N093-216 TITLE: Magazine Lightweight Synthetic Decking

TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: PEO Aircraft Carriers

OBJECTIVE: The proposed topic intends to focus innovation on a cost effective, lightweight alternative to latex concrete for air launched ordnance and ammunition magazine decks. Advanced lightweight materials are becoming the norm for new designs in buildings, aircraft, autos, watercraft, etc. New, synthetic decking materials are increasingly being used in applications that traditionally utilize wood. A synthetic material with characteristics capable of equaling the performance of concrete to provide a level working surface for shipboard ordnance handling and stowage is a technological challenge. A relatively lightweight (50% or more weight reduction over the current approximate 350 tons of MIL-D-21631 latex concrete per ship), easily installed and removed or repaired synthetic material for the demanding environment of CVN and LHD magazines is the objective of this topic.

DESCRIPTION: The Universal Tie-Down System (UTDS), installed in aircraft carrier and large deck amphibious ship magazines, consists of deck tracks constructed of C-channel that act as anchor points for weapons tie-down chains. The 3" wide C-channels are spaced on 9" centers, creating a 6" gap between them. With no filler material, the deck tracks create an obstruction 7/8" -1" high from the deck plate. To provide a level deck surface for ordnance handlers and fork trucks to operate on, latex concrete is used to fill the gaps between the C-channels. In accordance with MIL-D-21631 Deck Covering, Latex Concrete, the deck covering after curing shall not exceed 12.25 lbs per square foot for a thickness of 1". Also, per MIL-D-21631, the deck covering must be resistant to impact, elevated temperature, indentation, wear, etc. and have non-slip properties. While a new material may have somewhat different requirements than those of MIL-D-21631 depending on its physical properties, any new specification to be written for it will have a similar scope i.e., "�a non-sparking, fire retardant� deck surfacing for use over aluminum or steel decking or between channels in the holds of ammunition spaces."

The steel deck plates aboard ship and upon which the new material is to be installed, do not themselves provide a perfectly level surface and irregularities must be compensated for. Concrete applied by trowel and screed inherently compensates for irregularities in the deck plates. Should a substratum be required for the new decking, the weight of that substratum must be added to the weight of the synthetic decking when calculating weight savings, likewise for any necessary fastening hardware. Together with the adjoining C-channel, an overall uniformly level surface is desired; an acceptable margin for minor irregularities will be determined. MIL-D-21631 rev.A will be used as a guide in determining margins for properties such as flow or slip, coefficient of friction, impact resistance, live load resistance, etc. It is not, however, the topic writer�s intent to mandate strict adherence to MIL-D-21631A and its referenced specifications so as to impede innovation.

This Topic requires that innovative R&D be conducted to develop a new, lightweight, synthetic material that has preferably lower combined acquisition, installation and maintenance cost than latex concrete, that can provide a level and durable, fire, impact and slip resistant surface in aircraft carrier and large deck amphibious ship magazines. Solid or liquid state at installation is allowable, however in either case, a justifiable case for replacing latex concrete must be made.

PHASE I: Conduct the needed R&D to develop a concept proposal for affordable, lightweight, durable, non-sparking, slip resistant material for use in shipboard magazine spaces. Using the existing latex concrete and MIL-D-21631A as a reference, clearly show margins of the proposed material properties that fail to meet or exceed the properties of latex concrete. Explain the trade-offs that may be necessary to achieve the desired performance level. Explain any compensating measures that would mitigate the effects of less desirable properties should they exist. Explain and justify any ASTM, UL or other test methods or qualification steps that may be commonly used in synthetic materials manufacturing that would supersede, replace or supplement those in MIL-D-21631A for the proposed material. Describe and illustrate the installation process and any necessary preparatory steps such as mixing, or additional materials such as adhesives, fastening hardware or a substratum layer. Perform a detailed weight analysis clearly showing the estimated weight savings. Perform a first order of fidelity business case analysis of the proposed material vs. latex concrete considering acquisition, installation and maintenance costs including repair and replacement. Present findings in a Final Report with data, photographs, illustrations, experiments, related work, etc. to demonstrate the feasibility of a lightweight synthetic decking material for use in U.S. Navy shipboard magazines.

PHASE II: Complete the R&D identified in the Phase I final report and using MIL-D-21631A or other predetermined specification(s) as a guide, prepare test article specimens as necessary to conduct a series of qualification tests. Tests shall include but are not limited to: weight, resistance tests for impact, indentation, flow, shear, moisture absorption, wear, fire, sparking, electrical conductivity, live load and a test of nonslip properties. Tests can be conducted at the proposing company�s facility, U.S. Naval laboratory such as NSWCCD Philadelphia and/or independent testing laboratory satisfactory to the TPOC. A larger test specimen will be produced for actual load testing. Envisioned is a UTDS test area 10� x 10� or larger, complete with C-channel and the proposed concrete replacement. A series of tests simulating shipboard operations will be conducted using a 4,500 lb capacity reach and tier fork truck, ordnance loads and chain tie-downs typically found in aircraft carrier magazines. Based on the results of this test and other factors, a dynamic test of the UTDS test bed and stowed ordnance loads and MHE on a ship motion simulator may be warranted. A shock test in accordance with MIL-S-901D is a potential Phase II option activity.

PHASE III: Partnered with a prime contractor, a manufacturing and installation study will be conducted to determine the most cost effective and efficient production and installation methods. Separate testing and marketing for commercial applications would also be a joint effort with, and possibly led by, the prime contractor. It is envisioned that following U.S. Naval laboratory testing, an independent evaluation of the proposed concrete replacement will be conducted by Northrop Grumman Newport News Shipbuilding (NGNNS) at the Virginia Advanced Ships and Carriers Integration Center (VASCIC) laboratory. CVN 72 or 73 RCOH and CVN 78 would be candidates for initial shipboard installation and testing in selected magazine(s). Proven successful, complete ship set new construction installation is envisioned beginning with CVN 79.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Commercial sea, air and road shipping, barges and boats, docks, commercial and residential indoor-outdoor decking including decks, patios and walkways, staging areas, multi-level warehousing, roadways for bridges, portable and mobile magazines for law enforcement.

REFERENCES:
1. Military Specification MIL-D-21631A, Deck Covering, Latex Concrete

2. MIL-STD-1623E Department of Defense Design Criteria Standard Fire Performance Requirements and Approved Specifications for Interior Finish Materials and Furnishings (Naval Shipboard Use)

3. Military Specification MIL-S-901D, Shock Tests, High Impact, Shipboard Machinery, Equipment, And Systems, Requirements For

4. NAVSEA OP-4 Ammunition and Explosives Safety Afloat

KEYWORDS: lightweight materials, synthetic decking, magazine, concrete replacement, ordnance stowage, aircraft carrier

** TOPIC AUTHOR (TPOC) **

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