1 11.9
Roof load 5.2 11.10
Door load 5.3 11.11
Step 5.4 11.12
Airtightness 5.5 11.13
Low temperature 5.6 11.14
High temperature 5.6 11.15
Humidity and temperature aging 5.7 11.16
Heat transfer 5.18 11.36
Insert working load 5.9 11.19
Rail transportability 5.10 11.20
Impact resistance 5.1 11.21
Drop 5.12 11.22
Towing test 5.13 11.23
Fluorescent light temperature 5.15 11.25
Lifting 6.1 11.28
Six-high stacking 6.1 11.29
Longitudinal restraint 6.1 11.30
Racking 6.1 11.31
Lashing 6.1 11.32
Endwall strength 6.1 11.33
Sidewall strength 6.1 11.34
Lifting from forklift pockets 6.1 11.35
Blackout 5.8 11.17
Water leakage 5.14 11.24
Solar load 5.16 11.26
Operational test (second time) 5.17 11.27
E1978 − 18
panels. Eight (two of each size) inserts shall be installed within the panel in a vertical plane and eight (two of each size) inserts
shall be installed within the panel in a horizontal plane and so identified, that is, H or V. Failure of one or more inserts to pass the
tests specified in 11.8.1 and 11.8.2 shall be cause for rejection of the installation process. This test shall be repeated until an insert
installation process has been developed to pass the strength test.
9. Comparison Sample Inspection
9.1 Comparison Sample Inspection—When a comparison sample is required (see 13.4), it shall be inspected and tested as
specified in 8.1.
9.2 Comparison Sample Panel Specimen Inspection—Comparison sample panel specimen inspection shall be performed in
accordance with 8.1.1.
10. Quality Conformance Inspection
10.1 Quality Conformance Inspection—Unless otherwise specified, sampling for inspection shall be performed in accordance
with ANSI/ASQC Z1.4-1993. ANSI/ASQ Z1.4-2003 (R2013). The contractor’s quality control system shall conform to ISO 9001.
10.1.1 Component and Material Inspection—In accordance with 7.1, components and materials shall be inspected in accordance
with all the requirements of the referenced documents unless otherwise excluded, amended, modified, or qualified in this
specification or applicable purchase document.
10.2 In-Process Examination—Examination shall be made of the following fabrication operations to establish conformance with
the specified requirements:
10.2.1 That panel materials are as specified,
10.2.2 That rivet heads are sealed and tight for conformance with 3.4,
10.2.3 That parts are cleaned and free of adhesive sealer and other foreign materials for conformance with applicable drawings.
10.2.4 Prior to assembling other components over any welded area or prior to priming for painting, that welding processes and
welded assemblies conform to referenced documents when specified on the drawings and to the requirements of 3.6.
10.2.5 That electrical assemblies and wiring are fabricated in accordance with applicable drawings and industry standards.
10.2.6 That the primer thickness, topcoat thickness, and topcoat color are as specified in the applicable drawings (see 3.7.2 and
3.7.3), and
10.2.7 That the panels are processed, fabricated and inspected in accordance with the requirements of Practices E864 and ,
E874, and E1773, and Specifications E865, E866, E990, E1091, andand E1091 E1773(see 4.3.1).
10.2.8 Whenever nonconformance is noted, correction shall be made to the items affected and the process.
10.3 In-Process Testing:
10.3.1 Panel Watertightness Testing—Prior to assembly (that is, fabrication of cutouts, installation of inserts and hardware, and
so forth) one panel from every lot of both welded frame panels and unwelded frame panels shall be tested for watertightness as
specified in 11.18. The lot size shall not exceed 100 panels. The panels to be tested shall be 8 by 20 ft (2.4 by 6.1 m). Failure of
the test shall be cause for rejection of the panel lot represented.
10.3.2 Panel Insert Testing—Each type of shelter panel (roof, end wall, and so forth) shall be tested for insert working load by
first-piece inspection and by sample inspection of each lot of each type roof panel. The inspection lot shall consist of all of one
type of panels processed at one time. At the start of each panel and insert assembly operation, the first panel (first-piece) shall have
all inserts tested for working load in accordance with 11.19 and failure of any insert shall be cause for rejection of the panel and
the process. Each start-up of insert fabrication, change in type or formation of adhesive or potting compound, or any change in
the method of insert bonding shall be cause for necessary changes to the process and for repeat of the first-piece inspection.
Inspection lots shall be evaluated using inspection Level II and the acceptable quality level (AQL), expressed in terms of defects
per hundred units, shall be 10.0. Each sample panel shall have all inserts tested for insert working load in accordance with 11.19.
10.3.3 Panel Delamination Testing—All panels coming out of the press shall be tested as specified in 11.18. Failure to pass this
test shall be cause for rejection of that panel. The purchaser shall be notified within 72 h of any failures. In addition, a failure
analysis report shall be prepared with corrective action defined for inserts tested.
10.3.4 Panel Frame Airtightness Test—After welding, all welded panel frames shall be tested as specified in 11.41 and
reworked, if required, as specified in 11.41.1.
10.4 End Item Visual Examination—The end item shall be examined for the defects listed in Table 4. The lot size shall be
expressed in units of one shelter. The sample unit shall be one shelter. The inspection level shall be II and the AQL, expressed in
terms of defects per hundred units, shall be 4.0 for major defects and 6.5 for total (major and minor combined) defects.
10.5 End Item Dimensional Examination—The end item shall be examined for conformance to dimensions specified. Any
dimension not within the specified tolerance shall be classified as a defect. The lot size shall be expressed in units of one shelter.
The sample unit shall be one shelter. The inspection level shall be II and the AQL, expressed in terms of defects per hundred units,
shall be 4.0.
E1978 − 18
11. Required Tests
11.1 Electrical Continuity Testing—Every end item shall be tested as specified in 11.40. Any test failure shall be cause for
rejection of the end item.
11.2 Water Leakage and Operational Testing—The first ten production units shall be tested as specified in 11.24, 11.24.1, and
11.24.3. If no failures are experienced five of the next ten production units shall be tested. If no failures are experienced on the
50 % sample, one of each 25 production units shall be tested thereafter. Any failure on sampled units shall be cause for rejection
of the lot and return to 1008 testing, and repeat the above procedure (starting with the units of that lot).
11.2.1 Water Leakage (Fully Loaded)—One out of every fifty production units shall be tested as specified in 11.24.2 and 11.24.3.
The purchaser shall be notified of any test failure within 72 h. A failure analysis report shall be prepared with corrective action
defined, and one out of the next ten production units shall be tested followed by one out of the next fifty if no failures occur.
11.3 Performance Testing—One end item from each inspection lot shall be tested as specified in 11.13 (shelter mode only) and
11.26. After successful completion of these tests, the end item sample shall be tested as specified in 11.17. The size of the inspection
lot shall not exceed 25 shelters. Any test failure shall be cause for rejection of the lot.
11.4 Paint Adhesion Testing—One of every forty production units shall be tested as specified in 11.37. This unit in the deployed
mode shall be tested only after storage in a 70°F (21°C)70 °F (21 °C) minimum temperature indoor environment for 168 h
minimum after topcoat painting. The purchaser shall be notified of any test failure within 72 h. A failure analysis report shall be
prepared with corrective action defined, and one out of the next ten production units shall be tested, followed by one out of the
next forty if no failures occur.
11.5 Packaging Examination—An examination shall be made to determine that preservation and packing comply with the
requirements in Section 5. Defects shall be scored in accordance with Table 6. The sample unit shall be one shelter fully packaged
except the mechanical seals on the doors may be omitted to facilitate inspection. When omitted for internal inspection, after
acceptance of the lot for preservation, mechanical door seals shall be applied to the shelters and then the lot of shelters subsequently
inspected for sealing. The lot shall be the number of shelters offered for inspection at one time. The inspection level shall be II
and the AQL, expressed in terms of defects per hundred units, shall be 2.5.
11.6 Thermal Shock Test—Within 30 min after exposure cycling of 11.16 has been completed, the panel specimens shall then
be subject to a −65°F (−54°C)−65 °F (−54 °C) environment for 4 h to evaluate the effects of thermal shock. After thermal shock,
TABLE 6 Packing Defects
Examine Defect
Workmanship, doors are not closed, latched, and mechanically
exterior sealed.
exterior electrical connections are not covered and
covers are not secure (hand pressure).
expandable wall corner post-cam latch handles are
not in locked position with pin in retaining hole
puncture in exterior skin.
damage (such as bend, gouge, or dent) to frame
ends or to forklift opening.
steps are not folded closed.
any other protruding or not stowed part.
Workmanship, equipment container is not secured in place.
interior
parts in the equipment container are not in
accordance with the list of the parts.
the four lift jacks are not secured on the doors.
the two leveling jacks are not secured on the cargo
door.
the support struts are not secured with lock pin in
place.
the removable light fixtures are not secured to the
fixed ceiling by four captive studs with stowage
bracket plunger locked.
the movable utility outlets are not secured to the
hinged endwalls by their captive screws.
the area light and cable are not secured to the
interior of the personnel end panel with the
retaining wing nuts secured (hand pressure).
the area light does contain a bulb (bulb should be
packaged and packed in the equipment container).
any circuit breaker not in the OFF position.
the circuit breaker box keys are not inside the box.
air vents are not secured closed.
environmental control units (ECU) panels are not
stowed securely on the fixed ceiling.
any other loose or not stowed part.
E1978 − 18
the panel specimens shall be inspected for delamination (see 11.38), corrosion, and material degradation. Any delamination,
corrosion, or material degradation shall constitute a failure of the test.
11.7 Panel Interchange Test—The folding walls with the same part number and two fixed walls with the same part number
randomly selected from the first article or production lot of completed shelters, as applicable, shall be interchanged. The
interchange shall be accomplished by removing the hinge pins or bolts, as applicable, interchanging walls, and reinstalling the
hinge pins or bolts (see 4.3.4). Any wall that cannot be fully interchanged shall constitute a failure of the test.
11.8 Insert Proof Load Test—Test fixtures shall be fashioned by the contractor and approved by the purchaser prior to use, to
evaluate the inserts using bolts of the applicable thread size. Loads shall be applied to the insert in a tightening and loosening
direction and held at the specified torque for a minimum of 5 s. The test fixtures shall be fashioned to induce only a twisting load
to the insert for the torque test and, primarily, only on axial tensile load through the centerline of the insert for the pull-out test.
The Apply the reaction load from the in outside of a 3 in. (75 sert insert pull-out fixture onto the test specimen panel shall be applied
to the panelmm) panel, to the panel outside of a 3 in. (75 mm) radius measured from the centerline of the insert.
11.8.1 Insert Torque—To determine complianc
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