Defence Standard 81-055
Issue 7
Date:
14 February 2017
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Packaging of Mechanical
Components & Items
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DEF STAN 81-055 Issue 7
Section 1
Foreword
Defence Standard Structure
Section 1 (Generated by the StanMIS toolset)
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Revision Note
Historical Record
Warning
Standard Clauses
Section 2 (Technical information provided by Subject Matter Expert)
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Title
Introduction (optional)
Table of Contents
Scope
Technical Information to include Tables and Figures
Annexes (as required)
Section 3 (Generated by StanMIS toolset)
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Normative References
Definitions
Abbreviation
REVISION NOTE
Compilation of 81-039 Issue 6, 81-055 Issue 6, 81-056 Issue 5, 81-060 Issue 4, 81-063 Issue 4,
81-136 Issue 3
HISTORICAL RECORD
This standard supersedes the following:
Def Stan 81-055 Issue 6, 81-136, 81-60, 81-063, 81-056
WARNING
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and
European laws regarding Health and Safety at Work. Many Defence Standards set out processes
and procedures that could be injurious to health if adequate precautions are not taken. Adherence
to those processes and procedures in no way absolves users from complying with legal
requirements relating to Health and Safety at Work.
STANDARD CLAUSES
a) This standard has been published on behalf of the Ministry of Defence (MOD) by UK Defence
Standardization (DStan).
b) This standard has been reached following broad consensus amongst the authorities concerned with its
use and is intended to be used whenever relevant in all future designs, contracts, orders etc. and
whenever practicable by amendment to those already in existence. If any difficulty arises which prevents
application of the Defence Standard, DStan shall be informed so that a remedy may be sought.
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DEF STAN 81-055 Issue 7
c) Please address any enquiries regarding the use of this standard in relation to an invitation to tender or to
a contract in which it is incorporated, to the responsible technical or supervising authority named in the
invitation to tender or contract.
d) Compliance with this Defence Standard shall not in itself relieve any person from any legal obligations
imposed upon them.
e) This standard has been devised solely for the use of the MOD and its contractors in the execution of
contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all liability whatsoever
and howsoever arising (including, but without limitation, liability resulting from negligence) for any loss or
damage however caused when the standard is used for any other purpose.
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DEF STAN 81-055 Issue 7
Section 2
Packaging of Mechanical Components & Items
0 Introduction
This document is a compilation of a set of Standard Family Specification (SFS) for the packaging of various
Mechanical Components and Items. They are presented as Annexes to this document. This document and its
Annexes are to be used in conjunction with the requirements of "Def Stan 81-041, Packaging of Defence
Materiel". Its use is normally implemented contractually within Ministry of Defence orders requiring packaging
by the conditions of "DEFCON 129, Packaging (For Articles other than Munitions)"
1 Scope
1.1 This standard specifies requirements for packaging of similar Mechanical components or Items including
ancillary items / accessories, to a Military Level, e.g., P, N, and J as stated.
1.2. Each Annex has its own scope relating to the SFS of materiel covered.
2 Contents
0 Introduction .................................................................................................................................................. 2-1
1 Scope ........................................................................................................................................................... 2-1
2 Contents……………………………………………………………………………………………………………...2-1
3 General Requirements ................................................................................................................................ 2-2
4 Labelling ...................................................................................................................................................... 2-2
5 Recording of Package Production Data ...................................................................................................... 2-3
Annex A - Packaging of Mechanical Components ......................................................................................... 2-4
Annex B Packaging of Metal pipes and Pipe Assemblies .............................................................................. 2-8
Annex C Packaging of Fuel Injection Pumps and Fuel Injectors ................................................................. 2-10
Annex D Packaging of Pistons, Assembled or Unassembled and Piston Sets ........................................... 2-16
Annex E Packaging of Rubber Hoses, Plastics Hoses, and Hose Assemblies ........................................... 2-18
Annex F Packaging of Gaskets, Seals, "O" Rings, Grommets and Similar Materiel.................................... 2-21
Annex G Package Production Data Sheet ................................................................................................... 2-24
Figure 1 - Locating and Securing Fuel Injection Pumps of mass 10 kg or over to Level J ................ 2-15
Table 1 Container Selection ...................................................................................................................... 2-17
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DEF STAN 81-055 Issue 7
3 General Requirements
3.1 Only components of one domestic management code (DMC) / vocabulary section or class group shall be
bulked together. The DMC, vocabulary section or class group shall be shown on the outer package.
3.2 All Level P packages shall be over-packed in the lowest cost appropriate commercial manner by the
supplier for ease of handling and safe delivery to the MOD store or depot.
3.3 When items are supplied as kits or sets, care shall be taken during all stages of packaging to ensure they
are kept in their respective kits or sets.
3.4 Many rubber products are susceptible to deterioration when in contact with certain materials, such as
certain metals, plasticizers, and preservation chemicals found in plastics or wooden products respectively.
They shall be avoided where susceptible rubber products are involved. Further details may be found in BS
ISO 2230.
3.5 Where Def Stan 93-116 Type 1 and Type 2 is quoted for envelopes; to enhance protection of photodegradable material, (e.g., rubber in long term storage), Type 2 shall be used.
3.6 The Service or Project Team shall state if a reusable container is required.
3.7 Only items that are free from corrosion, staining and physical damage shall be accepted for packaging.
3.8 Mouldable waxed wrap, Def Stan 81-129, should only be used if there is no more environmentally friendly
alternative material available.
3.9 Fibreboard – General
a) All fibreboard material should contain a quantity of recycled material. The material shall be marked to
indicate whether recycled / recyclable and / or a sustainable source was used. Virgin fibreboard
material should only be used if there is a specific need.
b) Fibreboard container, Def Stan 81-015 ‘C’, should only be used if the alternative, fibreboard carton,
‘B’ is not suitable.
3.10 Fasteners
Steel; Nails (BS 1202-1) and Wood Screws (BS 1210), are listed in the normative references and the
individual container standards, and this document’s text. These are, with dowels, cylindrical fasteners for
wood can be alternatively specified using BS EN 14592 where they shall be at least equivalent in
performance.
3.11 Items that do not meet the Scope, Fragility, Mass, or PPQ stated in an Annex a SPIS Design shall be
raised (see Def Stan 81-041 Part 4), following the principles of the relevant Annex (SFS), with appropriate
cushion calculations being carried out where necessary.
4 Labelling
4.1 Labelling and marking shall comply with the requirements of Def Stan 81-041 (Part 6).
4.2 Identification numbers and names shall be as stated in the contract or order.
4.3 Packages containing vulcanized rubber material used for military vehicles, naval or aerospace purposes
shall be marked as contractually defined in accordance with either, BS 3F 69 or BS ISO 2230, and also Def
Stan 81-041 Part 6 with respect to marking of lifed items.
4.3.1 Additional packages for the Navy use shall be also marked to show material hardness.
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DEF STAN 81-055 Issue 7
4.4 Single item sub-quantities which make up the total PPQ shall be individually labelled with reference to the
total PPQ.
4.5 Items supplied with a calibration certificate shall have a label attached to the outer level of packaging
adjacent to the identification details, stating "CALIBRATION DATE" with the date of calibration (Month / Year)
stated below the text. This shall be the Information Text Label ‘T0002’ in Def Stan 81-041 Part 6.
4.6 Hose and hose assemblies used in clean air or oxygen breathing systems shall carry the Hazard
Information Label G0752, "Do not contaminate with oil or grease" (see Def Stan 81-041 Part 6).
5 Recording of Package Production Data
5.1 It is recommended that users of this Standard retain the details of the package used for each specific item
of materiel (e.g. for each NATO Stock Number) for future reference. A typical proforma for this purpose is
shown in Annex G.
5.2 There is no mandatory requirement on the user of this document to raise such data sheets or use the
proforma. When so raised, formal approval and acceptance by the authorities is not required.
5.3 These sheets are also known as ‘packaging record cards’ (PRC) or ‘SFS Record Sheets’ and can be
submitted for inclusion on SPIN. When a sheet with a given NSN is not already uploaded they will be added.
It is not recommended that other documents than the proforma are submitted.
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DEF STAN 81-055 Issue 7
Annex A- Packaging of Mechanical Components
Note: This Annex was Def Stan 81-055 Issue 6
A.1 Scope
A.1.1 This Annex specifies the requirement for the packaging of mechanical components to Military Levels P,
N, and J.
A.1.2 This Annex covers only components with a minimum fragility factor of 100 gn and Primary Packaged
Quantities (PPQ's) that are single, multiple, kits or sets, up to and including 5 kg mass.
A.1.3 Typical items covered by this standard include:
Brackets, bolts, bosses, bushes, caps, catches, cases, cleats, clips fasteners, collars, covers, decal transfers,
gears, hand tools, leavers, nails, nuts, pins, plates, retaining rings, retaining bands, rings, rivets, screws,
screw thread inserts, shafts, shims, spacers, spindles, springs, studs, tacks, washers and webbing straps.
A.2 Level P Packages with a PPQ of Mass 500 g or Less
Note: Equivalent to NATO Level 4
A.2.1 Metallic item(s) Resistant to Corrosion
Note: That is, those inherently resistant to corrosion or protected by an approved process, rigid non-metallic
item(s), composite item(s) and painted item(s) (partially or wholly)
A.2.1.1 The item(s) shall be cleaned and dried in accordance with process [C10, 14.2.1 or 14.2.2].
A.2.1.2 The cleaned and dried item(s) shall then be wrapped in polyethylene film, Def Stan 93-116, Type 1 or
2, 65 μm thick or polyethylene, bubble film, Def Stan 81-122, Type A in accordance with process [C41, 45.3.2]
and secured with tape, Def Stan 81-145 Type 3.
NOTE: Prior to wrapping, if the items contained are identical, or part of a kit or set. They shall be separated
into parts of the same type and collectively wrapped as A.2.1.2.
A.2.1.3 The item(s) wrapped in polyethylene film, Def Stan 93-116, Type 1 or 2 shall when required have all
sharp edges, corners, and projections padded in accordance with process [C49, 53.3.1(h)].
A.2.1.4 When the PPQ is for one item or multiples of identical items:
The wrapped and padded (if required) item(s) shall be enclosed in a barrier constructed from polyethylene
film, Def Stan 93-116, Type 1 or 2, 125 μm thick or polyethylene coated paper, Def Stan 81-134 in
accordance with process [C44]. The barrier shall be sufficiently large to accommodate the wrapped and
padded (if required) item(s) without causing any strain upon the barrier, its seals or the item(s).
A.2.1.5 When the PPQ is for a kit or set:
A.2.1.5.1 The items contained in the kit or set shall be prepared as in as A.2.1.1 to A.2.1.3 and enclosed in
individual barriers in their divisions as A.2.1.4.
A.2.1.5.2 The items in their barriers shall then be collectively heat-sealed in an outer envelope constructed
from polyethylene film, Def Stan 93-116, Type 1 or 2, 125 μm thick. The outer envelope shall be sufficiently
large to accommodate the items in their barriers without causing any strain upon the envelope, its seals, or
the items.
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DEF STAN 81-055 Issue 7
NOTE: A kit or set may contain items of various descriptions (e.g. Metallic items inherently or not inherently
resistant to corrosion, composite items, or non-metallic items). In this case, once the item(s) have been
enclosed in their respective barriers or outer envelopes. Each barrier or outer enveloped item(s) of the kit or
set shall then be secured together with tape, Def Stan 81-145 Type 3.
A.2.2 Metallic item(s) not Resistant to Corrosion
Note: That is, those not inherently resistant to corrosion or protected by an approved process
A.2.2.1 The item(s) shall be cleaned with a suitable hydrocarbon solvent or White Spirit BS 245, Type A in
accordance with process [C3].
NOTE: Inhibited trichloroethylene or similar hydrocarbon solvents shall not be used when the item(s) contain
plastic elements, have internal passages, are partially painted, or contain parts that are made from a porous
material.
A.2.2.2 The item(s) cleaned with a suitable hydrocarbon solvent or White Spirit BS 245, Type A shall be
dried in accordance with process [C11, 15.2.2 or 15.3.3, (65 ± 3) °C].
A.2.2.3 The cleaned and dried item(s) shall then be preserved with soft Grease, XG-279, Def Stan 91-27 in
accordance with process [C18] or Oil, PX-4, Def Stan 80-034 in accordance with process [C21].
NOTE: Prior to wrapping and padding (if required), if the items contained are identical, or part of a kit or set,
they shall be separated into parts of the same type and wrapped and padded (if required) collectively.
A.2.2.4 The preserved item(s) shall then if required have all sharp edges, corners, and projections padded in
accordance with process [C49, 53.3.1(a)].
A.2.2.5 The item(s) shall then be wrapped in accordance with process [C41, 45.3.2], using a greaseresisting material listed in the process, and secured with tape, Def Stan 81-145 Type 3.
NOTE: If the wrapping material selected is mouldable, waxed, wrap, Def Stan 81-129, then the securing tape
shall be Def Stan 81-145 Type 2a.
A.2.2.6 Alternatively, the preserved and padded (if required) item(s) shall be wrapped in a barrier using
mouldable, waxed, wrap, Def Stan 81-129 in accordance with process [C45, 49.3.3].
A.2.2.7 When the PPQ is for one item or multiples of identical items:
a) The wrapped and padded (if required) item(s) shall be enclosed in a barrier constructed from
polyethylene film, Def Stan 93-116, Type 1 or 2, 125 μm or polyethylene coated paper, Def Stan 81134 in accordance with [C44]. The barrier shall be sufficiently large to accommodate the wrapped and
padded (if required) item(s) without causing strain upon the barrier, its seals or the item(s).
b) Alternatively the padded (if required) item(s), wrapped in a barrier constructed from mouldable,
waxed, wrap, Def Stan 81-129 shall be overwrapped in accordance with process [C45, 49.4].
A.2.2.8 When the PPQ is for a kit or set:
a) The items contained in the kit or set shall be prepared as in A.2.2.1 to A.2.2.6 and enclosed as
A.2.2.7 in individual barriers.
b) The items in their barriers shall then be collectively heat-sealed in an outer envelope constructed from
polyethylene film, Def Stan 93-116, Type 1, 125 μm thick. The outer envelope shall be sufficiently
large to accommodate the items in their barriers without causing any strain upon the envelope, its
seals, or the items.
NOTE: see paragraph A.2.1.5.2 NOTE.
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DEF STAN 81-055 Issue 7
A.2.3 Flexible non-metallic item(s)
NOTE: Plastics or rubber items shall not be packed in a folded, creased, or strained condition.
A.2.3.1 As paragraph A.2.1.1
A.2.3.2 The cleaned and dried item(s) shall then be prepared as follows:
A.2.3.2.1 Fabric item(s) shall be folded or rolled to a convenient size.
A.2.3.2.2 Plastics item(s) suitable for rolling shall be rolled on formers of corrugated paper, Def Stan 81-099,
Type 1, in accordance with process [D5, 70.3.3(a)] or Post Tubes, of a suitable diameter.
A.2.3.2.3 Rubber item(s) suitable for rolling shall be rolled on formers as A.2.3.2.2, interposing paper,
wrapping, waxed, Def Stan 81-030 Type 1 between the items layers and the former.
NOTE: All items that have been rolled shall be secured using a band of tape, Def Stan 81-145 Type 3
interposing paper, wrapping, waxed, Def Stan 81-030 Type 1 between the tape and the item.
A.2.3.3 The prepared item(s) shall then be wrapped in polyethylene film, Def Stan 93-116, Type 1, 65 μm or
polyethylene bubble film, Def Stan 81-122, Type A in accordance with process [C41, 45.3.2] and secured with
tape, Def Stan 81-145 Type 3.
NOTE: Prior to wrapping, if the items contained are identical, or part of a kit or set. They shall be separated
into parts of the same type and collectively wrapped as A.2.3.3.
A.2.3.4 The item(s) wrapped in polyethylene film, Def Stan 93-116, Type 1 shall then if required have all
sharp edges, corners, and projections padded in accordance with process [C49, 53.3.1(h)].
A.2.3.4.1 Plastics or rubber item(s) not suitable for rolling may require additional support to prevent
creasing or deformation. These items after wrapping shall be placed between two pieces of 1.45 mm thick,
fibreboard, Def Stan 81-001, of such a size as to extend beyond the length and width of the item by (12 ± 3)
mm. The edges shall then be sealed with tape, Def Stan 81-145 Type 3.
A.2.3.5 When the PPQ is for one item or multiples of identical items:
a) The prepared items shall be enclosed in a barrier constructed from polyethylene film, Def Stan 93116, Type 2, 125 μm thick or polyethylene coated paper, Def Stan 81-134 in accordance with process
[C44].
b) The barrier shall be sufficiently large to accommodate the prepared item without causing any strain
upon the barrier, its seals, or the item(s).
A.2.3.6 When the PPQ is for a kit or set:
a) The items contained in the set or kit shall be prepared as in A.2.3.1 to A.2.3.4 and enclosed in their
divisions as A.2.3.5 in individual barriers.
b) Items of the same type shall then be collectively heat-sealed in an outer envelope constructed from
polyethylene film Def Stan 93-116, Type 1, 125 μm thick. The outer envelope shall be sufficiently
large to accommodate the items in their barriers without causing any strain upon the envelope, its
seals, or the items. The set or kit of items in their barriers or outer envelopes shall then be secured
together with tape Def Stan 81-145 Type 3.
NOTE: see paragraph A.2.1.5.2 NOTE.
A.3 Level P Packages with a PPQ of Mass between 500 g and 5 kg
Note: Equivalent to NATO Level 4
A.3.1 The items shall be prepared in accordance with clause A.2 except the following.
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DEF STAN 81-055 Issue 7
A.3.1.1 No barrier or outer envelope should contain a PPQ that is greater than 1 kg, unless the item is an
individual part of a kit or set, or has a single PPQ between 500 g and 5 kg.
A.3.1.1.1 The relevant number of multiple barriers or outer envelopes shall be bulked together in to a single
package to make the total PPQ by overwrapping in accordance with process [C45, 49.4].
A.4 Level N Packages
Note: Equivalent to NATO Level 3
A.4.1 The Level N package shall be the same as Level P packages in all respects except that the item(s) in
their barriers, outer envelopes or overwraps shall be further prepared as follows.
A.4.2 The item(s) in their barriers, outer envelopes, or overwraps shall be located centrally within a
fibreboard container, either;
a) Def Stan 81-015, A, (Style C, D or E), or
b) Def Stan 81-015, B, Type 1 (Style 1, 2 or 3, Class AC or AM), or
c) Def Stan 81-015, B, Type 2 (Style 1, 2 or 3).
The internal dimensions shall not exceed the dimensions of the item(s) to be packaged by 20 mm in any
direction.
A.4.2.1 The container shall be lined and excess space filled with a material selected from those listed in
process [D3].
A.4.2.2 The container shall be closed in accordance with process [D16] using tape, Def Stan 81-145 Type 4.
A.5 Level J Packages
Note: Equivalent to NATO Level 2
A.5.1 The Level J package shall be the same as the Level N packages in all respects except the following.
A.5.1.1 Barriers constructed from polyethylene film, Def Stan 93-116, Types 1 or 2, 125 μm thick, or
polyethylene coated paper, Def Stan 81-134, shall be constructed from polyethylene film, Def Stan 93-116,
Type 1, 250 μm thick.
A.5.1.2 The container after closure shall be over-wrapped using Kraft paper, Def Stan 81-048 (PKU) in
accordance with process [C42, 46.3.3] and secured with tape, Def Stan 81-145 Type 2a.
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DEF STAN 81-055 Issue 7
Annex B Packaging of Metal pipes and Pipe Assemblies
Note: This Annex was Def Stan 81-136
B.1 Scope
B.1.1 This Annex is applicable for items of 2 to 50 mm internal diameter and less than 3,000 mm in length
packaged to Military Levels P and N.
B.1.2 This Annex covers only items with a minimum fragility factor of 100 gn and a Primary Packaged
Quantity (PPQ) of one or less than 10 kg.
B.1.3 Pipes and assemblies used for the following systems include: oxygen, air, nitrogen, fuel, hydraulic and
wave guides.
B.2 Level P Package
B.2.1 Initial Preparation
B.2.1.1 Pipes and assemblies used for oxygen breathing, hydraulic, or other dedicated systems.
B.2.1.1.1 These pipes and assemblies will have been cleaned internally by the manufacturer or supplier and
end caps fitted. On no account shall the end caps be removed. Any item found to be damaged, not labelled
(i.e. "Oxygen Clean – Do Not Open Until Required For Use" ) or without caps fitted shall be immediately
rejected and returned to the manufacturer/supplier for rectification.
B.2.1.1.2 Pipes and assemblies covered by B.2.1.1.1 shall be externally dried in accordance with process
[C11, 15.2.4] and further packaged as stated at B.2.1.2.5 to B.2.1.4 inclusive.
B.2.1.2 All other pipes and assemblies without caps
B.2.1.2.1 These shall be cleaned internally and externally in accordance with process [C2, 6.4.1] or
[C3, 7.3.1] and dried using clean dry air, or nitrogen, in accordance with process [C11, 15.2.4].
NOTE 1: Ultrasonic cleaning using inhibited trichloroethylene and similar hydrocarbon solvents may cause
stress corrosion cracking of some titanium alloys and may produce corrosion on other light alloy items under
certain conditions. Adverse conditions exist when the solvent has become depleted in inhibitor due to
prolonged use or when items are in contact with either each other or the tank walls and are left in the solvent
for unduly long periods of time.
NOTE 2: For other information on the cleaning of metal surfaces see; AMS03-2, BS ISO 27831 Part 1, and
Part 2
B.2.1.2.2 Immediately after cleaning and drying, all open pipe ends of the item shall be closed using either
plastics/metal dust caps or plastics plug or by a covering of 125 µm polyethylene film, Def Stan 93-116 Type 1
or Type 2, and secured with Tape, Def Stan 81-145 Type 3.
B.2.1.2.3 In addition, items exceeding 1,000 mm in length or greater than 5 kg in mass shall have the
polyethylene protected ends overwrapped in accordance with process [C49, 53.3.1 (h)].
B.2.1.2.4 Any brackets or securing arrangements attached to the pipe/assembly shall be protected in
accordance with process [C49, 53.3.1 (h)]
B.2.1.2.5 The prepared item shall be enclosed in a barrier of sufficient size, constructed from 125 µm thick
polyethylene film, Def Stan 93-116 Type 1 or Type 2, in accordance with process [C44].
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DEF STAN 81-055 Issue 7
B.2.1.3 Place the item secured to its furniture fitments into a fibreboard container selected from the following:
a) Def Stan 81-015, A, (Style C, D, or E),
b) Def Stan 81-015, B, Type 1 or 2 (Styles 1, 2, 3),
c) Def Stan 81-015, C or
d) Postal tubes, commercial
B.2.1.3.1 The dimensions of the container/tube selected shall not exceed the dimensions of the prepared
item by 20 mm in any direction.
B.2.1.4 The fibreboard container shall be lined, and any excess space filled, in accordance with process [D3,
68.3.1 (c)] and closed with Tape, Def Stan 81-145 Type 4 in accordance with process [D16].
B.3 Level N Package
B.3.1 The Level N package shall be the same as the Level P packages in all respects except that the barrier
thickness shall be a minimum of 250 µm thick in all cases.
B.3.2 The item prepared and within its barrier; shall be located and attached onto a fitment constructed from
corrugated board with the flutes running longitudinally. The board shall be chosen from Defence Standards;
81-046, 81-106, 81-107, 81-108 or 81-115.
B.3.2.1 The construction of the fitment shall be determined by the configuration and construction of the
pipe/assembly. The fibreboard fitment dimensions shall exceed that of the item by 25 mm ± 5 mm in all
directions.
B.3.2.2 The prepared item shall be secured using nylon cable ties (commercial) or polypropylene film twines,
BS 4881 passing through the board adjacent to the points of contact with the pipe/assembly or where
additional fitments are positioned. The item shall be tightly secured in as many places as necessary to
prevent any movement, taking care not to cause undue damage or stress that may deform the item.
B.3.2.3 Additional furniture fitments, blocks, or pads, made from materials listed in B.3.2, may be necessary
to support the prepared item to the main fitment if the pipe/assembly is of a complex nature, (see process
[D5]). Expanded polyethylene pads, Def Stan 81-116 may be used as an additional fitment material when
required.
B.3.3 Place the item secured to its furniture fitments into a fibreboard container selected from the following,
appropriate to its mass and dimensions:
a) Def Stan 81-015, A, (Style C, D, or E),
b) Def Stan 81-015, B, Type 1 or 2 (Styles 1, 2, 3), or
c) Def Stan 81-015, C
B.3.3.1 The dimensions of the container selected shall not exceed the dimensions of the prepared item by
20 mm in any direction.
B.3.3.2 The fibreboard container shall be lined, and any excess space filled, in accordance with process
[D3 68.3.1 (c)] and closed with Tape, Def Stan 81-145 Type 4 in accordance with process [D16].
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DEF STAN 81-055 Issue 7
Annex C Packaging of Fuel Injection Pumps and Fuel Injectors
Note; this was Def Stan 81-063
C.1 Scope
C.1.1 This Annex specifies the requirements for the packaging of fuel injection pumps up to and including
30 kg mass, and fuel injectors, to Military Level P, N, and J.
C.1.2 The fuel injection pumps covered by this Annex are those fitted with mechanical governors, open or
closed circuit hydraulic governors and pneumatic governors.
C.1.3 This Annex is based on a Primary Package Quantity (PPQ) of one.
C.2 General Requirements
C.2.3 When the fuel injection pumps or fuel injectors being packaged are designed for a two stroke engine,
marine oil, NMMA TC-W3 (Certified) or equivalent shall be used instead of lubricating oil. OMD-90,
Def Stan 91-113.
C.2.4 Calibration certificates supplied with the item shall be enclosed in an envelope constructed from 125 µm
thick polyethylene film, Def Stan 93-116, Type 1 or 2 in accordance with process [C44].
C.2.4.1 The enclosed certificate shall be either placed within the container prior to its closure or attached to
the items barrier using tape, Def Stan 81-145 Type 3, where no container is required.
C.3 Level P Packages
C.3.1 Fuel Injection Pumps fitted with a Mechanical Governor or Open Circuit Hydraulic Governor
C.3.1.1 Cleaning & Drying
Before cleaning and drying ensure;
a) That all residual lubricating oil left in the camshaft sump and governor housing is drained off, and,
b) That all inlet and outlet ports and connections are blanked off using the manufacturer's blanking caps
or plugs if supplied.
c) All ports and connections (including electrical / electronic) not blanked off by the manufacturer's caps
or plugs shall be blanked off securely using commercial plastics equipment that are resistant to the
ingress of white spirit or cleaning solvent.
C.3.1.1.1 Only clean the item's external surfaces with white spirit, BS 245, Type A [C3, 7.3.2 or 7.3.3]
NOTE: The item shall not be immersed in the cleaning solvent.
C.3.1.1.2 The cleaned item shall be dried in accordance with process [C11, 15.2.2 or 15.2.3, (65 ± 3) °C].
C.3.1.2 Preservation
After cleaning and drying the camshaft and governor housing shall then have their relevant blanking caps or
plugs removed so that they can be preserved by filling with lubricating oil, OMD-90, Def Stan 91-113 to the
normal working level.
C.3.1.2.1 The relevant blanking caps or plugs shall then be replaced.
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DEF STAN 81-055 Issue 7
C.3.1.2.2 The pump shall then be mounted on a suitable stand and connected to an external drive.
C.3.1.2.3 The drive shall be either an electric motor unit with a reduction gear or a suitable hand-turning
mechanism incorporating an overload safety device.
C.3.1.2.4 The pumps preliminary filter inlet or feed / lift pump inlet shall then have a filtered reservoir,
containing lubricating oil, OMD-90, Def Stan 91-113 connected.
C.3.1.2.5 The outlet side of the pumps preliminary filter or feed / lift pump shall be connected to the inlet
connector of the fuel pump.
C.3.1.2.6 Each injector feed connected shall then be fitted with slave "spill off" pipelines. The contaminated
lubricating oil, OMD-90, Def Stan 91-113 expelled from the slave "spill off" pipelines shall be collected in a
suitable container.
C.3.1.2.7 If a feed / lift pump is fitted, the air vent screws shall be opened and the fuel pump gallery primed
manually by operating the primer lever. The air vent screws shall then be closed, when all air has been
expelled.
C.3.1.2.8 If a feed / lift pump is not fitted, the air vent screws shall be opened, and the fuel pump hand driven
at a maximum rate of 10 rpm, until all air has been expelled. The air vent screws shall then be closed.
C.3.1.2.9 The fuel pump shall then be driven continually at (100 ± 10) rpm until a liberal amount of air free
lubricating oil, has been pumped through each "spill off" pipeline, to ensure that all manufactures calibration
and testing oil is removed.
C.3.1.2.10 All pipelines connected during the preservation procedure shall be removed and all blanking caps
or plugs replaced.
C.3.1.2.11 The external drive shall then be disconnected and the fuel pump removed from the stand.
C.3.1.2.12 The fuel pump shall then be rotated in all directions to ensure total internal coverage with
lubricating oil, OMD-90, Def Stan 91-113.
C.3.1.2.13 The fuel pump shall then have all relevant blanking caps or plugs removed so excess lubricating
oil, OMD-90, Def Stan 91-113 can be drained off and the blanking caps or plugs replaced.
C.3.1.2.14 The fuel pump externals shall then be preserved with grease, XG-279, Def Stan 91-027 in
accordance with process [C18, 22.3.2 or 22.3.3].
C.3.1.2.15 The preserved fuel pump shall then be padded in accordance with process [C49, 53.3.1(a)].
C.3.1.3 Packaging
C.3.1.3.1 Fuel Pumps less than 10 kg mass
a) Wrap the padded item using a grease-resistant material in accordance with process [C41, 45.3.2] and
secured using tape, Def Stan 81-145 Type 3.
NOTE: If the wrapping material is mouldable waxed wrap, Def Stan 81-129 the securing tape shall be Def
Stan 81-145 Type 2a.
b) The wrapped item shall then be enclosed in a barrier, 125 µm thick, Polyethylene film, Def Stan
93-116, Type 1, or 2 in accordance with [C44].
c) The barrier shall be sufficiently large to accommodate the wrapped item without causing any strain
upon the barrier or its seals.
C.3.1.3.2 Fuel Pumps between 10 kg and up to and including 30 kg mass
2-11
DEF STAN 81-055 Issue 7
The preparation and preservation shall be the same in all respects as items of less than 10 kg mass except
that the item shall be further prepared as follows;
a) The item in its barrier shall be located centrally in a fibreboard container, Def Stan 81-015, B, Type 1,
(Style 1, 2, or 3, Class AC or AM) or Type 2, (Style 1, 2 or 3). The internal dimensions shall not
exceed the dimensions of the item(s) to be packaged by 20 mm in any direction.
b) The container shall be lined and excess space filled with a material selected from those listed in
process [D3].
c) The container shall be closed in accordance with process [D16] using tape, Def Stan 81-145 Type 4.
C.3.2 Fuel Injection Pumps fitted with a Closed Circuit Hydraulic Governor
Fuel injection pumps fitted with a closed circuit hydraulic governor shall be packed as fuel injection pumps
fitted with a mechanical governor or open circuit hydraulic governor in all respects except the following.
a) Draining of the fuel pump after it has been disconnected from its stand and rotated (see C.3.1.2.11),
shall exclude the draining of the governor housing.
b) After draining the fuel pump, where necessary the governor housing shall be topped up to the normal
working level with lubricating oil, OMD-90, Def Stan 91-113 and the blanking caps or plugs replaced.
C.3.2.1 Fuel Pumps less than 10 kg mass
The padded item shall be further prepared as paragraphs C.3.1.3.1
C.3.2.2 Fuel Pumps between 10 kg and up to and including 30 kg mass
The preparation and preservation shall be the same in all respects as items 10 kg mass or over except that
the item shall be further prepared as paragraphs C.3.3.1.2 a) to c).
C.3.3 Fuel Injection Pumps fitted with a Pneumatic Governor
Fuel injection pumps fitted with a pneumatic governor shall be packed as fuel injection pumps fitted with a
mechanical governor or open circuit hydraulic governor in all respects; except the governor housing after
drying shall not be internally preserved.
NOTE: The leather diaphragm prior to assembly shall be soaked in neat's foot oil, castor oil or similar and the
internal mechanism preserved by the manufacturer.
C.3.3.1 Fuel Pumps less than 10 kg mass
The padded item shall be further prepared as paragraphs C.3.1.3.1.
C.3.3.2 Fuel Pumps between 10 kg and up to and including 30 kg mass
The preparation and preservation shall be the same in all respects as items 10 kg mass or over except that
the item shall be further prepared as paragraphs C.3.1.3.2 a) to c).
C.3.4 Fuel Injectors
C.3.4.1 Cleaning & Drying
Prior to cleaning ensure that all inlet and outlet ports and connections are blanked off using the
manufacturer's caps or plugs if supplied.
2-12
DEF STAN 81-055 Issue 7
NOTE: All inlet and outlet ports and connections not blanked by manufacturer's caps or plugs shall be
blanked off using commercial plastics equivalents that are resistant to the ingress of white spirit, BS 245,
Type A.
C.3.4.1.2 The items external surfaces shall be cleaned with white spirit, BS 245, Type ‘A’, in accordance with
process [C3, 7.3.2 or 7.3.3].
NOTE: The item shall not be immersed in the cleaning solvent.
C.3.4.1.3 The cleaned item shall be dried in accordance with process [C11, 15.2.2 or 15.2.3, (65 ± 3) °C].
C.3.4.2 Preservation
After drying all blanking caps or plugs shall be removed and the injector connected to a self-primed hand
pump, incorporating a filtered reservoir of lubricating oil, OMD-90, Def Stan 91-113, then;
a) The fuel injector shall then be primed with lubricating oil, OMD-90, Def Stan 91-113 to ensure an airfree flow.
b) All the blanking caps or plugs removed shall then be replaced.
c) The fuel injector externals shall then be preserved with grease, XG-279, Def Stan 91-27 in
accordance with process [C18, 22.3.2 or 22.3.3].
C.3.4.2.1 The preserved fuel injector shall then be padded in accordance with process [C49, 53.3.1(a)].
C.3.4.3 Packaging
The preserved and padded item shall be further prepared as paragraphs C.3.1.3.1.
C.3.4.3.1 The item in its barrier shall be located centrally in a fibreboard container, either;
a)
Def Stan 81-015, A, (Style C, D or E)
b)
Def Stan 81-015, B Type 1 (Style 1, 2 or 3, Class AC or AM)
c)
Def Stan 81-015, B, Type 2 (Style 1, 2 or 3)
C.3.4.3.2 The internal dimensions shall not exceed the dimensions of the item(s) to be packaged by 20 mm in
any direction.
a) The container shall be lined and excess space filled with a material selected from those listed in
process [D3].
b) The container shall be closed in accordance with process [D16] using tape, Def Stan 81-145 Type 4.
C.4 Level N Packages
The Level N package shall be the same as the Level P package in all respects except that the barrier
thickness shall be 250 µm thick in all cases and the following.
C.4.1 Fuel Injection Pumps fitted with Mechanical, Open or Closed Circuit Hydraulic, or Pneumatic
Governors
C.4.1.1 Fuel Pumps less than 10 kg mass
The item in its barrier shall be further prepared as paragraphs C.3.4.3.1.
2-13
DEF STAN 81-055 Issue 7
C.4.1.2 Fuel Pumps between 10 kg and up to and including 30 kg mass
The item in its barrier shall be located centrally in a fibreboard container;
a)
Def Stan 81-015, B, Type 1, (Style 1, 2 or 3, Class AC or AM) or
b)
Def Stan 81-015, B, Type 2, (Style 1, 2 or 3).
The internal dimensions shall not exceed the dimensions of the item(s) to be packaged by 20 mm in any
direction. The item in its barrier shall be further prepared as C.3.4.3.2 a) and b).
C.5 Level J Packages
The Level J package shall be the same as the Level N package in all respects except that the barrier
thickness shall be 500 µm thick in all cases and the following:
C.5.1 Fuel Injection Pumps fitted with Mechanical, Open or Closed Circuit Hydraulic, or
Pneumatic Governors
C.5.1.1 Fuel Pumps less than 10 kg mass
The closed container shall then be over-wrapped using Kraft paper, Def Stan 81-048 (PKU) in accordance
with process [C42, 46.3.3] and secured using tape, Def Stan 81-145 Type 2a.
C.5.1.2 Fuel Pumps between 10 kg and up to and including 30 kg mass
C.5.1.2.1 The item in its barrier shall be located and secured in a wooden case Def Stan 81-012, (Style 1,
Grade 1) or Def Stan 81-014, (Style as required by Def Stan 81-041, Class X, and Grade II.). The internal
dimensions of the case shall be sufficient to accept the furniture fitments (see C.5.1.2.3)
C.5.1.2.2 Location and securing of the item in the case shall be by timber furniture fitments in accordance with
process [D6].
C.51.2.3 The fitments shall be designed and positioned as shown in Figure 1, so that the item in its barrier is
a minimum of 30 mm in all directions from the case internal faces.
NOTE 1: The fitments shall be positioned so that they locate on strong areas of the item with the bearers
shown in Figure 1, shall have a minimum thickness of 20 mm.
NOTE 2: The end blocks shown in Figure 1, shall be constructed to form a minimum thickness of 30 mm and
meet the requirements of C.5.2.2.3.
C.5.1.2.4 The case shall be closed in accordance with either process [D11] using steel nails, BS 1202-1 or
process [D12] using wood screws, BS 1210.
C.5.2 Fuel Injectors
The closed container shall then be over-wrapped using Kraft paper, Def Stan 81-048 (PKU) in accordance
with process [C42, 46.3.3] and secured using tape, Def Stan 81-145 Type 2a.
C.6 Handles
C.6.1 If the container package mass is 10 kg or over two handles complying with Def Stan 81-029 shall be
fitted.
C.6.2 The selection and attachment of handles shall be in accordance with Def Stan 81-029.
C.6.2.1 Handles if required shall be positioned centrally one on each end of the container, with the top edge
of the handle brackets a maximum of one third down from the top edge of the container.
2-14
DEF STAN 81-055 Issue 7
ITEM
DESCRIPTION
MATERIAL
QUANTITY
1
Tie Bolt (length to suit pump)
Def Stan 81-086, Figure 11, Type A
4
2
Plate
Def Stan 81-086, Figure 13, Type A
4
3
Bearer
Softwood
4
NOTE 1: The shape, size, and contours of the bearers and end blocks (if required) shall suit the individual fuel injection
pump.
NOTE 2: End blocks when used shall be secured in place using adhesive, BS EN 12765 and / or nails BS 1202-1.
NOTE 3: At points of contact between the item in its barrier and the furniture fitments, either 10 mm thick felt, BS 7200 or
expanded polyethylene, Def Stan 81-116, Type GP, Grade C shall be secured to the fitments using adhesive, rubber resin
No 7, Def Stan 80-117.
Figure 1 - Locating and Securing Fuel Injection Pumps of mass 10 kg or over to Level J
2-15
DEF STAN 81-055 Issue 7
Annex D Packaging of Pistons, Assembled or Unassembled and Piston
Sets
Note: This Annex was Def Stan 81-056
D.1 Scope
D.1.1 This Annex specifies the requirements for the packaging of individual assembled or unassembled
engine pistons and piston sets to Military Levels N and J.
D.1.2 This Annex only covers components with a Primary Packaging Quantity (PPQ) of one; that is single or
a set.
D.1.2.1 A PPQ of one with a maximum mass of contents of 10 kg and sets with a maximum mass of contents
of 55 kg is included and may be supplied assembled or unassembled.
D.1.3 All diesel and gasoline engine pistons are included, with the exception of those required for aircraft
engines.
D.2 Level N packages
D.2.1 Piston assemblies (consisting of piston, Gudgeon pin, Gudgeon pin circlip, and piston
rings)
D.2.1.1 Clean items in accordance with process [C3] using white spirit, BS 245, Type A.
D.2.1.2 Dry the cleaned items in accordance with process [C11, 15.2.2 or 15.2.3] at the highest controlled
temperature range available that will not cause damage to the items.
D.2.1.3 Preserve the cleaned and dried items in accordance with process [C21, 25.3.2] using lubricating oil,
OMD-90; Def Stan 91-113.
D.2.1.4 Wrap the preserved items in accordance with process [C41, 45.3.2] using a grease-resistant material
listed in the process and secured with tape, Def Stan 81-145 Type 3.
NOTE 1: Items supplied unassembled shall be divided into parts of the same denomination and wrapped in
their divisions. The divisions being; the piston, piston rings, and gudgeon pins with circlips
NOTE 2: Prior to wrapping, fitted piston rings shall be masked in accordance with process [C49, 53.3.1(a)]
NOTE 3: If the wrapping material selected is mouldable waxed wrap, Def Stan 81-129, the securing tape shall
be Def Stan 81-145 Type 2a.
D.2.1.5 The masked (if required) and wrapped items shall be individually enclosed in envelopes constructed
from 250 μm thick polyethylene film, Def Stan 93-116, Types 1 or 2 in accordance with process [C44].
D.2.1.6 The enveloped items shall be located centrally within a fibreboard container, either;
a) Def Stan 81-015, B, Type 1 (Style 1, 2 or 3, Class AC or AM)
b) Def Stan 81-015, B, Type 2 (Style 1, 2 or 3)
c) Def Stan 81-015, A, (Style C, D or E)
D.2.1.6.1 The internal dimensions of the container shall not exceed the combined dimensions of the
enveloped items to be packaged by 20 mm in any direction.
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DEF STAN 81-055 Issue 7
D.2.1.6.2 The fibreboard container shall be lined and excess space filled with a material selected from those
listed in process [D3].
NOTE: The piston head shall be separated from the other unassembled components with a disc of corrugated
board, Def Stan 81-046, Type B or fibreboard, Def Stan 81-001, of a minimum thickness of 0.70 mm of similar
diameter to the piston head. The piston rings shall be placed adjacent to the separator disc and if
unassembled the gudgeon pin and circlips placed centrally on the piston rings, located in place using rolls of
material in accordance with process [D5, 70.3.3(a)].
D.2.1.6.3 The container shall be closed in accordance with process [D16] using tape, Def Stan 81-145
Type 4.
D.2.2 Piston Sets
NOTE: When pistons are supplied in matched sets, care must be taken during all stages of packaging to
ensure they are kept in their respective sets.
D.2.2.1 Each piston assembly contained in the set shall be individually packed in accordance with D.2.1 to
D.2.1.6.3 above.
D.2.2.2 The packed items shall be centrally placed within a fibreboard container, as Table 1 appropriate to the
mass of the item to be packaged. The internal dimensions of the container shall not exceed the combined
dimensions of the packed items by 20 mm in any direction.
Table 1 Container Selection
Total Mass of Packed Items (kg)
Container Choice
≤ 10
Def Stan 81-015 A (Style C, D or E) or B Type 1 (Style 1, 2 or 3)
≤ 40
Def Stan 81-015 B Type 2 (Style 1, 2 or 3)
≤ 55
Def Stan 81-015 B Type 2 (Style 1, 2 or 3) or C Type A
D.2.2.3 The packed items shall be separated by sheets of corrugated board, Def Stan 81-046, Type B or
fibreboard, Def Stan 81-001, minimum thickness of 0.70 mm in accordance with process [D5, 70.3.2, figure
11(a)].
D.2.2.3.1 The packed items shall be internally packed in their segments, which shall be lined and excess
space filled with a material selected from those listed in process [D3].
D.2.2.3.2 The fibreboard container shall be lined, and excess space filled with a material selected from those
listed in process [D3].
D.2.2.3.3 The container shall be closed in accordance with process [D16] using tape, Def Stan 81-145 Type
4.
D.3 Level J Packages
D.3.1 The Level J package shall be the same as the Level N package in all respects except that the
polyethylene film thickness shall be 500 μm in all cases and the following:
D.3.2 The closed container shall be over-wrapped using Kraft paper, Def Stan 81-048 (PKU) in accordance
with process [C42, 46.3.3] and secured using tape, Def Stan 81-145 Type 2a.
NOTE: If the Fibreboard container is, Def Stan 81-015 ‘C’ the closure shall be in accordance with [D16] using
tape, Def Stan 81-145 Type 2a.
2-17
DEF STAN 81-055 Issue 7
Annex E Packaging of Rubber Hoses, Plastics Hoses, and Hose
Assemblies
Note: This Annex was Def Stan 81-039
E.1 Scope
E.1.1 This Annex specifies the requirements for the packaging of rigid, flexible, and pre-formed rubber or
plastics hose and hose assemblies to Military Levels P, N, and J.
E.1.2 This Annex is based on a Primary Packaged Quantity (PPQ) of one.
E.1.3 The following types of hose and hose assemblies are covered by this Annex:
a)
Hydraulic and pneumatic,
b)
Chemical and gas (including clean air, airborne and diving apparatus breathing systems),
c)
Automotive,
d)
General purpose and miscellaneous.
E.2 Level P Package
E.2.1 Initial preparation
E.2.1.1 All hose and hose assemblies used for clean air, airborne oxygen breathing systems (see
BS 5N 100-7) or diving apparatus oxygen breathing systems shall be cleaned externally in accordance with
process [C10] and internally by purging with clean, dry air or nitrogen, free from all lubricants.
E.2.1.2 All other hose and hose assemblies shall be cleaned internally and externally in accordance with
process [C10].
E.2.1.3 Immediately after cleaning, all open ends of the item shall be sealed using; either the manufacture's
dust caps, plugs or by a covering of 125 µm thick polyethylene film, Def Stan 93-116, Type 1 or 2, secured
with tape, Def Stan 81-145 Type 3.
E.2.1.3.1 In addition, for items exceeding 1000 mm in length the protected open ends of the item shall be
overwrapped in accordance with process [C49, 53.3.1(h)].
NOTE: For clean air, airborne or diving apparatus oxygen breathing systems the overwrap shall be
polyethylene, bubble film, Def Stan 81-122 secured with tape, Def Stan 81-145 Types 1 or 2.
E.2.2 Hose and Hose assemblies packaged in straight lengths
E.2.2.1 Whenever possible the prepared item shall be packaged in straight lengths in a relaxed condition,
free from tension, compression or any other deformation.
E.2.2.1.1 After initial preparation, the straight length shall be enclosed in a barrier constructed from 125 µm
polyethylene film, Def Stan 93-116, Type 1 or 2 in accordance with process [C44].
E.2.2.1.2 Prepared items that are considered to be vulnerable to bending forces shall be attached to a board,
(see E.2.2.1.3) using a minimum of three equidistant bands of tape, Def Stan 81-145 Type 3 whose ends
shall overlap by a minimum of 50 mm.
2-18
DEF STAN 81-055 Issue 7
E.2.2.1.3 The boards shall be fibreboard, Def Stan 81-001 or corrugated fibreboard, Def Stan 81-106,
Def Stan 81-107 or Def Stan 81-108 with flutes running longitudinally. The board dimensions shall exceed the
prepared item by 25 mm in both directions.
E.2.3 Hose and hose assemblies packaged as a coil
E.2.3.1 When packaging the item in a straight length is not practical, the prepared item shall be coiled to a
minimum diameter of 20 times the outer diameter of the hose section. When coiling, care shall be taken not to
flatten, kink or twist the hose section.
E.2.3.2 After initial preparation, to avoid rubber hoses adhering together whilst coiled they shall be either first:
a) Treated in accordance with process [C35] or;
b) Wrapped in accordance with process [C41], using a non-grease resistant material.
E.2.3.3 The coiled items shall be secured either:
a) With a minimum of three bands of 25 mm wide tape, Def Stan 145 Type 3, spaced equidistantly around the
coil circumference with the tape ends overlapping by a minimum of 50 mm, with paper, Def Stan 81-030 Type
1 interposed between the tape and the item or;
b) With a minimum of three equidistantly spaced ties of polypropylene twine, BS 4881, placed around the coil
circumference. The twine shall be applied with such tightness as not to cut into or cause deformation of the
hose it is applied to.
E.2.3.4 The cleaned and prepared item shall be enclosed in a barrier constructed from 125 µm thick
polyethylene film, Def Stan 93-116, Type 1 or 2 in accordance with process [C44].
E.3 Level N Package
E.3.1 The Level N package shall be the same as the Level P package in all respects except that:
a) For items packaged in straight lengths the procedure in E.2.2.1.2 and E.2.2.1.3 is not required;
b) The final barrier shall be 250 µm thick polyethylene film, Def Stan 93-116, Type 1 or 2.
E.3.1.1 The item in its barrier shall be located in a container as follows.
NOTE: The internal dimensions of the container shall not exceed the dimensions of the prepared item by
20 mm in any direction.
E.3.2 All hose and hose assemblies up to 1000 mm long or whose coil diameter is 300 mm or less
E.3.2.1 The item shall be located centrally in a fibreboard container; Def Stan 81-015 B Type 1 (Style 1 or 2,
Class AC or AM), or Type 2 (Style 1 or 2) or Def Stan 81-015, A (Style C, D or E). The container selected as
appropriate to mass and dimensions.
E.3.2.2 The container shall be lined and excess space filled with a material selected from those listed in
process [D3].
E.3.2.3 The container shall be closed in accordance with process [D16] using tape, Def Stan 81-145 Type 4.
E.3.3 All hose and hose assemblies exceeding 1000 mm long or with a coil diameter of over 300 mm.
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DEF STAN 81-055 Issue 7
E.3.3.1 The item shall be located centrally in one of the following fibreboard containers as appropriate to
mass and dimensions:
a) Hose and hose assemblies packaging straight shall be placed either in a container, Def Stan 81-015, B,
Type 1, (Style 3, Class AC or AM), Type 2, (Style 3) or Def Stan 81-015, A (Style C, D or E).
b) Coiled hose and hose assemblies shall be placed in container, Def Stan 81-015, B, Type 1 (Style 1 or 2,
Class AC or AM) or Type 2, (Style 1 or 2).
E.3.3.2 This shall be as E.3.2.2 – E.3.2.3.
E.4 Level J Package
E.4.1 The Level J package shall be the same as the Level N package in all respects except that:
a) The final barrier shall be 500 µm thick polyethylene film, Def Stan 93-116, Type 1 or 2;
b) The closed container shall be over-wrapped using Kraft paper, Def Stan 81-048 (PKU) in accordance with
process [C42, 46.3.3] and securing using tape, Def Stan 81-145 Type 2a
2-20
DEF STAN 81-055 Issue 7
Annex F Packaging of Gaskets, Seals, "O" Rings, Grommets and Similar
Materiel
Note: This Annex was Def Stan 81-060
F.1 Scope
F.1.1 This Annex specifies requirements for the packaging of; gaskets, seals, 'O' rings, grommets and similar
materiel, to Military Packaging Levels; P, N, and J.
F.1.2 This Annex is based on Primary Packaging Quantities (PPQ) that are single, multiple, kits, or sets.
F.1.3 This Annex does not cover the packaging of articles used in Oxygen Equipment.
F.2 Level P Packages
F.2.1 All items except Composite (i.e. Ferrous Metal / Rubber) and Steel items
F.2.1.1 All aerospace vulcanized rubber products shall be packed in accordance with BS 3F 69.
F.2.1.2 All other items(s) shall be cleaned and dried in accordance with process [C10, 14.2.1 or 14.2.2].
F.2.1.3 The cleaned and dried items shall be wrapped with paper, wrapping, waxed, Def Stan 81-30 in
accordance with process [C41, 45.3.2] and secured with tape, Def Stan 81-145 Type 3.
Note: Items constructed from flexible thin material require additional support to prevent creasing or
deformation. These items after wrapping shall be placed between two pieces of 1.45 mm thick, fibreboard,
Def Stan 81-001, of such size to extend beyond the length and width of the wrapped item by a minimum of 10
mm. The edges shall then be sealed with tape, Def Stan 81-145 Type 3.
F.2.1.4 When the Primary Packaged Quantity (PPQ) is one:
The prepared item shall be enclosed in a barrier constructed from polyethylene film, Def Stan 93-116,
Type 1, 125 μm thick or polyethylene coated paper, Def Stan 81-134 in accordance with process [C44]. The
barrier shall be sufficiently large to accommodate the wrapped and supported (if required) item without
causing any strain upon the barrier, its seals, or the item.
F.2.1.5 When the PPQ is greater than one:
The relevant number of prepared items as in 6.2.1 to 6.2.3 shall be enclosed in a barrier as 6.2.4 individually.
The items shall be then be collectively heat sealed in an outer envelope constructed from polyethylene film
Def Stan 93-116, Type 1, 125 μm thick. The outer envelope shall be sufficiently large to accommodate the
items in their barriers without causing any strain upon the envelope, its seals, or the items.
F.2.1.6 When the PPQ is a kit or set:
The number of items contained in the set or kit shall be prepared as in F.2.1.1 to F.2.1.3 and enclosed in a
barrier as 6.2.4 individually.
Items of the same denomination shall then be collectively secured together with tape Def Stan 81-145 Type 3.
The items then comprising the kit or set shall then be collectively heat-sealed in an outer envelope
constructed from polyethylene film, Def Stan 93-116, Type 1, 125 μm thick. The outer envelope shall be
sufficiently large to accommodate the items in their barriers without causing any strain upon the envelope, its
seals, or the items.
Note: A kit or set may contain items of various descriptions (e.g. wholly one material or composite). In this
case the respective clauses for the items shall be followed, up to the items being enclosed in their barriers or
2-21
DEF STAN 81-055 Issue 7
outer envelopes. Then all items contained in the set or kit shall be secured together with tape Def Stan 81145 Type 3.
F.2.2 Composite Items (i.e. Ferrous Metal / Rubber)
F.2.2.1 As per paragraph F.2.1.2
F.2.2.2 The cleaned and dried items shall be treated with silicon compound, XG-250, Def Stan 68-069 in
accordance with process [C19].
Note: Care shall be taken to ensure that contact between the silicon compound, XG-250, Def Stan 68-069
and the rubber is kept to a minimum. Any compound that does contact the rubber shall be removed
immediately with a cloth which is clean and free from residues of laundering chemicals.
F.2.2.3 The treated items shall then be wrapped in mouldable waxed wrap, Def Stan 81-129 in accordance
with process [C41, 45.3.2] and secured with tape, Def Stan 81-145 Type 2a.
Note: Items constructed from flexible thin material require additional support to prevent creasing or
deformation. These items after wrapping shall be placed between two pieces of 1.45 mm thick, fibreboard,
Def Stan 81-001, of such size to extend beyond the length and width of the wrapped item by a minimum of
10 mm. The edges shall then be sealed with tape, Def Stan 81-145 Type 3.
F.2.2.4 As per paragraph F.2.1.4
F.2.2.5 When the PPQ is a multiple greater than one:
The relevant number of prepared items as in F.2.1.1 to F.2.1.3 shall be enclosed in a barrier as F.2.1.4
individually. The items shall be then be collectively heat sealed in an outer envelope constructed from
polyethylene film Def Stan 93-116, Type 1, 125 μm thick. The outer envelope shall be sufficiently large to
accommodate the items in their barriers without causing any strain upon the envelope, its seals, or the items.
F.2.2.6 When the PPQ is a kit or set:
The number of items contained in the set or kit shall be prepared as in F.2.2.1 to F.2.2.3 and enclosed in a
barrier as F.2.1.4 individually.
Items of the same denomination shall then be collectively secured together with tape Def Stan 81-145 Type 3.
The items then comprising the kit or set shall then be collectively heat-sealed in an outer envelope
constructed from polyethylene film, Def Stan 93-116, Type 1, 125 μm thick. The outer envelope shall be
sufficiently large to accommodate the items in their barriers without causing any strain upon the envelope, its
seals, or the items.
Note: A kit or set may contain items of various descriptions (e.g. wholly one material or composite). In this
case the respective clauses for the items shall be followed, up to the items being enclosed in their barriers or
outer envelopes. Then all items contained in the set or kit shall be secured together with tape Def Stan 81-145
Type 3.
F.2.3 Steel Items
Articles of the type covered by this standard that are made of Steel shall be packaged to Def Stan 81-055.
2-22
DEF STAN 81-055 Issue 7
F.3 Level N Packages
F.3.1 The Level N package shall be the same as the Level P package in all respects except that the item in its
barrier or outer envelope shall be further prepared as follows;
F.3.2 The item(s) in their barrier(s) or outer envelope(s) shall be located centrally within a fibreboard
container; Def Stan 81-015, B, Type 1 (Style 1, 2 or 3, Class AC or AM), Type 2 (Style 1, 2 or 3) or Def Stan
81-015, A (Style C, D or E). The internal dimensions shall not exceed the dimensions of the item(s) to be
packaged by 20 mm in any direction.
F.3.2.1 The container shall be lined and excess space filled with a material selected from those listed in
process [D3].
F.3.2.2 The container shall be closed in accordance with process [D16] using tape, Def Stan 81145 Type 4.
F.4 Level J Packages
The Level J package shall be the same as the Level N Package in all respects except that the barrier material
shall be polyethylene film, Def Stan 93-116, Type 1, 250 μm thick, and the container after closure shall be
over-wrapped using Kraft paper, Def Stan 81-048 (PKU) in accordance with process [C42, 46.3.3] with all
seams and flaps secured with tape, Def Stan 81-145 Type 2a.
2-23
PPQ: _________________________________________________
Makers Part No: _______________________________________
2-24
External Dimensions: _______________________________ mm
PACKAGE
Additional Details / Notes:
Internal Dimensions: ____________________________ mm Gross Mass: _______________________________________ kg
Type / Spécification: ________________________________
CONTAINER
Method of Packaging in Accordance with Specification: __________________________________________________________
Level of Packaging: ________________________________
Item Name: ______________________________________
Item Reference No: _______________________________
PACKAGE PRODUCTION DATA SHEET
DEF STAN 81-055 Issue 7
Annex G Package Production Data Sheet
(Illustrative)
NOTE: This sheet may be filed in NATO Stock Number sequence in the SPIS Library (SPIN)
DEF STAN 81-055 Issue 7
Section 3
Normative References
1
The publications shown below are referred to in the text of this standard. Publications are
grouped and listed in alpha-numeric order.
Note: Def Stan’s can be downloaded free of charge from the DStan web site by visiting
<http://dstan.uwh.diif.r.mil.uk/> for those with RLI access or <https://www.dstan.mod.uk> for all other
users. All referenced standards were correct at the time of publication of this standard (see A.2, A.3 & A.4
below for further guidance), if you are having difficulty obtaining any referenced standard please contact the
DStan Helpdesk in the first instance.
Def Stans
Number
Title
81-041, Pt 4, Iss Packaging of Defence Materiel - Service Packaging Instruction Sheet (SPIS)
8
81-048, Iss 04
Paper, Kraft Union (PKU) and Paper, Creped, Kraft Union Reinforced
(PCKUR)
81-086, Iss 3
Metal Fittings for Wooden Containers
81-099, Iss 4
Paper Wrapping or Location
81-003, Iss 10
Cases, Wood (Comb-Jointed Construction)
81-116, Iss 3
Expanded Polyethylene Sheet, Types GP and QX, Grades A, B, C and D
81-122, Iss 3
Polyethylene, Closed Cell Film for Packaging
81-129, Iss 3
Wrapping, Mouldable, Waxed, Grease-resisting
81-134, Iss 3
Paper, Kraft, Polyethylene Coated (Heat Sealable)
81-145, Iss 3
Tape, Pressure-Sensitive Adhesive for General Packaging
91-027, Iss 3
Grease, Automotive and Artillery NATO Code No: G-403 Joint Service
Designation: XG-279
91-113, Iss 2
Lubricating Oil, Engine: Severe Duty Diesel, Extended Service - SAE 10W/30
NATO Code: O-1176 Joint Service Designation: OMD-90
68-069, Iss 1
Silicone Compound Electrical Insulating - NATO Code S-736 - Joint Service
Designation XG-250
80-034, Iss 3
Corrosion Preventive, Compound Oil, Thin Film Joint Service Designation: PX4
80-117, Iss 3
Synthetic Rubber Resin Adhesive No.7
3-1
DEF STAN 81-055 Issue 7
81-001, Iss 05
Fibreboard, Solid, Kraft-Lined Chipboard
81-012, Iss 08
Cases, Wood (Panel and Batten Construction)
81-015, Iss 7
Containers, Fibreboard
81-029, Iss 05
Handles, Webbing or Rope, with Metal Brackets or Wood Blocks for Use on
Containers
81-030, Iss 5
Paper, Wrapping
81-041, Pt 1, Iss Packaging of Defence Materiel - Introduction to Defence Packaging
9
Requirements
81-041, Pt 2, Iss Packaging of Defence Materiel - Design
9
81-041, Pt 3, Iss Packaging of Defence Materiel - Environmental Testing
06
81-041, Pt 5, Iss Packaging of Defence Materiel - Packaging Processes
8
81-041, Pt 6, Iss Packaging of Defence Materiel - Package Marking
09
81-046, Iss 5
Board, Corrugated for Military Packaging
93-116, Iss 3
Polyethylene (Low Density) Film for Packaging Types 1, 2 and 3
STANAGs
Number
Title
Allied Publications
Number
Title
Other References
Standard Type
Standard Name
CIVIL
BS 1202-1 Specification for nails. Steel nails
CIVIL
BS 1210
CIVIL
BS 245
Specification for Mineral Solvents (White Spirit and Related
Hydrocarbon Solvents) for Paints and Other Purposes
Specification for wood screws (obsolescent)
3-2
DEF STAN 81-055 Issue 7
CIVIL
BS 3F 69
Specification for Packaging and Identification of Vulcanized
Rubber Items
CIVIL
BS 4881
CIVIL
BS 5N 100-7
Aircraft Oxygen Systems and Equipment - Part 7: Guide
to Cleaning Labelling and Packaging
CIVIL
BS 7200
CIVIL
BS EN 12765 Classification of thermosetting wood adhesives for nonstructural applications
CIVIL
BS ISO 2230 Rubber Products. Guidelines for storage
CIVIL
BS ISO 27831 - 1
Metallic and other inorganic coatings – Cleaning and
preparation of metal surfaces: Part 1 Ferrous Metals and alloys
CIVIL
BS ISO 27831 - 2
Metallic and other inorganic coatings – Cleaning and
preparation of metal surfaces: Part 2 Non-ferrous metals and alloys
CIVIL
BS EN 14592 Timber structures - Dowel-type fasteners - Requirements
Other
Commercial
Equipment
Other
NMMA TC-W3 (Certified) 2-Cycle Outboard Marine Oil
Other
SAE AMS03-2* Cleaning and Preparation of Metal Surfaces
Specification for Polypropylene Film Cords, Lines and Twines
Specification for synthetic-fibre needle felts
Suitable Solvent for Cleaning Electrical and Aerospace
2
Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. Care should be taken when referring out to specific portions of other standards to ensure that they
remain easily identifiable where subsequent amendments and supersession’s might be made. For some
standards the most recent editions shall always apply due to safety and regulatory requirements.
3
In consideration of clause A.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Correct identification of standards is as defined in the ITT or contract.
4
DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.
3-3
DEF STAN 81-055 Issue 7
Definitions
For the purpose of this standard, ISO/IEC Guide 2 ‘Standardization and Related Activities –
General Vocabulary’ and the definitions shown below apply.
Definition
Description
General
For the purpose of this standard the definitions given in Def Stan 81-41 apply
Production
Processes
This standard refers to production process numbers as detailed in Def Stan
81-41 (Part 5), e.g. [C10].
Units
Dimensions
- All film thicknesses are in µm and are minima. All other dimensions are in mm.
Container dimensions should be stated in the order Length x Width x Height,
(L x W x H), where appropriate
Units Weight
Mass
/ All weight / mass are measured in kilograms (kg).
Intimate
Packaging
Packaging material which makes direct contact with the item to be packaged
Proximity
Packaging
Packaging material not making direct contact with the item to be packaged but
which is used to enclose one or more items or devices, on the outside of any
intimate packaging.
Secondary
Packaging
Packaging material used primarily to give additional climatic and physical
protection on the outside of a proximity package.
Metal Pipes
These include pipes and attachments with or without couplings or other
assemblies
Plastics Hose - This is a hose made largely or entirely of thermoplastic material, but not rubber
materials
Rubber Hose - This is a hose made largely or entirely of rubber, but not general thermoplastic
materials
materials.
Hose
Reinforcement
Both rubber and plastics hoses can use; textile, polymer or metallic
reinforcement.
3-4
DEF STAN 81-055 Issue 7
Abbreviations
Abbreviation
Description
3-5
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The DStan file reference relating to work on this standard is DStan/81/55.
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Information on all Defence Standards can be found on the DStan Websites https://www.dstan.mod.uk
and http://dstan.uwh.diif.r.mil.uk/, updated weekly. Any person who, when making use of a Defence
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