FOREWORD This Manual is issued under the authority of, and in accordance with, DoD Instruction 4145.26, "DoD Contractors' Safety Requirements for Ammunition and Explosives," April 4, 1996. The Manual provides safety standards common to DoD and private industry ammunition and explosives (A&E) operations and facilities. DoD 6055.9-STD, "DoD Ammunition and Explosives Safety Standards," October 1992, establishes these safety standards and serves as the primary source document from which this unclassified Manual is derived. The DoD Supplement to the Federal Acquisition Regulation requires contracting officers to incorporate this Manual in A&E procurement actions to achieve parity between contractor and DoD component compliance. The purchasing activity may include additional A&E or related safety requirements as it deems necessary. This revision adds chapters on manufacturing propellants and hazardous component safety data statements, updates basic principles of A&E safety, and provides sufficient information to enable the contractor to make appropriate and reliable decisions affecting his or her facility and operations. The methods of compliance are the responsibility of the contractor. Questions on interpretation of any aspect of this Manual or recommendations for revisions by the contractor shall be submitted to the contractor's assigned Administrative Contracting Officer (ACO) for further review and processing. This Manual applies to the Office of the Secretary of Defense, Military Departments, Joint Chiefs of Staff and Joint Staff, Combatant Commands, and the Defense Agencies (hereafter referred to collectively as the DoD Components). This Manual is effective immediately, and is mandatory for use by all DoD Components specified in DoD Instruction 4145.26. Forward recommended changes to this Manual through appropriate channels to: Commander U.S. Army Industrial Operations Command ATTN: AMSIO-DMS Rock Island, IL 61299-6000 DoD Components may obtain copies of this Manual through their publications channels. This Manual is approved for public release, distribution unlimited. Authorized registered users may obtain copies from the Defense Technical Information Center, 8725 John J. Kingman Road, Suite 0944, Ft. Belvoir, VA 22060-6128. Other federal agencies and the public may obtain copies from the U.S. Department of Commerce, National Technical Information Service, 5285 Port Royal Rd, Springfield, VA 22161. R. Noel Longuemare Acting Under Secretary of Defense (Acquisition and Technology) TABLE OF CONTENTS Page FOREWORD2 Table of Contents3 Figures8 Tables9 References10 Definitions11 Glossary of Acronyms22 CHAPTER 1 - INTRODUCTION C1.1. Purpose24 C1.2. Applicability24 C1.3. Mandatory and Advisory Requirements24 C1.4. Responsibilities24 C1.5. Compliance with Mandatory Requirements25 C1.6. Site and Construction Plans25 C1.7. Pre-award Safety Survey27 C1.8. Pre-operational Survey28 CHAPTER 2 - MISHAP INVESTIGATION AND REPORTING C2.1. General29 C2.2. Reporting Criteria29 C2.3. Mishap Scene30 C2.4. Telephone Report30 C2.5. Written Report30 C2.6. On-site Government Assistance31 C2.7. Technical Mishap Investigation and Report31 CHAPTER 3 - SAFE PRACTICES C3.1. General32 C3.2. Personnel and Materials Limits32 C3.3. Standard Operating Procedures (SOPs)22 C3.4. Storage in Operating Buildings34 C3.5. Housekeeping in Hazardous Areas35 C3.6. Explosives Waste in Operating Areas36 C3.7. Procedure Before Electrical Storms37 TABLE OF CONTENTS Page C3.8. Explosives in Process During Shutdown37 C3.9. Maintenance and Repairs to Equipment and Buildings38 C3.10. Safety-hand Tools39 C3.11. Operational Shields39 C3.12. Special Clothing40 C3.13. Conductive Footwear41 C3.14. Materials Handling Equipment41 C3.15. Parking of Privately Owned Vehicles42 C3.16. Prohibited Articles in Hazardous Areas42 C3.17. Photographic Materials in Hazardous Areas42 C3.18. Operational Explosives Containers42 C3.19. Intraplant Rail Transportation43 C3.20. Intraplant Motor Vehicle Transportation45 C3.21. Inspection of Pyrotechnic, Propellant and Explosive Mixers46 CHAPTER 4 - PRINCIPLES AND APPLICATION OF Q/D, STANDARD EXPLOSIVES FACILITIES, AND SITING REQUIREMENTS C4.1. General48 C4.2. Quantity-distance (Q-D)48 C4.3. Establishment of Quantity of Explosives and Distances49 C4.4. Permissible Exposures to Blast Overpressure56 C4.5. Ammunition and Explosives Facilities59 C4.6. Specific Siting Requirements63 CHAPTER 5 - STORAGE COMPATIBILITY SYSTEM C5.1. General67 C5.2. Compatibility Groups (CGs)68 C5.3. Explosives Hazard Classification Procedures71 CHAPTER 6 - HAZARD CLASSIFICATION AND QUANTITY-DISTANCE (Q-D) CRITERIA C6.1. General73 C6.2. Hazard Classes and Class Divisions73 C6.3. Hazard Division 1.1 - Mass Detonating77 C6.4. Application of Intermagazine Distances for Hazard Division 1.1 Only77 C6.5. Hazard Division 1.2 - Nonmass-denotating, Fragment-producing80 C6.6. Hazard Division 1.3. - Mass Fire81 C6.7. Hazard Division 1.4 - Moderate Fire, No Blast81 C6.8. Hazard Division 1.5 and 1.681 TABLE OF CONTENTS Page C6.9. Airfields82 C6.10. Pier and Wharf Facilities83 CHAPTER 7 - LIQUID PROPELLANTS REQUIREMENTS C7.1. Application113 C7.2. Determination of Propellant Quantity113 C7.3. Measurement of Separation Distances113 C7.4. Q-D Considerations113 C7.5. Hazard Grouping114 C7.6. Hazards115 C7.7. Incompatible Storage116 C7.8. Compatible Storage116 CHAPTER 8 - MANUFACTURING AND PROCESSING PYROTECHNICS C8.1. General123 C8.2. Machinery, Equipment, and Facilities123 C8.3. Weighing of Raw Materials124 C8.4. Drying of Materials124 C8.5. Mixing and Blending124 C8.6. Pressing, Extruding, and Pelleting126 C8.7. Assembly Operations127 C8.8. Granulation, Grinding, and Screening127 C8.9. Transportation128 C8.10. Rebowling128 C8.11. Machining of Pyrotechnic Material128 C8.12. Spill Control130 C8.13. Collection of Pyrotechnic Wastes130 C8.14. Cleaning of Pyrotechnic Processing Equipment131 C8.15. Personal Protective Equipment131 C8.16. Additional Controls132 C8.17. Reworking Pyrotechnic Components132 C8.18. Fire Protection133 CHAPTER 9 - STORAGE OF EXPLOSIVES AND AMMUNITION C9.1. General134 C9.2. Storage Considerations134 C9.3. Magazine Operational Regulations134 C9.4. Stacking134 TABLE OF CONTENTS Page C9.5. Loose Rounds, Damaged Containers135 C9.6. Repairs to Magazines135 C9.7. Open Storage (Outdoors)136 C9.10. Storage of Bulk Initiating Explosives136 C9.11. Rockets and Rocket Motors136 CHAPTER 10 - FIRE PROTECTION C10.1. General137 C10.2. Fire Plan137 C10.3. Firefighting Agreements137 C10.4. Smoking137 C10.5. Hot Work Permits138 C10.6. Portable Fire Extinguishers138 C10.7. Hazards in Fighting Fires Involving Ammunition and Explosives138 C10.8. Automatic Sprinkler Systems140 C10.9. Clearance Under Sprinklers15 C10.10. Deluge Systems140 C10.11. Hazards in Fighting Fires Involving Liquid Propellants141 C10.12. Firebreaks141 CHAPTER 11 - PROCESS SAFETY MANAGEMENT C11.1. General142 CHAPTER 12 - SAFETY REQUIREMENTS FOR EXPLOSIVES FACILITIES C12.1. General143 C12.2. Requirements143 C12.3. Requirements for Buildings143 C12.4. Electrical Requirements147 C12.5. Lightning Protection149 C12.6. Static Electricity and Grounding149 CHAPTER 13 - SAFETY REQUIREMENTS FOR SPECIFIC EXPLOSIVES MATERIALS AND OPERATIONS C13.1. General153 C13.2. Properties of Explosives153 TABLE OF CONTENTS Page C13.3. Handling Low-Energy Initiators155 C13.4. Laboratory Operations156 C13.5. Electrical Testing of Ammunition and Ammunition Components158 C13.6. Heat-Conditioning of Explosives and Ammunition158 C13.7. Spray Painting160 C13.8. Drying Freshly Painted Loaded Ammunition161 C13.9. Rework, Disassembly, Renovation, and Maintenance161 C13.10. Munitions Loading and Associated Operations162 CHAPTER 14 - TESTING REQUIREMENTS C14.1. Program Requirements168 C14.2. Operating Precautions168 C14.3. Test Hazards169 C14.4. Test Clearance169 C14.5. Warning and Communication Systems169 C14.6. Specific Items for Test170 C14.7. Malfunctions170 C14.8. Ammunition and Dud Recovery171 C14.9. Personnel Shelters173 C14.10. Testing of Ammunition or Devices for Small Arms174 C14.11. Velocity and Pressure Tests175 C14.12. Primer Drop Tests175 CHAPTER 15 - COLLECTION AND DESTRUCTION REQUIREMENTS FOR AMMUNITION AND EXPLOSIVES C15.1. General185 C15.2. Protection During Disposal Operations185 C15.3. Collection of Ammunition and Explosives185 C15.4. Destruction Sites189 C15.5. Destruction by Burning192 C15.6. Destruction by Detonation193 C15.7. Destruction by Neutralization194 C15.8. Destruction Chambers and Incinerators194 C15.9. Support in Disposal of Waste195 CHAPTER 16 - MANUFACTURING AND PROCESSING PROPELLANTS C16.1. General196 C16.2. In-Process Hazards196 TABLE OF CONTENTS Page C16.3. Quantity-Distance (Q-D) Requirements197 C16.4. Separation of Operations and Buildings197 C16.5. Equipment and Facilities198 C16.6. In-Process Quantities and Storage200 C16.7. Ingredients Processing201 C16.8. Mixing202 C16.9. Casting and Curing205 C16.10. Extrusion Processes207 C16.11. Propellant Loaded Items207 C16.12. Disassembly208 CHAPTER 17 - HAZARDOUS COMPONENT SAFETY DATA STATEMENTS (HCSDS) C17.1. General210 C17.2. Purpose210 C17.3. Explanation of Terms210 C17.4. Application211 C17.5. HCSDS Data Entries211 APPENDIX 1 - BIBLIOGRAPHY222 FIGURES FigureTitle Page C4.F1.Determination of Barricade Height (Level Terrain) 60 C4.F2.Determination of Barricade Height (Sloping Terrain) 60 C4.F3.Determination of Barricade Length 61 C6.F1.Effects of Magazine Orientation on Q-D 99 C6.F2.Application of Separation Distances for Ship and Barge Units 110 C14.F1.Misfire of Machine Guns, Rifles, Pistols, and Other Automatic Weapons 176 C14.F2.Misfire of Automatic Guns, 20mm and Larger 177 C14.F3.Misfire of Fixed or Semi-Fixed Ammunition 178 C14.F4.Misfire Under Possible Cook-Off Conditions 179 C14.F5.Misfire of Lever- (Trigger-) Fired Mortar Ammunition 180 C14.F6.Misfire of Fixed Firing Pin- or Lever-Type (Set for Drop Fire) Mortar Ammunition 181 C14.F7.Misfire of Rockets 182 C14.F8.Misfire of Separate Loading Ammunition 183 C14.F9.Emplacement of Bombproofs at Firing Points 184 C17.F1.Hazardous Component Safety Data Statement (HCSDS), DD Form 2357 221 TABLES TableTitle Page C5.T1.Storage Compatibility Mixing Chart 72 C6.T1.Hazard Division 1.1 - Inhabited Building Distance and Public Traffic Route Distances 88 C6.T2.Hazard Division 1.1 - Intraline Distances 91 C6.T3.Hazard Division 1.1 - Intraline Distances from Earth-Covered Magazines 92 C6.T4.Hazard Division 1.1 - Intermagazine Hazard Factors and Distances 94 C6.T5.Hazard Division 1.1 - Fragment Hazard (Primary/Secondary) 97 C6.T6.Hazard Division 1.1 - Minimum Fragment Protection Distances for Selected Items 98 C6.T7.Category (04), Hazard Division 1.2 - Nonmass-Detonating, Fragment-Producing 100 C6.T8.Category (08), Hazard Division 1.2 - Nonmass-Detonating, Fragment-Producing 100 C6.T9.Category (12), Hazard Division 1.2 - Nonmass-Detonating, Fragment-Producing 101 C6.T10.Category (18), Hazard Division 1.2 - Nonmass-Detonating, Fragment-Producing 101 C6.T11.Hazard Division 1.3 - Mass Fire 102 C6.T12.Hazard Division 1.4 - Moderate Fire, No Blast 103 C6.T13.Hazard Division 1.6N and EIDS Components 104 C6.T14.Quantity-Distance Criteria for Hazard Division 1.6 Ammunition 105 C6.T15.Hazard Division 1.1 - Q-D Standards for Airfields 107 C6.T16.Application of Ammunition and Explosives Safety Distances 108 C6.T17.Q-D Separations for Pier and Wharf Facilities 111 C7.T1.Liquid Propellants Hazard and Compatibility Groupings 117 C7.T2.Quantity-Distance for Propellants 119 C7.T3.Liquid Propellant Explosives Equivalents 121 C7.T4.Distances for Separation of Propellant Static Testing, Launching, and Storage Sites From Other Facilities 122 C13.T1.Hazard Division 1.1 - Laboratories Q-D 167 C13.T2.Hazard Division 1.3 - Laboratories Q-D 167 C16.T1.Control and Personnel Protection Requirements for Certain Propellant Processing Operations 209 REFERENCES (a) MIL-STD 398, "Shields, Operational for Ammunition Operations, Criteria for Design of and Tests for Acceptance" (b) Title 14, Code of Federal Regulations, Part 77, "Federal Aviation Administration Regulation, Objects Affecting Navigable Airspace" (c) DoD Directive 6055.9, "DoD Explosives Safety Board (DDESB) and DoD Component Explosives Safety Responsibilities," July 29, 1996 (d) "Blue Book," Occupational Safety and Health Administration (OSHA) (e) TB 700-2, NAVSEA Instruction 8020.8, T011A-1-47, Defense Logistics Agency Regulation (DLAR) 8220.1, "Explosives Hazard Classification Procedures," December 1989, current edition (f) TM 5-1300, AFM 88-22, and NAVFAC P-397, "Structures to Resist the Effects of Accidental Explosions," November 1990 (g) Title 49, Code of Federal Regulations, Parts 100 through 199, "Transportation" (h) National Fire Protection Association 491M, "Hazardous Chemical Reactions," 1986 (i) National Fire Protection Association Standard No. 13, "Installation of Sprinkler Systems," 1989 (j) National Fire Protection Association Standard No. 15, "Water Spray Fixed Systems," 1985 (k) National Fire Protection Association Standard No. 70, "National Electric Code," 1989 (l) National Fire Protection Association Standard No. 78, "Lightning Protection Code," 1989 (m) National Fire Protection Association Standard No. 77, "Static Electricity," 1988 (n) National Fire Protection Association Standard No. 33, "Spray Application Using Flammable & Combustible Materials," 1989 (o) "Federal Aviation Administration Handbook" (p) Title 29, Code of Federal Regulations, Part 1910, "Occupational Safety and Health Standards" (q) Federal Standard (FED-STD-) 313, "Material Safety Data, Transportation Data and Disposal Data for Hazardous Materials Furnished to Government Activities" (r) Defense Federal Acquisition Regulation Supplement (DFARS) 252.223-7002, "Safety Precautions for Ammunition and Explosives" (s) Defense Federal Acquisition Regulation Supplement (DFARS) 252.223-7006, "Change in Place of Performance - Ammunition and Explosives" DL1. DEFINITIONS The following are descriptions of terms and phrases commonly used in conjunction with ammunition, explosives, and other dangerous materials. These are listed to provide a degree of uniformity of description in the use of technical information throughout these standards. DL1.1.1. Aboveground Magazines. Any type of magazines above ground other than standard or nonstandard earth-covered types of magazines. DL1.1.2. Administrative Area. The area in which administrative buildings that function for the installation as a whole are located, excluding those offices located near and directly serving components of explosives storage and operating areas. DL1.1.3. Aircraft Parking Area. Any area set aside for parking aircraft not containing explosives. DL1.1.4. Ammunition and Explosives. As used herein, includes (but is not necessarily limited to) all items of ammunition; propellants, liquid and solid; high explosives; guided missiles; warheads; devices; pyrotechnics; components thereof; and substances associated therewith presenting real or potential hazards to life and property. DL1.1.5. Ammunition and Explosives Aircraft Cargo Area. Any area specifically designated for the following: DL1.1.5.1. Aircraft loading or unloading of transportation-configured ammunition and explosives. DL1.1.5.2. Parking aircraft loaded with transportation-configured ammuntion and explosives. DL1.1.6. Ammunition and Explosives Area. An area specifically designated and set aside from other portions of an installation for the development, manufacture, testing, maintenance, storage, or handling of ammunition and explosives. DL1.1.7. Auxiliary Building. Any building accessory to or maintained and operated to serve an operating building, line, plant, or pier area. Explosive materials are not present in an auxiliary building (examples: power plants and change houses, paint and solvent lockers, and similar facilities). DL1.1.8. Barricade. An intervening barrier, natural or artificial, of such type, size, and construction as to limit in a prescribed manner the effect of an explosion on nearby buildings or exposures. DL1.1.9. Blast Impulse. The product of the overpressure from the blast wave of an explosion and the time during which it acts at a given point (that is, the area under the positive phase of the overpressure vs. time curve). DL1.1.10. Blast Overpressure. The pressure, exceeding the ambient pressure, manifested in the shock wave of an explosion. DL1.1.11. Change House. A building provided with facilities for employees to change to and from work clothes. Such buildings may be provided with sanitary facilities, drinking fountains, lockers, and eating facilities. DL1.1.12. Classification Yard. A railroad yard used for the receiving, dispatching, classifying, and switching of cars. DL1.1.13. Compatibility. Ammunition and explosives are considered compatible if they may be stored or transported together without significantly increasing either the probability of an accident or, for a given quantity, the magnitude of the effects of such an accident. DL1.1.14. Deflagration. A rapid chemical reaction in which the output of heat is sufficient to enable the reaction to proceed and be accelerated without input of heat from another source. Deflagration is a surface phenomenon with the reaction products flowing away from the unreacted material along the surface at subsonic velocity. The effect of a true deflagration under confinement is an explosion. Confinement of the reaction increases pressure, rate of reaction and temperature, and may cause transition into a detonation. DL1.1.15. Demilitarize. To disarm, neutalize, and accomplish any other action required to render ammunition and explosives innocuous or ineffectual for military use. DL1.1.16. Detonation. A violent chemical reaction within a chemical compound or mechanical mixture evolving heat and pressure. A detonation is a reaction that proceeds through the reacted material toward the unreacted material at a supersonic velocity. The result of the chemical reaction is exertion of extremely high pressure on the surrounding medium forming a propagating shock wave that is originally of supersonic velocity. A detonation, when the material is located on or near the surface of the ground, normally is characterized by a crater. DL1.1.17. Dud. Explosive munition that is not armed as intended, or that has failed to function after being armed. DL1.1.18. Establishment. Any plant, works, facility, installation, or other activity. DL1.1.19. Explosion. A chemical reaction of any chemical compound or mechanical mixture that, when initiated, undergoes a very rapid combustion or decomposition releasing large volumes of highly heated gases that exert pressure on the surrounding medium. Also, a mechanical reaction in which failure of the container causes the sudden release of pressure from within a pressure vessel; for example, pressure rupture of a steam boiler. Depending on the rate of energy release, an explosion can be categorized as a deflagration, a detonation, or a pressure rupture. DL1.1.20. Explosive. Any chemical compound or mechanical mixture that, when subjected to heat, impact, friction, detonation, or other suitable initiation, undergoes a very rapid chemical change with the evolution of large volumes of highly heated gases that exert pressures in the surrounding medium. The term applies to materials that either detonate or deflagrate. DL1.1.21. Explosives Facility. Any structure or location containing ammunition and explosives. DL1.1.22. Exposed Site (ES). A location exposed to the potential hazardous effects (blast, fragments, debris, and heat flux) from an explosion at a potential explosion site (PES). The distance to a PES and the level of protection required for an ES determine the quantity of ammunition or explosives permitted in a PES. DL1.1.23. Fire-Resistive. Applies to generally combustible materials or structures that have been treated or have surface coverings designed to retard ignition or fire spread. DL1.1.24. Firebrand. A projected burning or hot fragment from which thermal energy is transferred to a receptor. DL1.1.25. Firewall. A wall or fire-resistive construction designed to prevent the spread of fire from one side to the other. A firewall also may be termed a "fire division wall." DL1.1.26. Flame-Resistant. Applies to combustible materials, such as clothing, which have been treated or coated to decrease their burning characteristics. DL1.1.27. Flammable. Combustible. A flammable material is one that is ignited easily and burns readily. DL1.1.28. Fragmentation. Breaking up of the confining material of a chemical compound or mechanical mixture when an explosion takes place. Fragments may be complete items, subassemblies, pieces of equipment or building containing the items. DL1.1.29. Hangfire. Temporary failure or delay in the action of a primer, igniter, or propelling charge. DL1.1.30. Hazard Analysis. The logical, systematic examination of an item, process, condition, facility, or system to identify and analyze the probablility, causes, and consequences of potential or real hazards. DL1.1.31. High Explosive Equivalent or Explosive Equivalent. The ratio of the weight of TNT to that of another explosive when both quantities produce equivalent blast effects at the same distance from their detonations. The ratio is expressed as a percent. DL1.1.32. Holding Yard. A location for groups of rail cars, trucks, or trailers used to hold ammunition and explosives for interim periods before storage or shipment. DL1.1.33. Hypergolic. The term used to describe the self-ignition of certain fuels and oxidizers upon contact with each other. DL1.1.34. Inhabited Building Distance. The separation between potential explosive sites (PES) and non-associated exposed sites (ES) requiring a high degree of protection from an accidental explosion. Such exposed sites include facility boundaries, wholly inert administrative facilities, the public, etc. DL1.1.35. Inhabited Building. A building or structure, other than an operating building, occupied in whole or part by human beings; or a building or structure where people customarilyassemble, such as a church, schoolhouse, railroad station and similar transportation facilities, store, theater, or factory, inside or outside the establishment. DL1.1.36. Inspection Station. A designated location at which trucks and rail cars containing ammunition and explosives are inspected. DL1.1.37. Interchange Yard. An area set aside for the exchange of railroad cars or vehicles between the common carrier and establishment. DL1.1.38. Intraline Distance. The distance to be maintained between any two operating buildings and sites within an operating line, at least one of which contains or is designed to contain explosives. DL1.1.39. Launch Pads. The load-bearing base, apron, or platform upon which the rocket, missile, or space vehicle and its launcher are positioned. DL1.1.40. Liquid Propellant(s). Liquid and gaseous substances (fuels, oxidizers, or monopropellants) used for propulsion or operation of missiles, rockets, and related devices. DL1.1.41. Loading Docks. Facilities structure, or paved areas, designed and installed for transferring ammunition and explosives. DL1.1.42. Lunchrooms. Facilities where food is prepared or brought for distribution by food service personnel. It may serve more than one PES. A break room in an operating building may be used by personnel assigned to the PES to eat meals. DL1.1.43. Magazine. Any building or structure, except an operating building, used for the storage of ammunition and explosives. The types and general specifications of various magazines for ammunition and explosives follow: DL1.1.43.1. Reinforced concrete, arch-type, earth-covered magazines whose construction is at least equivalent in strength to the requirements of The Office of Chief Engineers (OCE), Department of the Army, drawings 652-693, December 27, 1941, as revised March 14, 1942, 33-15-06, 33-15-58 (atomic blast resistant), 33-15-61, and 33-15-74. For new construction use drawings 33-15-74.1 1 Copies available from U.S. Army, Chief of Engineers, Pulaski Building, 20 Massachusetts Avenue, NW, Washington, DC 20001. 2 Copies available from Commander, Naval Facilities Engineering Command, 200 Stovall Street, Alexandria, VA 22332-2300. DL1.1.43.2. Magazines constructed according to Navy drawings 357428 through 357430, August 9, 1944, and modified in accordance with NAVFAC drawing 626739, March 19, 1954; and NAVFAC drawings 627954 through 627957, 764597, 658384 through 658388, 724368, 751861, 764596, 793746, and 793747.2 DL1.1.43.3. Box-type A magazines constructed according to NAVFAC drawings 1404000 through 1404007; box-type B magazines constructed according to NAVFAC drawings 1404018 through 1404025; box-type C magazines constructed according to NAVFAC drawings 1404430 through 1404440, dated September 1985; box-type D magazines constructed according to NAVFAC drawings 1404464 through 1404478, dated 20 September 1985; box-type E magazines constructed according to NAVFAC drawings 1404523 through 1404535, dated 23 April 1987; and box-type F magazines constructed according to NAVFAC drawings 1404541 through 1404555, dated 23 April 1987. DL1.1.43.4. Earth-covered, corrugated steel, arch-type magazines at least equivalent in strength to those shown on Army OCE drawings numbered AW 33-15-63, March 5, 1963; AW 33-15-64, May 10, 1963; 33-15-65, January 10, 1963; and NAVFAC drawings numbered 1059128-30, 1059132, 1069906, and 1355460-61. OCE 33-15-73 (oval 1-ga steel arch) is no longer approved construction of large magazines of this type. Use the earth-covered steel, semi-circular-arch magazine design shown on Army OCE drawing number 421-80-01, and for new construction of smaller magazines of this type, use OCE drawing number AW 33-15-65 addressed above. DL1.1.44. Mass Detonating Explosives. High explosives, black powder, certain propellants, certain pyrotechnics, and other similar explosives, alone or in combination, or loaded into various types of ammunition or containers, most of which can be expected to explode virtually instantaneously when a small portion is subjected to fire, to severe concussion or impact, to the impulse of an initiating agent, or to the effect of a considerable discharge of energy from without. Such an explosive will normally cause severe structural damage to adjacent objects. Explosive propagation may occur immediately to other items of ammuntion and explosives stored sufficiently close to and not adequately protected from the initially exploding pile with a time interval short enough so that two or more quantities shall be considered as one for quantity-distance (Q-D) purposes. DL1.1.45. Maximum Credible Event (MCE). In hazards evaluation, the MCE from a hypothesized accidental explosion, fire, or agent release is the worst single event that is likely to occur from a given quantity and disposition of ammunition and explosives. Event shall be realistic with a reasonable probability of occurence, considering the explosion propagation, burning rate characteristics, and physical protection given to the items involved. The MCE evaluated on this basis may then be used as a basis for effects calculations and casualty predictions. DL1.1.46. Military Pyrotechnics. Ammunition manufactured specifically for use as signals, illuminants, and like items. DL1.1.47. Misfire. Failure of a component to fire or explode as intended. DL1.1.48. Navigable Streams. Those parts of streams, channels, or canals capable of being used as highways of commerce over which trade and travel are or may be conducted, excluding streams that are not navigable by barges, tugboats, and other large vessels, unless they are used extensively and regularly for the operation of pleasure boats. DL1.1.49. Net Explosive Weight (NEW). Net Explosive Weight, expressed in pounds. The TNT equivalence of the explosive material may be used where known. If TNT equivalence is not known then the total weight net exlosive weight must be used to express the NEW. DL1.1.50. Nitrogen Padding (or Blanket). Filling the void or ullage of a closed container with nitrogen gas to prevent oxidation of the chemical therein and to avoid formation of a flammable atmosphere above the liquid. Nitrogen padding (or blanket) also means maintaining a nitrogen atmosphere in or around an operation, piece of equipment, etc. DL1.1.51. Noncombustible. Not burnable. DL1.1.52. Operating Building. Any structure, except a magazine, in which operations pertaining to manufacturing, processing, handling, loading, or assembly of ammunition and explosives are performed. DL1.1.53. Operating line. A group of buildings, facilities, or related work stations so arranged as to permit performance of the consecutive steps in the manufacture of an explosive or in the loading, assembly, modification, and maintenance of ammunition. DL1.1.54. Operational Shield. A barrier constructed at a particular location or around a particular machine or operating station to protect personnel, material, or equipment from the effects of a possible localized fire or explosion. Operational shields, when designed in accordance with MIL-STD-398 (reference (a)) should protect personnel and assets from thermal, pressure, and fragmentation hazards resulting from an accidental or intentional detonation and deflagration of ammunition or explosives. Existing reinforced concrete walls built to resist the effects of accidental explosions and designed and built in accordance with requirements applicable at the time of construction may be used as operational shields, with the following guidance as a minimum requirement: DL1.1.54.1. A 12-inch reinforced cncrete wall (see definition "substantial dividing wall") provides adequate protection for operations involving an item containing 15 pounds TNT equivalent or less of high explosives when the nearest part of the item is at least 3 feet from the wall and the item is 2 feet from the floor. Care shall be taken to use appropriate equivalence data for close-in-effects. Explosives characterized by greater brisance than that of TNT may have very high equivalencies at small distances from the explosives. When equivalence data is not available, existing 12-inch reinforced cncrete walls may be used for operational shields for protection from items cntaining not more than 6 pounds of high explosives. DL1.1.54.2. A 30-inch reinforced concrete wall provides adequate protection against the effects of an item containing not more than 50 pounds TNT equivalent of high explosives. The same separation distance as stated in paragraph DL1.1.54.1., above, of this definition applies. When equivalence data is not available, a 30-inch wall may be used for an operational shield for protection from items containing not more than 20 pounds of high explosives. DL1.1.54.3. A 30-inch reinforced cncrete wall provides adequate protection against the effects of an item containing not more than 70 pounds TNT-equivalency of high explosives. The separation distance as stated in definition "operational shield," paragraph DL1.1.54.1., above, applies. When equivalence data is not available, a 36-inch wall may be used for an operational shield for protection from items containing not more than 28 pounds of high explosives. DL1.1.55. Potential Explosive Site (PES). The location of a quantity of explosives that will create a blast, fragment, thermal, or debris hazard in the event of an accidental explosion of its contents. Quantity limits for ammunition and explosives at a PES are determined by the distance to an ES. DL1.1.56. Prohibited Area. A specifically designated area at airfields, seadromes, or heliports in which all ammunition and explosives facilities are prohibited. DL1.1.57. Propellant. Explosives compositions used for propelling projectiles and rockets and to generate gases for powering auxiliary devices. DL1.1.58. Public Highway. Any street, road, or highway used by the general public for any type of vehicular travel. DL1.1.59. Public Traffic Route. Any public street, road (including any on an establishment or military reservation), highway, navigable stream, or passenger railroad that is routinely used for through traffic by the general public. DL1.1.60. Pyrotechnic Material. The explosive or chemical ingredients, including powdered metals, used in the manufacture of military pyrotechnics. DL1.1.61. Quantity-Distance (Q-D). The quantity of explosives material and distance separation relationships providing defined types of protection. These relationships are based on levels of risk considered acceptable for the stipulated exposures and are tabulated in the appropriate Q-D tables. Separation distances afford less than absolute safety. DL1.1.62. Renovation. That work performed on ammunition, missiles, or rockets to restore them to a completely serviceable condition; usually involves the replacement of unserviceable or outmoded parts. DL1.1.63. Restricted Area. Any area, normally fenced, from which personnel, aircraft, or vehicles, other than those required for operations, are excluded for reasons of safety. DL1.1.64. Runway. Any surface on land designated for aircraft takeoff and landing operations, or a lane of water designated for takeoff and landing operations of seaplanes. DL1.1.65. Service Magazine. A building in an operating line used for the intermediate storage of explosives materials. The amount of explosives normally is limited to a minimum consistent with safe, efficient production. DL1.1.66. Standard Earth-Covered Magazine (Igloo). An earth-covered, arch-type magazine, with or without a separate door barricade, constructed according to an approved standard drawing. These magazines are approved for all quantities of explosives up to 5000,000 lbs (226,798 kg) net explosive weight. DL1.1.67. Static Test Stand. Locations whereon liquid propellant engines or solid propellant motors are tested in place. DL1.1.68. Substantial Dividing Wall. An interior wall designed to prevent simultaneous detonation of explosives on opposite sides of the wall. However, such walls may not prevent propagation (depending on quantities and types of explosives involved). DL1.1.68.1. Substantial dividing walls are one way of separating explosives into small groups to minimize the results of an explosion and allow a reduction in Q-D. These walls do not protect personnel near the wall from high explosives because the spalling of wall surface opposite the explosion source may form dangerous secondary fragments. DL1.1.68.2. Reinforced concrete-type walls may vary in thickness, but shall be at least 12 inches thick. At a minimum, both faces shall be reinforced with rods at least 1/2 inch in diameter. The rods shall be spaced not more than 12 inches on centers horizontally and vertically, interlocked with the footing rods and secured to prevent overturning. Rods on one face shall be staggered with regard to rods on the opposite face and should be approximately 2 inches from each face. Concrete should have a design compressive strength of 2,500 psi or more. The capability to prevent simultaneous detonation is based on a limit of 425 net pounds of mass-detonating explosives. All storage plans and Q-D calculations shall be based on the total quantity of mass-detonating explosives on both sides of a dividing wall when the quantity of either side exceeds 425 pounds. Explosives should be 3 feet or more from the wall. DL1.1.68.3. Retaining walls filled with earth and sand shall be at least 5 feet wide, with earth or sand packed between concrete, masonry, or wooden retaining walls. DL1.1.69. Suspect Vehicle and Rail Car Site. A designated location for placing trucks and rail cars containing ammuntion or explosives that are suspected of being in hazardous condition. These sites also are used for trucks and rail cars that may be in a condition that is hazardous to their contents. DL1.1.70. Taxiway/Taxilane. Any surface designated as such in the basic airfield clearance criteria specified by Title 14, Code of Federal Regulations, Part 77, current edition (reference (b)).3 3 Copies may be obtained from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. DL1.1.71. Unit Risk. The risk to personnel and/or facilities that is associated with debris, fragment and/or blast hazards that is the result of the detonation of a single round of ammunition. DL1.1.72. Waiver. Written authority that provides a temporary exception, permitting deviation from mandatory requirements of this Manual. It generally is granted for short periods of time pending cancellation as a result of termination of scheduled work commitments or correction of the waived conditions. AL1. GLOSSARY OF ACRONYMS AL1.1. A&E ammunition and explosives AL1.2. ACO administative contracting officer AL1.3. AIT auto-ignition temperature AL1.4. CBU cluster bomb unit AL1.5. CFR Code of Federal Regulations AL1.6. COCO contractor-owned, contractor-operated AL1.7. DFARS Defense Federal Acquisition Regulation Supplement AL1.8. DNT dinitrotoluene AL1.9. DoD Department of Defense AL1.10. DODIC Department of Defense Identification Code AL1.11. DOT Department of Transportation AL1.12. DTA differential thermal analysis AL1.13. EIDS extremely insensitive detonating substances AL1.14. ES exposed site AL1.15. FAA Fedral Aviation Administration AL1.16. FAE fuel air explosive AL1.17. FAR Federal Acquisition Regulation AL1.18. H/D hazard division AL1.19. HC hexachloroethane AL1.20. HCSDS Hazardous Component Safety Data Statement AL1.21. HE high explosive AL1.22. IBD inhabited building distance AL1.23. ILD intraline distance AL1.24. IMD intermagazine distance AL1.25. IMO International Maritime Organization AL1.26. IR Infrared AL1.27. JHCS Joint Hazard Classification System AL1.28. LP liquified petroleum AL1.29. MCE maximum credible event AL1.30. MILVANS military vans/tractor vans (i.e., 8'x8'x20' container) AL1.31. MK Mark AL1.32. MOD Model AL1.33. NATO North Atlantic Treaty Organization AL1.34. NAVFAC Naval Facilities Engineering Command AL1.35. NEC National Electric Code AL1.36. NEW net explosive weight AL1.37. NFPA National Fire Protection Association AL1.38. NIOSH National Institute for Occupational Safety and Health AL1.39. NSN national stock number AL1.40. OCE Office of Chief of Engineers AL1.41. OSHA Occupational Safety and Health Administration AL1.42. PCO procuring contracting officer AL1.43. PES potential explosive site AL1.44. PETN pentaerythritol tetranitrate AL1.45. POPO privately owned-privately operated AL1.46. PSI pounds per square inch AL1.47. PSIG pounds per square inch gauge AL1.48. PTR public traffic route AL1.49. PWP plasticized white phosphorous AL1.50. Q-D quantity-distance AL1.51. RDX dyclorotrimethylenetrinitramine (cyclonite) AL1.52. RF radio frequency AL1.53. SCG storage compatibility group AL1.54. SOP standard operating procedure AL1.55. TDP technical data package AL1.56. TEA triethylaluminum AL1.57. TNT trinitrotoluene AL1.58. TP target practice AL1.59. TPA thickened TEA AL1.60. UL Underwriters' Laboratories AL1.61. UN United Nations AL1.62. UNO United Nations Organization AL1.63. UV ultraviolet AL1.64. WP white phosphorus C1. CHAPTER 1 INTRODUCTION C1.1. Purpose This Manual provides reasonable, standardized safety principles, methods, practices, requirements, and information for contractual work or services involving ammunition and explosives (A&E). Understanding and compliance with the applicable requirements of this Manual and additional safety requirements of the contract, if any, are intended to minimize the potential for mishaps that could interrupt Department of Defense (DoD) operations or delay production, damage or destroy DoD material, cause injury to DoD personnel, or endanger the general public. Adherence to the Manual's requirements and principles are intended to support DoD mission, provide a safe environment, and foster cooperation between contractor and DoD personnel. C1.2. Applicability The requirements of this Manual apply to contractors performing work or services on DoD contracts, subcontracts, purchase orders, or other purchasing methods for ammunition or explosives. These requirements also apply to other contractor operations to the extent they impact DoD work or services. C1.3. Mandatory and Advisory Requirement The term "shall" is used in this Manual to indicate mandatory requirements. Waivers to these requirements may be authorized by the procuring contracting officer (PCO) as explained in subsections C1.5.1. and C1.5.2. The terms "should" and "may" are advisory. When advisory provisions are not met, adverse consequences could develop, becoming proximate causes of A&E mishaps. C1.4. Responsibilities The contractor shall: C1.4.1. Comply with the requirements of this Manual and any other safety requirements contained within the contract; C1.4.2. Develop and implement a demonstrable safety program, including operational procedures, intended to prevent A&E-related mishaps; C1.4.3. Designate qualified individuals to administer and implement this safety program; C1.4.4. Provide information to the administrative contracting officer (ACO) pertaining to subcontractors retained for A&E work; C1.4.5. Require A&E subcontractors to comply with C1.4.1. through C1.4.3., above; and C1.4.6. Conduct mishap investigations in accordance with, but not limited to, provisions of this Manual. C1.5. Compliance with mandatory requirements C1.5.1. During pre-award safety surveys, violations of mandatory requirements contained in this Manual shall be resolved. The contractor may choose to correct the deficiencies immediately, submit a written letter of intent to correct the deficiencies (which will become binding if awarded the contract), or request acceptance of specifically identified existing conditions or facilities by the purchasing activity. C1.5.2. When the contractor cannot comply with the mandatory safety provisions of the contract, the contractor shall develop and submit a request for a waiver through the ACO to the PCO for final determination. The request shall contain complete information concerning the requirements violated, actions planned to minimize the hazard, and a proposed date for correction of the deficiency. C1.6. Site and Construction Plans C1.6.1. Development and submission of site plans, modifications, construction, and utility drawings pertaining to DoD-owned facilities shall be processed in accordance with the requirements of DoD Directive 6055.9 (reference (c)),1 as implemented by the applicable Military Service requirements. 1 Copies may be obtained, at cost, from the National Technical Information Service, U.S. Department of Commerce, 5285 Port Royal Road, Springfield, VA 22161. C1.6.2. For contractor-owned, contractor-operated (COCO) facilities, the contractor shall submit, through the ACO to the PCO, site and construction plans for all new construction or major modification of facilities for A&E activities and for the facilities that may be exposed to A&E hazards if improperly located. The contractor shall provide sufficient copies for the review process. The contractor shall not begin construction or modification of proposed facilities until receiving site and construction plan acceptance from the PCO through the ACO. C1.6.3. Modification or rehabilitation plans for existing facilities that are essentially minor, introduce no new hazards, and do not increase the net explosive capacity for which the facility was designed or sited, need not be submitted. The ACO shall make the final determination as to whether a site plan is necessary. C1.6.4. Site plans shall comply with the following specifications: C1.6.4.1. Drawings shall be drawn to a scale of 1 inch to 400 feet or less. Other-scale drawings may sometimes be necessary to reflect certain distance and structure relationships within the area surrounding a given project. In such instances, changes in scale are acceptable. C1.6.4.2. Drawings shall identify distances between the facility or location proposed for siting and other establishment facilities, the establishment boundary, public railways and highways, power transmission and other utility lines. C1.6.4.3. All other facilities within the inhabited building distance (IBD) of the proposed facility shall be identified by a brief description of their function and occupancy. C1.6.4.4. A&E items or energetic materials to be stored or processed in the facilities shall be described. This includes items such as bombs, rockets, artillery ammunition, liquid propellants, or other items regulated by this Manual. C1.6.4.5. Site plans shall provide the net explosives weight (NEW), number of units and hazard class(es) of ammunition, explosives, liquid and solid propellants and other hazardous materials for the proposed facility, including a breakdown by room or bay. C1.6.4.6. Site plans shall provide the NEW, number of units and hazard class(es) of ammunition, explosives, liquid and solid propellants and other hazardous materials stored or handled in facilities located within inhabited distance of the proposed facility. C1.6.4.7. All facilities whose inhabited building distance arcs include the facility under consideration shall be identified. C1.6.4.8. Site plans shall provide a topographical map with appropriate contours when terrain features are considered to constitute natural barricading, or when topography otherwise influences the layout. C1.6.5. Construction plans for the proposed facility shall contain the information in paragraphs C1.6.4.1. through C1.6.4.8., above, and the following: C1.6.5.1. Show the personnel limits for the new or modified facility, including a breakdown by room or bay, when appropriate. C1.6.5.2. Give general details regarding dividing walls, vent walls, firewalls, roofs, operational shields, barricades, exits, types of floor finish, fire protection system installations, electrical systems and equipment, ventilation systems and equipment, A&E waste disposal systems, lightning protection systems, static grounding systems, process equipment, and auxiliary support structures, as well as general materials of construction. C1.6.5.3. Include information relative to the types and arrangement of explosive operations or chemical processing equipment. C1.6.5.4. Explain any deviations from pertinent safety requirements due to local conditions. C1.7. Pre-award Safety Survey C1.7.1. When A&E materials and operations are involved in a solicitation, mishaps could adversely affect production capability, assets or schedules essential to DoD program milestones. Therefore, the contractor's capability and preparedness shall be evaluated. Pre-award safety surveys shall be conducted by DoD safety personnel. C1.7.2. During the pre-award safety survey, the contractor, as a minimum, shall provide the following for review: C1.7.2.1. Site plans conforming to the requirements of paragraphs C1.6.4.1. through C1.6.4.8., above; C1.7.2.2. Safety program, organization, and training; C1.7.2.3. Fire prevention program and available firefighting resources, including local agreements or other documentation demonstrating coordination; C1.7.2.4. Description of facilities, including size, construction design and materials, fire resistive capability, utilities, and current compliance with existing building regulations and codes; C1.7.2.5. Operational compliance with applicable Federal, State, and local requirements; C1.7.2.6. Required licenses or capability to obtain those required to perform proposed contract work; C1.7.2.7. Past safety history, including reports of safety surveys by Federal, State, or local safety, fire prevention, insurance, or other authorities; current status of waivers or exemptions issued by Federal, State, or local authorities; and mishap experience; C1.7.2.8. A&E collection and disposal systems and procedures (the contractor may wish to request specific clarification of A&E residue/reject item disposition at this time.); and C1.7.2.9. Hazard analysis, as appropriate. C1.8. Pre-operational Survey After contract award, a significant mishap or completion of new construction or major modifications, DoD review and evaluation of the facilities and operations may be necessary before startup of production or services. The contractor shall contact the ACO to offer an opportunity for a pre-operational review by authorized DoD personnel. C2. CHAPTER 2 MISHAP INVESTIGATION AND REPORTING C2.1. General This chapter sets forth requirements to be followed for mishaps involving ammunition and explosives. C2.2. Reporting Criteria All mishaps involving ammunition and explosives that result in one or more of the following shall be investigated by the contractor and reported to the ACO. C2.2.1. One or more fatalities; C2.2.2. One or more lost-workday cases (Refer to the Occupational Safety and Health Administration (OSHA) Blue Book lost-workday injury case guidelines.) (reference (d));2 C2.2.3. Ten or more nonfatal injuries without lost workdays (reference (d)); C2.2.4. Damage to Government property exceeding $10,000; C2.2.5. Delay in delivery schedule exceeding 24 hours (This requirement is not to be construed as a waiver of any delivery schedules mandated by the contract.); C2.2.6. Mishaps that are reportable in accordance with specific contractual requirements other than C2.2.1. through C2.2.5., above; or C2.2.7. Any mishap that may degrade operational or production capability or is likely to arouse unusual media interest because of exceptional circumstances. NOTE: Based upon the seriousness of the mishap and the criticality of the munitions or explosives involved, the ACO may determine that an additional, more comprehensive mishap investigation and report is desired. 2 Copies may be obtained from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. C2.3. Mishap Scene In the event of an ammunition or explosives mishap, the contractor shall implement emergency procedures, such as controlling the spread of fire and attending to the injured. The contractor shall also secure the scene of the mishap, preventing unauthorized persons from entering the area in order to preserve evidence for an investigation. C2.4. Telephone Report The contractor shall report any mishap described in section C2.2., above, by telephone to the ACO as soon as practicable, but not later than 3 hours after the incident. The format provided for the written report, section C2.5., below, will serve as a guide for the telephone report. C2.5. Written Report C2.5.1. The contractor shall submit to the ACO a written mishap report by the end of the second working day after the mishap occurrence. At a minimum, this written report shall include the following: C2.5.1.1. Contractor's name and location; C2.5.1.2. Date, local time, and plant/facility location of the accident; C2.5.1.3. Category of accident (explosion, fire, and so forth); C2.5.1.4. Contract, subcontract, or purchase order; C2.5.1.5. Item nomenclature, hazard classification, lot number; C2.5.1.6. Narrative (or abstract) of events pertaining to the mishap; C2.5.1.7. Number of injuries/fatalities, degree of injuries; C2.5.1.8. Description of property damage and approximate damage cost; C2.5.1.9. Quantity of explosives involved (pounds, units, rounds); C2.5.1.10. Probable cause(s); C2.5.1.11. Corrective action taken or planned; C2.5.1.12. Effect on production; C2.5.1.13. Name, title or position, and phone number of person submitting report; and C2.5.1.14. Remarks. C2.5.2. Follow-up information to the initial written report shall be provided to the ACO within 30 days of the mishap. C2.6. On-site Government Assistance To help determine the cause or causes of the mishap, DoD representatives may monitor the contractor's on-site mishap investigation. Additional investigation or reporting may be required by the PCO. C2.7. Technical Mishap Investigation and Report If determined by the PCO, a technical mishap investigation may be conducted by a panel chaired by DoD personnel. Otherwise, the contractor will conduct the investigation at the PCO's request. In either case, a document will be produced that provides details such as missile fragmentation maps, photographs, description of mishap, effects on adjacent operations, structural and equipment damage, quantity-distance (Q-D) drawings, detailed description of occurrence, findings, and conclusions. The technical mishap investigation report shall be forwarded to the PCO through the ACO within 60 days of the official establishment of the investigative panel or, in the case of the contractor's investigation, from the date of the accident. The contractor will be informed immediately upon determination that the Department of Defense will form a panel to go on-site for an accident investigation. C3. CHAPTER 3 SAFE PRACTICES C3.1. General This chapter provides general safe practices for all A&E operations addressed in this Manual. When these practices exceed or differ from local or national codes or requirements, the more restrictive shall apply. C3.2. Personnel and Materials Limits C3.2.1. The cardinal rule to be observed in any location or operation involving explosives, ammunition, severe fire hazards, or toxic materials is to limit exposure to a minimum number of personnel, for a minimum amount of time, to the minimum amount of the hazardous material consistent with safe and efficient operations. All operations shall be examined to devise methods for reducing the number of people exposed, the time of exposure, and the quantity of material subject to a single incident. Determination of personnel limits requires that jobs not essential to a particular hazardous operation be performed elsewhere; that no unnecessary personnel visit the location; and that frequent, consecutive operations not be permitted in the same room or building without adequate dividing walls, firewalls, or operational shields, depending upon the nature of the hazard. Personnel limits should allow for necessary supervision, workers, and transient workers. C3.2.2. Determination of limits for hazardous materials requires a careful analysis of all facts including normal operation times, intraplant transportation methods, size of the items, and the chemical and physical characteristics of the material. Lower limits are required for more sensitive or hazardous materials. Ensure no worker exceeds the established limit. Limits need not be expressed in units of weight or in the number of items. They may be given in terms of trays, boxes, racks, or other units more easily observed and controlled. Limits shall not be based on the maximum quantity of explosives allowed by the existing Q-D separations when lesser quantities of explosives will suffice for the operations. C3.2.3. The maximum number of personnel and quantity of explosives permitted at any one time shall be prominently displayed in all buildings, cubicles, cells, and rooms containing A&E. These limits shall be kept current, and enforced by the supervisor, foreman, or worker in charge. The personnel and explosives limits for all operations shall be recorded in the applicable standard operating procedure (SOP). Personnel limits need not be posted in storage magazines, magazine areas, or transfer points. Explosives limits need only be posted in storage magazines for which the limit differs from that for other magazines in the block, or when unusual circumstances prevent the limit from being readily apparent. C3.3. Standard Operating Procedures (SOPs) Before starting any operation involving hazardous materials, qualified personnel shall develop, review, and approve written procedures. The procedures shall be clearly written to avoid confusion and ensure process control at all times. C3.3.1. Preparation. All aspects of an SOP shall be examined to determine a safe and orderly course of action for accomplishing the work. Controlled tests may be necessary in order to establish SOPs for certain operations. The SOPs shall include, at a minimum, such items as safety requirements; specific emergency SOPs; personal protective clothing and equipment; personnel and explosives limits for each operation; equipment designation; location and sequence of operations; the particulars regarding how, when, where, and by whom each task of the operation shall be performed; and spill cleanup. C3.3.2. Dissemination. Supervisors shall be responsible for explaining duties prescribed by the SOP to all personnel involved in an A&E operation. C3.3.3. Posting. Those portions of the SOPs necessary to facilitate operations shall be posted in a spot convenient to all workers at stations involved in the operation. SOPs do not have to be posted at work stations if their presence could distract workers and cause and accident. Supervisory personnel shall be responsible for enforcing provisions in the SOP; and should maintain copies of the entire document. C3.3.4. Emergency Procedures. Action to be taken in the event of electrical storms, utility or mechanical failures and the like, occurring during the manufacturing, handling, or processing of A&E and other hazardous materials, shall be set forth in the SOPs as described in the preceding paragraphs, or shall be set forth in separate SOPs prepared specifically for such purposes. C3.3.5. Recertification. SOPs shall be reviewed on a regular basis by qualified personnel, changed and recertified by the managing authority as often as necessary to reflect improved methods, equipment substitutions, facility modification, or process revisions. C3.3.6. Training. Operator training shall cover SOPs, hazardous materials information, safety and warning devices, personal protective clothing and equipment, and emergency equipment. Operator training shall be documented as having been conducted. C3.4. Storage in Operating Buildings C3.4.1. Only those quantities of hazardous materials (excluding explosives, propellant and pyrotechnic materials) essential for current operations shall be stored within an operating building. Explosive materials exceeding work requirements shall be stored in a separate service magazine area located at the appropriate intraline distance from the operating building or area, based on the quantity of explosives stored in the service magazine. C3.4.2. If storage is required by operational necessity, and intraline distance is not available for a separate storage magazine, contractors may designate in-process holding containers or structures within the operating building, provided the following apply: C3.4.2.1. Those containers or structures would preclude propagation from the operational location to the holding site if an explosives mishap should occur at the operational site. C3.4.2.2. Consideration is given to the structural containment afforded, venting, and the use of non-propagating packaging within the temporary holding site. C3.4.2.3. Quantities of A&E in these holding sites are kept as low as possible, not exceeding amounts required for one half of a work shift. C3.4.2.4. Procedures have been developed to minimize exposure during transfer operations. C3.4.2.5. Plant managers review documented test results that confirm non-propagation characteristics. C3.4.3. If operationally required, A&E that are a part of the work in process within the building may be stored in operating buildings during non-operational hours, providing the following requirements are strictly observed: C3.4.3.1. Explosives limits are not exceeded. C3.4.3.2. Containers of bulk explosives or propellants are secured and covered. C3.4.3.3. Processing equipment, such as powder hoppers and pipelines, is empty. C3.4.4. Before an operation in a building shuts down for longer than a weekend or normal holiday period, all hazardous materials should be processed through the facility. If this is not possible, as much of the in-process material as possible should be processed and transferred to an approved storage area before shutdown; no new material should be introduced. The additional precautions listed in subsection C3.4.3., above, shall apply. All supervisory personnel at A&E sites shall be familiar with these conditions for weekend and holiday storage and shall ensure that workers comply with them. C3.5. Housekeeping in Hazardous Areas C3.5.1. Structures containing explosives shall be kept clean and orderly. C3.5.2. Explosives and explosives dusts shall not accumulate on structural members, radiators, heating coils, steam, gas, air or water supply pipes, or electrical fixtures. C3.5.3. Spillage of explosives and other hazardous materials shall be prevented by proper design of equipment, training of employees, and other provisions such as catch pans. For example, hoppers should be large enough to comfortably accommodate the size of charges used. A painted stripe on the inside of the hopper may serve as a reminder of the proper filling height. Catch pans or splash pans should be provided beneath draw-off pipes and trinitrotoluene (TNT) flakers, around transfer piping, and beneath powder bags on small arms ammunition charging machines, and so forth. Spillage shall be promptly removed. C3.5.4. A regular program of cleaning shall be conducted to maintain safe conditions. General cleaning shall not be conducted while hazardous operations are being performed. C3.5.5. Hot water, steam or other cleaning methods that do not create ignition hazards for the material being removed shall be used for cleaning floors in buildings containing explosives. When these methods are impractical, sweeping compounds that are nonabrasive and compatible with the explosives involved may be used. Such compounds may be combustible, but not volatile (closed cup flash point shall not be less than 230°F). Sweeping compounds containing wax shall not be used on conductive flooring. Because nitrated organic explosives can form sensitive explosive compounds with caustic alkalies, cleaning agents containing such alkalies shall not be used around them. C3.5.6. Nonferrous wire brushes may be used in cleaning explosives-processing equipment only when other methods of cleaning are ineffective; a thorough inspection should follow such cleaning to ensure that no wire bristles remain in the equipment. This applies also to cleaning magnesium ingot molds and molds for any other metal used in an explosive. Substituting fiber brushes for hair brushes is recommended to reduce generation of static. C3.5.7. All loose explosives swept up from floors of operating buildings shall be destroyed. Explosives recovered from sources other than ammunition breakdown operations and equipment shall be thoroughly inspected to determine disposition. It may be reused, screened, reprocessed, or destroyed, as the situation warrants. C3.6. Explosives Waste in Operating Areas C3.6.1. At this writing, the Environmental Protection Agency (EPA) is developing regulations which will also apply to each contractor and may impose requirements beyond those in this Manual. Explosive safety should not be compromised while meeting environmental considerations. C3.6.2. All waste material generated in an explosives area shall require analysis to determine appropriate methods for safe handling and disposition. All explosives waste and contaminated materials shall be kept in covered containers marked to indicate their contents, preferably located in isolated bays or outside the buildings. C3.6.3. Containers for scrap black powder and smokeless powders shall contain water. Certain pyrotechnic, tracer, flare and similar compositions shall be totally immersed in mineral oil or fuel oil in the waste containers. Waste initiating explosives shall be kept to a minimum, usually under water or other selected media, and shall be handled with great care. Explosives waste materials should not be left in operating buildings overnight during normal periods of shutdown or over weekends and holidays. C3.6.4. Workers shall transport explosives wastes in designated vehicles (see section C3.20.) to storage locations specifically assigned for that purpose. Explosives waste shall not be stored with serviceable explosives. A minimum of magazine distance shall be maintained between locations where explosives wastes are stored and those used for serviceable A&E. C3.7. Procedure Before Electrical Storms C3.7.1. When an electrical storm approaches, all personnel shall evacuate locations where lightning could initiate explosions. Such locations include: C3.7.1.1. Operating buildings or facilities containing explosives or explosives-loaded ammunition, not equipped with lightning protection systems, and locations within unbarricaded intraline distance of such facilities; C3.7.1.2. Buildings containing explosives dust or vapors, whether or not equipped with lightning protection systems, and locations within unbarricaded intraline distance of such buildings; C3.7.1.3. Magazines, open storage sites, or loading docks, not equipped with lightning protection systems; and C3.7.1.4. Locations, with or without lightning protection, where operations involving unprotected electro-explosive devices or circuitry are being performed. C3.7.2. Qualified supervisory personnel in authority should make final decisions about evacuation. When special warning is required for shutdown, volunteer observers or a lightning detection system may be used. C3.7.3. All personnel shall evacuate to locations identified in the SOP. These locations shall be at unbarricaded intraline distance or greater, or in a shelter providing equivalent protection. C3.8. Explosives in Process During Shutdown When electrical storms cause evacuation of explosives buildings, operations requiring constant attention shall be manned by the minimum number of personnel consistent with safety requirements. Once the process has reached a condition that can be left safely, the building shall be completely evacuated. Explosives processes requiring constant attention should not be started when an electrical storm threatens. C3.9. Maintenance and Repairs to Equipment and Buildings C3.9.1. All new or newly repaired explosives processing equipment shall be examined and tested to ensure that it is in safe working condition before being placed in service. C3.9.2. Before repairs can proceed on equipment exposed to explosives, a decontamination tag, signed by supervisory personnel, shall be placed on the equipment. The tag shall certify all explosives have been removed from the equipment or identify parts that could not be cleaned, and shall provide maintenance personnel with instructions on safe handling. C3.9.3. Major repairs or changes shall not be undertaken in a building during regular operations until the hazardous material has been removed and the employee in charge of the building informed. C3.9.4. Repairs cannot start in an explosives location until all explosives have been removed from equipment, crevices, vents and dust or fume collection systems, areas beneath floors, within walls and pipes, and under fittings where explosives could be ignited. The entire area should be wetted or washed down thoroughly. An inspection of the immediate vicinity shall assure no explosives remain. C3.9.5. After repairing, maintaining or adjusting machines and equipment, an inspection shall be made to assure all tools used for the work are removed. Before work resumes, operators should check their own equipment to ensure its safe operating condition. C3.9.6. Electricians shall not wear conductive shoes while working on electrical equipment. Exposed explosives and other static-sensitive hazardous material shall be removed before work begins. C3.9.7. Safe practices specified elsewhere in this Manual shall also apply to maintenance employees. C3.9.8. Maintenance and tool rooms in an operating line should be separated from explosives by intraline distance. Protection equivalent to that afforded by a suitable barrier shall be provided when this proves impractical. C3.10. Safety Hand Tools C3.10.1. Hand tools constructed of wood or non-sparking metals such as bronze, lead, and "K" Monel shall be used for work in locations that contain exposed explosives or hazardous concentrations of flammable dusts, gases, or vapors. The nonferrous metals used in so-called non-sparking tools may produce sparks. C3.10.2. If their strength makes the use of ferrous metal hand tools necessary, exposed explosives and other highly combustible materials shall be removed from the area as required in subsections C3.9.2. through C3.9.4., above. C3.11. Operational Shields C3.11.1. The purpose of operational shields is to prevent propagation of explosions from one explosives operation or location to another, to protect facilities and equipment and to provide personnel protection. Therefore, all A&E operations and processes shall be assessed prior to work performance to determine the type of hazard involved, the level of risk associated with the A&E material or item, and the corresponding level of protection normally provided. C.3.11.2. The primary hazards that accompany explosions and deflagrations are potential blast overpressure, fragmentation (primary and secondary) and thermal effects. These hazards and the following factors shall be considered, as a minimum, during the assessment specified in C3.11.1.: C3.11.2.1. Initiation sensitivity, C3.11.2.2. Potential ignition sources, C3.11.2.3. Quantity of A&E, C3.11.2.4. Rate of burning, C3.11.2.5. A&E and personnel resource exposures, and C3.11.2.6. Protection capabilities of shields. C3.11.3. When analysis of these factors indicates an unacceptable probability of explosion or deflagration, additional resources shall be provided for personnel and equipment. If operational shields are selected for this purpose, they shall be tested prior to installation to assure compliance with the following criteria: C3.11.3.1. Prevent propagation due to blast overpressure. C3.11.3.2. Contain all fragmentation or direct fragments (primary and secondary) away from areas requiring protection. C3.11.3.3. Contain thermal effects to prevent propagation. C3.11.4. Operational shields shall be tested under conditions that simulate the operational environment. A&E materials or items used in the test shall correspond to those that may be involved in a maximum credible event (MCE), plus a 25 percent overcharge. Test methods, recording instrumentation and written documentation shall clearly demonstrate that the above protection criteria are met before the operational shield is used. Shields meeting the requirements of MIL-STD-398, (reference (a)), are acceptable. Analysis rather than testing of shields may be acceptable on a case-by-case basis. When the doors of explosives processing equipment function as operational shields, interlocking devices shall be installed to prevent the operator from opening the door while the equipment is in operation. C3.12. Special Clothing C3.12.1. A changing area shall be established for employees who must remove their street clothes to wear special clothing (explosives plant clothing, anti-contamination clothing, impervious clothing, and so forth). To avoid exposing people not involved in A&E operations to unnecessary risks, special clothing worn during A&E operations shall not be worn or taken away from the premises. Special clothing should not be altered. Cotton undergarments, including socks, shall be worn whenever static electricity is a hazard. C3.12.2. Explosives plant clothing, generally referred to as powder uniforms, shall be fastened with nonmetallic fasteners and easily removable. Pockets should be of the lattice type. Pants and sleeves should be tapered and without cuffs, and pants should extend over the tops of footwear. These garments should be flame resistant or made of flame retardant material. Each plant should have laundering facilities available for removing contaminants from explosives plant clothing. Hazardous waste procedures should be established for the laundry. Regular testing shall verify the effectiveness of the laundering operations. C3.12.3. When explosives-contaminated clothing is sent to an off-plant laundry facility, the contractor is responsible for informing the laundry of the hazards associated with the contamination and any special laundering or disposal requirements. C3.13. Conductive Footwear C3.13.1. When conductive mats, floors, or runners are required, operators shall wear conductive shoes. Personnel visiting any such area shall wear conductive shoes, ankle straps, or similar devices, one on each leg. C3.13.2. Tests of conductive shoes or their equivalent shall be made initially and daily thereafter to ensure that the resistance from the person through the conductive shoes is less than or equal to one million ohms. Supervisors shall keep documentation of all testing, including calibration of test equipment. The test voltage shall not exceed 500 volts. The short circuit current across the electrodes (plates) shall not exceed 2.0 milliamperes (0.5 milliamperes is preferred). The instruments shall have built-in safeguards preventing the test subject from experiencing electric shock. Tests shall not be performed in rooms with exposed explosives. Shoes should be tested first without cleaning the soles and heels; if the resistance does not exceed allowed levels, the shoes may be worn. If resistance exceeds 450,000 ohms per shoe, the pair shall be cleaned and retested. Sandpaper, solvents, or other agents affecting the structure or conductivity of the sole materials should not be used. Separating or removing the conductive sock liner from the conductive plug or depressing the conductive plugs below the surface of the insole of the shoe can cause high resistance. Nonconductive stockings such as silk, wool, and synthetics; and foot powders, which have a drying action, shall be avoided. Conductive shoes should be clearly identifiable as such. C3.14. Materials Handling Equipment C3.14.1. Gasoline-, diesel-, and LP-powered equipment shall not be used inside warehouses or similar buildings containing A&E. If the fuel supply is exhausted while the equipment is inside a building, the equipment shall be towed outside to a safe location for refueling: at least 20 feet from inert buildings and inert loading docks and 90 feet from explosives locations or buildings. Doors and windows through which vapors may enter the building shall be closed during refueling. Refueling trucks shall not be located close to explosives buildings during refueling operations, but shall be parked as far as practicable from these buildings, in accordance with the above requirements. C3.14.2. Gasoline-, diesel-, and LP-powered equipment shall not be stored in buildings containing explosives or ammunition or on explosives loading docks or piers when A&E is present. A central storage location for gasoline-, diesel-, and liquefied petroleum (LP)-powered equipment is preferred. Such a building should be located at least 50 feet from other buildings to avoid a fire hazard. C3.14.3. Gasoline-, diesel-, and LP-powered equipment shall receive periodic inspections of exhaust and electrical systems with the results documented. Spark arresters shall be required on exhaust systems. C3.15. Parking of Privately-Owned Vehicles Controlled parking of privately-owned vehicles within an establishment minimizes fire and explosion hazards and prevents congestion in an emergency. Vehicles should be parked in designated areas only, at intraline distance and outside of restricted areas. Vehicles shall not be parked so close to an explosives building or structure that fire could spread from them to the building, or that they could impede firefighters. C3.16. Prohibited Articles in Hazardous Areas Except as authorized, personnel shall not carry matches, cigarette lighters, or other flame-producing devices into explosives areas. Personal articles that increase existing hazards are also prohibited. C3.17. Photographic Materials in Hazardous Areas Photoflash bulbs or electronic flash attachments shall not be used around exposed explosives, explosive dusts, flammable gases, or vapors. Only lighting equipment approved by a nationally recognized testing laboratory shall be used. C3.18. Operational Explosives Containers C3.18.1. Containers used for intraplant transportation or temporary storage of process explosives and energetic materials shall be designed to prevent leakage. These containers should be equipped with covers (lids) and constructed of materials in the following order of precedence: C3.18.1.1. Conductive rubber or conductive plastic, C3.18.1.2. Nonferrous metal-lined boxes without seams or rivet heads under which explosive dusts could accumulate, C3.18.1.3. Paper-lined wooden boxes, or C3.18.1.4. Fiber drums. C3.18.2. These containers should be marked with the type of explosive or hazard involved. C3.18.3. Because of their fragility and potential for fragmentation, glass containers shall not be used. C3.19. Intraplant Rail Transportation This section addresses intraplant transportation of explosives and may exceed national requirements because of material characteristics and operational hazards. When construction or major modification of transportation, packaging, or loading facilities is planned, the A&E contractor is responsible for ensuring that applicable Federal, State, and local requirements and those contained within this manual are met. The applicable requirements promulgated by Department of Transportation (DoT) and other Federal or local regulatory agencies concerning preparation, marking, and shipment of ammunition and explosives should be incorporated by reference in the contract. C3.19.1. Operating Rules. Local procedures to ensure safe and efficient rail movement of A&E shall be developed, and shall include the following minimum requirements: C3.19.1.1. Movements in the classification yards are considered switch movements. All others are considered transfer movements. Before cars containing A&E move, air hoses shall be coupled, air brakes cut-in and in proper working order, and the car doors closed. Cars should remain coupled while in motion. Safety precautions shall be observed when breaking air hose connections. C3.19.1.2. When single explosives-loaded cars are spotted, the hand brakes shall be set and the wheels properly chocked. When more than one car is spotted and its engine detached, the hand brakes shall be set on enough cars to ensure sufficient braking. Hand brakes shall be set on the downgrade end of the cut of rail cars. Reliance should not be placed on the automatic air brakes to hold spotted cars. C3.19.1.3. A person should be stationed at the hand brake of a car mover when in use. C3.19.1.4. During transfer movements within establishments, full or partial loads in rail cars shall be blocked and braced so they cannot shift position. C3.19.1.5. Empty rail cars shall remain in warehouses, magazines, buildings, or loading docks until all warning placards have been removed or reversed, as appropriate. C3.19.1.6. Special care shall be taken to avoid rough handling of cars containing A&E. These cars shall not be "sent off" while in motion and shall be carefully coupled to avoid unnecessary shocks. Other cars shall not be "cut off" and allowed to strike a car containing explosives. C3.19.1.7. A buffer car should separate rail cars containing explosives and the switching engine when in motion. C3.19.1.8. Flags or signals at both ends of a rail car or cut of cars shall protect personnel working in, on, or under the cars. During these periods, cars shall not be coupled or moved. C3.19.1.9. Portable transmitters and railroad locomotives equipped with two-way radios shall not transmit when passing explosives operating buildings where electro-explosive devices are in use. The contractor shall determine minimum safe distances based on radio frequency (RF), frequency modulation (FM), and amplitude modulation (AM) of the transmitter. C3.19.2. Pre-loading Rail Car Inspections C3.19.2.1. Qualified personnel shall inspect empty rail cars intended to transport A&E upon arrival, verifying that the carrier has complied with DOT requirements. C3.19.2.2. Before loading, the brakes shall be set on cars spotted for loading, and bridge plates equipped with side boards and stops shall be provided. C3.19.3. Loaded Incoming Rail Car Inspections C3.19.3.1. Railroad cars with A&E should, upon arrival, be inspected at remote sites. If no problems are found, rail cars may be opened for interior inspection or moved to the designated unloading point. C3.19.3.2. A&E-loaded cars on which foreign and suspicious articles have been attached outside or underneath the car, or that have a defect that could affect the safety of the establishment or the contents of the car, shall be moved to the suspect car site for disposition. C3.19.3.3. Cars should be inspected after unloading A&E to ensure that they are clean and free from loose explosives and flammable materials, and that placards and car certificates have been removed. Explosives swept from the floors shall be disposed of properly. C3.20. Intraplant Motor Vehicle Transportation C3.20.1. Operating Rules. Procedures for safe transportation of A&E in motor vehicles shall be developed locally, and should include the following: C3.20.1.1. Brakes shall be set and the wheels chocked while loading and unloading. C3.20.1.2. A&E shall not be loaded or unloaded when a motor vehicle's engine is running, unless the engine is providing power to accessories used in the loading and unloading, such as mechanical handling equipment. C3.20.1.3. Vehicles, including, partly or completely loaded flatbeds, shall have the load blocked and braced to prevent shifting during transit. C3.20.2. Vehicle Inspections. All motor vehicles used to transport A&E shall be inspected before loading to ensure the following: C3.20.2.1. Batteries and wiring shall not come into contact with containers of A&E. C3.20.2.2. Exposed ferrous metal in the interior of the vehicle body shall be covered with nonsparking material when scrap and bulk explosives are being transported in containers that could be damaged, or when explosives could otherwise become exposed. C3.20.2.3. A portable fire extinguisher of the appropriate class shall be carried on motor vehicles used for transporting A&E. C3.20.2.4. Motor vehicles transporting A&E within the establishment but outside the explosives area, shall bear at least two appropriate placards. These placards should be removed or covered whenever the vehicle is not loaded. Reflectorized placards are preferred. C3.20.2.5. Motor vehicles or equipment with internal combustion engines, used near explosives scrap, waste, or items contaminated with explosives, shall have exhaust system spark arresters and carburetor flame arresters (authorized air cleaners). They should be inspected and cleaned to prevent accumulation of carbon. C3.20.3. Loaded Incoming Vehicle Inspections C3.20.3.1. Vehicles with A&E should, upon arrival, be inspected at remote sites. If no problems are found, vehicles may be opened for interior inspection or moved to the designated unloading point. C3.20.3.2. A&E-loaded vehicles on which foreign and suspicious articles have been attached outside or underneath the vehicle, or that have a defect which could affect the safety of the establishment or the contents of the vehicle, shall be moved to the suspect car site for disposition. C3.20.3.3. Vehicles should be inspected after unloading A&E to ensure that they are clean and free from loose explosives and flammable materials, and that placards and vehicle certificates have been removed. Explosives swept from the floors shall be disposed of properly. C3.21. Inspection of Pyrotechnic, Propellant and Explosive Mixers Mixers used for manufacturing pyrotechnics, propellants and explosives shall have an initial inspection prior to use and shall be on a periodic inspection schedule during operating life. C3.21.1. The initial inspection shall, as a minimum, require radiographic and dye-penetrant inspection of the blades and blade to shaft areas, blade to bowl clearances, allowable tolerances, testing for proper function of operating systems such as bowl positioning mechanisms, safety interlocks, fire detection and prevention and test of computer controller software self-check. C3.21.2. Periodic inspection shall be provided during the operating life of the mixer. The inspection program shall be based on manufacturer's recommendations, operating history of like mixers, and any items identified in hazards analysis of the particular mixer and its operation. The inspection program shall include: C3.21.2.1. Tests and visual inspection criteria to be performed prior to each use to include associated equipment which might come loose and fall into the mixer. C3.21.2.2. Periodic inspections of clearances between blades and bowl at sufficient points to detect any distortion of the bowl or kettle. C3.21.2.3. Inspection and test for drive system wear, bearings condition and gear alignment with loading to establish operation within tolerances when applicable. C3.21.2.4. Inspection and test of proper function of operating subsystems such as bowl handling, safety and fire and control, including computer software self-check. C3.21.3. It is recommended that large (over 80 gallon) vertical blade mixers in high-torque applications have a dye-penetrant check of the blades annually or after every 300 hours of operation. Melt-cast kettles are not considered high torque mixers. Also, it is recommended that an inspection of clearances and operating systems be performed after any maintenance, or unusual events such as severe weather exposure, mishandling of bowl or mixer, or long idle period. C3.21.4. A log of the maintenance and inspection shall be maintained. Trend analysis of clearances should be used to detect wear which might become hazardous. C4. CHAPTER 4 PRINCIPLES AND APPLICATION OF QUANTITY-DISTANCE (Q-D), STANDARD EXPLOSIVES FACILITIES, AND SITING REQUIREMENTS C4.1. General Explosives classes and divisions identified in this chapter are defined in TB 700-2,3 Explosives Hazard Classification Procedures (reference (e)), and more fully explained in chapter 6. Chapter 4 sets forth the following: C4.1.1. Rules for establishing quantities of explosives; C4.1.2. Computations and determinations of quantity distance; C4.1.3. Assessment of the explosion effects, such as facility damage and personnel injury expected at specific scaled distances for Hazard Division 1.1, explosives; C4.1.4. Recommended methods for controlling the effects of Hazard Division 1.1, explosions; C4.1.5. Acceptable exposures at specific scaled distances; C4.1.6. Types and general specifications of various ammunition and explosives facilities; and C4.1.7. Siting requirements for specific facilities. C4.2. Quantity-distance (Q-D) C4.2.1. Quantity distances are determined by establishing a NEW at a point and measuring from that point to an exposure. The source of a Q-D measurement is called a potential explosive site, or PES. For Q-D purposes, one considers the total NEW that will be involved in an accidental explosion at the PES. A PES may be a round of ammunition, a vehicle, an operating building, or simply a location where explosives are stacked. 3 Copies may be obtained from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. C4.2.2. Any building, vehicle, location, or ammunition that is to be protected from an accidental explosion at another source, is called the exposed site, or ES. An ES may contain explosives requiring protection from a second explosive source located a distance away. An ES may also be a home, stadium, a high-rise apartment, a public highway or any other facility or location requiring protection from an accidental explosion. C4.3. Establishment of Quantity of Explosives and Distances C4.3.1. Quantity of Explosives. The Q-D tables are used to provide appropriate distances from potential explosion sites (PES). The hazard classification of the A&E and the weight of explosives involved are primary characteristics governing the use of Q-D tables. The definitions and methods for determining hazard classifications are in chapter 6. Methods for determining the NEW is explained in the following: C4.3.1.1. Mass-detonating Explosives (Hazard Division 1.1). The total weight of explosives (NEW). C4.3.1.2. Nonmass-detonating explosives C4.3.1.2.1. Propellants (Hazard Division 1.3). The total weight of the propellants alone is the net propellant weight. C4.3.1.2.2. Pyrotechnic Items (Hazard Division 1.1 and Hazard Division 1.3). The sum of the net weights of the pyrotechnic composition and the explosives involved. C4.3.1.2.3. Bulk Metal Powder and Pyrotechnic Compositions. The sum of the net weights of metal powders and pyrotechnic compositions in the containers. C4.3.1.2.4. Other Ammunition. The net weight of high explosives (Hazard Division 1.1), plus any blast contribution determined by test, if any, from propellant, pyrotechnic components, or expelling charges (percent of Hazard Division 1.3). C4.3.1.3. Combinations of Mass-detonating and Nonmass-detonating A&E (Excluding Hazard Division 1.4). C4.3.1.3.1. When Hazard/Division 1.1 and 1.2 are located in the same site, determine the distances for the total quantity considered first as 1.1 and then as 1.2. The required distance is the greater of the two. When the 1.1 requirements are controlling and the high explosive (HE) equivalence of the 1.2 is known, the HE equivalent weight of the 1.2 items may be added to the total explosive weight of 1.1 items to determine the NEW for 1.1 distance determination. C4.3.1.3.2. When Hazard/Division 1.1 and 1.3 are located in the same site, determine the distances for the total quantity considered first as 1.1 and then as 1.3. The required distance is the greater of the two. When 1.1 requirements are controlling and the high explosive (HE) equivalence of the 1.3 is known, the HE equivalent weight of the 1.3 items may be added to the total explosive weight of 1.1 items to determine the NEW for 1.1 distance determinations. C4.3.1.3.3. When Hazard/Division 1.1, 1.2, and 1.3 are located in the same site, determine the distances for the total quantity considered first as 1.1, next as 1.2, and finally as 1.3. The required distance is the greatest of the three. As permitted by paragraphs C4.3.1.3.1. and C4.3.1.3.2., above, HE equivalent weights for 1.2 and 1.3 items may be used in NEW determinations for Q-D purposes. For each of the above, when using composite propellants in the presence of HD 1.1 explosives, a TNT equivalency of 50 percent may be considered for the composites. C4.3.1.4. Combinations of Nonmass-detonating Ammunition and Explosives of Different Class 1 Divisions shall be treated as follows: C4.3.1.4.1. Determine the required separation for each division. C4.3.1.4.2. Use the greatest separation of those determined. C4.3.2. Q-D Computations and Determinations. C4.3.2.1. Throughout these requirements, NEW is used to calculate distance by means of formula D = KW1/3, where D is the distance in feet, K is the appropriate risk factor and W is the NEW in pounds. Distance requirements are sometimes expressed by the value of K, such as K9, K11, and K18 to signify K = 9, K = 11, K = 18, respectively. C4.3.2.2. The quantity of explosives in a magazine, operating building, or other explosives site shall be the net weight of all the explosives contained therein. Q-D shall be based on the hazard division (H/D) requiring the greatest separation, unless the NEW is divided by walls or shields for that purpose. C4.3.2.2.1. When dividing a quantity of mass-detonating explosives into smaller stacks, a suitable barrier or adequate separation distance shall prevent propagation from one stack to another. Barriers designed and constructed in accordance with TM 5-1300/AFM 88-22/NAVFAC P-397,4 Structures to Resist the Effects of Accidental Explosions (reference (f)), satisfy this requirement. In such cases, the explosives content of the stack requiring the greatest distance shall govern. Otherwise Q-D computations shall be based on the sum of the mass-detonating explosives in all of the stacks. C4.3.2.2.2. Blast waves coalesce when two or more stacks of mass-detonating explosives detonate within short time intervals (that is, when the time in milliseconds is less than 4 times the cube root of the explosive weight in pounds for lateral target positions and less than 5.6 times the cube root of the explosive weight in pounds for axial target positions). The resultant shock wave shall be that of a single detonation of a charge equal to the sum of the several stacks. The actual separation time between successive detonations is influenced by the spatial separation, geometry, and distribution of explosives; the character of the dividing wall or other barrier; and the sensitivity of the explosives. C4.3.2.3. The quantity of explosives permitted in each of two or more locations shall be determined by considering each location as a PES. The quantity of explosives permitted in each of these locations shall be the amount permitted by the distance specified in the appropriate Q-D tables considering each as a potential target site in turn, except for service magazines (see paragraphs C4.4.1.2. and C4.4.2.6., below). C4.3.2.4. Q-D tables are in chapter 6. The formulae specified in tables C6.T1. through C6.T4. may be used to interpolate exact distances for Hazard Division 1.1 explosives. The notes to table C6.T11. provide distance formulae for Hazard Division 1.3 distances. 4 Tri-service document. Copies may be obtained from Superintendent of Documents, U.S. Government Printing Office, Washington, DC 20402. C4.3.2.5. It is impractical to specify Q-D separations large enough to allow for the designed flight range of propulsive units (rockets, missile motors, and catapults) that properly belong in Hazard Divisions 1.1, 1.2 or 1.3. Therefore, maximum flight ranges for self-propelling munitions shall be disregarded. The distance required to afford protection from fragments in credible accident situations, however, shall be established in accordance with the principles in chapter 6, subsection C6.2.6. C4.3.2.6. Separation distances for Q-D purposes shall be measured from the nearest part of an exposed structure or site to the nearest wall of the controlling subdivision or structure containing explosives, as appropriate. Separation distances are measured along straight lines. See C4.2.3. C4.3.2.7. Where railroad cars or motor vehicles containing ammunition and explosives are not separated from operating buildings, magazines, or open A&E storage sites in a manner precluding their mass detonation, the separation distance shall be based on the total quantity of explosives and measured from the outside wall of the building, rail car, vehicle, or edge of open stack closest to the target. If the explosives are separated into smaller units so that mass detonation of the explosives in the rail cars and motor vehicles and inside unit or units shall not occur, the separation distance shall be measured from the controlling explosives unit, rail car, or vehicle closest to an ES. C4.3.3. Hazard Division 1.1, Explosion Effects, Exposure Controls, and Degrees of Safety Afforded. Facility damage and personnel injury from Hazard Division 1.1 A&E principally depend on blast overpressure and impulse, although for limited quantities fragment hazards may control Q-D. For general purposes, peak incident overpressure is the blast parameter defining maximum permissible levels of exposure. However, in specific instances the physical characteristics of exposed structures (such as mass, stiffness, ductility, and so forth) can make blast impulse the principal damage-causing factor. C4.3.3.1. Separation distances for earth covered magazines (see tables C6.T4. and C6.T5.) provide virtually complete protection against propagation of explosions among earth-covered magazines by blast, fragments, or fire. Some cracking of concrete barrels and rear walls, spalling and severe cracking of front walls, and damage to doors and ventilators may, however, occur. C4.3.3.2. Above ground magazine distances (see columns 10 and 12 of table C6.T4.) provide considerable protection against propagation of explosions among above-ground magazines by blast. Depending on explosive type, however, there is a risk of delayed propagation by fragments or of fire spreading from one magazine to another. Properly designed and placed barricades reduce the risk of communicating explosion through high-velocity, low-angle fragments. Without barricades, this risk is high. C4.3.3.2.1. The above ground magazine separation distance of 6W1/3 feet corresponds to a peak overpressure level of 27 psi (1.8 bars) (1 bar = 14.5 psi) when the explosion source is in the open. Neither the overpressure nor any other pertinent blast parameter, such as impulse, are significantly reduced by an ordinary storage building of conventional unstrengthened industrial construction at the explosion site, or by the barricade required between aboveground magazines at this distance. Conventional unstrengthened buildings exposed at this distance are destroyed, vehicles overturned and crushed, and all occupants killed. C4.3.3.2.2. The unbarricaded aboveground magazine separation distance of 11W1/3 feet corresponds to a peak overpressure level of 8 psi (0.5 bars) from an explosion source in the open. Blast observed at this distance is suppressed only slightly by a storage building of conventional construction at the explosion site. Conventional unstrengthened buildings exposed at this distance are destroyed. Blast will seriously injure eardrums and lungs of any survivor, as will being blown down or struck by fragments or building debris. Vehicles will be severely damaged by blast and may be inoperable. C4.3.3.3. At blast overpressure of 12 psi (0.7 bars) occurring at scaled distance of 9W1/3 feet (see tables C6.T2. and C6.T3.): C4.3.3.3.1. Unstrengthened buildings will suffer severe structural damage approaching total destruction. C4.3.3.3.2. People at the exposed site will be killed or severely injured by being thrown about by blast or by building collapse. C4.3.3.3.3. Aircraft will be damaged beyond repair. If the aircraft are loaded with explosives, delayed explosions are likely to result from subsequent fires. C4.3.3.3.4. Transport vehicles will be heavily damaged, probably to the extent of total loss. C4.3.3.3.5. Direct propagation of explosion between two explosives locations is unlikely when barricades between them intercept high-velocity, low-angle fragments (see subsection C4.4.1., below). C4.3.3.3.6. Improperly designed barricades or structures increase the hazard from flying debris; further, their probable collapse threatens personnel and equipment. C4.3.3.3.7. Exposed structures housing personnel or containing equipment that is monetarily valuable or critically important to the mission, may require hardening. C4.3.3.4. At blast overpressure of 3.5 psi (0.24 bars) occurring at scaled distance of 18W1/3 (see table C6.T2.): C4.3.3.4.1. Direct propagation of explosion is not expected. C4.3.3.4.2. Delayed communication of explosion from fires, or equipment failure at the exposed site (ES), is possible. C4.3.3.4.3. Unstrengthened buildings will sustain serious damage, approximating 50 percent of the total replacement cost. C4.3.3.4.4. Personnel will be critically injured or killed by fragments, debris, firebrands, and so forth. C4.3.3.4.5. There is a 1 percent chance of eardrum damage to personnel. C4.3.3.4.6. Aircraft will be severely damaged from blast, fragments, and debris. C4.3.3.4.7. Transport vehicles' body panels will be dished and shatter-resistant window glass will crack. Though extensive, this damage will not prevent the vehicles from operating. C4.3.3.4.8. Overpressure control by suppressive construction at the PES, or by protective construction at the ES, is recommended if it is more economical than distance alone, or if distance cannot suffice. C4.3.3.5. At blast overpressure of 2.3 psi (0.16 bars) occurring at scaled distance of 24W1/3 (for quantities up to 100,000 pounds, see column 8 of table C6.T3.). C4.3.3.5.1. Unstrengthened buildings will sustain damage approximating 20 percent of their replacement cost. C4.3.3.5.2. Occupants of exposed structures may suffer temporary hearing loss or be injured by such blast effects as building debris and being bodily thrown about. C4.3.3.5.3. Personnel in the open should not be seriously injured by the blast itself. Fragments and debris could, however, cause injuries, depending on the PES structure and the fragmentation characteristics and amount of ammunition or explosive within. C4.3.3.5.4. Vehicles on the road should not be damaged unless hit by fragments or the operator loses control during the blast wave. C4.3.3.5.5. Aircraft appendages and sheet metal skin could be damaged by blast and possibly fragment penetrations, but should be operational after minor repairs. C4.3.3.5.6. Barricading at the PES reduces injury and damage from fragments from limited quantities of explosives. Suppressive construction at the PES or protective construction at the ES are practical ways of controlling blast over-pressure. C4.3.3.6. At blast overpressure of between 2.3 psi (0.16 bars) and 1.7 psi (0.1 bars) effects and controls are intermediate between those described in paragraphs C4.3.3.5., above and C4.3.3.7., below (for quantities between 100,000 and 250,000 pounds, see column 8 of table C6.T1.). C4.3.3.7. At blast overpressure of 1.7 psi (0.1 bars) occurring at scaled distance of 30W1/3 (for quantities over 250,000 pounds, see column 8 of table C6.T1.): C4.3.3.7.1. Unstrengthened buildings will sustain damage approximating 10 percent of their replacement cost. C4.3.3.7.2. Occupants of exposed unstrengthened structures may suffer injury from secondary effects, such as building debris. C4.3.3.7.3. Aircraft landing and taking off could lose control and crash. C4.3.3.7.4. Parked military and commercial aircraft, with minor damage due to blast, should remain airworthy. C4.3.3.7.5. Personnel in the open should not be seriously injured by the blast itself. Depending largely upon the PES structure and the fragmentation characteristics and amount of ammunition or explosive within, however, fragments and debris could cause injuries. C4.3.3.7.6. Barricading at the PES or application of minimum fragment distance requirements may reduce injury or damage due to fragments from limited quantities of explosives. C4.3.3.8. At blast overpressure of 1.2 - 0.90 psi (0.08 - 0.06 bars) occurring at scaled distance of 40W1/3 - 50W1/3 (see column 5 of table C6.T1.): C4.3.3.8.1. Unstrengthened buildings will sustain damage approximating 5 percent of their replacement cost. C4.3.3.8.2. Personnel injuries are principally caused by glass breakage and building debris. C4.3.3.8.3. Personnel in the open should not be seriously injured by the blast itself. Depending largely upon the PES structure and the fragmentation characteristics and amount of ammunition or explosive within, however, fragments and debris could cause injuries. C4.3.3.8.4. Both orientation and limiting the surface area of exposed glass panels can reduce breakage and structural damage. C4.4. Permissible Exposures to Blast Overpressure C4.4.1. At sites exposed to potential blast overpressure of 12 psi (0.7 bars) occurring at 9W1/3 (see column 3 of table C6.T2. and table C6.T3.), a barricade is required unless otherwise indicated (see subparagraph C4.3.3.3.7., above), the following facilities or operations are permitted: C4.4.1.1. Buildings housing successive steps of a single production, renovation, or maintenance operation. C4.4.1.2. Breakrooms and change houses, if part of an operating line and used exclusively by personnel employed in operations of the line. C4.4.1.3. Temporary holding areas for trucks or rail cars containing explosives to service production or maintenance facilities. C4.4.1.4. Field operations in magazine areas, when performing minor maintenance, preservation, packaging, or surveillance inspection. C4.4.1.5. Unmanned auxiliary power facilities, transformer stations, water treatment and pollution abatement facilities, and other utility installations that serve the PES but are not integral, the loss of which would not create an immediate secondary hazard. These do not need barricades. However, unmanned auxiliary power generating or converting facilities supplying power exclusively to the explosives storage area and security fence lighting may be located as close as fire distance from explosives facilities (50 feet for fire resistant structures and 100 feet for non-fire resistant structures). C4.4.1.6. Dunnage preparation and similar support structures housing non-explosives operations, if used only by PES employees. C4.4.1.7. Service magazines that are a part of operating lines. Distances are based on the quantity/type of ammunition or explosives in the service magazine(s), not in the operating building. C4.4.1.8. Exposures as indicated in subsection C4.4.2., below, if blast suppression, structure hardening, and so forth, provides comparable protection for the personnel and equipment involved. C4.4.2. At sites exposed to potential blast overpressure of 3.5 psi (0.24 bars) occurring at 18W1/3 (see column 4 of table C6.T2. and table C6.T3.), the following facilities or operations are permitted: C4.4.2.1. Construction workers in the vicinity of ammunition production areas, waterfront areas where ammunition is being handled, or areas for loading explosives onto aircraft. C4.4.2.2. Surveillance, maintenance, and inspection buildings; and labor-intensive operations closely related to the PES. C4.4.2.3. Comfort, safety, and convenience buildings exclusively supporting PES, including lunchrooms, motor pools, area offices, auxiliary fire stations, transportation dispatch points, and shipping and receiving buildings (not magazine area loading docks). C4.4.2.4. Operations and training functions manned or attended only by personnel operating the PES. C4.4.2.5. Service magazines that are part of operating lines. Distances are based on quantity/type of ammunition or explosives in the service magazine(s), not in the operating building. C4.4.2.6. Container stuffing and unstuffing operations that are routine support of the PES. This applies to main support functions set aside for support of manufacturing operations. Container stuffing and unstuffing in magazine areas are permitted at intermagazine distances. C4.4.3. At sites exposed to potential blast overpressure of 2.3 psi (0.16 bars) occurring at 24W1/3 (see column 8 of table C6.T1.), the following facilities or operations are permitted: C4.4.3.1. Public traffic routes for NEW under 100,000 pounds. C4.4.3.2. Personnel exposed to remotely controlled operations. NOTE: Personnel at control stations less than 24W1/3 from the PES, though provided with blast-attenuating and fragment-defeating shields, shall not be exposed to overpressure greater than 2.3 psi (0.16 bars). C4.4.3.3. Open-air recreation facilities exposed to PES containing NEW of up to 100,000 pounds, such as baseball diamonds, volleyball courts, and so forth, used by personnel assigned to the facility, where structures are not involved. C4.4.4. At sites exposed to potential blast overpressure of 1.7 psi (0.1 bars) occurring at 30W1/3, the following facilities or operations are permitted: C4.4.4.1. Public traffic routes. C4.4.4.2. Private vehicle parking in administrative areas. Minimum fragment distance should be applied. C4.4.5. At sites exposed to potential blast overpressure of 1.2 - 0.90 psi (0.08 - 0.06 bars) occurring at 40W1/3 to 50W1/3 (see column 5 of table C6.T1.), the following facilities or operations are permitted: C4.4.5.1. Inhabited buildings; administrative and housing areas. C4.4.5.2. Plant boundaries and magazines servicing the establishment in general (see subsection C4.6.10.). C4.4.5.3. Athletic fields and other recreation areas when structures are present. C4.4.5.4. Flight line passenger service facilities. C4.4.5.5. Utilities providing power to most of an establishment. C4.4.5.6. Storehouses and shops having strategically or intrinsically valuable contents that shall not be jeopardized. C4.4.5.7. Functions which, if momentarily out of action, would cause an immediate secondary hazard. C4.5. Ammunition and Explosives Facilities This section identifies the types, general specifications, and siting requirements of various magazines for ammunition, explosives, and other dangerous materials. C4.5.1. Barricades and Earth Cover for Magazines C4.5.1.1. General. Both constructed barricades and undisturbed earth can protect ammunition and explosives, structures, and operations against high-velocity, low-angle fragments, although the barricades may be destroyed in the process. However, barricades provide limited protection against blast in their immediate vicinity, provide no protection against high-angle fragments, and are ineffective in reducing the blast pressure in the far field (inhabited building or public traffic route distance). C4.5.1.2. Barricade Requirements. Protection is considered effective when barricades meet the following minimum requirements: C4.5.1.2.1. The slope of a barricade will not be steeper than 2/3 (rise/run). To reduce erosion and facilitate maintenance operations, future constructions should have a slope of 1/2. C4.5.1.2.2. The earth barricade shall consist of material described in paragraph C4.5.1.4. C4.5.1.2.3. Barricade height and length shall be determined as follows: C4.5.1.2.3.1. Heights. Establish a reference point at the top of the far edge of one of the two stacks that the barricade is to separate. If the tops of the stacks are at different elevations, this reference point shall be on the lower stack. Draw a line from the reference point to the top of the other stack. Draw a second line from the reference point to form a 2 degree angle above the first line. To limit barricade height, each should be as close as possible to the stack that served as the reference point. See figures C4.F1. and C4.F2. Figure C4.F1. Determination of Barricade Height (Level Terrain). Figure C4.F2. Determination of Barricade Height (Sloping Terrain). Figure C4.F3. Determination of Barricade Length. C4.5.1.2.3.2. Lengths. The length of the barricade shall be determined as shown in figure C4.F3. C4.5.1.2.4. Earth barricades meeting the previously identified requirements may be modified by substituting a retaining wall, preferably of concrete, for the slope on one side. The other side shall have slope and thickness sufficient to ensure that the width of earth required for the top is held firmly in place. C4.5.1.2.5. Other barriers, such as earth-filled steel bin barricades for explosives-loaded aircraft, may also be used. C4.5.1.3. Location of Barricades. The distance between the foot of the barricade and the stack of ammunition or explosives or the buildings containing explosives represents a compromise. The shorter the distance, the shorter the height and length required for the barricade. However, it may be necessary to extend the distance to provide access for maintenance and vehicles. If it is impracticable to locate the barricades near the stack of ammunition or explosives or building containing explosives, barricades may be located adjacent to the facility to be protected. C4.5.1.4. Earth Cover for Magazines and Barricades C4.5.1.4.1. Earth cover material for magazines and barricades shall be relatively cohesive (solid or wet clay and similar types of soil are too cohesive and should not be used), free from unsanitary organic matter, trash, debris, and stones heavier than 10 pounds or larger than 6 inches in diameter. The larger stones should be limited to the lower center of fill and never used for earth cover over magazines. Compaction and surface preparation shall be provided, as necessary, to maintain structural integrity and avoid erosion. Where cohesive material cannot be used, as in sandy soil, the barricade or the earth cover over magazines should be finished with a suitable material to ensure structural integrity. C4.5.1.4.2. The earth fill or earth cover between earth-covered magazines may be either solid or sloped, in accordance with the requirements of other construction features, but a minimum of 2 feet of earth cover shall be maintained over the top of each magazine and a minimum slope of 2/3 (rise/run) starting directly above the spring line of each arch shall be maintained. To reduce erosion and facilitate maintenance operations, future constructions should have a slope of 2 horizontal to 1 vertical. C4.5.2. Application of Q-D to Earth-covered Magazines C4.5.2.1. For application of Q-Ds, magazines shall not have been structurally weakened to the extent that they could not be expected to prevent propagation of explosives. The specified thickness and slope of the earth cover shall be maintained. C4.5.2.2. Normally, earth-covered magazines shall not be constructed to face door-to-door. They should face in the same direction with the long axes parallel to each other. In special cases where topographic or other important considerations would result in different orientations, they shall be sited in accordance with chapter 6, section C6.4. C4.5.3. Policy on Protective Construction. The present "state of the art" in protective construction is such as to permit any calculated level of protection from explosion communication between adjacent bays or buildings, personnel protection against death or serious injury from incidents in adjacent bays or buildings, and protection of vital and expensive equipment installations. Therefore, the major objectives in facility planning should be: C4.5.3.1. Protection against explosion communication between adjacent bays or buildings and protection of personnel against death or serious injury from incidents in adjacent bays or buildings. In situations where the protection of personnel and facilities would be greatly enhanced or costs significantly reduced by having separate buildings to limit explosion propagation rather than using protective construction and separation of explosive units within one building, planning should reflect this fact. C4.5.3.2. Provision of protection for vital and expensive equipment, if the additional cost is warranted. C4.5.3.3. When an appropriate degree of protection can be provided either by hardening a target building or constructing a source building to suppress/explosion effects, these factors may be taken into account and the distances required by the standard Q-D tables reduced. The rationale or test results justifying the reduction shall accompany A&E site and general construction plans proposing reduced distances based on protective construction, when submitted through the ACO for PCO approval. C4.6. Specific Siting Requirements C4.6.1. Rail and Truck Holding Yards C4.6.1.1. Generally, rail holding yards should be laid out on a unit car/group basis with each unit car/group separated by the applicable aboveground magazine distance. C4.6.1.2. If the rail holding yard is formed by two parallel ladder tracks connected by diagonal spurs, the parallel tracks and the diagonal spurs shall be separated by applicable aboveground magazine distances for the unit/group/quantities of high explosives. C4.6.1.3. If the rail holding yard is a "Christmas tree" arrangement, consisting of a ladder track with diagonal dead-end spurs projecting from each side at alternate intervals, the spurs should be separated by the applicable aboveground magazine distance for the net quantity of HE in the cars on the spurs. C4.6.1.4. Generally, truck holding yards should be laid out on a unit truck/group basis with each group separated by the applicable aboveground magazine distances. C4.6.1.5. Both rail and truck holding yards shall be separated from other facilities by the applicable Q-D criteria. C4.6.1.6. In addition to the temporary parking of rail cars, trucks or trailers containing ammunition and explosives, holding yards also may be used to interchange truck trailers or rail cars between commercial carrier and the contractor and to conduct visual inspections. C4.6.2. Classification Yards C4.6.2.1. To protect the classification yard from external explosions, separation distances shall, at least, be the applicable magazine distance. C4.6.2.2. Specific Q-D separation is not required from the classification yard to targets other than explosive locations when the classification yard is used exclusively for the following: C4.6.2.2.1. Receiving, dispatching, classifying, and switching of cars. C4.6.2.2.2. Interchanging of trucks, trailers, rail cars, or military vans (MILVANS)/tractor vans between the common carrier and the establishment. C4.6.2.2.3. Conducting external inspection of motor vehicles and rail cars, or opening of free-rolling doors of rail cars for the purpose of removing documents and making a visual inspection of the cargo. C4.6.2.3. If the yard is used at any time for any purpose other than listed in paragraph C4.6.2.2., such as placing or removal of dunnage or explosive items into or from cars, Q-D tables apply. See paragraphs C4.3.2.1. through C4.3.2.7., above. C4.6.3. Rail Car and Motor Vehicle Inspection Stations C4.6.3.1. Specific Q-D separations are not required for inspection stations; however, they should be as remote as practicable from hazardous or populated areas. The following activities may be performed at the inspection station after rail cars or motor vehicles containing ammunition and explosives are received from the delivering carrier, before further routing within the installation: C4.6.3.1.1. Visual inspection of rail car and motor vehicle exteriors. C4.6.3.1.2. Visual inspection of the cargo in vehicles (trucks, trailers, rail cars, MILVANS, and so forth) that have passed the external inspection previously indicated. C4.6.3.1.3. Interchange of trucks, trailers, rail cars, or MILVANS between the common carrier and the establishment. C4.6.3.2. If any activities, other than those previously listed, are conducted at the inspection station, Q-D tables apply. C4.6.3.3. Any cars or trucks suspected of being hazardous shall be isolated consistent with applicable Q-D separation for the hazard class and explosives quantity involved. This shall be accomplished before any subsequent action. C4.6.4. Administration, Industrial, and Convenience Areas C4.6.4.1. Administration and industrial areas shall be separated from PESs by inhabited building distances. C4.6.4.2. Auxiliary facilities such as heating plants, line offices, break areas, briefing rooms for daily work schedules or site safety matters, joiner shops, security posts, and similar functions that are required to be at explosives operations and servicing only one building or operation shall be so located and constructed as to provide prudent fire protection. C4.6.5. Underground Tanks or Pipelines. These should be separated from buildings or stacks containing A&E of Hazard Divisions 1.2 through 1.4 by a minimum distance of 80 feet. The separation for Hazard Division 1.1, should correspond to the formula D = 3W1/3 with a minimum distance of 80 feet, unless the donor building is designed to contain the effects of an explosion. C4.6.6. Storage Tanks Built on or Above the Surface of the Ground. If protection of above-ground storage tanks is required, the distances in column 5 of table C6.T1. shall apply. C4.6.7. Recreational, Training, and Other Such Areas. Open areas between explosives storage and handling sites and between these sites and non-explosives buildings and structures, should be carefully controlled, when used as employee recreation or training facilities. The severe fragment hazard will usually extend from the explosion site to approximately the public traffic route distances. Accordingly, exposed recreation and training facilities where employees are in the open shall be sited at not less than public traffic route distances and as close to inhabited building distances as practicable. When structures, including bleachers, are included as part of these facilities, they shall be sited at not less than inhabited building distances. C4.6.8. Demolition or Burning Areas. Sites for demolition and burning of explosives shall be separated from other facilities based on the hazards associated with the quantity and type of material to be destroyed. See chapter 15, section C15.4., for specific requirements. C4.6.9. Adjacent Operating Lines. These shall be separated from one another by no less than unbarricaded intraline distance (18W1/3) for the hazard class and explosive quantities involved, whether or not barricaded, and provided that ammunition and explosives involved in each operating line present similar hazards. The criticality of survivability of one or more of the operating lines may require that each line be given an inhabited building distance level of protection. C4.6.10. A&E Storage Magazines. A&E storage locations that service the establishment in general shall be separated by appropriate inhabited building distance (blast overpressure or fragmentation, whichever applies) from A&E operating lines/locations, inert areas (warehouses, shops, administrative facilities, and so forth) and property boundaries. C4.6.11. Spacing for Movement of Ammunition and Explosives Within Operating Lines. Items or groups of items of ammunition and explosives that are transported from one operating building to another, or from bay to bay within an operating building, shall be separated to preclude the establishment of a path for the propagation of an explosion or fire between the buildings or bays. For this purpose, the minimum spacing between items, or groups of items, in transport shall be intraline distance unless reduced distances have been approved by the PCO. C5. CHAPTER 5 STORAGE COMPATIBILITY SYSTEM C5.1. General C5.1.1. Storage of A&E is based on the compatibility requirements of this chapter and the hazard classification requirements of chapter 6. C5.1.2. Compatibility groups (CGs) and hazard classification for DoD A&E items and materials are listed in the Joint Hazard Classification System (JHCS) (see TB 700-2, Explosive Hazard Classification Procedures (reference (e))). Additional information may be available from the procuring activity in the form of Hazardous Component Safety Data Statements (HCSDS) for intermediate materials and items. When the solicitation or contract lacks such information, it may be requested through contract channels. C5.1.3. Compatibility and hazard classification information relating to other hazardous materials, including A&E, not contained within the JHCS, can be derived from references such as those cited below. C5.1.3.1. Title 49, Code of Federal Regulations, Transportation, Parts 100 - 199 (reference (g)). C5.1.3.2. National Fire Protection Association, Manual 491M (reference (h)).5 C5.1.3.3. Data sheets developed by the National Safety Council.