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This Catalog
HESCO Bastion Concertainer® Technical Information January 2005 HESCO Bastion Concertainer® Technical Information Contents Introduction . . . . . . . . . . . . . . . .1 Life Saving Blast Mitigation . . .1 Typical Structures . . . . . . . . . . .2 Fill Material . . . . . . . . . . . . . . . .2 Construction Techniques . . . . . .3 Training . . . . . . . . . . . . . . . . . . . .6 Other Considerations . . . . . . . . .6 Annexes © HESCO Military Products Ltd January 2005 HESCO Bastion Concertainer® Technical Information Introduction 1. HESCO Bastion Concertainer® units can be installed in various configurations to provide effective and economical structures which can be tailored to protect personnel, vehicles, equipment and facilities in military, peacekeeping, humanitarian and civilian operations. The patented design has been subjected to testing with explosive charges up to 20,000lbs. Correctly configured, a wall made from HESCO Bastion Concertainer® units will mitigate the effects of truck bomb attack. It has been tested and proven against small arms fire and RPG, and is acknowledged as the most significant development in field fortifications since WWII. 2. HESCO Bastion Concertainer® units are delivered flat-packed and is manufactured in nine sizes from the smallest unit, Mil 2 to the largest unit, the Mil 7. It is constructed with either 4mm or 5mm galvanized steel weld mesh, depending on the cell size and lined with a 2mm non- woven polypropylene geotextile. (For a more complete and comprehensive breakdown of the product data, please see Annex A). Life Saving Blast Mitigation 3. HESCO Bastion Concertainer® units have undergone a huge array of testing worldwide. This testing has been conducted by the leading authorities in the world in the field of blast mitigation, containment of blast effects and force protection. 4. The sort of weapons systems used in typical testing has been: • Small arms (5.56 - 14.5mm AP) • Cannon (20 - 40mm including HE, AP and long rod) • Grenades • Mortars (81 and 82mm) • Artillery (122, 152 and 155mm) • Air delivered bombs (US Mk 82) • Conventional plastic and home made explosive bare charges. Including ANFO • Vehicle delivered improvised explosive devices 5. Due to the nature of some of the testing, specific data is considered classified. Therefore, an unclassified synopsis of some of the main testing that has taken place over last 13 years can be found in Annex B. 6. HESCO Bastion Concertainer® units are constantly and continually undergoing testing by leading authorities. This level and variety of testing demonstrates the pedigree of the system and the number of different protective uses it can be put to. For example, the © HESCO Military Products Ltd January 2005 1 HESCO Bastion Concertainer® Technical Information system is currently being tested against mortars and rockets and in the near future against the effects of Hesh rounds. The company has also developed a new overhead protection system which is scheduled to be tested in early 2005. Typical Structures 7. The use of HESCO Bastion Concertainer® units is wide and diverse and ranges from civil engineering with soil retaining walls, flood prevention and the prevention of coastal erosion. Military uses are considerably more diverse. HESCO Bastion Concertainer® units have been used in the construction of: • Ammo compounds • Noise abatement barriers • Sentry towers • Guard posts, both improvised and in kit form • Vehicle barriers • Entry Control Points • Blast mitigation walls • Cover from view • Protection from ballistics • Protection for aircraft (revetments) • Protection of adjacent occupants from the accidental discharge of aircraft weapons • Protection of living accommodations • Provision of bomb shelters • Asset protection 8. The list is not exhaustive. The use that which HESCO Concertainer® units can be put to is only limited by the user's imagination and a few construction engineering considerations. 9. Examples of typical structures can be found in Annex C. Fill Material 10. One of the main advantages of HESCO Bastion Concertainer® units is its ability to be filled with almost any fill material. Only large rocks and clumps of earth should not be used. Fill materials fall into three categories (very good, good and poor). Very good material would be well graded sand or gravel with clay being an example of a poor fill material. 11. Comprehensive details on fill material including blast, ballistic and construction characteristics can be found at Annex D. © HESCO Military Products Ltd January 2005 2 HESCO Bastion Concertainer® Technical Information Construction Techniques 12. Equipment: There are a variety of equipment types that can be utilized to fill HESCO Bastion Concertainer® units. The simplest and easiest to use is a front end-loading shovel, particularly when the structure is below 3.5 metres (11') high. 13. Front end loading shovel size should be selected to match the size of concertainer cell being filled. The front bucket of a backhoe loader is suitable for all cells up to Mil 1 in size. Larger 2 Cu m3 (2.6 Cu Yd) buckets can be used for Mil 1, 3, 4, 8 and 9. Loading shovels with buckets in excess of 2 cu m3 (2.6 Cu Yd) are ideal for the larger Mil 7 and Mil 10. 14. Other loading equipment that can be used: • Skid steer loaders • Wheeled and tracked excavators fitted with either standard buckets or clamshell grabs • Tipper truck/dump trucks fitted with lorry loader grab attachments • Concrete skips lifted by cranes 15. Fill Material Requirements: The user of a particular fill material is going to be dependent on one or more of the following: • The type of material available • The length of time the structure is likely to be employed • The perceived threat • The handling equipment available 16. For hastily required defensive positions almost any locally won fill material will suffice. The only material that should be avoided is that which contains large lumps that may create voids or damage the cells during the filling operation. Large pieces of material may also become dangerous pieces of shrapnel. Avoid organic material if possible but it is realized that in some tactical situations this may not be possible as it may be the only material available. 17. If during the planning of the structure it is believed that it is to be in place for a time exceeding 6 months it is essential that a material with good construction characteristics is chosen. Well graded sand (with low ‘fines’ content), or crushed rock is ideal for longterm structures. The provision of foundations for long-term structures should not be overlooked. Topsoil should be removed and replaced with a well-graded crushed rock to a depth of 500mm (20”) or until all organic material is disposed of. The use of geotextile and geogrids should be considered. The depth of excavation can be reduced if hard, competent ground is struck earlier. © HESCO Military Products Ltd January 2005 3 HESCO Bastion Concertainer® Technical Information 18. The expected threat will dictate to a certain extent what material should be used. Sand is ideal where the threat is likely to be from blast as this will present no secondary fragmentation. Sand is also ideal for the construction of walls within an ammunition storage area. 19. The handling equipment will to a lesser extent dictate the material to be used; cohesive materials do not flow from concrete skips. 20. Placement of Fill Material: Fill material should be placed centrally in the cells. If it is placed to either side it is likely to topple the concertainer. The material should be placed in layers of around 150 - 300mm (6” - 12”). It should be spread out by shovel and then compacted down and into the corners and edges by foot. There is no requirement for mechanical compaction equipment to be used. 21. It is vitally important that when the first 150 - 300mm (6” - 12”) of material is placed in each cell that the bottom center is pulled out 25 -75 mm (1” - 3”). If this is not done the cells will bulge in the center and may become unstable if multiple layers are to be constructed. This is only applicable for Mil 1, 4, 7, 8, 9 and 10. 22. The following is a guide to the fill material required to fill HESCO Concertainer® Units. It takes into account swell factors for the cells, compaction factor of the material and an additional 10% to cover material loss. Mil 1 9 cell Concertainer 22 m3 29 Cu yd Mil 2 2 cell Concertainer 0.46 m3 0.6 Cu yd Mil 3 10 cell Concertainer 12.06 m3 15.76 Cu yd Mil 4 10 double cell Concertainer 20 m3 26 cu yd Mil 5 5 cell Concertainer 1.6 m3 2 Cu Yd Mil 7 13 cell Concertainer 190 m3 248 Cu Yd Mil 8 9 cell Concertainer 25 m3 33 Cu Yd Mil 9 12 cell Concertainer 9 m3 12 Cu yd Mil 10 20 cell Concertainer 147 m3 191 Cu Yd 23. HESCO Bastion Ltd produces various packages that for ease of use and ordering come complete and ready to use. All that you must provide is the fill material and the means to fill the cells. • Bunker Package: To construct a 20 foot single entry bunker will typically take 170 m3 of fill material. It will normally take around 8 - 10 hours to construct. • Two-Man Guard Post/Sanger Package: To construct a 2 man Sanger kit will take approx 20 m3 of fill material. This will take around 2 - 3 hours to construct. © HESCO Military Products Ltd January 2005 4 HESCO Bastion Concertainer® Technical Information 24. Calculation of Time, Manpower and Equipment: It is important with any construction task that you can calculate or estimate the time required to complete the task and also what resources in respect of filling equipment is required. 25. Many factors will effect the time and numbers of operatives that it takes to construct any given structure, but the more common ones are: • Time of Year • Light • Availability of resources and manpower • Haul distance from stockpile for the fill material • Accessibility and ground conditions • Type of plant available for your use • Tactical situation and threat level • Type of HESCO Bastion Concertainer® unit being used • Experience of the operatives with the system and the structure being built. 26. The key to working out the quantity of manpower required: • Ascertain time available for the construction • Calculate the construction time with 4 men and loading equipment This is your basic construction figure, if you cannot achieve completion within the given time frame then an increase in manpower and equipment is required. 27. For basic linear construction of a HESCO Bastion Concertainer® Mil 1 unit, of 10m length, 9 cells, allow 20 minutes using one loading shovel and 4 men. This includes unpacking from a pallet, bouncing the cells out and filling. This is as good a figure as any to use as a guide figure for basic HESCO Concertainer construction. More comprehensive guidance on construction timing can be found at Annex E. 28. Maintenance: If the guidance provided in the HESCO Construction Guide for Engineers is followed then this will avoid the need for any in depth or comprehensive maintenance. However, for longer term structures, some simple basic maintenance will be required. This will probably consist of the repair of cells damaged by vehicles, personnel or UV. Damage to the Geotextile by the UV can be prevented by either the application of HESCO UV-Cam, cement slurry or the shading of the wall by use of fabric or foliage. 29. Repair: There are two methods of repair which can be found in the HESCO Construction Guide for Engineers. An additional method would be when a cell is not badly damaged but © HESCO Military Products Ltd January 2005 5 HESCO Bastion Concertainer® Technical Information simply requires some reinforcement. A new cell or unit can simply be placed against the damaged area and securely attached. The supplied HESCLIPS would be suitable for this task. 30. Health & Safety: As with all construction tasks the relevant health and safety guidance and regulations should be followed. Particular areas of risk when constructing HESCO Concertainer® structures are: • Working on structures that are often 14' or higher • Manual handling • The movement of plant, risk of collision between pedestrians and vehicles • Dust particularly in desert environments • Working in areas where there is limited visibility, particularly when placing and compacting material inside Mil 7 and 10 units. Training 31. HESCO Bastion Ltd can provide training and this can range from a one hour lecture to comprehensive courses for operatives, supervisors or planners. 32. Courses can be tailored to client's requirements and can also be conducted on site at the commencement of the project. Other Considerations 33. There are a number of alternatives to HESCO Concertainer® units when protection is required. The most common alternative is to use concrete T walls. These walls are quick and easy to deploy but do suffer from a number of drawbacks, not least the secondary fragmentation issue. 34. A comprehensive document discussing concrete versus HESCO Concertainer® units is at Annex F. 35. Another alternative to HESCO Concertainer® units is the ever present counterfeit material. There are number of counterfeit products available, some purporting to be the genuine material. They are, in some cases, using very similar markings. The counterfeit products are far from being as competent and strong as the genuine material. Counterfeit products are characterised by a lack of UV resistance in the geotextile (typically leading to excessive premature degradation), and low weld strength, which would almost certainly be an indicator of ‘one hit protection’, with potential fragmentation hazard. © HESCO Military Products Ltd January 2005 6 HESCO Bastion Concertainer® Technical Information 36. Annex G contains phrases that can be used by specifies to ensure that procurement staff will only buy the genuine material. © HESCO Military Products Ltd January 2005 7 HESCO Bastion Concertainer® Technical Information Annex A © HESCO Military Products Ltd January 2005 HESCO TECHNICAL SPECIFICATION SHEETS MIL 1 UNIT Unit Height Width Length Mil 1 1.37m 1.06m 10m (Beige) 4’6” 3’6” 32’ Mil 1 1.37m 1.06m 10m (Green) 4’6” 3’6” 32’ Stock Number 5680-99-835-7866 5680-99-835-7866 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 2 UNIT Unit Height Width Length Stock Number Mil 2 0.61m 0.61m 1.21m 5680-99-968-1764 (Beige) 2’ 2’ 4’ Mil 2 0.61m 0.61m 1.21m (Green) 2’ 2’ 4’ 5680-99-001-9397 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 3 UNIT Unit Height Width Length Mil 3 1.0m 1.0m 10m (Beige) 3’3” 3’3” 32’ Mil 3 1.0m 1.0m 10m (Green) 3’3” 3’3” 32’ Stock Number 5680-99-001-9392 5680-99-001-9398 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 4 UNIT Unit Height Width Length Mil 4 1.0m 1.5m 10m (Beige) 3’3” 5’ 32’ Mil 4 1.0m 1.5m 10m (Green) 3’3” 5’ 32’ Stock Number 5680-99-001-9393 5680-99-001-9399 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 5 UNIT Unit Height Width Length Stock Number Mil 5 0.61m 0.61m 3.05m 5680-99-001-9394 (Beige) 2’ 2’ 10’ Mil 5 0.61m 0.61m 3.05m (Green) 2’ 2’ 10’ 5680-99-001-9400 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 7 UNIT Unit Height Width Length Stock Number Mil 7 2.21m 2.13m 27.74m 5680-99-169-0183 (Beige) 7’3” 7’ 90’ Mil 7 1.37m 1.06m 10m (Green) 4’6” 3’6” 32’ 5680-99-126-3716 TS GEOTEXTILE 3” x 3” x 5.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (5.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 4.9 / 4.92 mm 4.92 / 5.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 87” x 42” - 6 mm max 87” x 84” - 8 mm max 87” x 60” - 6 mm max 87” x 30” - 6 mm max Panel Flatness : 25 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 8 UNIT Unit Height Width Length Mil 8 1.37m 1.22m 10m (Beige) 4’6” 4’ 32’ Mil 8 1.37m 1.22m 10m (Green) 4’6” 4’ 32 Stock Number 5680-99-335-4902 5680-99-517-3281 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 9 UNIT Unit Height Width Length Stock Number Mil 9 1.0m 0.76m 9.14m 5680-99-563-5949 (Beige) 3’3” 2’6” 30’ Mil 9 1.0m 0.76m 9.14m (Green) 3’3” 2’6” 30’ 5680-99-052-0506 TS GEOTEXTILE 3” x 3” x 4.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (6.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 3.89 / 3.91 mm 3.92 / 4.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 39” x 39” - 3 mm max 54” x 21” - 3 mm max 54” x 42” - 5 mm max 24” x 24” - 3 mm max Panel Flatness : 39” x 39” - 12 mm max 54” x 21” - 12 mm max 54” x 42” - 16 mm max 24” x 24” - 12 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO TECHNICAL SPECIFICATION SHEETS MIL 10 UNIT Unit Height Width Length Stock Number Mil 10 2.12m 1.52m 30.5m 5680-99-391-0852 7’ 5’ 95’ 2.12m 1.52m 30.5m 7’ 5’ 95’ (Beige) Mil 10 (Green) 5680-99-770-0326 TS GEOTEXTILE 3” x 3” x 5.0 mm TECHNICAL DATA BEZINAL PRE-COATED MESH WIRE ANALYSIS Properties Unit TS 50 Steel Properties : 0.10% Carbon Max Mild Steel (5.50mm base rod) N 2300 Coating Weight : (g/m2) Zinc / Aluminium 145 min Wire Tensile : (N/mm2) 540 / 770 Mesh Tensile : (N/mm2) 70% of Wire tensile CBR Puncture resistance BS 6906 / 4 x Strip Tensile Strength BS6906 / 1 ISO 10319 / 1 md cd kN/m kN/m 13.9 13.9 Elongation at break BS6906 / 1 ISO 10319 / 1 md cd % % 80 45 mm 23 Cone drop test BS 6906 / 6 Hole diameter Apparent pore BS 6906 / 2 size 090 mm 0.10 Tolerance : Wire (Un-Coated) Wire (Coated) Panel Permeability BS 6096 / 3 normal to the plane (water head 100mm) 1/m2S 230 Panel Squareness : Breakthrough head mm 2 Permeability in-plane BS 6096 / 7 i=1 25kPa 100kPa 200kPa 10-3 m/s 10-3 m/s 10-3 m/s 7 4 2 mm mm mm 1.4 1.1 0.9 g/m2 200 Thickness ASTM D 1777, ISO 9863 25kPa 25kPa 25kPa Weight ASTM D 3776, ISO 9864 Note: For extreme UV stress we estimate a life of approximately 2.5 years or longer depending on the locally prevailing conditions. The values given are indicative and correspond to average results obtained in our suppliers laboratories and in testing institutes. The rights is reserved to make changes without notice at any time. 4.9 / 4.92 mm 4.92 / 5.00 mm +/- 3 mm on length +/- 3 mm on width +/- 2 mm on mesh spacing 87” x 42” - 6 mm max 87” x 84” - 8 mm max 87” x 60” - 6 mm max 87” x 30” - 6 mm max Panel Flatness : 25 mm max Elongation : Approx 5% All wires conform to BS 1052 Bezinal coatings are to BS / EN 10244 - 2 HESCO Bastion Concertainer® Technical Information Annex B © HESCO Military Products Ltd January 2005 SUMMARY OF HESCO BASTION TESTING INTRODUCTION 1. HESCO Bastion Concertainer® has undergone a huge array of testing worldwide. This testing has been conducted by the leading test authorities in the world in the field of blast mitigation, containment of blast effects and force protection. 2. The sort of weapon systems used in typical testing has been: Small arms (5.56 - 14.5mm AP) Cannon (20 - 40mm including HE, AP and long rod) Shaped charges (RPG 7 and RPG 18) Grenades Mortars (81 and 82mm) Artillery (122, 152 and 155mm) Air delivered bombs (US Mk 82) Conventional plastic and home made explosive bare charges. Including ANFO Vehicle delivered improvised explosive devices. AIM 3. The aim of this document is to summarise the testing carried out on HESCO Bastion Concertainer® from early 90s to date. DOCUMENTATION LIMITATIONS 4. The majority of test information is owned by Military Authorities and in the case of the British MOD is still subject to the Official Secrets Act. Therefore some critical data has been omitted to allow a wider circulation of this document. TESTING 4. HESCO Bastion Concertainer® was first introduced to the British Military in 1991; it was then subjected to testing against a wide range of small arms. These tests were conducted by DERA Fortifications section, (UK MOD research agency) and by the British Army Infantry Trials Team. DERA Fortifications is now part of QinetiQ 5. Weapons used were: a. b. c. d. Shot gun 7.62mm, single shot and general-purpose machine gun. 0.5” Armour piercing AP, Soviet, 12.7 and 14.5 mm AP Rarden 30mm long rod penetrator cannon. 6. The above tests were against HESCO Concertainer® Mil 2 filled with a good quality fill material. None of the rounds achieved complete penetration of the HESCO Concertainer®. The Mil 2 at 600mm thick is the smallest unit manufactured by HESCO Bastion. 1 7. HESCO Concertainer® Mil 1 Units were also tested against .50" machine gun fired in bursts of 3 - 5 rounds. The cells were sand filled and no rounds penetrated 8. The Mil 1 was also tested: a. b. c. 81mm mortar. 155mm HE artillery shell. . Simulated 120mm HESH round in direct contact. 9. In 1993 HESCO Bastion in conjunction with the UK MOD developed a collective protection system (COLPRO). This was to provide protection against 155mm artillery shells. These were fitted with super quick fuses. The COLPRO system is made up of a 20ft ISO container protected by HESCO Concertainer® Mil 1. Overhead protection is provided by steel sheet piles, HESCO Concertainer® Mil 2 and 600mm of soil fill. This test proved that the COLPRO system would prevent casualties even when the structure was subjected to a direct hit. This system has subsequently been used extensively around the world to provide mortar, bomb and artillery type shelters. Shells fitted with delay fuse will cause casualties with a direct hit. 10. 1995 saw the US military at Fort Leanordwood test HESCO Concertainer® against 155mm artillery shells close into the target of HESCO Concertainer® Mil 3. Damage was judged to be "superficial". 11. 1997 saw a substantial amount of testing take place both in the US, UK and Germany. Testing included: a. The UK tested the system against RPG7 . Gravel filled HESCO Concertainer® Mil 1 will approx 90% of the time prevent penetration of RPG7 but clay fill will not. At least 1.8m of poor fill material is required. b. HESCO Concertainer® was tested in the US at Wright Laboratories, Tyndall. This testing was 235lbs of ANFO, minor damage. 2nd test was an Mk 82 bomb at fairly short range this resulted in the complete wall moving back a little. The wall was not breached. The 3rd and last test was over 7 tonnes of C4 explosive to simulate the Khobar Towers bombing. HESCO Concertainer® was one of 3 wall systems tested; HESCO Concertainer® faired the best of the 3 with no secondary fragmentation. It also far outshone the other systems when a cost benefit analysis was carried out. HESCO Concertainer® was by far the most economical system to employ. c. The Germans tested HESCO Concertainer® along with other gabion systems in 1997. Weapons systems used were similar to previous testing. The results achieved for HESCO Concertainer® were much the same as previously achieved. The system was also attacked by anti tank grenades and 82mm mortar in contact. The damage was judged as “not significant”. 12. The Dutch Trials Agency, TNO has also conducted trials. This originated with the Dutch testing the COLPRO system, this achieved the same results as the UK testing. The Dutch have also recently trialled HESCO Concertainer® for use as ammunition stack separation walls within large ammunition compounds. This has resulted in the Quantity distances being reduced, you can now store more, closer together. The test consisted of 5011kg of explosives loaded in 155mm shells in a 20ft ISO container. Live detonators were then stored within Containers adjacent to the donor. The explosive charge was initiated and 2 resulting in severe damage to the adjacent containers but no sympathetic detonation of the detonators. 13. The HESCO Concertainer® system was tested in June 2004 as a vehicle barrier. This testing was conducted by The Transport Research Laboratory at the request of the UK security services. Two tests were carried out, the first with two cells of Mil 1 HESCO Concertainer® filled with a gravel mix. The truck weighing 7500 kgs was crashed into the barrier at 42 miles per hour. The vehicle was stopped within half a vehicle length. The 2nd test was with 4 cells with gravel. The vehicle again weighed 7500kgs and travelled at 42 miles per hour. It stopped within 2 metres and was extensively damaged. We have long held the belief in the company that the barrier system was effective against vehicles but had never had it tested, these tests have confirmed our confidence in the system. 14. A similar test has been conducted by ARA in the USA. The vehicle weighed 15000 lbs and travelled at 50 MPH. The barrier was 32 foot in length, 2 with a double thickness HESCO Mil 1 wall on the base and a single Mil 1 on top. The results were almost identical with the vehicle being stopped in a very short distance. CONCLUSION 15. The above is a quick summary of some of the main testing that has taken place over the last 13 years that we have been privy to. It can be seen from the above that the system has been comprehensively tested and continues to be so; further testing on the system is being conducted by QinetiQ at the moment. This level and variety of testing demonstrates the pedigree of the system and the number of different protective uses it can be put to. 3 HESCO Bastion Concertainer® Technical Information Annex C © HESCO Military Products Ltd January 2005 CONCERTAINER® 1-1 Defence Wall Typical Concertainer Defence Structure NSN 5680-99-835-7866 5680-99-001-9396 Mil 1B Mil 1G Unit Size HxWxL 4’6” x 3’6” x 32’ For each 1000ft wall you require: • 64 units of Mil 1 3 3 • Fill material required 1200yd (1400m ) • 24 hours to construct with one front end 3 loader (1yd bucket) and 4 men. Features: • 3’6” (1.06m) Wall Thickness • 9’ (2.74m) Wall Height • Simple Procurement - only 1 type of Concertainer unit used. 9’ 4’6” 3’6” MIL 1 MIL 1 w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions CONCERTAINER® 2-1 Defence Wall Typical Concertainer Defence Structure NSN 5680-99-835-7866 5680-99-001-9396 Mil 1B Mil 1G Unit Size HxWxL 4’6” x 3’6” x 32’ For each 1000ft wall you require: • 96 units of Mil 1 3 3 • Fill material required 2700yd (2100m ) • 36 hours to construct with one front end 3 loader (1yd bucket) and 4 men. 9’ 4’6” Features: • 7’ (2.12m) Wall Thickness • 9’ (2.74m) Wall Height • Simple Procurement - only 1 type of Concertainer unit used. 3’6” 7’ MIL 1 MIL 1 w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions CONCERTAINER® 3-2-1 Defence Wall Typical Concertainer Defence Structure NSN 5680-99-835-7866 5680-99-001-9396 Mil 1B Mil 1G Unit Size HxWxL 4’6” x 3’6” x 32’ For each 1000ft wall you require: • 176 units of Mil 1 • 198 units if a solid base is employed. 3 3 • Fill material required 3750yd (4400m ) • 60 hours to construct with one front end 3 loader (1yd bucket) and 4 men. 13’6” 4’6” Bottom tier view showing missing cells that are not required. Features: • 10’6” (3.18m) Wall Thickness • 13’6” (4.11m) Wall Height • Simple Procurement - only 1 type of Concertainer unit used. 10’6” MIL 1 MIL 1 MIL 1 w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions CONCERTAINER® Aircraft Revetment Typical Concertainer Defence Structure Mil 7B Mil 7G Unit Size Mil 8B Mil 8G Unit Size 3’3” 4’6” 15’ 7’3” Mil 9B Mil 9G Unit Size 7’ MIL 9 MIL 8t MIL 7 NSN 5680-99-169-0183 5680-99-126-3716 HxWxL 7’3” x 7’ x 91’ (2.21m x 2.13m x 21.64m) NSN 5680-99-335-4902 5680-99-517-3281 HxWxL 4’6” x 4’ x 32’ (1.37m x 1.06m x 10m) NSN 5680-99-563-5649 5680-99-052-0506 HxWxL 3’3” x 2’6” x 30’ (1m x 0.76m x 10m) For each 1000ft wall you require: • 11 units of Mil 7 • 32 units of Mil 8 • 34 units of Mil 9 3 3 • Fill material required 4200yd (3200m ) • 54 hours with 1 front end loader and 4 men. Features: Rapidly constructed simple revetment. w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions CONCERTAINER® 7’9” Defence Wall Typical Concertainer Defence Structure Mil 1B Mil 1G Unit Size Mil 3B Mil 3G Unit Size 3’3” 7’9” 4’6” 3’6” MIL 3 NSN 5680-99-835-7866 5680-99-001-9396 HxWxL 4’6” x 3’6” x 32’ (1.37m x 1.06m x 10m) NSN 5680-99-001-9392 5680-99-001-9398 HxWxL 3’3” x 3’3” x 32’ (1m x 1m x 10m) Requirement for 1000ft of wall: • Qty 32 units of Mil 1 • Qty 32 units of Mil 3 3 3 • Fill material required 1450yd (1100m ) • 18 hours to construct with 1 front end loader and 4 men. Features: • 3’6” (1.06m) Wall Thickness • 7’9” (2.41m) ft Wall Height • Simple Procurement - only 2 types of Concertainer unit used. MIL 1 w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions CONCERTAINER® Culverts Typical Concertainer Reinforcement of Existing 20ft Concrete Culverts. External concrete dimensions: • 5’ x 6’ x 20’ (H x W x L) Mil 5B Mil 5G Unit Size NSN 5680-99-001-9394 5680-99-001-9400 HxWxL 2’ x 2’ x 10’ (0.61m x 0.61m x 3.05m) One 20ft bunker and 2 ends: • 30 units of Mil 5 7’ 20’ 6’ One 20ft Bunker & 1 End: • Qty 30 units of Mil 5 3 10’ 3 • Fill material required 65yd (50m ) • 2 hours to construct (extra time allowed due to complexity of structure). 4’ Features: • 2ft (0.61m) Wall Thickness • 2ft (0.61m) Overhead Protection • 4ft (1.22m) Thick x 6’ High End Cap • Simple Procurement - only 1 type of Concertainer unit used. MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 MIL 5 w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions CONCERTAINER® 20ft Single Entry Bunker Typical Concertainer Defence Structure Bunker Kit NSN 5680-99-302-3132 External Dimensions: •Height - 11’5” (3.5M) •Width - 17’4” (5.3M) •Length - 44’10” (13.7M) Internal Dimensions: 11’5” 31’6” 17’5” •Height - 9’2” (2.8M) •Width - 10’5” (3.18M) •Length - 24’4” (7.42M) Mil 1 Concertainer comes configured as: • 4 x 3 Cell • 2 x 5 Cell • 2 x 7 Cell • 2 x 9 Cell Mil 2 Concertainer comes configured as: • 2 x 3 Cell • 2 x 8 Cell • 2 x 10 Cell Steel sheet piles are supplied: 7 sheet 8mm thick 5.5m long 7 sheet 6mm thick 5.5m long Each sheet is 600mm wide MIL 2 MIL 1 MIL 1 Features: Ordered as a kit complete with roofmembers. Can easily accommodate a 20 ft container. Note: ISO Container should be inverted Takes 8 - 10 Hours to build Requires approx 170m3 of fill w: www.hescobastion.com Worldwide Patents Apply. USA Patent No. 5472297, European Patent No. 0466726. Hesco & Concertainer are trademarks of Hesco Bastion Ltd. © Hesco Bastion Ltd 2004 e: [email protected] The above quantity figures are an estimate. It may vary with local site conditions HESCO Bastion Concertainer® Technical Information Annex D © HESCO Military Products Ltd January 2005 Protective Structure Design Guide Cell Thickness Required Relative to Concertainer® Type & Size Threat Mil 1 1.37 x 1.06 x 10 Mil 2/5/6 0.61 x 0.61 x 1.2/3.05/6.1 Mil 3 1x1 x 10 Mil 4 1 x 1.5 x 10 Mil 7 2.21 x 2.13 x 8.52 Mil 8 1.37 x 1.22 x 10 Remarks Mil 9 1 x 0.76 x 9.14 Mil 10 2.13 x 1.52 x 7.62 HxW xL Good Fill Poor Fill Good Fill Poor Fill Good Fill Poor Fill Good Fill Poor Fill Good Fill Poor Fill Good Fill Poor Fill Good Fill Poor Fill Good Fill Poor Fill Small Arms Single Shot Burst 1 1 1 2 1 2 1 4 1 1 1 2 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 5.56 - 14.5mm including all AP rounds Cannon HE Volley AP Volley 1 2 2 3 2 4 4 5 1 2 2 3 1 2 2 2 1 1 1 2 1 2 2 2 2 3 3 3 1 1 2 2 Up to 30mm 1 - 3 shots 1 - 3 shots RPG7 1 2 2 3 2 2 1 1 1 1 1 2 2 2 1 1 Grenade 1 1 2 2 1 1 1 1 1 1 1 1 2 2 1 1 Mortars Up to 81mm 1 1 2 2 1 1 1 1 1 1 1 1 2 2 1 1 Artillery & Mortars Over 82mm 2 2 3 3 2 2 2 2 1 1 2 2 3 3 2 2 Air Delivered Bombs 3 3 6 6 4 4 3 3 2 2 3 3 5 5 3 3 Vehicle Borne Explosives Devices Note: 321 structure 66644422 structure 4433 structure 3321 structure 21 structure 321 structure 5533 structure 32 structure Suggested pyramid structures to enable a suitable height and width to be achieved 1. This table provides a guide as to the number of HESCO Bastion cells wide a structure needs to be to provide protection from the indicated threat. 2. The dimensions and structure widths have been derived from the results of extensive testing and trials by DERA (UK MOD) and other leading testing agencies worldwide. HESCO Bastion Concertainer® Technical Information Annex E © HESCO Military Products Ltd January 2005 Time Calculation Guide 1. Other considerations to take into account when calculating additional time are: To unpack and lay out a 9 cell section of Mil 1 will take approx 3 minutes. To bounce out further cells and connect to one already laid out will take approx. 2 minutes. To form corners takes longer. To lay out a section and form a corner from it will take approx. 5 minutes. To lay out sections on top of a previously built layer will take approx. 10 minutes; this includes bouncing out and securing by means of the cable ties or HESCLIPS. To fill cells at height will take a little longer than that on the floor and whereas cells on the floor using a medium sized loading shovel will take about 17 minutes with those only one layer higher taking 20 minutes. An increase in time will be incurred as the height of the structure increases and in particular when working at excessive heights. 2. To calculate time we should follow a simple method such as this. Draw a plan of each structure showing as many dimensions as possible. Divide the length required by the length of the Concertainer unit to be used to calculate how many you require. Work on the base first then the second and subsequent layers. Calculate the time to form the corners first then calculate the straight lengths. Calculate the time to fill the bottom layer and then any subsequent layers. Calculate any time required to cap the top layer to prevent the loss of fill material 3. It will take 4 men to manually fill one cell of Mil 1 and take approx 14 minutes with the fill being close by. 4. HESCO Bastion produce kit forms that for ease of use and ordering come complete and ready to use. All that you must provide is the fill material and the means with which to place it. HESCO Bastion Concertainer® Technical Information Annex F © HESCO Military Products Ltd January 2005 HESCO Bastion Concertainer® Units Versus Concrete T walls in Blast Mitigation One of the many questions that the HESCO Technical team get asked is about the comparison between HESCO and concrete when subjected to a blast load. The following document is written to address just such a question. HESCO Bastion was asked to comment on the use of a concrete wall with an internal wall of brick or block work with the cavity filled with sand. HESCO were also asked to comment on the difference and in a nutshell, why the user should use HESCO Concertainer® units and not T walls. We have made the following assumptions for the purpose of providing advice: Assumptions • • • • • • • ‘T’ shaped retaining wall units are 3m high, 1m wide (weight approximately 2T) Threat is from vehicle borne IED’s (car bomb approximately 250kg equivalent weight TNT, van bomb approximately 10T equivalent TNT) Charge standoff from wall 5m (educated arbitrary figure chosen) UN based design consists of a masonry wall on the attack side of the RC wall units with a soil infill Masonry wall be approximately the same height as retaining wall unit Overall thickness of wall will be comparable to HESCO Concertainer® design Blast Protection Provided by Walls Although materials used in the construction of protective walls can have an influence on ‘blast’ reduction, generally speaking the geometry of the wall has a much greater influence. Walls have a finite size, and blast waves will pass over and around them to the extent that at a certain distance behind the wall, the wave will have reformed as if the wall had not been there at all in the first place. However, as you will know the blast wave will now have reduced in intensity due to the distance that it will have travelled. The distance behind the wall at which the blast wave reforms is related to the charge size and distance from the protective wall, and the geometry of the wall itself. One of the primary uses of defence walls is to generate stand off, it is this which nd really provides protection. The 2 reason for the defence wall is to intercept potentially damaging fragmentation from the device. It is from this aspect that the concrete T walls are let down. When a concrete T wall is subjected to blast it almost always breaks up in an alarming way and it itself becomes the weapon. Fragments of concrete have been found several hundred metres from the blast in some trials. It is obviously these 2 last points where HESCO Concertainer units perform far better than concrete; - HESCO Concertainer has a proven ability to stop fragmentation; it is after all a soil mass, this has long been the best way of protecting you from the effects of blast and ballistics. - HESCO Concertainer generally remains intact under all but the largest of attack charge sizes; it therefore does not generate secondary fragmentation. Even when it has been found to break up (charge size of 20,000lb of military explosives) it still creates “insignificant fragmentation” HESCO Concertainer® Design Standard designs are available from HESCO Bastion that will effectively stop a vehicle bomb from getting close to the intended targets. HESCO Concertainer® walls are tied together by high strength galvanised steel wire with proven weld strength between joints to form continuous walls. These when filled with desirable material (ideally sand or other relatively fine grained cohesionless material) do not form a significant secondary hazard from either the fill or Concertainer material itself. They are general considered to ‘fail safe’ i.e. when they do fail (which they will inevitably do against large threats as mentioned above), they do not contribute significant secondary hazards. It has been known for attackers to employ 2 vehicles, one sacrificial to burst through to allow the second primary device carrying vehicle access to the protected area. We have trialled the HESCO Concertainer® units against moving vehicles this year with excellent results, 7500kg vehicle at 42mph stopped within 3 metres with 4 single cells and a 15000lb vehicle at 50mph almost stopped dead by a 10 metre long wall of Mil 1. Alternative design Retaining wall units alone Against primary blast it is likely that a reinforced concrete (RC) retaining wall design will have a similar effect on the blast wave from an explosive device as a HESCO Concertainer design (assuming that the overall geometry is similar in terms of wall height and length). However retaining wall units are generally freestanding and are not tied to adjacent units. Such units are less massive than a HESCO Concertainer® unit wall and under ideal conditions (i.e. assuming that the units do not break up in any way), car or lorry borne IED’s may turn the units into projectiles with velocities ranging from approximately 10m/s to over 100m/s (predictions involve some crude assumptions – see above). In reality however, the units would tend to tumble as well as break up (the extent to which this would happen depending on the strength of concrete, degree of reinforcement, standard of workmanship etc). Both are undesirable in terms of the secondary hazards created. Reports from servicemen in Iraq indicate that some of the manufacturing of the concrete walls leaves lots to be desired, we have even heard of instances of concrete units being padded out with Styrofoam, which means that what you thought you were getting is far from the reality of the situation. This information is third hand and has not been substantiated. Retaining wall/ earth/ masonry wall protective barrier This idea although theoretically workable would be incredibly difficult to implement, but more importantly there is still the highly significant hazard from secondary fragmentation even with a sand blanket between. This wall would most certainly “fail dangerously” In many cases when this happens you would actually have been better off without the wall The practical problems for this idea are: - You will require a significant foundation for the masonry wall. - A masonry wall say 3m tall will not hold the required amount of sand fill unsupported, it will require significant buttressing. - Workmanship will always be a problem with this type of construction. - The construction of such a wall will be a significant undertaking, involving a wide variety of resources which must all be quality controlled and a fair amount of time, not forgetting setting time for concrete and such like. Recommendations - The most effective way to generate blast protection is through the use of stand-off. The use of barriers is an effective way of achieving this. - Although HESCO Bastion Concertainer® structures may fail under large terrorist threats, they do so in a reasonably safe manner. They are also easy to construct. - Retaining wall units alone are likely to have a similar effect against primary blast as HESCO Concertainer® but may not be as effective at preventing the threat from getting closer to the intended target. They are also likely to produce a more significant secondary projectile problem. The retaining wall/ earth/ masonry wall design, although probably the most aesthetically appealing of the three designs is unlikely to provide any superior performance against blast and is more than likely to contribute a significant secondary hazard. It is not an option that I or the scientific community would endorse. There are some excellent examples in Iraq where T walls have been used to create stand off and HESCO Concertainer® has been used to provide the inner defence wall, this works well. HESCO Bastion Concertainer® Technical Information Annex G © HESCO Military Products Ltd January 2005 Specification Requirements For Soil Filled Gabion Baskets The requirement is for geotextile lined gabion baskets which are rapidly deployed, erected and filled which will then provide proven blast mitigation and ballistic protection to personnel and property. Specification: The gabion baskets must be manufactured from heavily galvanised 4 mm steel wire. Cells in excess of 1.52m x 2.21m x 2.13m must use a heavily galvanised 5 mm steel wire. The mesh size must be 76.2mm x 76.2mm. The coil hinges must be manufactured from 4 mm heavily galvanised hardened steel wire with the joining pins manufactured from 3mm and 4 mm heavily galvanised hardened steel wire. The wire must be galvanised to an extent where it will not be affected by the use of a fill material which has a very high salt content. This would be demonstrated by the wire being guaranteed for at least 25 years in a marine environment. The geotextile must be treated with material to resist the effects of UV radiation. The geotextile should be a 2mm heavy duty non woven polypropylene. The gabions must be available in at least 9 different sizes to allow flexibility of protective structure design and use. The system must be capable of being stacked to allow higher walls to be built. The gabion system must have been comprehensively trialled and tested by leading worldwide agencies in the field of blast and ballistic mitigation over a number of years. The system must have a proven track record of successful use in arduous environments. It would be highly desirable if the system were already in use by major military organisations around the world. This would be demonstrated by the system already having been designated military stock numbers. The supplier must be able to supply construction manuals and will with agreement provide construction training (Possibly subject to extra cost) The supplier on request will provide guidance on structures to be built to provide mitigation of specified threats. HESCO Military Products Ltd Molasses House Plantation Wharf London SW11 3TN United Kingdom Tel: +44 207 350 5454 Fax: +44 207 350 5455 Email: [email protected] Web: www.hescobastion.com Worldwide Patents Apply. Patent No. 0466726 (Europe), Patent No. 5472297 & 5333970 (USA) Concertainer is a registered trade mark of Hesco Bastion Limited