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ASTM F2639-15

(Practice)

Standard Practice for Design, Alteration, and Certification of Aircraft Electrical Wiring Systems

Standard Practice for Design, Alteration, and Certification of Aircraft Electrical Wiring Systems

SIGNIFICANCE AND USE
4.1 Design—The design procedures defined in this practice are intended to provide acceptable guidance in the original design of electrical systems.  
4.2 Alteration—The alteration procedures defined in this practice are intended to provide acceptable guidance for modification of general aviation aircraft. Design of any modification shall follow the practices and processes defined in the design sections of this practice.  
4.3 Certification—Certification guidance provided in this practice is intended to provide generally accepted procedures and processes for certification of original and modified electrical systems and equipment. Requirements for certification shall be coordinated with the applicable National Aeronautics Association/Civil Aeronautics Administration (NAA/CAA) regulatory agency.
SCOPE
1.1 Definition—This practice defines acceptable practices and processes for the design, alteration, and certification of electric systems and installations in general aviation aircraft. This practice does not change or create any additional regulatory requirements nor does it authorize changes in or permit deviations from existing regulatory requirements.  
1.2 Applicability—The guidance provided in this practice is directed to air carriers, air operators, design approval holders, Supplemental Type Certificate (STC) holders, maintenance providers, repair stations, and anyone performing field approval modifications or repairs.  
1.3 Protections and Cautions—This practice provides guidance for developing actions and cautionary statements to be added to maintenance instructions for the protection of wire and wire configurations. Maintenance personnel will use these enhanced procedures to minimize contamination and accidental damage to electrical wiring interconnection system (EWIS) while working on aircraft.  
1.4 “Protect and Clean As You Go” Philosophy—This philosophy is applied to aircraft wiring through inclusion in operators’ maintenance and training programs. This philosophy stresses the importance of protective measures when working on or around wire bundles and connectors. It stresses how important it is to protect EWIS during structural repairs, STC installations, or other alterations by making sure that metal shavings, debris, and contamination resulting from such work are removed.  
1.5 This practice includes the following sections:    
Title  
Section  
Wire Selection  
5  
General  
5.1  
Aircraft Wire Materials  
5.2  
Table of Acceptable Wires  
5.3  
Severe Wind and Moisture Problems (SWAMP)  
5.4  
Grounding and Bonding  
5.5  
Electrical Wire Chart  
5.6  
Wire and Cable Identification  
6  
General  
6.1  
Wire and Cable Identification  
6.2  
Types of Markings  
6.3  
Sleeve and Cable Marker Selection  
6.4  
Placement of Identification Markings  
6.5  
Wiring Installation  
7  
General  
7.1  
Wire Harness Installation  
7.2  
Power Feeders  
7.3  
Service Loops  
7.4  
Drip Loops  
7.5  
Soldering  
7.6  
Strain Relief  
7.7  
Grounding and Bonding  
7.8  
Splicing  
7.9  
Fuel Tank Wiring  
7.10  
Corrosion Preventative Compounds (CPC)
(MIL-C-81309)  
7.11  
Electrical Load Considerations  
8  
General  
8.1  
Methods for Determining the Current-Carrying
Capacity of Wires  
8.2  
Acceptable Means of Monitoring and
Controlling the Electrical Load  
8.3  
Electrical System Components  
9  
General  
9.1  
Alternators  
9.2  
Generators  
9.3  
Ground Power Units  
9.4  
Auxiliary Power Units  
9.5  
Batteries  
9.6  
Circuit Protection Devices  
9.7  
Conduit  
9.8  
Connectors  
9.9  
Inverters and Power Converters  
9.10  
Junctions  
9.11  
Junction Boxes  
9.12  
Electronic Assemblies  
9.13  
Relays  
9.14  
Studs  
9.15  
Switches  
9.16  
Terminals and Terminal Blocks  
9.17 ...

General Information

Status
Historical
Publication Date
31-Jul-2015
ICS
49.060 - Aerospace electric equipment and systems
Technical Committee
F39 - Aircraft Systems
Drafting Committee
F39.01 - Design, Alteration, and Certification of Electrical Systems
Current Stage
Ref Project

Relations

Replaces
ASTM F2639-07e1 - Standard Practice for Design, Alteration, and Certification of Airplane Electrical Wiring Systems
Effective Date
01-Aug-2015
Replaced By
ASTM F2639-18 - Standard Practice for Design, Alteration, and Certification of Aircraft Electrical Wiring Systems
Effective Date
01-Oct-2018
Referred By
ASTM F3231/F3231M-23 - Standard Specification for Electrical Systems for Aircraft with Combustion Engine Electrical Power Generation
Effective Date
01-Aug-2015
Referred By
ASTM F3060-20 - Standard Terminology for Aircraft
Effective Date
01-Aug-2015
Referred By
ASTM F2799-14(2019) - Standard Practice for Maintenance of Aircraft Electrical Wiring Systems
Effective Date
01-Aug-2015
Referred By
ASTM F3316/F3316M-19 - Standard Specification for Electrical Systems for Aircraft with Electric or Hybrid-Electric Propulsion
Effective Date
01-Aug-2015

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REDLINE ASTM F2639-15 - Standard Practice for Design, Alteration, and Certification of Aircraft Electrical Wiring SystemsREDLINE ASTM F2639-15 - Standard Practice for Design, Alteration, and Certification of Aircraft Electrical Wiring Systems
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Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
Contact ASTM International (www.astm.org) for the latest information
Designation:F2639 −15
Standard Practice for
Design, Alteration, and Certification of Aircraft Electrical
1
Wiring Systems
This standard is issued under the fixed designation F2639; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope
Grounding and Bonding 5.5
Electrical Wire Chart 5.6
1.1 Definition—This practice defines acceptable practices
Wire and Cable Identification 6
and processes for the design, alteration, and certification of General 6.1
Wire and Cable Identification 6.2
electric systems and installations in general aviation aircraft.
Types of Markings 6.3
This practice does not change or create any additional regula-
Sleeve and Cable Marker Selection 6.4
tory requirements nor does it authorize changes in or permit Placement of Identification Markings 6.5
Wiring Installation 7
deviations from existing regulatory requirements.
General 7.1
Wire Harness Installation 7.2
1.2 Applicability—The guidance provided in this practice is
Power Feeders 7.3
directed to air carriers, air operators, design approval holders,
Service Loops 7.4
Supplemental Type Certificate (STC) holders, maintenance
Drip Loops 7.5
Soldering 7.6
providers, repair stations, and anyone performing field ap-
Strain Relief 7.7
proval modifications or repairs.
Grounding and Bonding 7.8
Splicing 7.9
1.3 Protections and Cautions—This practice provides guid-
Fuel Tank Wiring 7.10
ance for developing actions and cautionary statements to be
Corrosion Preventative Compounds (CPC) 7.11
(MIL-C-81309)
added to maintenance instructions for the protection of wire
Electrical Load Considerations 8
and wire configurations. Maintenance personnel will use these
General 8.1
enhanced procedures to minimize contamination and acciden-
Methods for Determining the Current-Carrying 8.2
Capacity of Wires
tal damage to electrical wiring interconnection system (EWIS)
Acceptable Means of Monitoring and 8.3
while working on aircraft.
Controlling the Electrical Load
Electrical System Components 9
1.4 “Protect and Clean As You Go” Philosophy—This
General 9.1
philosophy is applied to aircraft wiring through inclusion in
Alternators 9.2
operators’maintenanceandtrainingprograms.Thisphilosophy
Generators 9.3
Ground Power Units 9.4
stresses the importance of protective measures when working
Auxiliary Power Units 9.5
on or around wire bundles and connectors. It stresses how
Batteries 9.6
important it is to protect EWIS during structural repairs, STC
Circuit Protection Devices 9.7
Conduit 9.8
installations, or other alterations by making sure that metal
Connectors 9.9
shavings, debris, and contamination resulting from such work
Inverters and Power Converters 9.10
are removed. Junctions 9.11
Junction Boxes 9.12
1.5 This practice includes the following sections:
Electronic Assemblies 9.13
Relays 9.14
Title Section
Studs 9.15
Wire Selection 5
Switches 9.16
General 5.1
Terminals and Terminal Blocks 9.17
Aircraft Wire Materials 5.2
Waveguides 9.18
Table of Acceptable Wires 5.3
Electrical System Component Installation 10
Severe Wind and Moisture Problems (SWAMP) 5.4
General 10.1
Alternators 10.2
Generators 10.3
1
Auxiliary Power Units (APUs) 10.4
This practice is under the jurisdiction of ASTM Committee F39 on Aircraft
Batteries 10.5
Systems and is the direct responsibility of Subcommittee F39.01 on Design,
Circuit Protection Devices 10.6
Alteration, and Certification of Electrical Systems.
Conduit 10.7
Current edition approved Aug. 1, 2015. Published September 2015. Originally
ϵ1 Connectors 10.8
approved in 2007. Last previous edition approved in 2007 as F2639–07 . DOI:
Inverters and Power Converters 10.9
10.1520/F2639-15.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
1

---------------------- Page: 1 ----------------------
F2639−15
4
2.4 FAA Standards:
Junctions 10.10
Junction Boxes, Panels, Shields, and 10.11
Advisory Circular 20-53AProtection of Aircraft Fuel Sys-
Microswitch Housings
tems Against Fuel Vapor Ignition Due To Lightning
PC Board Assemblies 10.12
AC 20-136Protection of Aircraft Electrical/Electronic Sys-
Relays 10.13
Studs 10.14
tems Against the Indirect Effects of Lightning
Switches 10.15
AC 21-160ERTCA Document DO-160E
Terminals and Terminal Blocks 10.16
AC 23.1309-1CEquipment, Systems, and Installations in
Waveguides 10.17
EMI/RFI 11
Part 23 Airplanes
General 11.1
AC 25-16Electrical Fault and Fire Prevention and Protec-
Grounding and Bonding 11.2
HIRF 11.3 tion
Lightning 11.4
AC 25.869-1Electrical System Fire and Smoke Protection
Alterations 12
AC25.981-1BFuelTankIgnitionSourcePreventionGuide
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
´1
Designation: F2639 − 07 F2639 − 15
Standard Practice for
Design, Alteration, and Certification of AirplaneAircraft
1
Electrical Wiring Systems
This standard is issued under the fixed designation F2639; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1
ε NOTE—Added 1.5 editorially in September 2012.
1. Scope
1.1 Definition—This practice defines acceptable practices and processes for the design, alteration, and certification of electric
systems and installations in general aviation aircraft. This practice does not change or create any additional regulatory requirements
nor does it authorize changes in or permit deviations from existing regulatory requirements.
1.2 Applicability—The guidance provided in this practice is directed to air carriers, air operators, design approval holders,
Supplemental Type Certificate (STC) holders, maintenance providers, repair stations, and anyone performing field approval
modifications or repairs.
1.3 Protections and Cautions—This practice provides guidance for developing actions and cautionary statements to be added
to maintenance instructions for the protection of wire and wire configurations. Maintenance personnel will use these enhanced
procedures to minimize contamination and accidental damage to electrical wiring interconnection system (EWIS) while working
on aircraft.
1.4 “Protect and Clean As You Go” Philosophy—This philosophy is applied to aircraft wiring through inclusion in operators’
maintenance and training programs. This philosophy stresses the importance of protective measures when working on or around
wire bundles and connectors. It stresses how important it is to protect EWIS during structural repairs, STC installations, or other
alterations by making sure that metal shavings, debris, and contamination resulting from such work are removed.
1.5 This practice includes the following sections:
Title Section
Wire Selection 5
General 5.1
Aircraft Wire Materials 5.2
Table of Acceptable Wires 5.3
Severe Wind and Moisture Problems (SWAMP) 5.4
Grounding and Bonding 5.5
Electrical Wire Chart 5.6
Wire and Cable Identification 6
General 6.1
Wire and Cable Identification 6.2
Types of Markings 6.3
Sleeve and Cable Marker Selection 6.4
Placement of Identification Markings 6.5
Wiring Installation 7
General 7.1
Wire Harness Installation 7.2
Power Feeders 7.3
Service Loops 7.4
Drip Loops 7.5
Soldering 7.6
Strain Relief 7.7
Grounding and Bonding 7.8
Splicing 7.9
Fuel Tank Wiring 7.10
1
This practice is under the jurisdiction of ASTM Committee F39 on Aircraft Systems and is the direct responsibility of Subcommittee F39.01 on Design, Alteration, and
Certification of Electrical Systems.
Current edition approved Sept. 1, 2007Aug. 1, 2015. Published October 2007September 2015. Originally approved in 2007. Last previous edition approved in 2007 as
ɛ1
F2639 – 07 . DOI: 10.1520/F2639-07E01.10.1520/F2639-15.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
1

---------------------- Page: 1 ----------------------
F2639 − 15
Corrosion Preventative Compounds (CPC) 7.11
(MIL-C-81309)
Electrical Load Considerations 8
General 8.1
Methods for Determining the Current-Carrying 8.2
Capacity of Wires
Acceptable Means of Monitoring and 8.3
Controlling the Electrical Load
Electrical System Components 9
General 9.1
Alternators 9.2
Generators 9.3
Ground Power Units 9.4
Auxiliary Power Units 9.5
Batteries 9.6
Circuit Protection Devices 9.7
Conduit 9.8
Connectors 9.9
Inverters and Power Converters 9.10
Junctions 9.11
Junction Boxes 9.12
Electronic Assemblies 9.13
Relays 9.14
Studs 9.15
Switches 9.16
Terminals and Terminal Blocks 9.17
Waveguides 9.18
Electrical System Component Installation 10
General 10.1
Alternators 10.2
Generators 10.3
Auxiliary Power Units (APUs) 10.4
Batteries 10.5
Circuit Protection Devices 10.6
Conduit 10.7
Connectors 10.8
Inverters and Power Converters 10.9
Junctions 10.10
Junction Boxes, Panels, Shields, and 10.11
Microswitch Housings
PC Board Assemblies 10.12
Relays 10.13
Studs 10.14
Switches 10.15
Terminals and Terminal Blocks 10.16
Waveguides 10.17
EMI/RFI 11
General 11.1
Grounding and Bonding 11.2
HIRF 11.3
Lightning 11.4
Alterations 12
General 12.1
Wire Substitutions 12.2
Commercial Off-the-Shelf (COTS) Components 12.3
Electrical Load
...

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SIGNIFICANCE AND USE
4.1 The term “electrical system” as used in this practice means those parts of the aircraft that generate, distribute, and use electrical energy, including their support and attachments.  
4.2 The satisfactory performance of an aircraft is dependent upon the continued reliability of the electrical system.  
4.3 Damaged wiring or equipment in an aircraft, regardless of how minor it may appear to be, cannot be tolerated. It is, therefore, important that maintenance be accomplished using the best techniques and practices to minimize the possibility of failure.  
4.4 When inspecting and evaluating EWIS, improper wiring, routing, or repairs shall be corrected regardless of the origin of the error.  
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SIGNIFICANCE AND USE
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4.2.1 For normal, utility, and acrobatic category airplanes, by an electrical load analysis or by electrical measurements that account for the electrical loads applied to the electrical system in probable combinations and for probable durations; and  
4.2.2 For commuter category airplanes, by an electrical load analysis that accounts for the electrical loads applied to the electrical system in probable combinations and for probable durations.  
4.3 The primary purpose of the electrical load analysis (ELA) is to determine electrical system capacity (including generating sources, converters, contactors, bus bars, and so forth) needed to supply the worst-case combinations of electrical loads. This is achieved by evaluating the average demand and maximum demands under all applicable flight conditions. A summary can then be used to relate the ELA to the system capacity and can establish the adequacy of the power sources under normal, abnormal, and emergency conditions.
Note 1: The ELA should be maintained throughout the life of the aircraft to record changes to the electrical system, which may add or remove electrical loads to the system.  
4.4 The ELA that is produced for aircraft-type certification should be used as the baseline document for any subsequent changes. When possible, the basic format of the original ELA should be followed to ensure consistency in the methodology and approach.  
4.5 The original ELA may be lacking in certain information, for instance, time available on emergency battery. It may be necessary to update the ELA using the guidance material contained in this guide.
SCOPE
1.1 This guide covers how to prepare an electrical load analysis (ELA) to meet Federal Aviation Administration (FAA) requirements.  
1.2 This guide is intended to address aircraft level electrical load analysis. Electric propulsive power load analysis was not considered in the development of this guide.  
1.3 The values stated in SI units are to be regarded as standard.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM
ASTM F3425-20(Guide)
Standard Guide for Aircraft Electronics Installation Technician Certification

SIGNIFICANCE AND USE
4.1 The guide is intended to be used to assess competencies of qualified individuals who wish to become certified as an aircraft electronics installation technician through a program such as the National Center for Aerospace and Transportation Technologies (NCATT).  
4.2 The guide is intended to be used in concert with a certification provider’s structure and materials for management, exam delivery, and candidate preparation.
SCOPE
1.1 The purpose of this guide is to address the fundamental subject knowledge activities and functions for avionics professionals to be titled Aircraft Electronics Installation Technicians (AEIT).  
1.2 This guide is the basis for the Aircraft Electronics Installation Technician (AEIT) certification, an endorsement to the Aircraft Electronics Technician (AET) certification. Candidates must be a certified AET to take the certification exam associated with this guide.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM
ASTM F2339-19a(Practice)
Standard Practice for Design and Manufacture of Reciprocating Spark Ignition Engines for Light Sport Aircraft

SIGNIFICANCE AND USE
3.1 This practice provides designers and manufacturers of engines for light sport aircraft design references and criteria to use in designing and manufacturing engines.  
3.2 Declaration of compliance is based on testing and documentation during the design and testing or flight testing of the engine type by the manufacturer or under the manufacturers' guidance.
SCOPE
1.1 This practice covers minimum requirements for the design and manufacture of reciprocating spark ignition engines for light sport aircraft, VFR use.  
1.2 The values stated in inch-pound units are to be regarded as standard. No other units of measurement are included in this standard.  
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.4 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM
ASTM F3316/F3316M-19(Specification)
Standard Specification for Electrical Systems for Aircraft with Electric or Hybrid-Electric Propulsion

ABSTRACT
This specification applies to the electrical systems, electrical equipment, and electrical power distribution aspects of airworthiness and design for aircraft with electric or hybrid-electric propulsion. Developed through open consensus of international experts in general aviation, this material focused on Normal Category Airplanes. The content may be more broadly applicable; it is the responsibility of the applicant to substantiate broader applicability as a specific means of compliance.
This specification establishes the Aircraft Type Code (ATC) compliance matrix based on certification level, number of engines, type of engine(s), stall speed, cruise speed, meteorological conditions, altitude, and maneuvers. An ATC is defined by taking into account both the technical considerations regarding the design of the aircraft and the airworthiness level established based upon risk-based criteria. Requirements for electrical systems for electric propulsion cover power source capacity and distribution, electrical systems and equipment, circuit protective devices, master switch arrangement, switches, electrical cables and equipment, electrical system fire protection, electronic equipment, and storage battery design and installation.
SCOPE
1.1 This specification covers the electrical systems, electrical equipment, and electrical power distribution aspects of airworthiness and design for aircraft with Electric or Hybrid-Electric Propulsion. This specification was written with the focus on electric propulsion systems with conventional system layout, characteristics, and operation. This specification does not address all of the requirements that may be necessary for possible hybrid-electric configurations where an EPU and a combustion engine are used in combination to provide propulsion. The use of this specification combined with the applicable portions of Specification F3231/F3231M may be necessary for hybrid-electric configurations. This material was developed through open consensus of international experts in general aviation. This material was created by focusing on Normal Category Aeroplanes. The content may be more broadly applicable; it is the responsibility of the applicant to substantiate broader applicability as a specific means of compliance.  
1.2 An applicant intending to propose this information as a means of compliance for design approval shall seek guidance from their respective oversight authority (for example, published guidance from applicable CAAs) concerning the acceptable use and application thereof. For information on which oversight authorities have accepted this standard (in whole or in part) as a Means of Compliance to their regulatory requirements (Hereinafter referred to as “the Rules”), refer to ASTM F44 webpage (www.ASTM.org/COMMITTEE/F44.htm).  
1.3 Units—This standard may present information in either SI units, English Engineering units, or both. The values stated in each system are not necessarily exact equivalents; therefore, to ensure conformance with the standard, each system shall be used independently of the other, and values from the two systems shall not be combined.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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ASTM
ASTM F319-19(Practice)
Standard Practice for Polarized Light Detection of Flaws in Aerospace Transparency Heating Elements

SIGNIFICANCE AND USE
4.1 This practice is useful as a screening basis for acceptance or rejection of transparencies during manufacturing so that units with identifiable flaws will not be carried to final inspection for rejection at that time.  
4.2 This practice may also be employed as a go-no go technique for acceptance or rejection of the finished product.  
4.3 This practice is simple, inexpensive, and effective. Flaws identified by this practice, as with other optical methods, are limited to those that produce temperature gradients when electrically powered. Any other type of flaw, such as minor scratches parallel to the direction of electrical flow, are not detectable.
SCOPE
1.1 This practice covers a standard procedure for detecting flaws in the conductive coating (heater element) by the observation of polarized light patterns.  
1.2 This practice applies to coatings on surfaces of monolithic transparencies as well as to coatings imbedded in laminated structures.  
1.3 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.  
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use. For specific precautionary statements, see Section 6.  
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

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