Coping Blocks

Specification

MCB Camp Pendleton Range 132 & Range 133 Ballistic Concrete Blocks
18 August 2016

1. Introduction

Marine Corps Training and Education Command requires infrastructure materials and supplies in support of Range Training systems. Items are of infrastructure class and type material required to design, build, deliver and maintain training systems.

2. Background

Program Manager Training Systems (PM TRASYS), Marine Corps Systems Command has a requirement to provide shock absorbing concrete structures that can be easily sustained by repairing and replacing components over time, capable of capturing small arms ammunition and grenades for live fire training at Range 132 and 133, at Marine Corps Base (MCB) Camp Pendleton.

3. Scope

This requirement upgrades the existing live fire training range at Marine Corps Base Camp Pendleton Ranges 132 and 133.  In order to meet these requirements, PM TRASYS requires the ballistic concrete blocks that comply with all requirements and instructions contained within this Specification Document.

4.  Figures

Layout/Configuration of the ballistic concrete blocks shall be in accordance with the following drawings:

Figure 1: R132 Building Shoot House 3D Illustration:

Figure 2: R132 Building Shoot House Floor Plan:

Figure 3: R133 Building Shoot House 3D Illustration:

Figure 4: R133 Building Shoot House Floor Plan:

Figure 5: 12x12x18 Keyed Brick:

Requirements

Block Part Number
ID
Qty UI Description
A 13 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Left Corner ‐Male/ Female
C 3 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Right Intersecting ‐ Male/ Female
C-1 10 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Left Intersecting ‐ Male/ Female
DL 7 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Left Door ‐ Male/ Female
DR 7 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Right Door ‐ Male/ Female
E 118 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Male/ Female
E-1 4 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, End ‐ Female
E-3 12 EA 30″D x 3′-3”W x 10’H Shock-absorbing concrete Keyed Block, Male/ Female
E-4 3 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, End ‐ Male
E-24 14 EA 30″D x 2’W x10’H Shock-absorbing concrete Keyed Block, Male/ Male
F 6 EA 30″D x 3’W x 10’H Shock-absorbing concrete Keyed Block, Male/ Male
F-1 1 EA 30″D x 3′-3”W x 10’H Shock-absorbing concrete Keyed Block, Male/ Male
G 30 EA 24”D x 3’W Coping Block
GLC 2 EA 24”D x 3’W Coping Block, Left Entry
Block Part Number
ID
Qty UI Description
GRC 2 EA 24”D x 3’W Coping Block, Right Entry
GL 4 EA 24”D x 3’W Coping Block, Left Corner
GR 4 EA 24”D x 3’W Coping Block, Right Corner
G33 2 EA 33”D x 2’ Coping Block
MB 400 EA Keyed Brick 12”x12”x18”
N/A N/A Technical Assistance provided on-site for the duration of the installation for R132 and R133
N/A N/A Sealed & Signed engineered block configuration, detail and assembly drawings
N/A N/A Shipping and off-loading of material to a designated area adjacent to R132 and R133

Range 132 Wall Block Panels

All Range 132 Blocks shall have a 7” W x 5” H notch along the bottom of each block for seismic restraint as shown on the figures below.

Additional Specifications

Performance and Testing
• At a minimum of 14 days, each ballistic concrete element shall undergo ballistic certification testing, consistent with industry accepted best practices.
• Dimensional tolerances for individual ballistic concrete elements shall be in accordance with ACI 117-10
• The acceptable range of initial slurry density shall be 131 pounds per cubic food (PCF) ± 3 PCF.
• The acceptance range of the final ballistic concrete mixture, with all admixtures included shall be 91 PCF ± 3 PCF.
• The unconfined compressive strength, at 28 days, of a ballistic element shall be 1200 pounds per square inch (PSI) ± 700 PSI
• Ballistic penetration testing shall consist of a single round fired at the face of the element using a stationary rifle. The single round shall be 5.56, 62 grain green tip ammunition. The penetration of the round shall be no less than 1 inch and no greater than 5 inches.
• Fine aggregate shall be regular concrete sand and conform to ASTM C144-11.

Material

• Shock absorbing concrete
• Color: grey
• Shall conform to ASTM C150-11.
Shoot House Block Dimensions
• Wall Block Panels shall meet the following:
Width: shall not exceed 3FT
Height: 10 FT
Depth: 2.5 FT
• Coping Blocks shall meet the following:
Width: 36 in (max)
Height: 24 in
Depth: 24 in

The shoot house block panels shall incorporate a male-female interlocking keyed system with lifting capability. The interlocking system shall hold adjacent panels together and prevent the panels from moving or slipping. In addition, the shoot house block panels shall have a steel connection plate system on the top of each block to interconnect the blocks together and to resist lateral loads. The interlocking keyed and steel connection plate systems description shall be included with the proposal submitted. The panels shall be cast to a tolerance that will allow panels to be installed on a level surface so there is no greater than 3/8″ gap anywhere between adjoining panels. The panel’s ballistic concrete mixture shall have an injection repair method to restore any damaged blocks.
Ballistic test data and Shock-Absorbing Concrete Certification from the Army Corps of Engineers shall be included with the proposal submitted.

Drawings

Engineering drawings shall be included for each product. The drawings for the Range 132 and Range 133 shoot houses shall include the overall floor plans, wall elevations, building dimensions, individual block type details and block connection details. The drawings shall also include assembly instructions on how the blocks shall be integrated to build the R132 and R133 shoot houses. Drawing and specifications for the 400 keyed blocks shall also be included. All engineered block diagrams, details and assembly drawings shall be sealed & signed by a registered professional engineer.

Shipping and Delivery Limitations:

The blocks shall be shipped to two designated locations at Camp Pendleton, California as shown on Figure 6. Access to both Range 132 and Range 133 can be achieved via maintained dirt roads. However, access to Range 133 requires crossing a bridge with capacity and width limitations. The access bridge has a rating of 15-tons and the bridge dimensions are shown on Figure 7. The vendor shall be responsible for delivering the R133 blocks to the R133 site using a method that does not exceed the bridge limitations.

Figure 6: R132 and R133 Delivery Locations

Figure 7: R133 Access Bridge Approximate Dimensions