[Federal Register Volume 59, Number 241 (Friday, December 16, 1994)]
[Unknown Section]
[Page 0]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 94-30503]
[[Page Unknown]]
[Federal Register: December 16, 1994]
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DEPARTMENT OF DEFENSE
Office of the Secretary
32 CFR Part 184
[DoD 4145.26-M]
Contractors' Safety for Ammunition and Explosives
AGENCY: Office of the Secretary of Defense, DoD.
ACTION: Proposed rule.
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SUMMARY: The Department of Defense (DoD) proposes to codify its revised
explosives safety standards for ammunition and explosives (A&E) work
performed under DoD contracts. This proposed rule is necessary to
minimize the potential for mishaps that could interrupt DoD operations,
delay project completion dates, adversely impact DoD production base or
capability, damage or destroy DoD-owned material/equipment, cause
injury to DoD personnel, or endanger the general public.
DATES: Comments are requested by February 14, 1995.
ADDRESSES: Send inquiries, data, views, and arguments concerning the
proposed standards to: Chairman, Department of Defense Explosives
Safety Board, (DDESB), 2461 Eisenhower Avenue, Alexandria, VA 22331-
0600.
FOR FURTHER INFORMATION CONTACT:
Ray B. Sawyer, Director, Technical Programs Division, DDESB, telephone
(703) 325-8624.
SUPPLEMENTARY INFORMATION:
Pursuant to the authority vested in the Secretary of Defense in
accordance with 10 U.S.C. 172, DoD Directive 6055.9 established the
Department of Defense Explosives Safety Board as a joint activity of
the Department of Defense subject to the direction, authority and
control of the Secretary of Defense. The majority of the standards
impacting upon the public were adopted prior to the enactment of the
Administrative Procedure Act. This proposed rule is intended to ensure
public awareness of the extent of the explosives safety standards as
well as offer the public an opportunity to comment on the standards.
Written comments may be submitted to the addressee above. All comments
will be available for examination upon request.
Subpart Q is under development. When complete, it will provide
information only--no requirements. The information will address the
HCSDS sometimes furnished with solicitations or contracts to provide an
insight into potentially hazardous characteristics of the materials
involved in the production of the item addressed in the solicitation.
Contractors retain the ultimate responsibility for assuring the safety
of their personnel and establishment.
Information provided by the HCSDS is derived from other sources.
Verification of such data as shipping and storage hazard division and
storage compatibility group information must be done through the DoD
Joint Hazard Classification System (JHCS) or Title 49, Code of Federal
Regulations.
As stated in Sec. 184.47(d) to Subpart E, these classifications
pertain to A&E packaged for transportation or storage. Such hazard
classification information may not be valid when applied to the hazards
associated with manufacturing or loading processes, For such processes,
the materials and processes must be analyzed on a case-by-case basis.
Sources of information to support this analysis are available from
service research and development organizations through contract
channels and other sources. The methodologies described in
Sec. 184.199(d) to Subpart P for propellants is an example of an
acceptable approach. Subpart H, Sec. 184.73 through Sec. 184.81
provides examples of processes requiring analysis to determine the
hazards.
The benefits of this proposed rule in terms of the protection of
the public and ensuring contract performance are expected to balance
its potential cost or administrative impacts. Only provisions related
to conventional A&E operations have been included in this proposed
rule. No attempt was made to encompass general industrial safety,
occupational health concerns, chemical warfare agents, radiation, or
over-the-road transportation requirements, because these are either the
responsibility of other regulatory agencies (for example, DOT, DOL/
OSHA, or NRC) or may be addressed elsewhere in the contract by the
procuring activity. Budgetary effects of this proposed rule are minimal
since existing DoD Federal Acquisition Regulation Supplement coverage
already requires compliance with safety requirements in A&E
solicitations and contracts. Finally, because this proposed rule is
needed to minimize the potential for A&E mishaps that could adversely
impact DoD and the public, timely publication in the Federal Register
is important.
E.O. 12866, Federal Regulation
This proposed rule does not: (1) Have an annual effect on the
economy of $100 million or more or adversely affect in a material way
the economy, a sector of the economy, productivity, competition, jobs,
the environment, public health or safety, or state, local, or tribal
governments.
(2) Create a serious inconsistency or otherwise interfere with an
action taken or planned by another agency.
(3) Materially alter the budgetary impact of entitlement, grants,
user fees, or loan programs or the rights and obligations of recipients
thereof; or
(4) Raise novel legal or policy issues arising out of legal
mandates, the President's priorities, or the principles set forth in
this Executive Order.
Paperwork Reduction Act
The proposed rule imposes no obligatory information requirements
beyond internal Department of Defense needs.
Regulatory Flexibility Act
It has been certified that this proposed rule, if promulgated,
shall be exempt from the requirements under 5 U.S.C. 601-612. This
proposed rule does not have a significant economic impact on small
entities as defined in the Act.
Lists of Subjects in 32 CFR Part 184
Arms and munitions, Civil defense, Hazardous substances,
Organization and functions (Government agencies).
L. M. Bynum,
Alternate OSD Federal Register Liaison Officer, Department of Defense.
Accordingly, it is proposed that 32 CFR chapter I, subchapter H, be
amended to add part 184 to read as follows:
PART 184--DOD CONTRACTORS' SAFETY FOR AMMUNITION AND EXPLOSIVES
Subpart A--Introduction
Sec:
184.1 Acronyms.
184.2 Purpose.
184.3 Applicability.
184.4 Mandatory and advisory requirement.
184.5 Responsibilities.
184.6 Compliance with mandatory requirements.
184.7 Site and construction plans.
184.8 Pre-award safety survey.
184.9 Pre-operational survey.
Subpart B--Mishap Investigation and Reporting
184.11 General.
184.12 Reporting criteria.
184.13 Mishap scene.
184.14 Telephone report.
184.15 Written report.
184.16 On-site government assistance.
184.17 Technical mishap investigation and report.
Subpart C--Safe Practices
184.19 General.
184.20 Personnel and materials limits.
184.21 Standing operating procedures (SOPs).
184.22 Storage in operating buildings.
184.23 Housekeeping in hazardous areas.
184.24 Explosives waste in operating areas.
184.25 Procedure before electrical storms.
184.26 Explosives in process during shutdown.
184.27 Maintenance and repairs to equipment and buildings.
184.28 Safety hand-tools.
184.29 Operational shields.
184.30 Special clothing.
184.31 Conductive footwear.
184.32 Materials handling equipment.
184.33 Parking of privately owned vehicles.
184.34 Prohibited articles in hazardous areas.
184.35 Photographic materials in hazardous areas.
184.36 Operational explosives containers.
184.37 Intraplant rail transportation.
184.38 Intraplant motor vehicle transportation.
184.39 Inspection of pyrotechnic, propellant and explosive mixers.
Subpart D--Principles and Application of Quantity/Distance (Q/D),
Standard Explosives Facilities, and Siting Requirements
184.40 General.
184.41 Quantity/distance (Q/D).
184.42 Establishment of quantity of explosives and distances.
184.43 Permissible exposures to blast overpressure.
184.44 Ammunition and explosives facilities.
184.45 Specific siting requirements.
Appendix A to Subpart D of Part 184--Determination of Barricade Height
(Level Terrain)
Appendix B to Subpart D of Part 184--Determination of Barricade Height
(Sloping Terrain)
Appendix C to Subpart D of Part 184--Determination of Barricade Length
Subpart E--Storage Compatibility System
184.47 General.
184.48 Storage compatibility grouping.
184.49 Explosives hazard classification procedures.
Appendix A to Subpart E of Part 184--Storage Compatibility Mixing Chart
Subpart F--Hazard Classification and Q/D Criteria
184.51 General.
184.52 Hazard classes and class divisions.
184.53 Hazard Division 1.1--mass detonating.
184.54 Application of intermagazine distances for Hazard Division
1.1 only.
184.55 Hazard Division 1.2--nonmass detonating, fragment producing.
184.56 Hazard Division 1.3--mass fire.
184.57 Hazard Division 1.4--moderate fire, no blast.
184.58 Hazard Division 1.5 and 1.6.
184.59 Airfields.
184.60 Pier and wharf facilities.
Appendix A to Subpart F of Part 184--Hazard Division 1.1-Inhabited
Building Distance And Public Traffic Route Distances
Appendix B to Subpart F of Part 184--Hazard Division 1.1-Intraline
Distances
Appendix C to Subpart F of Part 184--Hazard Division 1.1-Intraline
Distances From Earth-Covered Magazines
Appendix D to Subpart F of Part 184--Hazard Division 1.1-
Intermagazine Hazard Factors and Distances
Appendix E to Subpart F of Part 184--Hazard Division 1.1-Fragment
Hazard (Primary/Secondary)
Appendix F to Subpart F of Part 184--Hazard Division 1.1-Minimum
Fragment Protection Distances for Selected Items
Appendix G to Subpart F of Part 184--Effects of Magazine Orientation
on Q/D
Appendix H to Subpart F of Part 184--Category (04), Hazard Division
1.2-Nonmass detonating, Fragment Producing
Appendix I to Subpart F of Part 184--Category (08), Hazard Division
1.2-Nonmass detonating, Fragment Producing
Appendix J to Subpart F of Part 184--Category (12), Hazard Division
1.2-Nonmass detonating, Fragment Producing
Appendix K to Subpart F of Part 184--Category (18), Hazard Division
1.2-Nonmass detonating, Fragment Producing
Appendix L to Subpart F of Part 184--Hazard Division 1.3-Mass Fire
Appendix M to Subpart F of Part 184--Hazard Division 1.4-Moderate
Fire, No Blast
Appendix N to Subpart F of Part 184--Hazard Division 1.6N and EIDS
Components
Appendix O to Subpart F of Part 184--Quantity/Distance Criteria for
Hazard Division 1.6 Ammunition
Appendix P to Subpart F of Part 184--Hazard Division 1.1-Q/D
Requirements for Airfields
Appendix Q to Subpart F of Part 184--Application of Ammunition and
Explosives Safety Distances (Airfields, Heliports, and Seadromes)
Appendix R to Subpart F of Part 184--Application of Separation
Distances for Ship and Barge Units
Appendix S to Subpart F of Part 184--Q/D Separations for Pier and
Wharf Facilities
Subpart G--Liquid Propellants Requirements
184.62 Application.
184.63 Determination of propellant quantity.
184.64 Measurement of separation distances.
184.65 Q/D considerations.
184.66 Hazard grouping.
184.67 Hazards.
184.68 Incompatible storage.
184.69 Compatible storage.
Appendix A to Subpart G of Part 184--Liquid Propellants Hazard and
Compatibility Groupings
Appendix B to Subpart G of Part 184--Quantity/Distance for
Propellants
Appendix C to Subpart G of Part 184--Liquid Propellant Explosives
Equivalents
Appendix D to Subpart G of Part 184--Distances for Separation of
Propellant Static Testing, Launching, and Storage Sites From Other
Facilities
Appendix E to Subpart G of Part 184--Factors To Be Used When
Converting Gallons of Propellant Into Pounds
Subpart H--Manufacturing and Processing Pyrotechnics
184.71 General.
184.72 Machinery, equipment, and facilities.
184.73 Weighing of raw materials.
184.74 Drying of materials.
184.75 Mixing and blending.
184.76 Pressing, extruding, and pelleting.
184.77 Assembly operations.
184.78 Granulation, grinding, and screening.
184.79 Transportation.
184.80 Rebowling.
184.81 Machining of pyrotechnic material.
184.82 Spill control.
184.83 Collection of pyrotechnic wastes.
184.84 Cleaning of pyrotechnic processing equipment.
184.85 Personal protective equipment.
184.86 Additional controls.
184.87 Reworking pyrotechnic components.
184.88 Fire protection.
Subpart I--Storage of Explosives and Ammunition
184.90 General.
184.91 Storage considerations.
184.92 Magazine operational regulations.
184.93 Stacking.
184.94 Loose rounds, damaged containers.
184.95 Repairs to magazines.
184.96 Open storage (outdoors).
184.97 Storage of bulk initiating explosives.
184.98 Rocket and rocket motors.
Subpart J--Fire Protection
184.100 General.
184.101 Fire plan.
184.102 Firefighting agreements.
184.103 Smoking.
184.104 Hot work permits.
184.105 Portable fire extinguishers.
184.106 Hazards in fighting fire involving ammunition and
explosives.
184.107 Automatic sprinkler systems.
184.108 Clearance under sprinklers.
184.109 Deluge systems.
184.110 Hazards in fighting fires involving liquid propellants.
184.111 Firebreaks.
Subpart K--Specific Chemicals
184.113 General.
184.114 Repairs to acid equipment.
184.115 Mixed acids.
184.116 Waste acids (spent acids).
184.117 Nitric acid.
184.118 Sulfuric acid (oil of vitriol).
184.119 Oxidizing agents.
184.120 Handling oxidizing agents.
184.121 Chlorates.
184.122 Perchlorates.
184.123 Peroxides.
184.124 Nitrates.
184.125 Powdered metals: aluminum, magnesium, and aluminum alloys.
184.126 Charcoal.
184.127 Sulfur.
184.128 Flammable solids.
184.129 Volatile flammable liquids.
184.130 Calcium carbide.
184.131 Sodium hydroxide (caustic soda) and potassium hydroxide.
184.132 Metallic sodium.
184.133 Nitrocellulose and derivatives.
184.134 Red phosphorus.
184.135 Thermite (TH).
184.136 Incendiary bombs.
184.137 Colored smoke mixtures.
184.138 Smoke.
184.139 Adamsite (DM).
184.140 O-chlorobenzylidene malononitrile (CS).
184.141 Sulfur trioxide-chlorosulfonic acid mixture (FS).
184.142 Titanium tetrachloride (FM).
184.143 Hexachloroethane mixture (HC).
184.144 Burning mixture (CN-DM).
184.145 Phosphorus munitions agents.
184.146 Storage for phosphorus munitions.
184.147 Special protective equipment for phosphorus munitions.
184.148 First aid for phosphorus burns.
184.149 Leaking phosphorus munitions.
184.150 Removal of phosphorus munitions.
184.151 Incendiary and smoke munitions.
184.152 Special protective equipment for incendiary and smoke
munitions.
184.153 First aid for incendiary and smoke munitions injuries.
184.154 Leaking incendiary and smoke munitions.
184.155 Fire in incendiary and smoke munitions magazines.
Subpart L--Safety Requirements for Explosives Facilities
184.157 General.
184.158 Requirements.
184.159 Requirements for buildings.
184.160 Electrical requirements.
184.161 Lightning protection.
184.162 Static electricity and grounding.
Subpart M--Safety Requirements for Specific Explosive Materials and
Operations
184.164 General.
184.165 Properties of explosives.
184.166 Handling low-energy initiators.
184.167 Laboratory operations.
184.168 Electrical testing of ammunition and ammunition components.
184.169 Heat-conditioning of explosives and ammunition.
184.170 Spray painting.
184.171 Drying freshly painted loaded ammunition.
184.172 Rework, disassembly, renovation, and maintenance.
184.173 Munitions loading and associated operations.
Appendix A to Subpart M of Part 184--Hazard Division 1.1-Laboratories
Q/D
Appendix B to Subpart M of Part 184--Hazard Division 1.3-Laboratories
Q/D
Subpart N--Testing Requirements
184.175 Program requirements.
184.176 Operating precautions.
184.177 Test hazards.
184.178 Test clearance.
184.179 Warning and communication systems.
184.180 Specific items for test.
184.181 Malfunctions.
184.182 Ammunition and dud recovery.
184.183 Personnel shelters.
184.184 Testing of ammunition or devices for small arms.
184.185 Velocity and pressure tests.
184.186 Primer drop tests.
Appendix A to Subpart N of Part 184--Misfire of Machine Guns, Rifles,
Pistols, and Other Automatic Weapons
Appendix B to Subpart N of Part 184--Misfire of Automatic Guns, 20mm
and Larger
Appendix C to Subpart N of Part 184--Misfire of Fixed or Semi-fixed
Ammunition
Appendix D to Subpart N of Part 184--Misfire Under Possible Cook-off
Conditions
Appendix E to Subpart N of Part 184--Misfire of Lever- (Trigger-) Fired
Mortar Ammunition
Appendix F to Subpart N of Part 184--Misfire of Fixed Firing Pin- or
Lever-Type (Set for Drop Fire) Mortar Ammunition
Appendix G to Subpart N of Part 184--Misfire of Rockets
Appendix H to Subpart N of Part 184--Misfire of Separate Loading
Ammunition
Appendix I to Subpart N of Part 184--Emplacement of Bombproofs at
Firing Points
Subpart O--Collection and Destruction Requirements for Ammunition and
Explosives
184.188 General.
184.189 Protection during disposal operations.
184.190 Collection of ammunition and explosives.
184.191 Destruction sites.
184.192 Destruction by burning.
184.193 Destruction by detonation.
184.194 Destruction by neutralization.
184.195 Destruction chambers and incinerators.
184.196 Support in disposal of waste.
Subpart P--Manufacturing and Processing Propellants
184.198 General.
184.199 In-process hazards.
184.200 Quantity/distance (Q/D) requirements.
184.201 Separation of operations and buildings.
184.202 Equipment and facilities.
184.203 In-process quantities and storage.
184.204 Ingredients processing.
184.205 Mixing.
184.206 Casting and curing.
184.207 Extrusion processes.
184.208 Propellant loaded items.
184.209 Disassembly.
Appendix A to Subpart P of Part 184--Remote Control and Personnel
Protection Requirements for Certain Propellant Processing Operations
Subpart Q--Hazardous Component Safety Data Statements (HCSDS)
[Reserved]
Subpart R--Bibliography
184.230 List of Publications.
Subpart S--Glossary
184.240 Terminology.
Authority: 10 U.S.C. 172.
Subpart A--Introduction
Sec. 184.1 Acronyms.
ACO Administrative Contracting Officer
A&E Ammunition and Explosives
CBU Cluster Bomb Unit
COCO Contractor-Owned, Contractor-Operated
DNT Dinitrotoluene
DoD Department of Defense
DOT Department of Transportation
DTA Differential Thermal Analysis
EIDS Extremely Insensitive Detonating Substances
ES Exposed Site
FAA Federal Aviation Administration
FAE Fuel Air Explosive
HC Hexachloroethane
HCSDS Hazardous Component Safety Data Statement
H/D Hazard Division
HE High Explosive
IBD Inhabited Building Distance
ILD Intraline Distance
IMD Intermagazine Distance
IMO International Maritime Organization
IR Infrared
LP Liquified Petroleum
MCE Maximum Credible Event
MILVANS Military Vans/Tractor Vans (i.e., 8'x8'x20' container)
MK Mark
MOD Model
NATO North Atlantic Treaty Organization
NAVFAC Naval Facilities Engineering Command
NEC National Electrical Code
NEW Net Explosive Weight
NFPA National Fire Protection Association
OCE Office of Chief of Engineers
PCO Procuring Contracting Officer
PES Potential Explosive Site
PETN Pentaerythritol Tetranitrate
POPO Privately Owned-Privately Operated
PSI Pounds Per Square Inch
PSIG Pounds Per Square Inch Gauge
PTR Public Traffic Route
PWP Plasticized White Phosphorous
Q/D Quantity/Distance
RDX Cyclonite
RF Radio Frequency
SCG Storage Compatibility Group
SOP Standing Operating Procedure
TEA Triethylaluminum
TNT Trinitrotoluene
TP Target Practice
TPA Thickened TEA
UL Underwriters' Laboratories
UNO United Nations Organization
UV Ultraviolet
WP White Phosphorus
Sec. 184.2 Purpose.
This part 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 part and any
additional safety requirements of the contract, if any, shall minimize
the potential for mishaps that could interrupt DoD operations or delay
production, damage or destroy DoD material, cause injury to DoD
personnel, or endanger the general public. Adherence to the part's
requirements and principles shall support DoD mission, provide a safe
environment, and foster cooperation between contractor and DoD
personnel.
Sec. 184.3 Applicability.
The requirements of this part apply to contractors performing work
or services on DoD contracts, subcontracts, purchase orders, or other
purchasing methods for ammunition or explosives. These are minimum
requirements and shall be accepted as final authority over applicable
A&E contractor operations, whether inside or outside their
establishment.
Sec. 184.4 Mandatory and advisory requirement.
The term ``shall'' is used in this part to indicate mandatory
requirements. Waivers to these requirements may be authorized by the
procuring contracting officer (PCO) as explained in Sec. 184.6 (a) and
(b). The terms ``should'' and ``may'' are advisory. When advisory
provisions are not met, adverse consequences could develop, becoming
proximate causes of A&E mishaps.
Sec. 184.5 Responsibilities.
The contractor or subcontractor shall: (a) Comply with the
requirements of this part and any other safety requirements contained
within the contract;
(b) Develop and implement a demonstrable safety program, including
operational procedures, that ensures prevention of A&E-related mishaps;
(c) Designate qualified individuals to administer and implement
this safety program;
(d) Provide information to the Administrative Contracting Officer
(ACO) pertaining to subcontractors retained for A&E work;
(e) Provide advice and assistance to subcontractors during their
work performance; and
(f) Conduct mishap investigations in accordance with, but not
limited to, provisions of this part.
Sec. 184.6 Compliance with mandatory requirements.
(a) During pre-award safety surveys, violations of mandatory
requirements contained in this part 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.
(b) 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 Procuring Contracting
Officer (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.
Sec. 184.7 Site and construction plans.
(a) 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,\1\ as implemented by the applicable military service
requirements.
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\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.
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(b) 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 ammunition and explosive 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.
(c) 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.
(d) Site plans shall comply with the following specifications:
(1) Drawings shall be drawn to a scale of 1 inch to 400 feet.
Smaller-scale drawings may sometimes be necessary to reflect certain
distance and structure relationships within the area surrounding a
given project. In such instances, reductions in scale are acceptable.
(2) Drawings shall list 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.
(3) All other facilities within the inhabited building distance of
the proposed facility shall be identified by a brief description of
their function and occupancy.
(4) A&E items or hazardous 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 part.
(5) Site plans shall provide the net explosives weight, 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.
(6) Site plans shall provide the net explosives weight, 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.
(7) All facilities whose inhabited building distance arcs include
the facility under consideration shall be identified.
(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.
(e) Construction plans for the proposed facility shall contain the
information in Sec. 184.7(d)(1) through (d)(8), and the following:
(1) Show the personnel limits for the new or modified facility,
including a breakdown by room or bay, when appropriate.
(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.
(3) Include information relative to the types and arrangement of
explosive operations or chemical processing equipment.
(4) Explain any deviations from pertinent safety requirements due
to local conditions.
Sec. 184.8 Pre-award safety survey.
(a) When A&E materials and operations are involved in a
solicitation, mishaps could adversely affect production capability,
production assets, or long lead time products or services 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.
(b) During the pre-award safety survey, the contractor, as a
minimum, shall provide the following for review:
(1) Site plans conforming to the requirements of Sec. 184.7 (d)(1)
through (d)(8).
(2) Safety program, organization, and training.
(3) Fire prevention program and available firefighting resources,
including local agreements;
(4) Description of facilities, including size, construction design
and materials, fire resistive capability, utilities, and current
compliance with existing building regulations and codes;
(5) Operational compliance with applicable Federal, state, and
local requirements;
(6) Required licenses or capability to obtain those required to
perform proposed contract work;
(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;
(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
(9) Hazard analysis, as appropriate.
Sec. 184.9 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.
Subpart B--Mishap Investigation and Reporting
Sec. 184.11 General.
This subpart sets forth requirements to be followed for mishaps
involving ammunition and explosives.
Sec. 184.12 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.
(a) One or more fatalities;
(b) One or more lost-workday cases (Refer to the Occupational
Safety and Health Administration (OSHA) Blue Book.);\2\
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\2\Copies may be obtained from Superintendent of Documents, U.S.
Government Printing Office, Washington, DC 20402.
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(c) Ten or more nonfatal injuries without lost workdays (Refer to
the Occupational Safety and Health Administration (OSHA) Blue Book.);
(d) Damage to Government property exceeding $10,000;
(e) Delay in delivery schedule exceeding 24 hours:
(f) Mishaps that are reportable in accordance with specific
contractual requirements other than paragraphs (a) through (e) of this
section; or
(g) Any mishap that may degrade operational or production
capability or 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.
Sec. 184.13 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 the investigation.
Sec. 184.14 Telephone report.
The contractor shall report any mishap described in Sec. 184.12, 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 will
serve as a guide for the telephone report.
Sec. 184.15 Written report.
(a) The contractor shall develop and 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:
(1) Contractor's name and location;
(2) Date, local time, and plant/facility location of the accident;
(3) Category of accident (explosion, fire, and so forth);
(4) Contract, subcontract, or purchase order;
(5) Item nomenclature, hazard classification, lot number;
(6) Narrative (or abstract) of events pertaining to the mishap;
(7) Number of injuries/fatalities, degree of injuries;
(8) Description of property damage and approximate damage cost;
(9) Quantity of explosives involved (pounds, units, rounds, and so
forth);
(10) Probable cause(s);
(11) Corrective action taken or planned;
(12) Effect on production;
(13) Name, title or position, and phone number of person submitting
report; and
(14) Remarks.
(b) Information not furnished in the initial written report shall
be provided to the ACO within 30 days of the mishap.
Sec. 184.16 On-site government assistance.
To help determine the cause or causes of the mishap, DoD
representatives may monitor the contractor's mishap investigation on-
site. Additional investigation or reporting may be required by the PCO.
Sec. 184.17 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, 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.
Subpart C--Safe Practices
Sec. 184.19 General.
This subpart provides general safe practices for all A&E operations
addressed in this part. When these practices exceed or differ from
local or national codes or requirements, the more restrictive shall
apply.
Sec. 184.20 Personnel and materials limits.
(a) 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 shall 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.
(b) Determination of limits for hazardous materials requires a
careful analysis of all facts including operation timing, intraplant
transportation methods, size of the items, and the chemical and
physical characteristics of the material. Lower limits are required for
the more sensitive or hazardous materials. Limits should be established
for each operation, so that each worker may be charged with the
responsibility of not exceeding the established limit. Limits need not
be expressed in units of weight or in the number of items as such. 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 quantity/
distance separations when lesser quantities of explosives will suffice
for the operations.
(c) 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 standing 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.
Sec. 184.21 Standing operating procedures (SOPs).
Prior to starting any operation involving hazardous materials,
adequate SOPs shall be developed, reviewed, and approved by qualified
personnel. The SOPs shall be clearly written to avoid confusion and
ensure process control at all times.
(a) Preparation. All aspects of a procedure 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 SOP shall include, at a minimum, such items as
safety requirements; specific emergency procedures; personal protective
clothing and equipment; personnel and explosives limits for each
operation; equipment designation; location and sequence of operations;
and the particulars regarding how, when, where, and by whom each task
of the operation shall be performed.
(b) Dissemination. Supervisors shall be responsible for explaining
duties prescribed by the SOP to all personnel involved in an A&E
operation.
(c) Posting. Those portions of the approved SOP, determined by the
managing authority to be necessary to facilitate operations, shall be
posted in a spot convenient to all stations involved in the operation.
This need not be at the work station if the worker could be distracted,
causing an accident. Supervisory personnel shall assume responsibility
for enforcing provisions of the SOP; and should maintain copies of the
entire document.
(d) 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 SOP as described
in the preceding paragraphs, or shall be set forth in separate SOPs
prepared specifically for such purposes.
(e) Recertification. SOPs shall be constantly reviewed 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.
(f) Training. Operator training shall cover approved safety
procedures, hazardous materials information, safety and warning
devices, personal protective clothing and equipment, and emergency
equipment.
Sec. 184.22 Storage in operating buildings.
(a) 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 storage 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.
(b) 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:
(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.
(2) Consideration is given to the structural containment afforded,
venting, and the use of non-propagating packaging within the temporary
holding site.
(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.
(4) Procedures have been developed to minimize exposure during
transfer operations.
(5) Plant managers acquire and approve documented test results that
confirm non-propagation characteristics.
(c) If operationally required, A&E that are a part of the work in
process within the building may be stored in operating buildings non-
operational hours, providing the following requirements are strictly
observed:
(1) Explosives limits are not exceeded.
(2) Containers of bulk explosives or propellants are secured and
covered.
(3) Processing equipment, such as powder hoppers and pipelines, is
empty.
(d) 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 Sec. 184.22(c), shall
apply, and responsible personnel shall be informed of the above storage
conditions.
Sec. 184.23 Housekeeping in hazardous areas.
(a) Structures containing explosives shall be kept clean and
orderly.
(b) Explosives and explosives dusts shall not accumulate on
structural members, radiators, heating coils, steam, gas, air, water
supply pipes, or electrical fixtures.
(c) Spillage of explosives and other hazardous materials shall be
prevented by proper design of equipment, training of employees,
provision for catch pans, and so forth. For example, hoppers should be
large enough to comfortably accommodate the size of charges used. A
painted stripe on the inside of the hopper shall serve as a reminder of
the proper filling height. Catch pans or splash pans should be provided
beneath drawoff pipes and TNT flakers, around transfer piping, beneath
powder bags on small arms ammunition charging machines, and so forth.
Spillage shall be promptly removed.
(d) A regular program of cleaning shall be conducted to maintain
safe conditions. General cleaning shall not be conducted while
hazardous operations are being performed.
(e) Hot water or steam should be used for cleaning floors in
buildings containing explosives. When neither is practical, 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 deg.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.
(f) 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.
(g) 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.
Sec. 184.24 Explosives waste in operating areas.
(a) At this writing, the Environmental Protection Agency is
developing rules which shall apply to each contractor beyond the scope
of this part. Explosive safety should not be compromised while meeting
environmental considerations.
(b) Each 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.
(c) 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.
(d) Workers shall be trained to transport explosives wastes in
designated vehicles (see Sec. 184.38) 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 ammunition and explosives.
Sec. 184.25 Procedure before electrical storms.
(a) When an electrical storm approaches, all personnel shall
evacuate locations where lightning could initiate explosions. Such
locations include:
(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;
(2) Buildings containing explosives dust or vapors, whether or not
equipped with lightning protection systems, and locations within
unbarricaded intraline distance of such buildings;
(3) Magazines, open storage sites, or loading docks, not equipped
with lightning protection systems; and
(4) Locations, with or without lightning protection, where
operations involving unprotected electro-explosive devices or circuitry
are being performed.
(b) A qualified person in authority should make the final decision
about evacuation. When special warning is required for shutdown,
volunteer observers or a detector (lightning detection system) may be
used.
(c) 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.
Sec. 184.26 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 in which it is considered safe to
leave, the building shall be completely evacuated. Explosives processes
requiring constant attention should not be started when an electrical
storm threatens.
Sec. 184.27 Maintenance and repairs to equipment and buildings.
(a) 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.
(b) 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.
(c) 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.
(d) Repairs cannot start in an explosives location until all
explosives have been removed from equipment, crevices, 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.
(e) 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.
(f) 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.
(g) Safe practices specified elsewhere in this part shall also
apply to maintenance employees.
(h) 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.
Sec. 184.28 Safety hand-tools.
(a) Hand tools constructed of wood or materials such as bronze,
lead, and ``K'' Monel metal shall be used for work in locations that
contain exposed explosives or hazardous concentrations of flammable
dusts, gases, or vapors. While safer, the nonferrous metals used in so-
called non-sparking tools may produce sparks.
(b) 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 Sec. 184.27 (b) through
(d).
Sec. 184.29 Operational shields.
(a) 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.
(b) 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 above assessment:
(1) Initiation sensitivity,
(2) Potential ignition sources,
(3) Quantity of A&E,
(4) Rate of burning,
(5) A&E and personnel resource exposures, and
(6) Protection capabilities of shields.
(c) When analysis of these factors indicates an unacceptable
probability of explosion or deflagration, resources shall be dedicated
to additional protection 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:
(1) Prevent propagation due to blast overpressure.
(2) Contain all fragmentation or direct fragments (primary and
secondary) away from areas requiring protection.
(3) Contain thermal effects to prevent propagation.
(d) 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 incident, 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,\3\ Shields, Operational for Ammunition Operations, Criteria
for Design of and Tests for Acceptance, 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.
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\3\Copies may be obtained from Naval Publications and Forms
Center, 5801 Tabor Avenue, Philadelphia, PA 19120.
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Sec. 184.30 Special clothing.
(a) A changing area shall be established for employees who must
remove their street clothes to wear special clothing (explosives plant
clothing, anticontamination 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.
(b) 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.
(c) 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.
Sec. 184.31 Conductive footwear.
(a) When conductive mats, floors, and 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.
(b) Tests of conductive shoes or 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. Documentation of this testing, to include calibration of
test equipment, shall be kept by supervisory personnel. 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 labeled as
such.
Sec. 184.32 Materials handling equipment.
(a) Gasoline-, diesel-, and LP-powered equipment shall not be
refueled inside warehouses or similar buildings containing ammunition
and explosives. 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.
(b) 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 LP-powered equipment is
preferred. Such a building should be located at least 50 feet from
other buildings to avoid a fire hazard.
(c) 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.
Sec. 184.33 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.
Sec. 184.34 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.
Sec. 184.35 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.
Sec. 184.36 Operational explosives containers.
(a) 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:
(1) Conductive rubber or conductive plastic,
(2) Nonferrous metal-lined boxes without seams or rivet heads under
which explosive dusts could accumulate,
(3) Paper-lined wooden boxes, or
(4) Fiber drums.
(b) These containers should be marked with the type of explosive or
hazard involved.
(c) Because of their fragility and fragment potential, glass
containers shall not be used.
Sec. 184.37 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 or
anticipated, the 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 appear in the contract.
(a) Operating rules. Local procedures to ensure safe and efficient
rail movement of A&E shall be developed, and shall include the
following minimum requirements:
(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.
(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.
(3) A person should be stationed at the hand brake of a car mover
when in use.
(4) During transfer movements within establishments, full or
partial loads in rail cars shall be blocked and braced so they cannot
shift position.
(5) Empty rail cars shall remain in warehouses, magazines,
buildings, or loading docks until all warning placards have been
removed or reversed, as appropriate.
(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.
(7) A buffer car should separate rail cars containing explosives
and the switching engine when in motion.
(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.
(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.
(b) Rail car inspections. (1) Qualified personnel shall inspect
empty rail cars intended to transport A&E upon arrival, verifying that
the carrier has complied with DOT requirements.
(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.
(c) Loaded incoming rail car inspections. (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.
(2) A&E-loaded cars on which foreign and suspicious articles have
been attached outside or underneath the car, or that have a defect
which could affect the safety of the establishment or the contents of
the car, shall be moved to the suspect car site for disposition.
(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.
Sec. 184.38 Intraplant motor vehicle transportation.
(a) Operating rules. Procedures for safe transportation of A&E in
motor vehicles shall be developed locally, and should include the
following:
(1) Brakes shall be set and the wheels chocked while loading and
un-loading on a grade.
(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.
(3) Vehicles, including flat-bed, partly or completely loaded,
shall have the load blocked and braced to prevent shifting during
transit.
(b) Vehicle inspections. All motor vehicles used to transport A&E
shall be inspected before loading to ensure the following:
(1) Batteries and wiring shall not come into contact with
containers of A&E.
(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.
(3) A portable fire extinguisher of the appropriate class shall be
carried on motor vehicles used for transporting A&E.
(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.
(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.
(c) Loaded incoming vehicle inspections. (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.
(2) A&E-loaded vehicles on which foreign and suspicious articles
have been attached outside or underneath the car, 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.
(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.
Sec. 184.39 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.
(a) 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 selfcheck.
(b) 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:
(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.
(2) Periodic inspections of clearances between blades and bowl at
sufficient points to detect any distortion of the bowl or kettle.
(3) Inspection and test for drive system wear, bearings condition
and gear alignment with loading to establish operation within
tolerances when applicable.
(4) Inspection and test of proper function of operating subsystems
such as bowl handling, safety and fire and control, including computer
software selfcheck.
(c) 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, unusual even such as severe weather exposure
mishandling of bowl or mixer or long idle period.
(d) A log of the maintenance and inspection shall be maintained.
Trend analysis of clearances should be used to detect wear which might
become hazardous.
Subpart D--Principles and Application of Quantity/Distance (Q/D),
Standard Explosives Facilities, and Siting Requirements
Sec. 184.40 General.
Explosives classes and divisions identified in this subpart are
defined in TB 700-2,\1\ Explosives Hazard Classification Procedures,
and more fully explained in subpart F of this part. This subpart D sets
forth the following:
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(a) Rules for establishing quantities of explosives;
(b) Computations and determinations of quantity distance;
(c) Assessment of the explosion effects, such as facility damage
and personnel injury expected at specific scaled distances for Hazard
Division 1.1, explosives;
(d) Recommended methods for controlling the effects of Hazard
Division 1.1, explosions;
(e) Acceptable exposures at specific scaled distances;
(f) Types and general specifications of various ammunition and
explosives facilities; and
(g) Siting requirements for specific facilities.
Sec. 184.41 Quantity/distance (Q/D).
(a) Quantity distances are determined by establishing a net
explosive weight (NEW) at a point and measuring from that point to an
exposure. The source of a Q/D measurement is called a potential
explosion site, or PES. For Q/D purposes, one considers the total net
explosives weight 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.
(b) Any building, vehicle, location, or ammunition that shall 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 secondary explosive source located a distance away. An ES may
also be a home, stadium, high-rise apartment, a public highway or any
other facility or location requiring protection from an accidental
explosion.
(c) Separation distances for Q/D purposes are measured in straight
lines from the nearest part of the room, bay or structure containing
explosives (PES) to the nearest point of the exposed structure.
Sec. 184.42 Establishment of quantity of explosives and distances.
(a) Quantity of explosives. The Quantity/Distance 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 subpart F of this part. Methods for determining the net explosives
weight (NEW) is explained in the following:
(1) Mass-detonating explosives (Hazard Division 1.1). The total
weight of explosives (NEW).
(2) Nonmass-detonating explosives--(i) Propellants (Hazard Division
1.3). The total weight of the propellants alone is the net propellant
weight.
(ii) 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.
(iii) Bulk metal powder and pyrotechnic compositions. The sum of
the net weights of metal powders and pyrotechnic compositions in the
containers.
(iv) 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).
(3) Combinations of mass-detonating and nonmass-detonating A&E
(excluding Hazard Division 1.4). The total net weight of the mass-
detonating and the nonmass-detonating A&E. If the nonmass-detonating
items, alone, require a greater distance than the total explosives so
computed, then this greater distance is mandatory.
(4) Combinations of nonmass-detonating ammunition and explosives of
different class 1 divisions shall be treated as follows:
(1) Determine the required separation of each division.
(ii) Use the greatest separation of those determined.
(b) Q/D computations and determinations. (1) Throughout these
requirements, NEW is used to calculate distance by means of formula
D=KW\1/3\, 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.
(2) The quantity of explosives in a magazine, operating building,
or other explosives site shall be the new weight of all the explosives
contained therein. Q/D shall be based on the H/D requiring the greatest
separation, unless the NEW is divided by walls or shields for that
purpose.
(i) 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,\5\
Structures to Resist the Effects of Accidental Explosions, 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.
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(ii) Blast waves shall 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.
(3) The quantity of explosives permitted in each of two or more
locations shall be determined by considering each location as a
potential explosion site (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
Sec. 184.43(a)(7) and Sec. 184.43(b)(6)).
(4) Quantity/distance tables are in Subpart F of this part. The
formulae specified in Appendices A through D to Subpart F of this part
may be used to interpolate exact distances for Hazard Division 1.1
explosives. The notes to Appendix L to Subpart F of this part provide
distance formulae for Hazard Division 1.3 distances.
(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
Sec. 184.52(f).
(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.
(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 (see Sec. 184.41(a)) and measured form the outside wall of
the building, railcar, 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 railcars and motor vehicles and
inside unit or units shall not occur, the separation distance shall be
measured from the controlling explosives unit, railcar or vehicle
closest to a target.
(c) 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.
(1) Separation distances for earth covered magazines (see
Appendices D and E to Subpart F of this part) 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.
(2) Aboveground magazine distances (see columns 10 and 12, Appendix
D to Subpart F of this part) provide considerable protection against
propagation of explosions among above-ground magazines by blast.
Depending on ammunition 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.
(i) 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,
shall be 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. A conventional unstrengthened building exposed at this
distance shall be destroyed, vehicles overturned and crushed, and all
occupants killed.
(ii) 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 shall be suppressed only slightly by a storage building of
conventional construction at the explosion site. A conventional
unstrengthened building exposed at this distance shall be destroyed.
Blast will seriously injure eardrums and lungs of any survivor, as will
being blown down or stuck by fragments or building debris. Vehicles
will be severely damaged by blast and may be inoperable.
(3) At blast overpressure of 12 psi (0.7 bars) occurring at scaled
distance of 9W1/3 feet (see Appendices B and C to Subpart F of
this part):
(i) Unstrengthened buildings will suffer severe structural damage
approaching total destruction.
(ii) People at the exposed site will be killed or severely injured
by being thrown about by blast or by building collapse.
(iii) Aircraft will be damaged beyond repair. If the aircraft are
loaded with explosives, delayed explosions are likely to result from
subsequent fires.
(iv) Transport vehicles will be heavily damaged, probably to the
extent of total loss.
(v) Direct propagation of explosion between two explosives
locations is unlikely when barricades between them intercept high-
velocity, low-angle fragments (see Sec. 184.43(a)).
(vi) Improperly designed barricades or structures increase the
hazard from flying debris; further, their probable collapse threatens
personnel and equipment.
(vii) Exposed structures housing personnel or containing equipment
that is monetarily valuable or critically important to the mission, may
require hardening.
(4) At blast overpressure of 3.5 psi (0.24 bars) occurring at
scaled distance of 18W1/3 (see Appendix B to Subpart F of this
part):
(i) Direct propagation of explosion is not expected.
(ii) Delayed communication of explosion from fires, or equipment
failure at the exposed site (ES), is possible.
(iii) Unstrengthened buildings will sustain serious damage,
approximating 50 percent of the total replacement cost.
(iv) Personnel will be critically injured or killed by fragments,
debris, firebrands, and so forth.
(v) There is a 1 percent chance of eardrum damage to personnel.
(vi) Aircraft will be severely damaged from blast, fragments, and
debris.
(vii) 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.
(viii) 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.
(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, Appendix A to Subpart F of this part).
(i) Unstrengthened buildings will sustain damage approximating 20
percent of their replacement cost.
(ii) Occupants of exposed structures may suffer temporary hearing
loss or be injured by such blast effects as building debris and being
bodily thrown about.
(iii) 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 within.
(iv) Vehicles on the road should not be damaged unless hit by
fragments or the operator loses control during the blast wave.
(v) Aircraft appendages and sheet metal skin could be damaged by
blast and possibly fragment penetrations, but should be operational
after minor repairs.
(vi) 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.
(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 (c)(5) and (c)(7) of this section (for
quantities between 100,000 and 250,000 pounds, see column 8, Appendix A
to Subpart F of this part).
(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, Appendix A to Subpart F of this part):
(i) Unstrengthened buildings will sustain damage approximating 10
percent of their replacement cost.
(ii) Occupants of exposed unstrengthened structures may suffer
injury from secondary effects, such as building debris.
(iii) Aircraft landing and taking off could lose control and crash.
(iv) Parked military and commercial aircraft, with minor damage due
to blast, should remain airworthy.
(v) 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 within, however,
fragments and debris could cause injuries.
(vi) Barricading at the PES or application of minimum fragment
distance requirements may reduce injury or damage due to fragments from
limited quantities of explosives.
(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,
Appendix A to Subpart F of this part):
(i) Unstrengthened buildings will sustain damage approximating 5
percent of their replacement cost.
(ii) Personnel injuries are principally caused by glass breakage
and building debris.
(iii) 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 within, however,
fragments and debris could cause injuries.
(iv) Both orientation and limiting the surface area of exposed
glass panels can reduce breakage and structural damage.
Sec. 184.43 Permissible exposures to blast overpressure.
(a) At sites exposed to potential blast overpressure of 12 psi (0.7
bars) occurring at 9W1/3 (see column 3, Appendix B to Subpart F
and Appendix C to Subpart F of this part), barricade required unless
otherwise indicated (see Sec. 184.42(c)(3)(vii)), the following
facilities or operations are permitted:
(1) Buildings housing successive steps of a single production,
renovation, or maintenance operation.
(2) Breakrooms and change houses, if part of an operating line and
used exclusively by personnel employed in operations of the line.
(3) Temporary holding areas for trucks or railcars containing
explosives to service production or maintenance facilities.
(4) Field operations in magazine areas, when performing minor
maintenance, preservation, packaging, or surveillance inspection.
(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).
(6) Dunnage preparation and similar support structures housing non-
explosives operations, if used only by PES employees.
(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.
(8) Exposures as indicated in paragraph (b) of this section, if
blast suppression, structure hardening, and so forth, provides
comparable protection for the personnel and equipment involved.
(b) At sites exposed to potential blast overpressure of 3.5 psi
(0.24 bars) occurring at 18W1/3 (see column 4, Appendix B to
Subpart F and Appendix C to Subpart F of this part), the following
facilities or operations are permitted:
(1) Construction workers in the vicinity of ammunition production
areas, waterfront areas where ammunition is being handled, or areas for
loading explosives onto aircraft.
(2) Surveillance, maintenance, and inspection buildings; and labor-
intensive operations closely related to PES.
(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).
(4) Operations and training functions manned or attended only by
personnel operating the PES.
(5) Parking lots for privately owned vehicles belonging to
personnel at the PES. See Sec. 184.33.
(6) 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.
(7) Container stuffing and unstuffing operations that are routine
support of 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.
(c) At sites exposed to potential blast overpressure of 2.3 psi
(0.16 bars) occurring at 24W1/3 (see column 8, Appendix A to
Subpart F of this part), the following facilities or operations are
permitted:
(1) Public traffic routes for NEW under 100,000 pounds.
(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).
(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.
(d) 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:
(1) Public traffic routes.
(2) Private vehicle parking in administrative areas. Minimum
fragment distance should be applied.
(e) 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, Appendix A, to Subpart F of this part), the following
facilities or operations are permitted:
(1) Inhabited buildings; administration and housing areas.
(2) Plant boundaries and magazines servicing the establishment in
general (see Sec. 184.45(j)).
(3) Athletic fields and other recreation areas when structures are
present.
(4) Flight line passenger service facilities.
(5) Utilities providing power to most of an establishment.
(6) Storehouses and shops having strategically or intrinsically
valuable contents which shall not be jeopardized.
(7) Functions which, if momentarily out of action, would cause an
immediate secondary hazard.
Sec. 184.44 Ammunition and explosives facilities.
This section identifies the types, general specifications, and
siting requirements of various magazines for ammunition, explosives,
and other dangerous materials.
(a) Barricades and earth cover for magazines--(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.
Further, 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).
(2) Barricade requirements. Protection is considered effective when
barricades meet the following minimum requirements:
(i) 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.
(ii) The earth barricade shall consist of material described in
paragraph (a)(4) of this section.
(iii) Barricade height and length shall be determined as follows:
(A) 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 he 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 Appendices A and B of this subpart.
(B) Lengths. The length of the barricade shall be determined as
shown in Appendix C of this subpart.
(iv) 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.
(v) Other barriers, such as earth-filled steel bin barricades for
explosives-loaded aircraft, may also be used.
(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.
(4) Earth cover for magazines and barricades. (i) 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.
(ii) 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.
(b) Application of Q/D to earth-covered magazines. (1) For
application of quantity/distances, 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.
(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 Sec. 184.54.
(c) 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 obstacles in
facility planning should be:
(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.
(2) Provision of protection for vital and expensive equipment, if
the additional cost is warranted.
(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.
Sec. 184.45 Specific siting requirements.
(a) Rail and truck holding yards. (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.
(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.
(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
high explosives in the cars on the spurs.
(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.
(5) Both rail and truck holding yards shall be separated from other
facilities by the applicable Q/D criteria.
(6) In addition to the temporary parking of railcars, trucks or
trailers containing ammunition and explosives, holding yards also may
be used to interchange truck trailers or railcars between commercial
carrier and the contractor and to conduct visual inspections.
(b) Classification yards. (1) To protect the classification yard
from external explosions, separation distances shall, at least, be the
applicable magazine distance.
(2) Specific quantity/distance separation is not required from the
classification yard to targets other than explosive locations when the
classification yard is used exclusively for the following:
(i) Receiving, dispatching, classifying, and switching of cars.
(ii) Interchanging of trucks, trailers, railcars, or MILVANS
between the common carrier and the establishment.
(iii) Conducting external inspection of motor vehicles and
railcars, or opening of free-rolling doors of railcars for the purpose
of removing documents and making a visual inspection of the cargo.
(3) If the yard is used at any time for any purpose other than
listed in paragraph (b)(2) of this section, such as placing or removal
of dunnage or explosive items into or from cars, Q/D tables apply. See
Sec. 184.42(b)(1) through (b)(7).
(c) Railcar and motor vehicle inspection stations. (1) Specific
quantity/distance 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 railcars or motor vehicles containing
ammunition and explosives are received from the delivering carrier,
before further routing within the installation:
(i) Visual inspection of railcar and motor vehicle exteriors.
(ii) Visual inspection of the cargo in vehicles (trucks, trailers,
railcars, MILVANS, and so forth) that have passed the external
inspection previously indicated.
(iii) Interchange of truck, trailers, railcars, or MILVANS between
the common carrier and the establishment.
(2) If any activities, other than those previously listed, are
conducted at the inspection station, Q/D tables apply.
(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.
(d) Administration, industrial, and convenience areas. (1)
Administration and industrial areas shall be separated from PES's by
inhabited building distances.
(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.
(e) 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.
(f) 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, Appendix A to Subpart F of this part shall apply.
(g) 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.
(h) 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.
(i) 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.
(j) 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.
(k) 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.
BILLING CODE 5000-04-M
TP16DE94.000
TP16DE94.001
TP16DE94.002
BILLING CODE 5000-04-C
Subpart E--Storage Compatibility System
Sec. 184.47 General.
(a) Storage of A&E is based on the capability requirements of this
subpart and the hazard classification requirements of Subpart F to this
part.
(b) Storage compatibility groups (SCG) 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). 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.
(c) 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.
(1) Title 49, Code of Federal Regulations, Transportation, Parts
100-199.
(2) National Fire Protection Association, Manual 491M.\6\
---------------------------------------------------------------------------
\6\Copies may be obtained from the National Fire Protection
Association, Batterymarch Park, Attn: National Fire Codes
Subscription--Service Department, Quincy, MA 02269.
---------------------------------------------------------------------------
(3) Data sheets developed by the National Safety Council.
(4) Data sheets developed by the Manufacturing Chemists
Association.
(5) Manuals and books providing information on the properties of
hazardous materials. There are a number of competent guides to the
safety precautions required when handling potentially hazardous
materials. These guides typically provide basic precautions, specific
hazardous reactions, and industrial hygiene information. Additional
guidance for industrial hygiene and industrial medicine is available
from the American Council of Governmental and Industrial Hygienists and
OSHA/NIOSH.
(d) The previous guidance is applicable for storage and
transportation only and is not intended for in-process applications.
For in-process application, refer to Subpart F of this part.
Sec. 184.48 Storage compatibility grouping.
(a) All A&E are assigned one of thirteen compatibility groups
(SCG).
(b) Storage principles. (1) The highest degree of safety in A&E
storage could be assured if each item or division were stored
separately. However, such ideal storage is not generally feasible. A
proper balance of safety and other factors frequently requires mixing
of several types of ammunition and explosives in storage.
(2) A&E shall not be stored with dissimilar materials or items that
present hazards to the munitions. Examples are mixed storage of A&E
with flammable or combustible materials, acids, or corrosives.
(3) Different types of A&E may be mixed in storage, by item and
division, provided they are compatible. A&E are assigned to a SCG when
they can be stored together without significantly increasing either the
probability of an accident or, for a given quantity, the magnitude of
the effects of such an accident.
(4) A&E should be mixed in storage only when such mixing will
facilitate safe operations and promote overall storage efficiency.
(5) As used in these requirements, the term ``with its own means of
initiation'' indicates that the ammunition has its normal initiating
device assembled to it and this device is considered to present a
significant risk during storage. However, the term does not apply when
the initiating device is packaged in a manner that eliminates the risk
of detonating the ammunition if the initiating device should
accidentally function, or when fuzed end items are configured and
packaged to prevent their inadvertent arming. The initiating device may
even be assembled to the ammunition, provided its safety features
preclude initiation or detonation of the explosives filler of the end
item if the initiating device should accidentally function.
(c) Compatible ammunition and explosives. (1) Different kinds of
A&E within one compatibility group are compatible and may be stored
together, except for some items in SCG K and L (see Appendix A to this
subpart).
(2) Ammunition and explosives in substandard or damaged packaging,
in a suspect condition, or with characteristics that increase the risk
in storage are not compatible with other A&E and shall be stored
separately.
(d) Storage compatibility group. A&E are assigned to one of
thirteen storage compatibility groups (A through H, J, K, L, N, and S):
(1) Group A--initiating explosives. Bulk initiating explosives that
have the sensitivity to heat, friction, or percussion necessary for use
as initiating elements in an explosive train. Examples are wet lead
azide, wet lead styphnate, wet mercury fulminate, wet tetracene, and
dry PETN.
(2) Group B. Detonators and similar initiating devices not
containing two or more independent safety features. Items containing
initiating explosives that are designed to initiate or continue the
functioning of an explosive train. Examples are detonators, blasting
caps, small arms primers, and fuzes.
(3) Group C. Bulk propellants, propelling charges, and devices
containing propellant with or without their own means of ignition.
Items that upon initiation will deflagrate, explode, or detonate.
Examples are single-, double-, triple-base, and composite propellants;
rocket motors (solid propellant); and ammunition with inert
projectiles. Liquid propellants are not included.
(4) Group D. Black powder, high explosives (HE), and ammunition
containing HE without its own means of initiation and without
propelling charge and fuzes with two or more safety features. A&E that
can be expected to explode or detonate when any given item/component
thereof is initiated (except for fuzes with two or more safety
features). Examples are bulk TNT, composition B, wet RDX or PETN,
bombs, and CBU's.
(5) Group E. A&E containing HE without its own means of initiation
and with propelling charge. See paragraph (b)(5) of this section.
Examples are artillery ammunition, rockets, and guided missiles.
(6) Group F. Ammunition containing HE with its own means of
initiation, not meeting requirements of paragraph (b)(5) of this
section, and with or without propelling charge. HE ammunition or
devices (fuzed), with or without propelling charges. Examples are
grenades, sounding devices, and similar items having an in-line
explosive train in the initiator.
(7) Group G. Fireworks; illuminating, incendiary, smoke (including
HC), or tear-producing munitions other than those munitions that are
water-activated or contain white phosphorus or flammable liquid or gel.
(8) Group H. Ammunition containing both explosives and white
phosphorus or other pyrophoric material. Ammunition in this group
contains fillers which are spontaneously flammable when exposed to the
atmosphere.
(9) Group J. Ammunition containing explosives and flammable liquids
or gels, with or without explosives. Ammunition in this group contains
flammable liquids or gels other than those that are spontaneously
flammable when exposed to water or the atmosphere. Examples are liquid-
or gel-filled incendiary ammunition; FAE devices; flammable, liquid-
fueled missiles; and torpedoes.
(10) Group K. Ammunition containing both explosives and toxic
chemical agents. Ammunition in this group contains chemicals
specifically designed for incapacitating effects more severe than
lachrymation. Examples are artillery or mortar ammunition, fuzed or
unfuzed, grenades, and rockets or bombs filled with a lethal or
incapacitating chemical agent (see note 8, Appendix A to this subpart).
(11) Group L. Ammunition not included in other compatibility
groups, having characteristics that do not permit storage with other
types of ammunition or kinds of explosives. Examples are water-
activated devices; prepackaged, hypergolic liquid-fueled rocket
engines; TPA (thickened TEA); and damaged or suspect ammunition of any
group. Types presenting similar hazards (that is, oxidizers with
oxidizers, fuels with fuels, etc.) may be stored together but not mixed
with other groups.
(12) Group N. Ammunition containing only extremely insensitive
detonating substance (EIDS); examples are bombs and warheads.
(13) Group S. Ammunition presenting no significant hazard. All
hazardous explosive effects are confined and self-contained within the
item or package. An incident may destroy all items in a single pack but
must not communicate to other packs. Examples are thermal batteries,
explosive switches or valves, and other ammunition items packaged to
meet this criterion.
(e) Mixed storage.
(1) Mixing of SCG's is permitted as indicated in Appendix A of this
subpart. For purposes of mixing, all items shall be packaged in
approved storage containers.
(2) Items from SCG's C, D, E, F, G, J, and S may be combined in
storage, provided the net quantity of explosives in the items or in
bulk does not exceed 1000 pounds per storage site.
(3) In addition to paragraph (e)(2) of this section, items assigned
to Hazard Division 1.4, SCG C, G, or S, may be combined in storage
without regard to explosives quantity limitations.
Sec. 184.49 Explosives hazard classification procedures.
TB 700-2/NAVSEAINST 8020.8/TO IIA-1-47/DLAR 8220, DoD Explosives
Hazard Classification Procedures, shall be used as a basis for
assignment of hazard class/division to all ammunition and explosives.
Appendix A to Subpart E of Part 184--Storage Compatibility Mixing Chart
--------------------------------------------------------------------------------------------------------------------------------------------------------
Groups A B C D E F G H J K L N S
--------------------------------------------------------------------------------------------------------------------------------------------------------
A............... X Z
B............... Z X Z Z Z Z Z X X
C............... Z X X X Z Z X X
D............... Z X X X Z Z X X
E............... Z X X X Z Z X X
F............... Z Z Z Z X Z X X
G............... Z Z Z Z Z X X X
H............... X X
J............... X X
K............... Z
L...............
N............... X X X X X X X X
S............... X X X X X X X X X X
--------------------------------------------------------------------------------------------------------------------------------------------------------
Notes:
1. An ``X'' indicates that the intersecting groups may be combined in storage. Otherwise, mixing is either prohibited or restricted per note 2.
2. A ``Z'' indicates that, when warranted by operational considerations or magazine nonavailability, and when safety is not sacrificed, the intersecting
groups may be combined in storage. Operational considerations include conditions that waste resources such as money, manpower, and energy, or
compromise security, readiness, or the ability to accomplish the installation mission. Storage personnel, after consultation with safety personnel,
should determine when operational considerations exist that warrant ``Z'' storage compatibility mixing. Examples of acceptable combinations of class 1
follow:
a. Division 1, group C, bulk propellants with division 1, group G, fireworks.
b. Division 1, group C, rocket motors with division 1, group F, ammunition with its own means of initiation.
c. Group C rocket motors with group B detonators and similar initiating items.
3. Equal numbers of separately packaged components of complete rounds of any single type of ammunition may be stored together. When so stored,
compatibility is that of the assembled round; that is, WP filler in group H, HE filler in group D, E, or F, as appropriate.
4. See Sec. 184.48(e) for permissible mixed storage of quantities of 1000 pounds or less.
5. Ammunition designated ``practice'' or ``target practice'' by national stock number and nomenclature may be stored with the fully loaded ammunition it
simulated (for example, 2.75 inch TP rockets with WP rockets).
6. Ammunition items without explosives containing substances more suited to another hazard division may be assigned to the same compatibility group as
items containing explosives and the same substances, and be stored with them.
7. Articles of Compatibility Group B and F shall each be segregated in storage from articles of other compatibility groups by means which are effective
in the prevention of propagation to those articles.
8. Group K requires not only separate storage from other groups, but also may require separation storage for different items within the group. Before
storage of mixed items in Group K, PCO approval shall be obtained.
9. If dissimilar Hazard Division 1.6, Group N munitions, such as Mk 82 and Mk 84 Bombs, are mixed together and have not been tested to assure non-
propagation; the mixed munitions are considered to be Hazard Division 1.2, Storage and Compatibility Group D for purposes of transportation and
storage.
Subpart F--Hazard Classification and Q/D Criteria
Sec. 184.51 General.
(a) This subpart outlines Q/D requirements applicable to storage,
processing, and handling of A&E. The maximum amount of explosives
permitted at any location is determined by the distance from that
location to other exposed sites and the hazard classification assigned
to the A&E involved. The applicable Q/D table in this subpart shall be
used to determine this distance. Greater distances than those shown in
the tables should be used when practicable.
(b) Distances required in the standard Q/D tables may be reduced if
structural data or engineering demonstrate that explosion effects will
be reduced or eliminated through containment, direction or suppression
shields or building volume. The rationale or test results justifying
the proposed distance reduction shall accompany A&E site and general
construction plans when submitted through the ACO for the PCO's
approval. See Sec. 184.7.
Sec. 184.52 Hazard classes and class divisions.
(a) The United Nations Organization (UNO) classification system
consists of nine hazard classes, with ammunition and explosives
included in Class 1; however, some items containing explosives
components may be included in other classes based upon the
``predominant hazard'' of that item (flammable liquids or compressed
gas). Thirteen compatibility groups are included for segregating
ammunition and explosives on the basis of similar characteristics,
properties, and potential accident effects.
(b) The A&E hazard classes are further subdivided into
``divisions'' according to the associate hazards, including the
potential for causing personnel casualties or property damage as shown:
------------------------------------------------------------------------
Hazard class and division
designator Hazards
------------------------------------------------------------------------
1.1.............................. Mass detonating.
1.2.............................. Nonmass-detonating fragment
producing.
1.3.............................. Mass fire.
1.4.............................. Moderate fire, no blast.
1.5.............................. Extremely insensitive detonating
substances (EIDS).
1.6.............................. EIDS loaded items.
------------------------------------------------------------------------
(c) DoD Explosives Hazard Classification Procedures (TB 700-2,
NAVSEAINST 8020.8, TO IIA-I-47 and DLAR 8220.1) shall be used as a
basis for assignment of hazard classes/divisions to all DoD ammunition
and explosives. As stated in Sec. 184.47(d), these classifications
pertain to A&E packaged for transportation or storage. Such hazard
classification information may not be valid when applied to the hazards
associated with manufacturing or loading processes. For such processes,
the materials and processes shall be analyzed on a case-by-case basis.
Sources of information to support this process of analysis are
available from service research and development organizations through
contract channels, and other sources. The methodologies described in
Sec. 184.199 for propellant is an example of an acceptable approach.
Sections 184.73 through 184.81 provide examples of processes requiring
analysis to determine the hazards.
(d) The separation of the A&E hazard classes into the several
divisions does not necessarily mean that the different items in a
division may be stored together. Also, some items may appear in more
than one division, depending upon factors such as the degree of
confinement or separation, type of packaging, storage configuration, or
state of assembly.
(e) The maximum amount of explosives permitted in any location is
limited by the Q/D criteria. Explosives limits shall be established in
amounts no greater than those consistent with safe and efficient
operations.
(f) A numerical figure (in parentheses) is used to indicate the
minimum separation distance (in hundreds of feet) for protection from
debris, fragments, and firebrands when distance alone is relied on for
such protection. This number shall be placed to the left of the
division designators 1.1 through 1.3, such as (18)1.1, (08)1.2, and
(06)1.3. The following apply to minimum fragment distances:
(1) A hazardous fragment is one having an impact energy of at least
58 ft-lb and a hazardous fragment density is constituted by at least
one hazardous fragment impacting in an area of 600 square feet or less.
Fragment distances do not indicate the maximum range to which fragments
may be projected.
(2) For divisions 1.1 and 1.3, a minimum distance number shall be
used where the ranges of hazardous fragments and firebrands EXCEED the
distances specified for inhabited buildings in the applicable Q/D
table.
(3) Minimum fragment distance protects personnel in the open;
minimum firebrand distance primarily protects facilities.
(4) Examples where minimum fragment and firebrand distances for
division 1.1 and 1.3 need not be applied follow:
(i) Recreation or training facilities, if these facilities are for
the exclusive use of personnel assigned to the PES.
(ii) Between PES and relatively static inert storage areas.
(iii) Between facilities in an operating line, between facilities
and holding sites in an operating line, between operating lines, and
between operating lines and storage locations normally separated by
inhabited building distances to protect workers and ensure against
interruption of production.
(5) The minimum distance for protection from hazardous fragments
shall be based on the debris producing characteristics of the PES and
the population density of the ES. For populous locations, the minimum
distance shall be that distance at which fragments, including debris
from structural elements of the facility or process equipment, shall
not exceed a hazardous fragment density of one hazardous fragment per
600 square feet (56 m\2\). If this distance is not known, the following
shall apply:
(i) For all Hazard Division 1.1 A&E, the minimum distance to
exposures shall be 670 feet for 100 pounds NEW or less. In quantities
of 101 to 30,000 pounds NEW, the minimum distance shall be 1,250 feet.
These distances may be reduced when it can be shown by test data that
reductions are warranted or when other alternatives, as described in
Sec. 184.52 (f)(6) through (f)(9) are used. For items that have been
evaluated adequately, different minimum distances may be used.
(Facilities sited at 1,235 or 1,245 feet in accordance with past
requirements shall be considered to be in compliance with the 1,250
foot minimum requirement.)
(ii) For public traffic routes that are not probable sites for
future construction, and for other exposures permitted at public
traffic route distances from PES, fragment and firebrand minimum
distances for Hazard Divisions 1.1 and 1.3 may be reduced to 60 percent
of these requisite distances.
(6) For sparsely populated locations on or off the establishment,
the minimum fragment distance can be reduced to 900 ft. if certain
specific conditions exist as follows:
(i) No more than 25 persons are located in any sector bounded by
the sides of a 45 degree angle, with the vertex at the PES, and the 900
ft. and 1,250 ft. arcs from the PES, and
(ii) The NEW of the PES does not exceed 11,400 pounds.
(7) Minimum fragment distances may extend onto uninhabited areas
such as wildlife preserve, desert, prairie, swamp, forest or
agricultural land, adjacent to contractor facilities but not within
control of the contractor. However, without a restrictive easement in
effect, construction of inhabited buildings or other exposures in these
areas, would reimpose minimum fragment distance.
(8) In lieu of the minimum fragment distances prescribed, other
alternatives, which reduce or eliminate the fragment hazard, may be
used for requirements compliance, per Sec. 184.51(b). Examples include:
(i) Use distance demonstrated by testing, accident experience or
engineering studies.
(ii) Use protective structures.
(iii) Use containment facilities or suppressive shields or other
fragment control devices.
(iv) Design/locate equipment to reduce fragment generation or to
control the direction of fragmentation.
(v) Use barricades or terrain where possible to stop low angle,
high velocity fragments.
(9) Fragment distance need not be applied when it is demonstrated
by structural analysis, shielding test or other documentation that
building construction and volume shall confine fragments and debris
resulting from an explosives accident.
(g) In the application of inhabited building and public traffic
route distances, the property boundary shall be treated as the
governing target. In interpreting application to navigable waterways as
public traffic routes, occasional small fishing and pleasure boats may
be ignored.
Sec. 184.53 Hazard Division 1.1--mass detonating.
(a) Entire quantities of items in this division can detonate almost
instantaneously. Some examples: bulk explosives, some propellants,
mines, bombs, demolition charges, torpedo and missile warheads,
rockets, palletized projectiles loaded with TNT or Composition B, 8-
inch and larger high-capacity projectiles loaded with Explosive D,
mass-detonating CBU's, and mass-detonating ammunition components.
(b) Use Appendix A to this subpart to determine inhabited building
and public traffic route distances, Appendices B and C to this subpart
for intraline distance, Appendix D to this subpart for intermagazine
distance and Appendices E and F to this subpart for fragment distances.
Sec. 184.54 Application of intermagazine distances for Hazard Division
1.1 only.
(a) In applying the intermagazine distances given in Appendix D to
this subpart, consideration shall be given to magazine construction and
orientation. For earth-covered magazine separation distances, the
following conditions apply:
(1) When standard earth-covered magazines containing Hazard
Division 1.1 ammunition are sited so that any one is in the forward
section, 60 degrees either side of the centerline of another, the two
shall be separated by distances greater than the minimum permitted for
side-to-side orientations. The greater distances primarily protect door
and headwall structures against blast from a potential explosion site
forward of the exposed magazine. When a blast wave is reflect from a
surface at other than grazing incidence (side-on orientation), the
overpressure may be increased substantially over the free-field value.
High reflected pressure impulse can damage doors and headwalls and
propel the debris into the earth-covered magazine, communicating the
explosion to the contents on impact. Some examples of the application
of these rules follow:
(i) If headwalls of both A and B are outside the 120-degree sector
(60 degrees either side of the centerline), they may be separated by
the column 4 distances based on the largest quantity of Hazard Division
1.1 stored in either. This is considered the equivalent of standard
side-to-side separation with the optimum orientation--all earth-covered
magazines facing the same direction and axes parallel. See paragraphs
(a) and (b), Appendix G to this subpart.
(ii) If headwall of A is outside the 120-degree sector of B, but
headwall of B is inside the 120-degree sector of A, separation distance
between these two earth-covered magazines is determined by column 6,
based on the largest quantity of Hazard Division 1.1 in either earth-
covered magazine. However, if the quantity in B were reduced to less
than \1/10\ of that in A, or if the storage in B is not class 1,
division 1, earth-covered magazine A would control as a potential
explosion site. Then, in accordance with Sec. 184.42, the distance
shall be taken from column 4, based on the quantity in A; that is, the
quantity in A would not need to be reduced. See paragraph c, Appendix G
to this subpart.
(iii) If headwalls of A and B are within the 120-degree sector of
each other and are not provided with a separate door barricade,
Appendix D to this subpart, column 12 distances shall be used to
separate them. If a door barricade is present (meeting requirements of
Sec. 184.44(a)) such as A to C, then column 10 distances may be used to
determine separation distances. See paragraph (a), Appendix G to this
subpart.
(iv) Although no separate barricade is shown between A and B, more
detailed analysis of a specific storage condition of this type might
show that the distribution of explosives within A and B is such that
the earth fill of one or the other or both meets the specifications of
an effective barricade according to Sec. 184.44(a). In such a case,
column 10 distances would apply between A and B. See paragraph (d),
Appendix G to this subpart.
(v) Two additional standard earth-covered magazine orientations
warrant analysis:
(A) Earth-covered magazines A and B significantly differ in length
(paragraph (f), Appendix G to this subpart) or are ``canted'' in such a
manner that one of them is within the 120-degree sector off the
headwall of the other, even though a straight line between headwall A
and earth-covered magazine B does pass through the earth cover of B.
See Appendix G to this subpart.
(B) If B is the potential explosion site and A is the exposed site,
the limit for B would be determined by column 7. With A as the
potential explosion site, however, the limit for A would be based upon
column 4.
(vi) For future construction when standard earth-covered magazines
containing Hazard Division 1.1 ammunition are sited so that any one is
in the forward sector of another, the two shall be separated by
distances greater than the minimum permitted for side-to-side
orientations. The forward sector, or ``front'', for earth-covered
magazines is the area 60 degrees either side of the magazine centerline
with the vertex of the angle placed so that the sides of the angle pass
through the intersection of the headwall and side walls. The greater
distances are required primarily for the protection of door and
headwall structures against blast from a PES forward of the exposed
magazine, and to a lesser extent due to the directionality of effects
from the source. When a blast wave is reflected from a surface at other
than grazing incidence (side-on orientation), the overpressure may be
increased substantially over the free-field value. High reflected
pressure and impulse can damage doors and headwalls and propel the
debris into the earth-covered magazine so that explosion is
communicated by impact of such debris upon the contents.
(2) When considering relationships between standard earth-covered
magazines and aboveground magazines or facilities requiring intraline
distances, each containing class 1, division 1, ammunition or
explosives, the question regarding the use of barricaded or
unbarricaded distances arises. The following criteria shall apply:
(i) Aboveground magazines or facilities requiring intraline
distances within the 120-degree sector in front of a standard earth-
covered magazine shall be provided unbarricaded distances, unless a
separate effective intervening barricade meeting requirements of
Sec. 184.44(a)(2) is present, in which case barricaded distances may be
applied. See paragraph (g), Appendix G to this subpart.
(ii) Aboveground magazines or facilities requiring intraline
distances outside of the 120-degree sector in front of a standard
earth-covered magazine shall be provided with barricaded distances
whether or not a separate intervening barricade is present. See
paragraph (g), Appendix G to this subpart.
(b) Distances in column 4 apply to nonstandard, earth-covered
magazines oriented so that all straight lines between the side and rear
walls of two magazines pass through an earth-covered surface of each;
similarly, column 10 distances apply to all orientations in which every
straight line between two magazine passes through the earth cover of
one and only one of them. If the above conditions cannot be met, column
12 distances apply. The earth cover of nonstandard magazines shall be
equal to or greater than that required for standard earth-covered,
arch-type magazines.
(c) Other factors limiting earth-covered magazine storage are as
follows:
(1) Earth-covered magazines that are equivalent in strength to
those specified under the definition of ``standard magazine'' in
Subpart S of this part are limited to 500,000 pounds NEW. Earth-covered
magazines, not equivalent in strength to those, are limited to 250,000
pounds NEW.
(2) Quantities above 500,000 pounds NEW in one storage location are
not authorized except for liquid propellants.
(3) The distance given for 0 to 100 pounds NEW constitutes the
minimum magazine spacing permitted.
(d) Examples given in Secs. 184.54 (a)(1)(i) through (a)(1)(v),
apply only to the storage of Hazard Division 1.1, ammunition and
explosives. Existing earth-covered magazines, regardless of
orientation, meeting the construction and barricading requirements of
Subpart D of this part and consistent with the definition of
``magazine'' in Subpart S of this part (and sited for any quantity of
class 1, division 1), may be used to their physical capacity for the
storage of Hazard Division 1.2, 1.3 and 1.4, A&E.
Sec. 184.55 Hazard Division 1.2--nonmass detonating, fragment
producing.
(a) Items in this division are those for which the principal
hazards are fragment and blast, either individually or in combination,
depending on such factors as storage configuration, type of packing,
and quantity. The designated minimum distances that are specified are
based on the limiting range of fragments for which protection by
distance is to be provided and shall be used for inhabited building and
public traffic route distances.
(b) The fragment hazard from items within a specified minimum
distance category varies with existing conditions, but is essentially
the same for one as for many items or components. For these items, the
required separation distances are influenced heavily by packing, state
of assembly, charge/weight ratio, and caliber. Items in this division
usually explode progressively when involved in a fire or otherwise
initiated. Therefore, the distances prescribed shall not be lessened if
the quantity to be stored is less than the maximum quantity specified
by the appropriate table. Use Appendices H through K to this subpart
for determining quantity/distance for Hazard Division 1.2.
Sec. 184.56 Hazard Division 1.3--mass fire.
Items in this division burn vigorously with little chance of being
extinguished in storage. Explosions shall normally be confined to
pressure ruptures of containers and shall not produce propagating shock
waves or damaging blast overpressure beyond the magazine distance
specified in Appendix L to this subpart. A severe hazard of the spread
of fire may result from burning container materials, propellant, or
other flaming debris being tossed about by the force of pressure
ruptures.
Sec. 184.57 Hazard Division 1.4--moderate fire, no blast.
Items in this division present a fire hazard with no blast hazard
and virtually no fragmentation hazard beyond the fire hazard clearance
ordinarily specified for high risk materials. Separate facilities for
storage and handling of this division should not be less than 100 feet
from other facilities, except those of fire-resistive construction,
which may be 50 feet from each other. The Q/D's for Hazard Division
1.1, 1.2, 1.3, 1.5 or 1.6 individually or in combination are not
affected by the presence of Hazard Division 1.4. Use Appendix M to this
subpart for determining quantity/distance of Hazard Division 1.4
material.
Sec. 184.58 Hazard Divisons 1.5 and 1.6.
(a) This section describes Q/D standards for EIDS (substances)
which are hazard classified 1.5, as well as ammunition items loaded
with EIDS which are hazard classified 1.6. Refer to Appendix N to this
subpart.
(b) Substances (1.5) and items (1.6) in these divisions are
designed to have a very low probability of detonating under normal
storage and handling conditions. In order to be so classified, these
A&E shall meet stringent tests prescribed in TB 700-2.
(c) Quantity/distance separations for Hazard Division 1.6
ammunition shall be based on the storage location and configuration.
This information is detailed in Appendix O to this subpart and
footnotes thereto. A maximum of 500,000 NEW shall be permitted at any
one location. Any special storage configuration and siting approved for
Hazard Division 1.1 ammunition or explosives may be used for storage of
like explosive weights of Hazard Division 1.6 ammunition.
(d) Blasting agents designated as Hazard Division 1.5 for
transportation are considered to be Hazard Division 1.1 for Q/D
purposes (storage).
(e) When Hazard Division 1.6 is located with Hazard Division 1.1 or
1.5, Hazard Division 1.6 is considered Hazard Division 1.1 for Q/D
purposes. When Hazard Division 1.6 is located with Hazard Division 1.2,
Hazard Division 1.6 is considered Hazard Division 1.2 for Q/D purposes.
(f) When Hazard Division 1.6 is located with Hazard Division 1.3,
add the explosives weight of the Hazard Division 1.6 to the weight of
Hazard Division 1.3 and consider as Hazard Division 1.3 for Q/D
purposes.
Sec. 184.59 Airfields.
(a) These provisions do not apply to explosives items installed on
aircraft or contained in survival and rescue kits such as signals,
flares, egress systems components, squibs and detonators for
jettisoning external stores, engine starter cartridges, fire
extinguisher cartridges, destructors in electronic equipment,
explosives components of emergency kits and equipment, and other such
items or materials necessary for safe flight operations.
(b) These Q/D requirements shall be applied:
(1) To any airfield at which A&E are handled or stored.
(2) In conjunction with airfield clearance criteria as prescribed
by DoD Components and 14 CFR part 77. Airfields, heliports, and
seadromes not used exclusively by DoD Components, combat aircraft
parking areas, ammunition and explosives cargo areas, alert hangars,
and shelters shall be located as prescribed in Appendix P to this
subpart.
(3) In separating ammunition and explosives facilities from
inhabited buildings, public traffic routes, and other ammunition and
explosives facilities, in accordance with Subparts D and F of this
part.
(c) In applying the requirements prescribed in Appendix P to this
subpart, distances shall be measured as follows:
(1) Loaded aircraft to loaded aircraft. Measure the distance from
explosives on one aircraft to explosives on adjacent aircraft.
(2) Ammunition and explosives location to taxiways and runways.
Measure from the nearest point of the A&E location to the nearest point
of the taxiway and to the centerline of the runway.
(d) Separation distances between the following areas and from these
areas to other targets shall be determined by applying Appendix Q to
this subpart:
(1) A&E cargo areas.
(2) A&E storage facilities.
(3) A&E operating facilities.
(e) A&E shall be prohibited under approach/departure zones of fixed
and rotary wing aircraft landing facilities. The approach/departure
zones for aircraft (surfaces or areas) are described in detail in
airfield and airspace criteria directives of the DoD Components. In
general, approach/departure zones begin near the end of a runway or
landing area and extend outward to a given distance along, and
symmetrically on each side of, the extended runway centerline or the
aircraft approach axis of a heliport. Such zones flare uniformly from
the landing area outward to a prescribed limit.
Sec. 184.60 Pier and wharf facilities.
(a) Applicability and scope. This section applies to piers and
wharfs and associated facilities at which ammunition and explosives may
be handled, or be present in ships' holds or service conveyances. Its
provisions do not apply to ammunition or explosives stored in ships'
magazines and intended for the service of shipboard armament or
aircraft. However, they do apply to loading, off-loading, stowing, and
shifting of such ammunition and explosives. Q/D's herein are for Hazard
Division 1.1. Effects of an explosion to be expected when these Q/D's
are applied are described in Subpart D of this part. If only ammunition
and explosives of other class/division are involved the Q/D's for such
hazards shall be applied as appropriate.
(b) Determination of quantity of explosives in a ship. (1) On board
ship, the various types of ammunition and explosives are stored
relatively close to each other, and a detonation in the HE part of the
cargo may receive considerable support from items that are considered
normally to be only fragment or fire hazards; therefore, the total
quantity of explosives on board a ship shall be determined in
accordance with Subpart D of this part.
(2) When ship units are separated by 11W1/3 distances or
greater, Q/D shall be based individually on the quantity of each ship
unit. Lesser separation distances require that the explosives in both
ship units be totalled for Q/D purposes.
(c) Measurement of separation distance--(1) Ships at a pier.
Measurement of separation distances between ships shall be from the
nearest point of one unit to the nearest point of the other. Movement
of cars passing through the clear space is considered as an operations
risk. It will generally be impracticable to separate berths at a single
pier by enough distance to prevent mass detonation of ships containing
complete cargoes of Hazard Division 1.1 ammunition. To the extent
operationally feasible, therefore, scheduling shall be such as to
reduce the number of such exposures and total time that they are
required.
(2) Piers. The separation distances between piers shall be measured
from the nearest point of the ship unit at one pier to the nearest
point of the ship unit under consideration at the other pier.
(3) Anchorages. Measurements from anchorages generally shall be
from the boundary of the area designated for the scuttling site or the
explosives anchorage. In the case of the explosives anchorage, the
separation distance to outside targets shall depend upon whether:
(i) The ship units that are loading or unloading within the
explosives anchorage are separated properly, taking into consideration
location and the amount of explosives in each ship unit. The ship unit
equivalent for an explosives anchorage is a circle, the radius of which
is the distance from the mooring buoy or the ship's anchor to the stern
of the ship or of the ammunition lighters alongside when riding to the
full scope of the chain. To maintain proper separation distance between
loading or unloading ship units in the explosives anchorage, the ships
shall moor or anchor so that at no time will they have a separation
distance less than 11W1/3 if quanities are not to be totalled.
(ii) The ships being loaded or unloaded at one area are separated
properly from the loaded ships in another area and whether the loaded
ships within the loaded ship area are separated properly from each
other. If the latter conditions do not apply, the quantity for entering
the table shall be the total quantity rather than the unit quantity.
(4) Dolphins or interrupted quays. Measurement of separation
distance between ships moored to dolphins or interrupted quays shall be
from the nearest point of one unit to the nearest point of the other.
(5) Fixed targets. The measurement of separation distance from
moored ships to fixed targets on land shall be from the nearest
boundary of the ship or barge unit to the nearest fixed target.
(d) Siting criteria and application of Q/D separation
requirements--(1) Scuttling site. (i) A properly located scuttling site
shall be provided, if practicable, for positioning a ship for its
flooding or sinking in the event a vessel catches fire and shall be
moved to avert damage to other ships or piers. It shall have sufficient
sea room and depth of water to permit the sinking of the largest vessel
that may be handled at the installation so that the holds will be
flooded completely at low water.
(ii) Since an explosion may occur while the vessel is being moved,
the location of the scuttling site shall provide the best available
protection to other ships, piers, and shore installations.
(iii) The location of the scuttling site will depend on the
greatest net quantity of mass-detonating explosives that may be in a
single ship at any one time. The Q/D tables to be used will depend on
the particular types of targets.
(2) Explosives anchorage. The location of an explosives anchorage
shall be separated not only from the main ship channel or from normally
traversed routes of ships entering or leaving the harbor by column 8,
Appendix A to this subpart distances but also by turning circles and
stopping distances of the ships. Assuming that the diameter of the
turning circle of a ship is 1,000 yards, an explosives anchorage shall
be located so that a ship in the channel with a jammed rudder will
clear an anchored explosives-laden ship. From the turning circle
standpoint, the separation distances shall be not less than 3,000 feet.
(i) Separation of ships at explosives anchorages. (A) When
explosives anchorages are used for loading and unloading ships, as well
as for fully loaded vessels anchored at their berths, ships that are
being loaded or unloaded shall be separated from fully loaded ships.
(B) When the explosives anchorage is used only for loading and
unloading ships, to prevent mass detonation, ships in the explosives
anchorage shall be separated by at least 11W1/3 distances.
Whenever posssible, these distances shall be increased to 18W1/3
to reduce the loss potential of any incident.
(C) Loaded ships shall be separated one from another by at least
18W1/3 distances.
(ii) Separation of explosives anchorages from other targets.
Explosives shall be from anchorages separated explosives piers by 40
W1/3 distances except when the anchorage is used only for the
loading or unloading of vessels. In such cases, 18W1/3 may be
used.
(3) Separation distances of ship units in tandem at the sam pier.
(i) Since the second ship would be in an area of heavy fragment density
from the exploding ship, it could be set afire and later caused to
mass-detonate. A direct hit by a steel fragment on ammunition alongside
the ship or in an open hold could also cause a mass detonation. The
separation distances based on blast damage alone accordingly are not
enough to take care of such fragment hazards. Berthing of the two ships
in tandem will help to decrease the fragment hazard to the explosives
cargo of the second ship because of the additional protection afforded
by the bow or stern.
(ii) When two ships cannot be separated by 11W1/3 distances
and are being loaded through all hatches, the spotting of cars and the
loading of hatches in both ships should be planned so as to put the
greatest possible distance between open hatches of both ships, and
between the trucks and freight cars serving the two ships. When
possible, the loading of the ships should be staggered.
(4) Separation of explosives ships from other ships. Explosives
ships being loaded or unloaded shall be separated from nonexplosives-
carrying ships and from loaded explosives ships that are not underway
by 40W1/3 distances. Column 8, Appendix A to this subpart
distances shall be used for protection of ships that are underway.
(5) Occasional watercraft passing through Q/D arcs are not subject
to Q/D requirements.
(e) Quantity/distance tables. Appendix R to this subpart shall be
used in applying Appendix S to this subpart, Q/D. Appendix A to this
subpart, Q/D shall be maintained between explosives pier and wharf
facilities and such ES's as administration and industrial areas,
terminal boundary, main ship channel, and public traffic routes. As ES,
ship or barge units shall be separated from explosives operating and
storage facilities (including holding yards) by Column 5, Appendix A to
this subpart, distances. As PES, ship or barge units shall be separated
from explosives operating facilities by Column 5, Appendix A to this
subpart, distances, and from explosives storage facilities by Column 2,
Appendix S to this subpart (barricaded) and Column 3 (unbarricaded),
distances, as appropriate.
Appendix A to Subpart F of Part 184.--Hazard Division 1.1--Inhabited Building Distance and Public Traffic Route
Distances
Net explosive weight Distance in feet to inhabited Distance in feet to public traffic
----------------------------------- building from route from
-----------------------------------------------------------------------------
Standard earth-covered Standard earth-covered
magazine magazine
Over Not over -------------------------- Other PES -------------------------- Other PES
Front or Front or
side Rear side Rear
Col 1 Col 2 Col 3 Col 4 Col 5 Col 6 Col 7 Col 8
----------------------------------------------------------------------------------------------------------------
0.................... 1 35 25 40 21 15 24
1.................... 2 44 32 50 26 19 30
2.................... 5 60 43 69 36 26 40
5.................... 10 75 54 87 45 32 52
10................... 20 95 68 110 57 41 65
20................... 30 110 78 125 65 47 75
30................... 40 120 86 140 72 51 83
40................... 50 130 92 150 77 55 89
50................... 100 160 115 190 97 70 115
100.................. 200 205 145 235 125 88 140
200.................. 300 235 165 270 140 100 160
300.................. 400 260 185 295 155 110 175
400.................. 500 280 200 320 165 120 190
500.................. 600 295 210 340 175 125 205
600.................. 700 310 220 355 185 135 215
700.................. 800 325 230 375 195 140 225
800.................. 900 340 240 390 205 145 235
900.................. 1,000 350 250 400 210 150 240
1,000................ 1,500 400 285 460 240 170 275
1,500................ 2,000 440 315 505 265 190 305
2,000................ 3,000 505 360 580 305 215 350
3,000................ 4,000 555 395 635 335 240 380
4,000................ 5,000 600 430 685 360 255 410
5,000................ 6,000 635 455 730 380 275 440
6,000................ 7,000 670 480 770 400 285 460
7,000................ 8,000 700 500 800 420 300 480
8,000................ 9,000 730 520 835 435 310 500
9,000................ 10,000 755 540 865 450 325 520
10,000............... 15,000 865 615 990 520 370 595
15,000............... 20,000 950 680 1,090 570 405 655
20,000............... 25,000 1,025 730 1,170 615 440 700
25,000............... 30,000 1,085 775 1,250 650 465 745
30,000............... 35,000 1,145 820 1,310 685 490 785
35,000............... 40,000 1,195 855 1,370 720 515 820
40,000............... 45,000 1,245 890 1,425 745 535 855
45,000............... 50,000 1,290 920 1,475 775 555 885
50,000............... 55,000 1,330 950 1,520 800 570 910
55,000............... 60,000 1,370 980 1,565 820 585 940
60,000............... 65,000 1,405 1,005 1,610 845 605 965
65,000............... 70,000 1,440 1,030 1,650 865 620 990
70,000............... 75,000 1,475 1,055 1,685 885 635 1,010
75,000............... 80,000 1,510 1,075 1,725 905 645 1,035
80,000............... 85,000 1,540 1,100 1,760 925 660 1,055
85,000............... 90,000 1,570 1,120 1,795 940 670 1,075
90,000............... 95,000 1,595 1,140 1,825 960 685 1,095
95,000............... 100,000 1,625 1,160 1,855 975 695 1,115
100,000.............. 110,000 1,740 1,290 1,960 1,045 770 1,175
110,000.............. 120,000 1,855 1,415 2,065 1,110 850 1,240
120,000.............. 125,000 1,910 1,480 2,115 1,145 890 1,270
125,000.............. 130,000 1,965 1,545 2,165 1,180 925 1,300
130,000.............. 140,000 2,070 1,675 2,255 1,245 1,005 1,355
140,000.............. 150,000 2,175 1,805 2,350 1,305 1,085 1,410
150,000.............. 160,000 2,280 1,935 2,435 1,370 1,160 1,460
160,000.............. 170,000 2,385 2,070 2,520 1,430 1,280 1,540
170,000.............. 175,000 2,435 2,135 2,565 1,460 1,280 1,540
175,000.............. 180,000 2,485 2,200 2,605 1,490 1,320 1,565
180,000.............. 190,000 2,585 2,335 2,690 1,550 1,400 1,615
190,000.............. 200,000 2,680 2,470 2,770 1,610 1,480 1,660
200,000.............. 225,000 2,920 2,810 2,965 1,750 1,685 1,780
225,000.............. 250,000 3,150 3,150 3,150 1,890 1,890 1,890
250,000.............. 275,000 3,250 3,250 3,250 1,950 1,950 1,950
275,000.............. 300,000 3,345 3,345 3,345 2,005 2,005 2,005
300,000.............. 325,000 3,440 3,440 3,440 2,065 2,065 2,065
325,000.............. 350,000 3,525 3,525 3,525 2,115 2,115 2,115
350,000.............. 375,000 3,605 3,605 3,605 2,165 2,165 2,165
375,000.............. 400,000 3,685 3,685 3,685 2,210 2,210 2,210
400,000.............. 425,000 3,760 3,760 3,760 2,250 2,250 2,250
425,000.............. 450,000 3,830 3,830 3,830 2,300 2,300 2,300
450,000.............. 475,000 3,900 3,900 3,900 2,340 2,340 2,340
475,000.............. 500,000 3,970 3,970 3,970 2,380 2,380 2,380
Notes:
1.Distances are computed using the following factors:
--------------------------------------------------------------------------------------------------------------------------------------------------------
NEW Col 3 Col 4 Col 5 Col 6 Col 7 Col 8
--------------------------------------------------------------------------------------------------------------------------------------------------------
0 to 100,000................................ 351/3 25W1/3 40W1/3 21W1/3 15W1/3 24W1/3
100,000 to 250,000.......................... .3955W 7227 .004125W 1.0898 2.42W 577 .2375W 7227 .002475W 1.0898 1.452W .577
250,000 to 15,000,000....................... 50W1/3 50W1/3 50W1/3 30W1/3 30W1/3 30W1/3
--------------------------------------------------------------------------------------------------------------------------------------------------------
2.The policy contained in Sec. 184.52(g), shall be employed for mass-detonating, fragment-producing items.
3.The distance for 0 to 50 points maybe used only when structures, blast mats, and so forth can completely confine fragments and debris. Lesser
distances may be used only if blast, fragments, and debris can be confined completely, as by certain test firing barricades.
4.Applies only to earth-covered magazines with dimensions of 26 feet wide and 60 feet long, or larger.
Appendix B to Subpart F of Part 184--Hazard Division 1.1--Intraline
Distances
------------------------------------------------------------------------
Net expl. wt. (lb) Distance in feet (Hazard
----------------------------------------------- factor)
-------------------------
No
Over Not over Barricade barricade
(k=9) (k=18)
Col 1 Col 2 Col 3 Col 4
------------------------------------------------------------------------
0................................ 50 30 60
50............................... 100 40 80
100.............................. 200 50 100
200.............................. 300 60 120
300.............................. 400 65 130
400.............................. 500 70 140
500.............................. 600 75 150
600.............................. 700 80 160
700.............................. 800 85 170
800.............................. 900 85 175
900.............................. 1,000 90 180
1,000............................ 1,500 105 210
1,500............................ 2,000 115 230
2,000............................ 3,000 130 260
3,000............................ 4,000 145 290
4,000............................ 5,000 155 310
5,000............................ 6,000 165 330
6,000............................ 7,000 170 340
7,000............................ 8,000 180 360
8,000............................ 9,000 185 370
9,000............................ 10,000 195 390
10,000........................... 15,000 225 450
15,000........................... 20,000 245 490
20,000........................... 25,000 265 530
25,000........................... 30,000 280 560
30,000........................... 35,000 295 590
35,000........................... 40,000 310 620
40,000........................... 45,000 320 640
45,000........................... 50,000 330 660
50,000........................... 55,000 340 680
55,000........................... 60,000 350 700
60,000........................... 65,000 360 720
65,000........................... 70,000 370 740
70,000........................... 75,000 380 760
75,000........................... 80,000 390 780
80,000........................... 85,000 395 790
85,000........................... 90,000 405 810
90,000........................... 95,000 410 820
95,000........................... 100,000 420 840
100,000.......................... 125,000 450 900
125,000.......................... 150,000 480 960
150,000.......................... 175,000 505 1,010
175,000.......................... 200,000 525 1,055
200,000.......................... 225,000 545 1,090
225,000.......................... 250,000 565 1,135
250,000.......................... 275,000 585 1,170
275,000.......................... 300,000 600 1,200
300,000.......................... 325,000 620 1,240
325,000.......................... 350,000 635 1,270
350,000.......................... 375,000 650 1,300
375,000.......................... 400,000 665 1,330
400,000.......................... 500,000 715 1,430
500,000.......................... 600,000 760 1,520
600,000.......................... 700,000 800 1,600
700,000.......................... 800,000 835 1,670
800,000.......................... 900,000 870 1,740
900,000.......................... 1,000,000 900 1,800
1,000,000........................ 1,500,000 1,030 2,060
1,500,000........................ 2,000,000 1,135 2,270
2,000,000........................ 2,500,000 1,220 2,440
2,500,000........................ 3,000,000 1,300 2,600
3,000,000........................ 3,500,000 1,365 2,730
3,500,000........................ 4,000,000 1,430 2,860
4,000,000........................ 5,000,000 1,540 3,080
------------------------------------------------------------------------
Note: For less than 50 pounds, shorter distances may be used when
structures, blast mats, and so forth can completely contain fragments
and debris. This distance must be, determined by formula D=kW1/3,
where k=9 for barricaded explosives and k=18 for unbarricaded
explosives. When blast, fragments, and debris are confined completely,
as by certain test firing barricades, this table is not applicable.
Appendix C to Subpart F of Part 184.--Hazard Division 1.1--Intraline Distances From Earth-Covered Magazines
----------------------------------------------------------------------------------------------------------------
Barricaded Unbarricaded
NEW (lbs) -----------------------------------------------------------------------------
Front Side Rear Front Side Rear
Col. 1 Col. 2 Col. 3 Col. 4 Col. 5 Col. 6 Col. 7
----------------------------------------------------------------------------------------------------------------
50................................ 35 25 20 60 60 4
100............................... 45 30 30 80 75 5
200............................... 60 40 35 100 95 7
300............................... 65 45 40 120 105 8
400............................... 75 50 45 130 120 9
500............................... 80 55 50 140 125 9
600............................... 85 60 50 150 135 10
700............................... 90 60 55 160 140 10
800............................... 90 65 55 170 150 11
900............................... 95 70 60 175 155 11
1,000............................. 100 70 60 180 160 12
1,500............................. 115 80 70 210 185 13
2,000............................. 125 90 75 230 200 15
3,000............................. 145 100 85 260 230 17
4,000............................. 160 110 95 290 255 19
5,000............................. 170 120 100 310 275 20
6,000............................. 180 125 110 330 290 22
7,000............................. 190 135 115 340 305 23
8,000............................. 200 140 120 260 320 24
9,000............................. 210 145 125 370 330 25
10,000............................ 215 150 130 390 345 26
15,000............................ 245 175 150 450 395 29
20,000............................ 270 190 165 490 435 32
25,000............................ 290 205 175 530 470 35
30,000............................ 310 220 185 560 500 37
35,000............................ 325 230 195 590 525 39
40,000............................ 340 240 205 620 545 410
45,000............................ 355 250 215 640 570 425
50,000............................ 370 260 220 660 590 440
55,000............................ 380 265 230 680 610 455
60,000............................ 390 275 235 700 625 470
65,000............................ 400 280 240 720 645 480
70,000............................ 410 290 245 740 660 495
75,000............................ 420 295 255 760 675 505
80,000............................ 430 300 260 780 690 520
85,000............................ 440 310 265 790 705 530
90,000............................ 450 315 270 810 715 540
95,000............................ 455 320 275 820 730 545
100,000........................... 465 325 280 840 745 555
125,000........................... 500 350 300 900 800 605
150,000........................... 530 370 320 960 850 650
175,000........................... 560 390 335 1,010 895 700
200,000........................... 585 410 350 1,055 935 745
225,000........................... 610 425 365 1,090 975 795
250,000........................... 630 440 380 1,135 1,005 840
275,000........................... 650 455 390 1,170 1,040 890
300,000........................... 670 470 400 1,200 1,070 935
325,000........................... 675 520 465 1,240 1,135 1,035
350,000........................... 680 570 530 1,270 1,200 1,130
375,000........................... 685 615 600 1,300 1,265 1,230
400,000........................... 690 665 665 1,330 1,330 1,330
500,000........................... 715 715 715 1,430 1,430 1,430
----------------------------------------------------------------------------------------------------------------
Note: Testing has shown some attenuation of the airblast overpressure occurs at the sides and rear of earth-
covered magazines relative to the unconfined surface burst configuration. Some slight overpressure increase
occurs at the front. To account for this attenuation, the 12 psi (Barricaded) and 3.5 psi (Unbarricaded)
Intraline Distances from earth-covered magazines are given according to the factors presented below.
------------------------------------------------------------------------
NEW Range (1
Exposure lbs) Vice K9 Vice K18
------------------------------------------------------------------------
Front.......................... 1-300K\1\ 10 18
300-500K 10-9 18
Side........................... 1-300K 7 16
300-400K 7-9 16-18
over 400K 9 18
Rear........................... 1-100K 6 12
100K-300K 6 12-14
300K-400K 6-9 14-18
over 400K 9 18
------------------------------------------------------------------------
\1\300K=300,000.
Appendix D to Subpart F of Part 184--Hazard Division 1.1--Intermagazine Hazard Factors and Distances
[Part A--Hazard Factors (K)]
Standard earth-covered magazine\1\ Nonstandard earth-covered magazine\2\ Above-ground
------------------------------------------------------------------------------------------ magazine (not Modules
earth covered)\3\ and/or
-------------------- cells
From (PES)...................... To (ES) S R FU FB S R FU FB U B B
--------------------------------------------------------------------------------------------------------------------------------------------------------
Standard earth-covered S 1.25 1.25 2.75 2.75 1.25 1.25 6 6 6 4.5 1.25
magazine\1\.
R 1.25 1.25 2 2 1.25 1.25 6 6 6 4.5 1.25
FU 2.75 2 11 6 2.75 2 11 6 11 6 6
FB 2.75 2 6 6 2.75 2 6 6 6 6 6
Nonstandard earth-covered S 1.25 1.25 2.75 2.75 1.25 1.25 6 6 6 6 1.25
magazine\2\.
R 1.25 1.25 2 2 1.25 1.25 6 6 6 6 1.25
FU 6 6 11 6 6 6 11 6 11 6 6
FB 6 6 6 6 6 6 6 6 6 6 6
Above-ground magazine (not earth U 4.0 4.0 11 6 4.0 4.0 11 6 11 6 6
covered)\3\.
B 4.0 4.0 6 6 4.0 4.0 6 6 6 6 6
Modules and/or Cells............ B 1.25 1.25 6 6 1.25 1.25 6 6 6 6 1.1
Legend: S--side; R--rear; F--front; B--barricaded; U--unbarricaded.
\1\Standard earth-covered, arch type magazines comprise all magazines equal to or stronger than Army igloo magazines; navy arch-type magazines; and
earth-covered, corrugated steel, arth-type magazines. See definition of magazine.
\2\Nonstandard earth-covered magazines with earth cover equal to or greater than that required by standard, earth-covered, arch-type magazines.
\3\Aboveground magazines are all type above grade (not earth-covered) magazines or storage pads.
Note: Use Part A of this table to find the hazard factor, K, corresponding to the types and aspects of the two magazines. Use the column for this hazard
factor in Part B to determine the appropriate distance for the net explosive weight involved. Sec. 184.54(a)(1) describes Q-D for various magazine
orientations.
Appendix D to Subpart F of Part 184--Hazard Division 1.1--Intermagazine Hazard Factors and Distances
[Part B]
--------------------------------------------------------------------------------------------------------------------------------------------------------
Net expl. wt. (lb) Hazard factor (k) from part A
--------------------------------------------------------------------------------------------------------------------------------------------------------
Over Not over 1.1 1.25 2 2.75 4 4.5 5 6 8 11
--------------------------------------------------------------------------------------------------------------------------------------------------------
0............................................. 100 7 7 9 13 18 21 24 28 36 51
100........................................... 200 7 7 12 16 24 26 30 35 48 64
200........................................... 300 7 8 13 18 26 30 32 40 52 74
300........................................... 400 8 9 15 20 30 33 36 44 60 81
400........................................... 500 9 10 16 22 32 36 40 48 64 87
500........................................... 600 9 11 17 23 34 38 44 51 68 93
600........................................... 700 10 11 18 24 36 40 44 53 72 98
700........................................... 800 10 12 19 26 38 42 48 56 76 102
800........................................... 900 11 12 19 27 38 43 48 58 76 106
900........................................... 1,000 11 13 20 28 40 45 50 60 80 110
1,000......................................... 1,500 13 14 23 31 46 52 56 69 92 126
1,500......................................... 2,000 14 16 25 34 50 57 64 76 100 139
2,000......................................... 3,000 16 18 29 40 58 65 72 86 116 158
3,000......................................... 4,000 17 20 32 44 64 72 80 95 128 175
4,000......................................... 5,000 19 21 34 47 68 77 84 103 136 188
5,000......................................... 6,000 20 23 36 50 72 82 92 109 144 200
6,000......................................... 7,000 21 24 38 53 76 86 96 115 152 210
7,000......................................... 8,000 22 25 40 55 80 90 100 120 160 220
8,000......................................... 9,000 23 26 42 57 84 94 104 125 168 230
9,000......................................... 10,000 24 27 43 59 86 97 108 130 172 235
10,000........................................ 20,000 30 35 55 75 110 120 140 165 220 300
20,000........................................ 30,000 35 40 60 85 120 140 160 185 240 340
30,000........................................ 40,000 40 45 70 95 140 150 170 205 280 375
40,000........................................ 50,000 40 45 75 100 150 170 180 220 300 405
50,000........................................ 60,000 45 50 80 110 160 180 200 235 320 430
60,000........................................ 70,000 45 50 80 115 165 185 210 245 320 455
70,000........................................ 80,000 45 55 85 120 170 195 220 260 340 475
80,000........................................ 90,000 50 55 90 125 180 200 220 270 360 495
90,000........................................ 100,000 50 60 95 135 190 210 230 280 380 510
100,000....................................... 125,000 55 65 100 140 200 225 250 300 400 550
125,000....................................... 150,000 60 65 105 145 210 240 260 320 420 585
150,000....................................... 175,000 60 70 110 155 220 250 280 335 440 615
175,000....................................... 200,000 65 75 115 160 230 260 290 350 460 645
200,000....................................... 225,000 65 75 120 165 240 270 300 365 480 670
225,000....................................... 250,000 70 80 125 175 250 285 320 380 500 695
250,000....................................... 300,000 75 85 135 185 270 300 340 400 540 735
300,000....................................... 350,000 80 90 140 195 280 320 350 425 560 775
350,000....................................... 400,000 80 90 145 205 290 330 370 440 580 810
400,000....................................... 450,000 85 95 155 210 310 345 380 460 620 845
450,000....................................... 500,000 85 100 160 220 320 360 400 475 640 875
500,000....................................... 600,000 95 105 170 230 340 380 420 505 680 930
600,000....................................... 700,000 100 110 180 245 360 400 440 535 720 975
700,000....................................... 800,000 100 115 185 255 370 420 460 555 740 1,020
800,000....................................... 900,000 105 120 195 265 390 435 480 580 780 1,060
900,000....................................... 1,000,000 110 125 200 275 400 450 500 600 800 1,100
1,000,000..................................... 1,250,000 120 135 215 295 430 485 540 645 860 1,185
1,250,000..................................... 1,500,000 125 145 230 315 460 515 570 685 920 1,260
1,500,000..................................... 1,750,000 135 150 240 330 480 540 600 725 960 1,325
1,750,000..................................... 2,000,000 140 160 250 345 500 570 630 755 1,000 1,385
2,000,000..................................... 2,250,000 145 165 260 360 520 590 660 785 1,040 1,440
2,250,000..................................... 2,500,000 150 170 270 375 540 610 680 815 1,080 1,495
2,500,000..................................... 2,750,000 155 175 280 385 560 630 700 840 1,120 1,540
2,750,000..................................... 3,000,000 160 180 290 395 580 650 720 865 1,160 1,585
3,000,000..................................... 3,250,000 165 185 295 405 590 670 740 890 1,180 1,630
3,250,000..................................... 3,500,000 165 190 305 415 610 680 760 910 1,220 1,670
3,500,000..................................... 3,750,000 170 195 310 430 620 700 780 930 1,240 1,710
3,750,000..................................... 4,000,000 175 200 315 435 630 715 790 950 1,260 1,745
4,000,000..................................... 4,250,000 180 200 325 445 650 730 810 970 1,300 1,780
4,250,000..................................... 4,500,000 180 205 330 455 660 740 830 990 1,320 1,815
4,500,000..................................... 4,750,000 185 210 335 460 670 760 840 1,010 1,340 1,850
4,750,000..................................... 5,000,000 190 215 340 470 680 770 860 1,025 1,360 1,880
5,000,000..................................... 5,500,000 195 220 355 485 710 795 880 1,060 1,420 1,940
5,500,000..................................... 6,000,000 200 225 365 500 730 820 890 1,090 1,460 2,000
6,000,000..................................... 6,500,000 205 235 375 515 750 840 930 1,120 1,500 2,055
6,500,000..................................... 7,000,000 210 240 385 525 770 860 960 1,150 1,540 2,105
7,000,000..................................... 7,500,000 215 245 390 540 780 880 980 1,175 1,560 2,155
7,500,000..................................... 8,000,000 220 250 400 550 800 900 1,000 1,200 1,600 2,200
8,000,000..................................... 8,500,000 225 255 410 560 820 920 1,020 1,225 1,640 2,245
8,500,000..................................... 9,000,000 230 260 415 570 830 935 1,040 1,250 1,660 2,290
9,000,000..................................... 9,500,000 235 265 425 580 850 950 1,060 1,270 1,700 2,330
9,500,000..................................... 10,000,000 235 270 430 595 860 970 1,080 1,295 1,720 2,370
10,000,000.................................... 11,000,000 245 280 445 610 890 1,000 1,110 1,335 1,780 2,415
11,000,000.................................... 12,000,000 250 285 460 630 920 1,030 1,140 1,375 1,840 2,520
12,000,000.................................... 13,000,000 260 295 470 645 940 1,060 1,160 1,410 1,880 2,585
13,000,000.................................... 14,000,000 265 300 480 665 960 1,085 1,210 1,445 1,920 2,640
14,000,000.................................... 15,000,000 270 310 495 680 990 1,110 1,230 1,480 1,980 2,715
--------------------------------------------------------------------------------------------------------------------------------------------------------
Appendix E to Subpart F of Part 184.--Hazard Division 1.1--Fragment Hazard
[Primary/Secondary]\1\
--------------------------------------------------------------------------------------------------------------------------------------------------------
New explosive weight Distance in feet to fragment/debris target from Distance in feet to public traffic route from
--------------------------------------------------------------------------------------------------------------------------------------------------------
Standard/non-standard earth-covered Standard/non-standard earth-covered
magazine magazine
Over Not over --------------------------------------- Other PES --------------------------------------- Other PES
Front Side Rear Front Side Rear
Col 1 Col 2 Col 3 Col 4 Col 5 Col 6\4\ Col 7 Col 8 Col 9 Col 10
--------------------------------------------------------------------------------------------------------------------------------------------------------
0.................................. 100 500 250 250 670 300 150 150 670\2\
100................................ 200 500 250 250 1,250\3\ 300 150 150 1,250\2\
200................................ 500 700 250 250 1,250 420 150 150 1,250
500................................ 30,000 1,250 1,250 1,250 1,250 750 750 750 1,250
30,000............................. 35,000 1,250 1,250 1,250 (\6\) 750 750 750 (\6\)
35,000............................. 40,000 1,250 1,250 1,250 750 750 750 ...........
40,000............................. 45,000 1,250 1,250 1,250 750 750 750 ...........
45,000............................. 50,000 1,250 1,250 1,250 750 750 750 ...........
50,000............................. 55,000 (\6\) (\6\) 1,250 (\6\) (\6\) 750 ...........
55,000............................. 60,000 1,250 750 ...........
60,000............................. 65,000 1,250 750 ...........
65,000............................. 70,000 1,250 750 ...........
70,000............................. 75,000 1,250 750 ...........
75,000............................. 80,000 1,250 750 ...........
80,000............................. 85,000 1,250 750 ...........
85,000............................. 90,000 1,250 750 ...........
90,000............................. 100,000 1,250 750 ...........
95,000............................. 100,000 1,250 750 ...........
100,000 (\6\) (\6\)
--------------------------------------------------------------------------------------------------------------------------------------------------------
\1\Distances in Appendix A to Subpart F of this part are authorized for use, if documentation assures that hazardous fragment density is controlled as
prescribed in Sec. 184.52(f)(5) or under the conditions of Sec. 184.52(f)(6) through Sec. 184.52(f)(9).
\2\A minimum distance equal to 60 percent of this distance may be used when the conditions of $184.52(f)(5)(ii) are met.
\3\For NEW not exceeding 11,400 lbs, distances may be reduced to 900 feet, if conditions of $184.52(f)(6) are met.
\4\For items that have been adequately evaluated, distances such as those shown in Appendix F to Subpart F of this part must be used.
\5\Distances for NEW between 30,000 and 250,000 lbs apply only for earth-covered magazines that are at least 26 feet wide and 60 feet long. For smaller
earth-covered magazines, containing between 30,000 and 250,000 lbs of NEW, use other PES distances of columns 6 and 10.
\6\Blast (overpressure) hazard distances contained in Appendix A to Subpart F of this part exceed fragmentation distances at this point and must be
used.
Appendix F to Subpart F of Part 184.--Hazardous Division 1.1--Minimum
Fragment Protection Distance for Selected Items
------------------------------------------------------------------------
Nomenclature Distance required in feet
------------------------------------------------------------------------
Col 2 Col 3 Col 4 Col 5
Col 1 ---------------------------------------------------
1 Unit 2 Units 5 Units 10 Units\1\
------------------------------------------------------------------------
AGM 65/A............ 400 500 500 500
AIM 7, Mk 38 Warhead 700 700 700 700
AIM 9............... 400 400 400 400
ASROC............... 500 \2\500
Bomb, 750 lb, M117A2 690 820 1020 1470
Bomb, 500 lb, Mk 82. 670 860 1080 1240
Chaparral........... 400 400 400 400
Harpoon............. 500
Improved Hawk....... 900 900 900 900
Nike Hercules....... 900 1150 1150 1150
Penguin............. 500 \2\500
Projectile, 175mm,
M437A2............. 450 580 830 2070
Projectile, 155mm,
M107............... 400 510 720 1490
Projectile, 105mm,
MI\3\.............. 270 350 500 1000
Projectile, 8 in, Mk
25................. 520 750 960 1240
Projectile, 5 in, Mk
49................. 280 430 660 1000
Tomahawk............ 500 \4\600 1250 1250
Torpedoes (Navy) not
over 1,500 lbs NEW. \5\500 \5\500 \5\500 \5\500
------------------------------------------------------------------------
\1\Ten units or more until the point is reached at which this distance
is exceeded by the distance requirements of Appendix A to Subpart F of
this part.
\2\This distance applies for a maximum of 3 units.
\3\105mm projectiles and 105mm complete rounds not in standard storage
and shipping containers are Hazard Division 1.1.
\4\This distance applies for a maximum of 4 units. Missiles must be
transported and/or handled only two at a time in a nose-to-tail
configuration and in their launch capsule and/or shipping container as
well as aligned and/or handled so that each group of two missiles is
located outside of the warhead fragment beam spray region of the other
two missiles.
\5\This distance applies to any torpedoes that are analogous in terms of
explosive hazard to those tested; that is, MK 16 war shot.
BILLING CODE 5000-04-M
TP16DE94.003
BILLING CODE 5000-04-C
Appendix H to Subpart F of Part 184.--Category (04), Hazard Division 1.2--Nonmass Detonating, Fragment
Producing\1\
----------------------------------------------------------------------------------------------------------------
Public Magazine distance (ft)
Inhabited traffic Intraline -------------------------
Net explosives weight building route distance
distance distance (ft) Above- Earth-
(ft) (ft) ground covered
----------------------------------------------------------------------------------------------------------------
No limit specifically required for safety
reasons....................................... 400 240 200 200 (\2\)
----------------------------------------------------------------------------------------------------------------
\1\Limited quantities of items in this class, for reasons of operational necessity, may be stored in facilities
such as hangars, troop buildings, and manufacturing or operating buildings without regard to Q/D. Examples:
small destructors, fuzes and firing devices.
\2\Earth-covered standard or nonstandard magazines may be used without limit for this category. However, the
construction, siting, and orientation requirements of subparts D and F of this part for Hazard Division 1.1
must be met.
Note: List of items (examples only): Small arms ammunition with explosive projectiles; 20mm ammunition with
explosive projectiles; fuzed ammunition with non-explosive projectiles when caliber and packing limit the
hazard in accordance with this class; WP smoke hand grenades; and nonmass detonating CBUs.
Appendix I to Subpart F of Part 184.--Category (08), Hazard Division 1.2--Nonmass Detonating, Fragment Producing
----------------------------------------------------------------------------------------------------------------
Public Magazine distance (ft)
Inhabited traffic Intraline -------------------------
Net explosives weight building route distance
distance distance (ft) Above- Earth-
(ft) (ft) ground covered
----------------------------------------------------------------------------------------------------------------
No limit specifically required for safety
reasons....................................... 800 480 400 \1\ 300 (\2\)
----------------------------------------------------------------------------------------------------------------
\1\If the HE in (08) 1.2 items at an operating line PES is limited to 5000 lbs, intraline distance may be
reduced to 200 ft.
\2\Earth-covered standard and nonstandard magazines may be used without limit for this category. However, the
construction, siting, and orientation requirements of subparts D and F of this part for Hazard Division 1.1
must be met.
Note: List of items (examples only): Fixed and semifixed ammunition, rockets and rocket components, chemical
ammunition containing explosive elements, and nonmass-detonating CBUs.
Appendix J to Subpart F of Part 184.--Category (12), Hazard Division 1.2--Nonmass Detonating, Fragment Producing
----------------------------------------------------------------------------------------------------------------
Public Magazine distance (ft)
Inhabited traffic Intraline -------------------------
Net explosive weight building route distance
distance distance (ft) Above- Earth-
(ft) (ft) ground covered
----------------------------------------------------------------------------------------------------------------
500,000........................................ 1,200 720 600\2\ 300 (\3\)
----------------------------------------------------------------------------------------------------------------
\1\Items of this category present a risk of propagation to adjacent aboveground magazines, particularly when
packed in combustible containers. Storage in earth-covered magazines is therefore preferred.
\2\If the HE in (12) 1.2 items at an operating line PES is limited to 5000 lbs, intraline distance may be
reduced to 200 ft.
\3\Earth-covered standard and nonstandard magazines may be used without limit for this category. However, the
construction, siting, and orientation requirements of subparts D and F of this part for Hazard Division 1.1
must be met.
Note: List of items (examples only): Separate projectiles with explosive ``D'' filler, except high capacity
types, caliber 8-inch or larger; fixed and semifixed ammunition; nonmass-detonating CBUs; rockets, rocket
motors and nonmass-detonating rocket heads.
Appendix K to Subpart F of Part 184.--Category (18), Hazard Division 1.2--Nonmass Detonating, Fragment
Producing1,2
----------------------------------------------------------------------------------------------------------------
Public Magazine distance (ft)
Inhabited traffic Intraline -------------------------
Net explosives weight building route distance
distance distance (ft) Above- Earth-
(ft) (ft) ground covered
----------------------------------------------------------------------------------------------------------------
500,000........................................ 1,800 1,080 900 300 (\2\)
----------------------------------------------------------------------------------------------------------------
\1\Items of this category present a risk of propagation to adjacent aboveground magazines, particularly when
packed in combustible containers. Storage in earth-covered magazines is therefore preferred.
\2\Earth-covered standard and nonstandard magazines may be used without limit for this category. However, the
construction, siting, and orientation requirements of subparts D and F of this part for Hazard Division 1.1
must be met.
Note: List of items (examples only): Nonmass-detonating HE-loaded projectiles, fixed and semifixed ammunition,
and rockets and rocket heads.
Appendix L to Subpart F of Part 184--Hazard Division 1.3--Mass Fire
------------------------------------------------------------------------
Above-
IBD or ground
Net explosives weight (lbs) PTR IMD OR
(ft) ILD
(ft)
------------------------------------------------------------------------
1,000................................................. 75 50
2,000................................................. 86 57
3,000................................................. 96 63
4,000................................................. 106 69
5,000................................................. 115 75
6,000................................................. 123 81
7,000................................................. 130 86
8,000................................................. 137 91
9,000................................................. 144 96
10,000................................................ 150 100
12,000................................................ 159 105
14,000................................................ 168 111
16,000................................................ 176 116
18,000................................................ 183 120
20,000................................................ 190 125
22,000................................................ 195 130
24,000................................................ 201 134
26,000................................................ 206 138
28,000................................................ 210 142
30,000................................................ 215 145
32,000................................................ 219 147
34,000................................................ 224 149
36,000................................................ 228 151
38,000................................................ 231 153
40,000................................................ 235 155
42,000................................................ 238 157
44,000................................................ 242 159
46,000................................................ 245 161
48,000................................................ 247 163
50,000................................................ 250 165
52,000................................................ 252 167
54,000................................................ 254 169
56,000................................................ 256 171
58,000................................................ 258 173
60,000................................................ 260 175
62,000................................................ 262 177
64,000................................................ 264 180
66,000................................................ 266 182
68,000................................................ 268 183
70,000................................................ 270 185
72,000................................................ 272 186
74,000................................................ 274 187
76,000................................................ 276 188
78,000................................................ 278 189
80,000................................................ 280 190
82,000................................................ 284 191
84,000................................................ 287 192
86,000................................................ 290 193
88,000................................................ 293 194
90,000................................................ 295 195
92,000................................................ 296 196
94,000................................................ 297 197
96,000................................................ 298 198
98,000................................................ 299 199
100,000............................................... 300 200
110,000............................................... 307 205
120,000............................................... 315 210
130,000............................................... 322 215
140,000............................................... 330 220
150,000............................................... 337 225
160,000............................................... 345 230
170,000............................................... 352 235
180,000............................................... 360 240
190,000............................................... 367 245
200,000............................................... 375 250
210,000............................................... 383 255
220,000............................................... 390 260
230,000............................................... 398 265
240,000............................................... 405 270
250,000............................................... 413 275
260,000............................................... 420 280
270,000............................................... 428 285
280,000............................................... 435 290
290,000............................................... 443 295
300,000............................................... 450 300
310,000............................................... 458 305
320,000............................................... 465 310
330,000............................................... 473 315
340,000............................................... 480 320
350,000............................................... 488 325
360,000............................................... 495 330
370,000............................................... 503 335
380,000............................................... 510 340
390,000............................................... 518 345
400,000............................................... 525 350
410,000............................................... 533 355
420,000............................................... 541 361
430,000............................................... 549 366
440,000............................................... 556 371
450,000............................................... 564 376
460,000............................................... 571 381
470,000............................................... 579 386
480,000............................................... 586 391
490,000............................................... 593 395
500,000............................................... 600 400
510,000............................................... 605 402
520,000............................................... 609 404
530,000............................................... 614 407
540,000............................................... 618 409
550,000............................................... 623 411
560,000............................................... 627 413
570,000............................................... 632 415
580,000............................................... 636 418
590,000............................................... 641 420
600,000............................................... 645 422
610,000............................................... 649 424
620,000............................................... 654 426
630,000............................................... 658 428
640,000............................................... 662 430
650,000............................................... 667 432
660,000............................................... 671 435
670,000............................................... 675 437
680,000............................................... 679 439
690,000............................................... 684 441
700,000............................................... 688 443
710,000............................................... 692 445
720,000............................................... 696 447
730,000............................................... 700 449
740,000............................................... 704 451
750,000............................................... 708 453
760,000............................................... 712 455
770,000............................................... 716 457
780,000............................................... 720 459
790,000............................................... 724 461
800,000............................................... 728 463
810,000............................................... 732 465
820,000............................................... 735 467
830,000............................................... 739 469
840,000............................................... 743 471
850,000............................................... 747 472
860,000............................................... 750 474
870,000............................................... 754 476
880,000............................................... 758 478
890,000............................................... 761 480
900,000............................................... 765 482
910,000............................................... 769 484
920,000............................................... 772 486
930,000............................................... 776 487
940,000............................................... 779 489
950,000............................................... 783 491
960,000............................................... 786 493
970,000............................................... 790 495
980,000............................................... 793 496
990,000............................................... 797 498
1,000,000............................................. 800 500
------------------------------------------------------------------------
Notes:
1. For quantities less than 1,000 lbs, the required distances are those
specified for 1,000 lbs. The use of lesser distances may be approved
when supported by test data and/or analysis.
2. Linear interpolation of NEW quantities between table entries is
permitted.
3. For quantities above 1,000,000 lbs, the values given above will be
extrapolated by means of cube-root scaling as follows:
4. For inhabited building distance (IBD) and public traffic route (PTR)
distance, use D=8W1/3.
5. For aboveground intermagazine distance (IMD) and intraline distance
(ILD), use D=5W1/3.
6. List of items (examples only): Military pyrotechnics; solid
propellants in bulk, in containers, or in ammunition items; and
nontoxic chemical ammunition.
7. Earth-covered buildings may be used to their physical capacity for
this division provided they comply with the construction and siting
requirements of Subparts D and F, respectively, for Hazard Division
1.1.
8. For reasons of operational necessity, limited quantities of items in
this class, such as document destroyers, signaling devices, riot
control munitions and the like, may be stored without regard to
quantity-distance in accordance with fire protection regulations in
facilities such as hangars, arms rooms, and manufacturing or operating
buildings.
Appendix M to Subpart F of Part 184.--Hazard Division 1.4--Moderate Fire, No Blast\1\,\2\
----------------------------------------------------------------------------------------------------------------
Public Magazine distance (ft)
Inhabited traffic ----------------------------------------------
Net explosives building route Intraline distance
weight distance distance (ft) Aboveground Earth-covered
(ft) (ft)
----------------------------------------------------------------------------------------------------------------
Larger quantities 100 100 50 (100 if combustible 50 (100 if combustible No specified
no limit construction). construction). separation
specifically requirement.
required for
safety reasons.
----------------------------------------------------------------------------------------------------------------
\1\With reasonable care in storage, Hazard Division 1.4 items may be stored in any weatherproof warehouse in a
warehouse area for general supplies provided such warehouse is separated from all other warehouses by at least
the aboveground magazine separation distance specified.
\2\Limited quantities of Hazard Division 1.4 items may be stored in facilities such as hangars and manufacturing
or operating buildings without regard to Q/D. Examples: small arms ammunition, riot control munitions, and
pyrotechnics. Also, small magazines used for similar purposes may be separated by applicable fire protection
distances.
Note: List of items (examples only): Small arms ammunition
without explosive projectiles, fuse lighters and squibs, distress
signals, 20mm ammunition without explosive projectiles, colored
smoke grenades, and explosive valves or switches (see
Sec. 184.22(b)).
Appendix N to Subpart F of Part 184.--Hazard Division 1.6N and EIDS
Components
------------------------------------------------------------------------
Hazard
EIDS and EIDS ammunition classification
------------------------------------------------------------------------
EIDS bulk............................................... 1.5D
EIDS loaded projectiles and/or warheads w/o fuzes or 1.6N
with EIDS fuzes\1\,\2\.
EIDS fuzes\1\........................................... 1.4D, 1.4S,
1.6N
EIDS loaded projectiles and/or warheads w/1.3 propelling 1.2C, 1.3C,
charges and without fuzes or with EIDS fuzes\1\,\2\. 1.4C
EIDS loaded projectiles and/or warheads with non-EIDS 1.2D\3\,\4\
fuzes and without 1.3 propelling charges. 1.4D\4\
EIDS loaded projectiles and/or warheads with non- 1.2E\3\,\4\
EIDS\2\,\4\ fuzes and with 1.3 propelling charges. 1.4E\4\
------------------------------------------------------------------------
\1\``EIDS Fuzed'' means that the fuze has an EIDS booster with an out-of-
line EIDS explosive and two or more independent safety features. The
fuze must be certified as invulnerable to accidental detonation of the
warhead.
\2\Fuzed configuration must be tested for propagation. Fuzed Hazard
Division 1.6 ammunition must contain either an EIDS fuze or a non-
explosive fuze (fuze contains no explosive); otherwise the ammunition
is classified as unit risk Hazard Division 1.2. Minimum fragment
distance is based on hazardous fragment areal density requirements, as
determined for Hazard Division 1.1 ammunition, applies for unit risk
Hazard Division 1.2.
\3\Unit risk Hazard Division 1.2 may be justified on a case-by-case
basis.
\4\Fuze must have two or more independent safety features and
independently classified Group D.
Appendix O to Subpart F of Part 184.--Quantity/Distance Criteria for
Hazard Division 1.6 Ammunition
------------------------------------------------------------------------
(Above-
IBD or ground
New (lbs) PTR (ft) IMD or
ILD (ft)
------------------------------------------------------------------------
100............................................... 37 23
200............................................... 47 29
300............................................... 54 33
400............................................... 59 37
500............................................... 64 40
600............................................... 67 42
700............................................... 71 44
800............................................... 74 46
900............................................... 77 48
1,000............................................. 80 50
2,000............................................. 101 63
3,000............................................. 115 72
4,000............................................. 127 79
5,000............................................. 137 86
6,000............................................. 145 91
7,000............................................. 153 96
8,000............................................. 160 100
9,000............................................. 166 104
10,000............................................ 172 108
15,000............................................ 197 123
20,000............................................ 217 136
25,000............................................ 234 146
30,000............................................ 249 155
35,000............................................ 262 164
40,000............................................ 274 171
45,000............................................ 285 178
50,000............................................ 295 184
55,000............................................ 304 190
60,000............................................ 313 196
65,000............................................ 322 201
70,000............................................ 330 206
75,000............................................ 337 211
80,000............................................ 345 215
85,000............................................ 352 220
90,000............................................ 359 224
95,000............................................ 365 228
100,000........................................... 371 232
110,000........................................... 383 240
120,000........................................... 395 247
125,000........................................... 400 250
130,000........................................... 405 253
140,000........................................... 415 260
150,000........................................... 425 266
160,000........................................... 434 271
170,000........................................... 443 277
175,000........................................... 447 280
180,000........................................... 452 282
190,000........................................... 460 287
200,000........................................... 468 292
225,000........................................... 487 304
250,000........................................... 504 315
275,000........................................... 520 325
300,000........................................... 536 334
325,000........................................... 550 344
350,000........................................... 564 352
375,000........................................... 577 361
400,000........................................... 589 368
425,000........................................... 601 376
450,000........................................... 613 383
475,000........................................... 624 390
500,000........................................... 635 397
------------------------------------------------------------------------
Notes:
1. The same distances are used for aboveground intermagazine
distances (IMD) and intraline distances (ILD). Earth-covered
magazines, both standard and non-standard, may be used to their
physical capacity for this hazard division, provided they comply
with the construction and siting requirements of subparts D and F of
this part for Hazard Division 1.1.
2. For quantities less than 100 lbs, the required distances are
those specified for 100 lbs. The use of lesser distances may be
approved when supported by test data and/or analysis.
3. Interpolation is permitted. For inhabited building distance
(IBD) and public traffic route (PTR) use D=8W1/3. For
aboveground IMD and intraline distance (ILD) use 5W1/3.
4. Unit risk distance applies as a minimum; that is, for IBD or
PTR, D=40W1/3 or minimum fragment distance, whichever is
greater; and for aboveground IMD or ILD, D=18W1/3, based on a
single round of ammunition. Minimum fragment distance is based on
hazardous fragment areal density requirements as determined for
Hazard Division 1.1 munitions.
5. For Hazard Division 1.6 items packed in non-flammable pallets
or packing, stored in earth-covered steel or concrete arch magazines
when acceptable to the cognizant safety office of the PCO on a site-
specific basic, the following quantity-distance criteria apply,
unless Appendix O to supart F of this part permits a lesser distance
requirement; IBD and PTR--100 ft; aboveground IMD and ILD--50 ft;
earth-covered IMD--No specified requirement.
Appendix P to Subpart F of Part 184.--Hazard Division 1.1--Q/D
Requirements for Airfields\1\
Net explosives weight (lb)
--------------------------------------------------------------- Distance
Over Not over (ft)
Col 1 Col 2 Col 3
------------------------------------------------------------------------
0................................................... \2\50 \3\110
50.................................................. 100 140
100................................................. 200 175
200................................................. 300 200
300................................................. 400 220
400................................................. 500 240
500................................................. 600 255
600................................................. 700 265
700................................................. 800 280
800................................................. 900 290
900................................................. 1,000 300
1,000............................................... 1,500 345
1,500............................................... 2,000 380
2,000............................................... 3,000 435
3,000............................................... 4,000 480
4,000............................................... 5,000 515
5,000............................................... 6,000 545
6,000............................................... 7,000 575
7,000............................................... 8,000 600
8,000............................................... 9,000 625
9,000............................................... 10,000 645
10,000.............................................. 15,000 740
15,000.............................................. 20,000 815
20,000.............................................. 25,000 875
25,000.............................................. 30,000 935
30,000.............................................. 35,000 980
35,000.............................................. 40,000 1,025
40,000.............................................. 45,000 1,070
45,000.............................................. 50,000 1,105
50,000.............................................. 55,000 1,140
55,000.............................................. 60,000 1,175
60,000.............................................. 65,000 1,205
65,000.............................................. 70,000 \3\1,235
70,000.............................................. 75,000 1,265
75,000.............................................. 80,000 1,295
80,000.............................................. 85,000 1,320
85,000.............................................. 90,000 1,345
90,000.............................................. 95,000 1,370
95,000.............................................. 100,000 1,390
100,000............................................. 125,000 1,500
125,000............................................. 150,000 1,595
150,000............................................. 175,000 1,675
175,000............................................. 200,000 1,755
200,000............................................. 225,000 1,825
225,000............................................. 250,000 1,890
250,000............................................. 275,000 1,950
275,000............................................. 300,000 2,005
300,000............................................. 325,000 2,065
325,000............................................. 350,000 2,115
350,000............................................. 375,000 2,165
375,000............................................. 400,000 2,210
400,000............................................. 425,000 2,250
425,000............................................. 450,000 2,300
450,000............................................. 475,000 2,340
475,000............................................. 500,000 2,380
\1\To protect against low-angle, high-speed fragments, barricades should
be provided; however, these distances will not be reduced.
\2\The distance given for 0 to 50 pounds net explosives weight
constitutes the minimum spacing permitted.
\3\The minimum distance for Hazard Division 1.1 of 1,250 feet (see Sec.
184.52(f)) does not apply to targets covered by this table.
Appendix Q to Subpart F of Part 184.--Application of Ammunition and Explosives Safety Distances (Airfields,
Heliports, and Seadromes)
[Table entries refer to the key at the end of the table]
----------------------------------------------------------------------------------------------------------------
From
------------------------------------------------------------------------------------
Ammunition/ Ammunition/ Ready
To Combat aircraft Ammunition/ explosives explosives ammunition
parking area explosives storage operating storage
cargo area facility facility facility
----------------------------------------------------------------------------------------------------------------
Combat Aircraft Parking 3a............. 3a............. 5.............. 5.............. 3a
Area.
Ammunition/Explosives Cargo 3a............. 3a............. 3.............. 3.............. 3a
Area.
Ammunition/Explosives 3.............. 3.............. 3.............. 3.............. 3
Storage Facility.
Ammunition/Explosives 4.............. 4.............. 4.............. 4.............. 4
Operating Facility.
Ready Ammunition Storage 3.............. 3.............. 3.............. 3.............. 3
Facility.
Inhabited Building......... 1.............. 1.............. 1.............. 1.............. 1
Public Traffic Route & 2.............. 2.............. 2.............. 2.............. 2
Taxiway (joint DoD-Non-DoD
use).
Runway (joint DoD-Non-DoD 1.............. 1.............. 1.............. 1.............. 1
use).
Runway/Taxiway (DoD None........... None........... 11............. 2.............. None
Component use only).
Aircraft Parking Area...... 10............. 10............. 6.............. 6.............. 10
Aircraft Passenger Loading/ 7.............. 7.............. 7.............. 7.............. 7
Unloading Area.
Recreation Area............ 8.............. 9.............. 9.............. 9.............. 8
----------------------------------------------------------------------------------------------------------------
KEY:
1--Use appropriate inhabited building distance.
2--Use appropriate public traffic route distance.
3--Use appropriate intermagazine distance.
3a--Use appropriate intermagazine distance. Protects against simultaneous detonation of ammunition on adjacent
aircraft, but does not prevent serious damage to aircraft and possible propagation of detonation due to
fragments, debris, or fire.
4--Use appropriate intraline distance.
5--Use Appendix P to Subpart F of this part distances for mass-detonating items and appropriate public traffic
route distances for nonmass-detonating items.
6--Use Appendix P to Subpart F of this part distances for DoD Component aircraft parking areas, and appropriate
inhabited building distance for non-DoD Component aircraft parking areas.
7--Use appropriate public traffic route distances for locations in the open where passengers enplane and
deplane; use appropriate inhabited building distance if a structure is included where passengers assemble,
such as a passenger terminal building.
8--No distance required to recreational areas that are used exclusively for alert personnel manning the combat-
loaded aircraft. Other recreational areas where people are in the open shall be at appropriate public traffic
route distance. When structures, including bleacher stands, are a part of such area, appropriate inhabited
building distance shall be used.
9--Recreational areas, where people are in the open, shall be at appropriate public traffic route distance. When
structures, including bleacher stands are part of such area, appropriate inhabited building distance shall be
used.
10--Within these areas of airfields, heliports, and seadromes exclusively used by DoD Components, the separation
of aircraft parking areas from combat aircraft parking areas and their ready ammunition storage facilities and
ammunition and explosives cargo areas are considered to be a command function. At joint DoD/non-DoD use
airfields, heliports, and seadromes, the combat aircraft parking areas and its ready ammunition storage
facilities and ammunition and explosives cargo area shall be separated from non-DoD aircraft as specified in
item 6., above.
11--Use 18W1/3 distances from side or rear of standard earth-cover magazine containing mass-detonating items to
taxiway; use appropriate public traffic route distance from side or rear of standard earth-covered magazine
containing nonmass-detonating items to taxiway; use appropriate public traffic route distance from front of
standard earth-covered magazines, and from any other storage location containing mass-detonating or nonmass-
detonating items to runway.
BILLING CODE 5000-04-M
TP16DE94.004
BILLING CODE 5000-04-C
Appendix S to Subpart F of Part 184.--Q/D Separations for Pier and Wharf
Facilities
[See Appendix R to Subpart F of Part 184]
------------------------------------------------------------------------
Distance in feet
---------------------------------------
Net explosives weight (lb) Hazard Factor (k)
---------------------------------------
6 11 18 40
------------------------------------------------------------------------
1,000........................... 60 110 180 400
10,000.......................... 130 235 390 860
100,000......................... 280 510 835 1,855
250,000......................... 380 690 1,135 2,520
500,000......................... 475 875 1,430 3,175
600,000......................... 505 930 1,520 3,375
700,000......................... 535 975 1,600 3,550
800,000......................... 555 1,020 1,670 3,715
900,000......................... 580 1,065 1,740 3,860
1,000,000....................... 600 1,100 1,800 4,000
1,250,000....................... 645 1,185 1,940 4,310
1,500,000....................... 690 1,265 2,060 4,580
1,750,000....................... 725 1,325 2,170 4,820
2,000,000....................... 755 1,385 2,270 5,040
2,250,000....................... 785 1,440 2,360 5,240
2,500,000....................... 815 1,495 2,445 5,430
2,750,000....................... 840 1,540 2,520 5,605
3,000,000....................... 865 1,585 2,595 5,770
3,250,000....................... 890 1,630 2,665 5,925
3,500,000....................... 910 1,670 2,735 6,075
3,750,000....................... 930 1,705 2,795 6,215
4,000,000....................... 955 1,750 2,855 6,350
4,250,000....................... 970 1,780 2,915 6,480
4,500,000....................... 990 1,815 2,970 6,605
4,750,000....................... 1,010 1,850 3,025 6,725
5,000,000....................... 1,025 1,880 3,080 6,840
5,500,000....................... 1,060 1,950 3,175 7,060
6,000,000....................... 1,090 2,000 3,270 7,270
6,500,000....................... 1,120 2,055 3,360 7,465
7,000,000....................... 1,145 2,100 3,445 7,650
7,500,000....................... 1,175 2,155 3,525 7,830
8,000,000....................... 1,200 2,200 3,600 8,000
8,500,000....................... 1,225 2,245 3,675 8,165
9,000,000....................... 1,250 2,290 3,745 8,320
9,500,000....................... 1,270 2,330 3,815 8,470
10,000,000...................... 1,290 2,365 3,880 8,620
11,000,000...................... 1,330 2,440 4,005 8,895
12,000,000...................... 1,375 2,520 4,120 9,160
13,000,000...................... 1,410 2,585 4,230 9,405
14,000,000...................... 1,445 2,655 4,340 9,640
15,000,000...................... 1,480 2,715 4,440 9,865
------------------------------------------------------------------------
Subpart G--Liquid Propellant Requirements
Sec. 184.62 Application.
(a) These criteria establish Q/D, storage compatibility groupings,
and high explosives equivalencies for liquid propellants. They apply to
liquid propellant storage facilities (including missiles, rockets, and
multi-compartment tanks in which both liquid fuels and liquid oxidizers
are stored).
(b) If hazard classifications and storage compatibility groups for
liquid propellants are not listed in Appendix A to Subpart G of this
part, they may be obtained from the PCO.
Sec. 184.63 Determination of propellant quantity.
(a) For Q/D purposes, the net weight of propellant in a tank, drum,
cylinder, or other container shall be used. The quantity of propellant
in associated piping (to the point(s) providing means for interrupting
the flow in an incident) shall be included in the net weight of
propellant in a storage container.
(b) When incompatible propellants are not separated by distances
prescribed in Appendix B to Subpart G of this part or provisions for
preventing their mixing are not available, the combined quantity of the
two shall be used with appropriate HE equivalency (Appendix C to
Subpart G of this part) to determine the Q/D (Appendix D to Subpart G
of this part).
(c) Appendix E to Subpart G of this part lists conversion factors
(gallons to pounds) for the various liquid propellants.
Sec. 184.64 Measurement of separation distances.
(a) Separation distances shall be measured from the nearest hazard
source (containers, buildings, or positive cutoff point in piping,
whichever is controlling).
(b) If a building contains a small number of drums or cylinders, or
if quantities of propellant in the building are subdivided effectively,
distances may be measured from the nearest container or controlling
subdivision.
Sec. 184.65 Q/D considerations.
(a) Q/D criteria in this section are based on these premises:
construction materials shall be compatible with propellants to which
they may be exposed; design shall take into account the properties of
the propellant; required fire protection and drainage controls shall be
provided; and other special controls (such as nitrogen padding, tank
cooling, etc.) shall be provided when required.
(b) If group I, II, and III propellants are contaminated, Appendix
B to Subpart G of this part is not applicable. In such cases, group IV
Q/D requirements shall apply except when the PCO specifically approves
other criteria.
Sec. 184.66 Hazard grouping.
Liquid propellants present various types and degrees of hazards.
The following propellant groupings are based on these hazards.
(a) Group I. Considered the least hazardous, these materials have a
fire hazard potential and require separation distance as specified in
Appendix B to Subpart G of this part. When group I materials are stored
with more hazardous materials under conditions described in
Sec. 184.67, Appendices C and D to Subpart G of this part, shall
determine Q/D requirements.
(b) Group II. Strong oxidizers, these materials may cause serious
fires when they come into contact with material such as organic matter.
Appendix B to Subpart G of this part specifies quantity limitations and
minimum distance requirements. When group II materials are stored with
more hazardous materials under conditions described in Sec. 184.67,
Appendices C and D to Subpart G of this part shall determine Q/D
requirements.
(c) Group III. Hazardous fragmentation of the container, its
protective structure, or other nearby material may be produced by
pressure rupture of the storage container or a vapor-phase explosion.
Appendix B to Subpart G of this part specifies quantity limitations and
minimum distance requirements for this group. When group III materials
are stored with more hazardous materials, under conditions described in
Sec. 184.67, Appendices C and D to Subpart G of this part shall
determine Q/D requirements.
(d) Group IV. These hazards are the same as for mass-detonating
explosives (such as air blast overpressure and fragments from the
containers and surrounding equipment and material). Appendix D to
Subpart G of this part shall determine Q/D requirements.
Sec. 184.67 Hazards.
Aside from the fact that the propellants differ from each other, as
explained for the above groups, the predominant hazard of the
individual propellant varies according to the location of the
propellant storage and the operation(s) involved. These conditions
follow, in order of decreasing hazard:
(a) Range launch pads. Activities at range launch pads include
research, development, and testing. The proximity of fuel to oxidizer,
the frequency of launchings and the possibility of fall-back (with
resultant dynamic mixing on impact) make operations at these facilities
very hazardous. Explosives equivalents (Appendix C to Subpart G of this
part) shall be used to determine Q/D (Appendix D to Subpart G of this
part).
(b) Static test stands. Although these can involve experimental
operations, the units remain static and are subject to better control
than dynamic ones. Except when run tankages for fuel and oxidizer are
mounted one above the other, it is possible to separate the tankages to
reduce the hazard. Except as provided in Sec. 184.68, explosives
equivalents (Appendix C to Subpart G of this part) shall be used to
determine Q/D (Appendix D to Subpart G of this part).
(c) Ready storage. Ready storage may be located at a minimum of
intraline distance from launch and static test stands, based on the
propellant requiring the greater distance. Normally, propellant from
ready storage is not fed directly into an engine, as is the case with
run tankage (see Sec. 184.67 (g)). HE equivalents (Appendix C to
Subpart G of this part) shall be used for propellants in ready storage
if the facility design does not guarantee against fuel and oxidizer
mixing and against propagation to, or initiation at, the ready storage
facility when a mishap occurs at the test stand or launch pad. If
prevention of detonation of ready storage is assured, Q/D's shall be
based on the prevailing fire or fragment hazards (Appendix B to Subpart
G of this part).
(d) Cold-flow test operations. Fire and fragment hazards (Appendix
B to Subpart G of this part) govern if the system is closed (except for
approved venting) and completely airtight; if fuel and oxidizer are
never employed concurrently, each has an isolated system, and fittings
are such that intermixing is impossible; and if the propellants are of
required purity. Otherwise, HE equivalents (Appendix C to Subpart G of
this part) shall be used to determine Q/D's (Appendix D to Subpart G of
this part).
(e) Bulk storage. This is the most remote storage with respect to
launch and test operations, never being directly connected to any of
them. It consists of the area, tanks, and other containers therein,
used to hold propellant for supplying ready storage and, indirectly,
run tankage where no ready storage is available. Individual bulk
storage facilities shall be separated from each other and from
unrelated exposures in accordance with Appendices B and D to Subpart G
of this part. If positive measures are not taken to prevent mixing of
group I, II and III fuels and oxidizers, TNT equivalents (Appendix C to
Subpart G of this part) shall be used to determine Q/D's (Appendix D to
Subpart G of this part).
(f) Rest storage. This temporary storage resembles bulk storage.
Barges, trailers, tank cars, and portable hold-tanks (used for topping
operations) may be used as rest storage facilities. Fire and fragment
hazards (Appendix B to Subpart G of this part) govern. The transporter
becomes a part of that storage to which it is connected during
propellant transfer.
(g) Run tankage (operating tankage). Run tankage (operating
tankage) consists of the tank and/or other containers and associated
piping used to hold the propellants for direct feeding into the engine
or device during operations (Sec. 184.67 (c)).
(h) Pipelines. A distance of 25 feet free of inhabited buildings
shall be maintained on either side of the pipelines used for the
transfer of group II and III propellants between unloading points and
storage areas or between storage areas and points of use.
Sec. 184.68 Incompatible storage.
Except where effectively subdivided by intervening barriers or
other positive means for preventing mixing, separation distance between
propellants of different compatibility groups shall be the inhabited
building distance for the propellant quantity and group that requires
the greater distance. Where prevention of mixing is assured,
incompatible storage shall be separated from each other by intragroup
distance. If different hazard groups are involved, the group requiring
the greater distance shall be controlling.
Sec. 184.69 Compatible storage.
Compatible storage of propellants of different hazard groups, shall
be separated from other exposures by the greater intragroup storage
distance (see Appendix A to Subpart G of this part).
Appendix A to Subpart G of Part 184--Liquid Propellants Hazard and
Compatibility Groupings
------------------------------------------------------------------------
Hazard Storage
Propellant group\1\ group\2\
------------------------------------------------------------------------
Alcohols CH3OH, C2H5OH, (CH3)2CHOH.................. I C
Anhydrous Ammonia NH3............................... I C
Aniline C6H5NH2..................................... I C
Hydrocarbon Fuels JP-4, JP-5, RP-1.................. I C
Monopropellant NOS-58-6............................. I C
Nitrogen Tetroxide N2O4............................. I A
Otto Fuel II........................................ I G
Red Fuming Nitric Acid HNO3......................... I A
Bromine Pentafluoride BrF5.......................... II A
Chlorine Trifluoride CIF3........................... II A
Hydrogen Peroxide Greater than 52% H2O2............. II3 A
Liquid Fluorine LF2................................. II A
Liquid Oxygen LO2................................... II A
Perchloryl Fluoride CLO3 F.......................... II A
Oxygen Difluoride OF2............................... II A
Ozone Difluoride O3F3............................... II A
Ethylene Oxide C2H4 O............................... III D
Hydrazine N2H4...................................... III C
Hydrazine-UDMH Mixtures............................. III C
Liquid Hydrogen LH2................................. III C
Mixed Amine Fuels................................... III C
Monomethylhydrazine CH3NHNH2........................ III C
Pentaborane B5H9.................................... III D
Triethyl Boron B (C2H5)3............................ I D
UDMH (CH3) NNH2..................................... III C
Nitromethane CH3 NO2................................ IV5 F4
Tetranitromethane C(NO2)4........................... IV F
------------------------------------------------------------------------
\1\For some of the materials listed, the toxic hazard may be an
overriding consideration. Consult applicable regulations and, if
necessary, other authorities or publications for determination of
toxic siting criteria.
\2\All propellants in a compatibility group are considered compatible.
Groupings are not to be confused with ammunition and explosives
compatibility groupings with like letters.
\3\Under certain conditions, this propellant can detonate. However, its
sensitivity to detonation is not greater than that of a standard
energetic double base solid propellant under the same conditions.
\4\Nitromethane is chemically compatible with compatibility storage
group C liquid propellants, but due to differences in hazards should
be stored separately.
\5\Technical grade nitromethane in unit quantities of 55 gallons or less
in DOT 17E or C drums may be stored as Hazard Group II provided the
following apply:
a. Drums are stored only one tier high.
b. Drums are protected from direct rays of sun.
c. Maximum storage life of 2 years, unless storage life tests indicate
product continues to meet purchase specification. Such tests are to be
repeated at 1 year intervals thereafter.
Appendix B to Subpart G of Part 184.--Quantity/Distance for Propellants
--------------------------------------------------------------------------------------------------------------------------------------------------------
Pounds of propellant Hazard group I Hazard group II Hazard group III
--------------------------------------------------------------------------------------------------------------------------------------------------------
IBD, PTR, & incompatible
IBD, PTR, & Intra-group IBD, PTR, & Intra-group group III Intra-group
Over Not over incompatible (ILD)\1\ & incompatible (ILD)\1\ & ------------------------------ (ILD)\1\ &
group I\4\ group I\5\ group II\6\ group II\7\ Protected\8\ group
Unprotected\9\ \10\ III\11\
--------------------------------------------------------------------------------------------------------------------------------------------------------
0..................................... \2\100 30 25 60 30 600 80 30
100................................... \2\200 35 30 75 35 600 100 35
200................................... \2\300 40 35 85 40 600 110 40
300................................... \2\400 45 35 90 45 600 120 45
400................................... \2\500 50 40 100 50 600 130 50
500................................... 600 50 40 100 50 600 135 50
600................................... 700 55 40 105 55 600 140 55
700................................... 800 55 45 110 55 600 145 55
800................................... 900 60 45 115 60 600 150 60
900................................... 1,000 60 45 120 60 600 150 60
1,000................................. 2,000 65 50 130 65 600 175 65
2,000................................. 3,000 70 55 145 70 600 190 70
3,000................................. 4,000 75 55 150 75 600 200 75
4,000................................. 5,000 80 60 160 80 600 210 80
5,000................................. 6,000 80 60 165 80 600 220 80
6,000................................. 7,000 85 65 170 85 600 225 85
7,000................................. 8,000 85 65 175 85 600 230 85
8,000................................. 9,000 90 70 175 90 600 235 90
9,000................................. 10,000 90 70 180 90 600 240 90
10,000................................ 15,000 95 75 195 95 1,200 260 95
15,000................................ 20,000 100 80 205 100 1,200 275 100
20,000................................ 25,000 105 80 215 105 1,200 285 105
25,000................................ 30,000 110 85 220 110 1,200 295 110
30,000................................ 35,000 110 85 225 110 1,200 300 110
35,000................................ 40,000 115 85 230 115 1,200 310 115
40,000................................ 45,000 120 90 235 120 1,200 315 120
45,000................................ 50,000 120 90 240 120 1,200 320 120
50,000................................ 60,000 125 95 250 125 1,200 320 125
60,000................................ 70,000 130 95 255 130 1,200 340 130
70,000................................ 80,000 130 100 260 130 1,200 350 130
80,000................................ 90,000 135 100 265 135 1,200 360 135
90,000................................ 100,000 135 105 270 135 1,200 365 135
100,000............................... 125,000 140 110 285 140 1,800 380 140
125,000............................... 150,000 145 110 295 145 1,800 395 145
150,000............................... 175,000 150 115 305 150 1,800 405 150
175,000............................... 200,000 155 115 310 155 1,800 415 155
200,000............................... 250,000 160 120 320 160 1,800 425 160
250,000............................... 300,000 165 125 330 165 1,800 440 165
300,000............................... 350,000 170 130 340 170 1,800 455 170
350,000............................... 400,000 175 130 350 175 1,800 465 175
400,000............................... 450,000 180 135 355 180 1,800 475 180
450,000............................... 500,000 180 135 360 180 1,800 485 180
500,000............................... 600,000 185 140 375 185 1,800 500 185
600,000............................... 700,000 190 145 385 190 1,800 515 190
700,000............................... 800,000 195 150 395 195 1,800 530 195
800,000............................... 900,000 200 150 405 200 1,800 540 200
900,000............................... 1,000,000 205 155 410 205 1,800 550 205
1,000,000\3\.......................... 2,000,000 235 175 470 235 1,800 630 235
2,000,000............................. 3,000,000 255 190 505 255 1,800 675 255
3,000,000............................. 4,000,000 265 200 535 265 1,800 710 265
4,000,000............................. 5,000,000 275 210 555 275 1,800 740 275
5,000,000............................. 6,000,000 285 215 570 285 1,800 760 285
6,000,000............................. 7,000,000 295 220 585 295 1,800 780 295
7,000,000............................. 8,000,000 300 225 600 300 1,800 800 300
8,000,000............................. 9,000,000 305 230 610 305 1,800 815 305
9,000,000............................. 10,000,000 310 235 620 310 1,800 830 310
--------------------------------------------------------------------------------------------------------------------------------------------------------
\1\See Sec. 184.68 and Sec. 184.69.
\2\A single standard minimum size shipping container such as one 55-gallon drum, one 500-pound (net weight) cylinder, and so forth, may be handled or
stored without regard to distances prescribed.
\3\Extrapolations above 1,000,000 lbs extend well outside data included in the Bureau of Mines report from which original Q/D tables were derived;
however, they are supported by independent calculations and knowledge of like phenomena.
\4\Values are one-half of the Group II inhabited building distance.
\5\Values are three-fourths the Group II and Group III intragroup distances.
\6\Distances were selected as three-fourths the Group III inhabited building distance and considered reasonable due to the lesser hazard.
\7\Distances were derived from the Bureau of Mines, Department of the Interior Report No. 5707, dated 1961, modified and expanded. They average 37.5
percent of the inhabited building distances given in this report.
\8\The term ``protected'' means that protection from fragments is provided by terrain, effective barricades, nets, or other physical means.
\9\Distances are necessary to provide reasonable protection from fragments of tanks or equipment that are expected to be thrown in event of a vapor
phase explosion.
\10\Distances are the recommended inhabited building distances given in the Bureau of Mines, Department of the Interior Report No. 5707, dated 1961, and
extrapolation thereof (2 cal/cm\2\ on 1 percent water vapor curve).
\11\Distances are an average of 37.5 percent of ``protected'' column.
Appendix C to Subpart G of Part 184--Liquid Propellant Explosive
Equivalents
------------------------------------------------------------------------
Propellant combinations Static test stands Range launch
------------------------------------------------------------------------
LO2LH2 or B5H9+an 60%.................... 60%.
oxidizer.
LO2LH2+LO2/RP-1........ Sum of (60% for Sum of (60% for
LO2LH2)+(10% for LO2LH2)+(20% for LO2/
LOs2sRP-1). RP-1).
LO2RP-1 or LO2NH3 or 10%.................... 20% up to 500,000
B5H9+a fuel. pounds plus 10% over
500,000 pounds.
IRFNA/Aniline (Note 1). 10%.................... 10%.
IRFNA/UDMH (Note 1).... 10%.................... 10%.
IRFNA/UDMH+JP-4 (Note 10%.................... 10%.
1).
N2O4/UDMH+N2H4 (Note 1) 5%..................... 10%.
N2O4/UDMH+N2H4 (Note 5% plus the explosive 10% plus the explosive
1)+solid propellants. equivalent of the equivalent of the
solid propellants. solid propellant.
Tetranitromethane 100%................... 100%.
(alone or in
combination).
Nitromethane (alone or 100%................... 100%.
in combination).
------------------------------------------------------------------------
Notes:
1.These are hypergolic combinations.
2.The percentage factors given in the table are to be used to determine
equivalencies of propellant mixtures at static test stands and range
launch pads when such propellants are located aboveground and are
unconfined except for their tankage. Other configurations shall be
considered on an individual basis to determine equivalencies.
3.The explosives equivalent weight calculated by the use of this table
shall be added to any non-nuclear explosive weight aboard before
distances can be determined from Appendices B and C to Subpart F of
this part.
4.These equivalencies apply also for the following substitutions:
a.Alcohols or other hydrocarbons for RP-1.
b.BrF5, CIF3, F2, H2, H2O2, OF2, or O2F2 for LO2.
c.MMH for N2H4 or UDMH.
d.C2H4O for any propellant.
e.NH3 for any fuel resulting in a hypergolic combination.
5.Use LO2/RP-1 distance for pentaborane plus a fuel and LO2/LH2
distances for pentaborane plus an oxidizer.
6.For quantities of propellant up to but not over the equivalent of 100
pounds of explosives, the distance shall be determined on an
individual basis by the PCO. All personnel and facilities, whether
involved in the operation or not, shall be protected by operating
procedures, equipment design, shielding, barricading, or other
suitable means.
7.Distance less than intraline area not specified. Where a number of
prepackaged liquid propellant units are stored together, separation
distance to other storage facilities shall be determined on an
individual basis by the PCO, taking into consideration normal hazard
classification procedures.
Appendix D to Subpart G of Part 184.--Distances for Separation of
Propellant Static Testing, Launching, and Storage Sites From Other
Facilities
Distance in feet from propellant explosive
hazard
Maximum weight of ---------------------------------------------
explosives or group IV To Intraline
propellant in pounds To public -------------------------
inhabited traffic
buildings routes Barricaded Unbarricaded
Col 1 Col 2 Col 3 Col 4 Col 5
------------------------------------------------------------------------
100....................... 190 115 40 80
200....................... 235 140 50 100
300....................... 270 160 60 120
400....................... 295 175 65 130
500....................... 320 190 70 140
600....................... 340 205 75 150
700....................... 355 215 80 160
800....................... 375 225 85 170
900....................... 390 235 90 180
1,000..................... 400 240 95 190
1,500..................... 460 275 105 210
2,000..................... 505 305 115 230
3,000..................... 580 350 130 260
4,000..................... 635 380 140 280
5,000..................... 685 410 150 300
6,000..................... 730 440 160 320
7,000..................... 770 460 170 340
8,000..................... 800 480 180 360
9,000..................... 835 500 190 380
10,000.................... 865 520 200 400
15,000.................... 990 595 225 450
20,000.................... 1,090 655 245 490
25,000.................... 1,170 700 265 530
30,000.................... 1,245 745 280 560
35,000.................... 1,310 785 295 590
40,000.................... 1,370 820 310 620
45,000.................... 1,425 855 320 640
50,000.................... 1,475 885 330 660
55,000.................... 1,520 910 340 680
60,000.................... 1,565 940 350 700
65,000.................... 1,610 965 360 720
70,000.................... 1,650 990 370 740
75,000.................... 1,685 1,010 385 770
80,000.................... 1,725 1,035 390 780
85,000.................... 1,760 1,055 395 790
90,000.................... 1,795 1,075 400 800
95,000.................... 1,825 1,095 410 820
100,000................... 1,855 1,115 415 830
125,000................... 2,115 1,270 450 900
150,000................... 2,350 1,410 475 950
175,000................... 2,565 1,540 500 1,000
200,000................... 2,770 1,660 525 1,050
225,000................... 2,965 1,780 550 1,100
250,000................... 3,150 1,890 575 1,150
275,000................... 3,250 1,950 585 1,170
300,000................... 3,345 2,005 600 1,200
325,000................... 3,440 2,065 620 1,240
350,000................... 3,525 2,115 635 1,270
375,000................... 3,605 2,165 650 1,300
400,000................... 3,685 2,210 665 1,330
500,000................... 3,970 2,380 715 1,430
600,000................... 4,215 2,530 780 1,560
700,000................... 4,440 2,665 825 1,650
800,000................... 4,640 2,785 860 1,720
900,000................... 4,825 2,895 895 1,790
1,000,000................. 5,000 3,000 925 1,850
1,500,000................. 5,725 3,435 1,060 2,120
2,000,000................. 6,300 3,780 1,170 2,340
2,500,000................. 6,785 4,070 1,260 2,520
3,000,000................. 7,210 4,325 1,340 2,680
3,500,000................. 7,590 4,555 1,405 2,810
4,000,000................. 7,935 4,760 1,470 2,940
5,000,000................. 8,550 5,130 1,585 3,170
Appendix E to Subpart G of Part 184--Factors To Be Used When Converting
Gallons of Propellant Into Pounds
------------------------------------------------------------------------
Pounds At
Item per temperature
gallon deg.F
------------------------------------------------------------------------
Anhydrous ammonia................................ 5.1 68
Aniline.......................................... 8.5 68
Bromine pentafluoride............................ 20.7 68
Chlorine trifluoride............................. 15.3 68
Ethyl alcohol.................................... 6.6 68
Ethylene oxide................................... 7.3 68
Fluorine (liquid)................................ 12.6 -306
Furfuryl alcohol................................. 9.4 68
Hydrocarbon fuel JP-4............................ 6.35 60
Hydrocarbon fuel JP-5............................ 6.84 60
Hydrogen peroxide (90 percent)................... 11.6 68
Hydrazine........................................ 8.4 68
Isopropyl alcohol................................ 6.6 68
Liquid hydrogen.................................. 0.59 -423
Liquid oxygen.................................... 9.5 -297
Methyl alcohol................................... 6.6 68
Mono methyl hydrazine............................ 7.3 68
Monopropellant NOS-58-6.......................... 9.46 68
Nitromethane..................................... 9.5 68
Nitrogen tetroxide............................... 12.1 68
Otto fuel........................................ 10.5 77
Oxygen difluoride................................ 12.7 -229
Ozone difluoride................................. 14.6 -297
Pentaborane...................................... 5.2 68
Perchloryl fluoride.............................. 12.0 68
Red fuming nitric acid (IFFNA)................... 12.5 68
RP-1............................................. 6.8 68
Tetranitromethane................................ 13.6 78
Triethyl Boron B................................. 5.8 73
UDMH............................................. 6.6 68
UDMH/hydrazine................................... 7.5 68
------------------------------------------------------------------------
Note: Conversion of quantities of propellant from gallons to pounds:
Pounds of propellant = gallons x density of propellant in pounds per
gallon.
Subpart H--Manufacturing and Processing Pyrotechnics
Sec. 184.71 General.
The safety precautions for manufacturing and processing
pyrotechnics parallel those of many types of explosives and other
energetic materials. Pyrotechnics, as a group, display many different
characteristics because they are formulated for different purposes.
Pyrotechnics can be divided into general categories, such as:
Initiators (igniters); illuminants; smokes; gas generators; sound
generators; heat producers; and timing compositions. Each has its own
characteristics and attendant processing requirements. Knowledge of
these characteristics is necessary to ensure safety in processing. The
range of characteristics associated with pyrotechnics includes easily
initiated compositions from those that burn in seconds at temperatures
exceeding 2763 deg.C (5000 deg.F) through those that require
substantial energy for initiation and have relatively low output
temperatures. As examples, the auto-ignition temperature for smoke
Compositions is typically about 180 deg.C while for illuminants it is
about 500 deg.C; illuminants burn approximately 2.7 times faster than
smokes and the heat of reaction is 1.5 times as great; infrared (IR)
flare compositions are both hotter and faster-burning than illuminants.
Many of the compositions in the ignitor or initiator class are as
sensitive to static electricity, friction, or impact as are initiating
explosives such as lead azide and lead styphnate. Initiation thresholds
to such stimuli as impact, friction, and electrostatic discharge must
be known for safety in specific processes. The response of the material
in terms of energy release shall be considered in ensuring personnel
safety. In addition to the safety precautions generally required for
the handling of explosives and other energetic materials, the following
paragraphs provide specific guidance pertinent to pyrotechnic
operations.
Sec. 184.72 Machinery, equipment, and facilities.
Except as provided for in this subpart, the design, layout, and
operation of facilities and equipment shall follow the mandatory
provisions for the processing of explosives and other energetic
materials contained elsewhere in this part. Where guidance is not
provided, operations should be governed by the results of hazard
analyses performed and documented to address specific operations. Since
most pyrotechnic compositions are sensitive to initiation by static
electricity, bonding and grounding, along with other means of static
elimination and control, have paramount importance.
Sec. 184.73 Weighing of raw materials.
Separate weight or measurement rooms, cubicles, or areas (dependent
upon the quantity and sensitivity of the materials handled) shall be
provided--one for oxidizers and one for combustible materials and
metallic powders. It is important that containers, equipment, hand
tools, scale pans, etc., used for weighing processes are not mixed with
those weighing or measuring oxidizers and fuels, particularly where
distance rather than physical barriers separates these areas. Positive
measures shall be adopted to ensure the complete separation of such
equipment and tools. Personnel weighing or handling exposed oxidizers
or fuels shall, at a minimum, wear flame retardant uniforms, cotton
undergarments, cotton socks, and conductive shoes.
Sec. 184.74 Drying of materials.
The minimum temperature necessary to meet processing requirements
shall be used to dry components and pyrotechnic materials. Drying rooms
or ovens shall meet the requirements of Sec. 184.169.
Sec. 184.75 Mixing and blending.
Mixing and blending of pyrotechnic compositions commands attention
because most injury-producing accidents have occurred during the
mixing, blending, or subsequent cleanup operations. Because of the
variety within and among these compositions, no single type of mixer or
blender can be the exclusively approved equipment for pyrotechnic
mixing and blending operations.
(a) Each mixing device shall be considered separately with respect
to the composition to be processed. When a history of safe operation
has not been established, the type of mixer or blender and batch size
should be evaluated by appropriate hazard analysis or tests. Generally,
devices that use a tumbling action shall be preferred to those using
rotating blades, to minimize points where frictional heat may develop
or where accidentally introduced foreign material can create hot spots
through friction or crushing of composition. Mixers and blenders shall
be equipped for pressure relief, to preclude a transition from burning
to detonation. Personnel exposures during charging and emptying of
mixers shall be minimal. When the energetic characteristics and
quantities of composition involved so dictate, mixers and blenders
shall be charged, operated, and emptied remotely. When hazard analysis
or testing has shown this to be safe, mixers or blenders may be charged
or emptied manually. Appropriate interlocks, clutch brakes, and similar
devices shall be used to preclude personnel exposure during mixer or
blender operation, and to preclude the movement of mixer or blender
parts during periods when operators are present.
(b) Mixing and blending operations shall be conducted in buildings
or cubicles designed for such purposes. Multiple mixing or blending
operations may be conducted in the same building, provided that each
blender or mixer is located in a separate room, bay, or cell, and
separated from other operations by substantial dividing walls. Two or
more mixers or blenders may be located in the same cubicle, provided
that the hazards are not increased by such installation. Normally, this
would require that the materials in process be of significantly low
energy content or slow energy release and the mixers be charged and
emptied simultaneously. At least one wall or equivalent panel area in
each bay shall be frangible so as to provide pressure relief in the
event of an incident. Cell arrangement and pressure relief areas shall
be located so that personnel cannot pass in front of these areas while
mixers or blenders are operating.
(c) Exhaust ventilation equipment shall be installed on mixers or
in bays where flammable solvents are used and interlocked with the
mixers. The interlock shall be designed to preclude mixer operation
without ventilation although operation of the ventilation system
without the mixer is permitted. Vapor sensors should be used to give
automatic warning of a build-up of flammable vapors to a level
approaching that of the lower explosive limit. Such sensors should be
interlocked to personnel access control devices. Ventilation system
designs shall not permit propagation of an incident in one bay to
others served by the same system.
(d) The operation of mixers or blenders may be observed by remote
means such as closed-circuit television, mirrors, or transparent shield
providing operator protection. Direct viewing of blender or mixer
operation without intervening barriers is prohibited.
(e) Manual scraping during the mixing or blending process is
prohibited. Manual mixing or blending of fuels and oxidizers is
prohibited.
(f) The following are the minimum criteria for rotating blade
mixing operations:
(1) The mix equipment shall be rigidly fixed and stable during
mixing to preclude contact between the bowl and the mix blades.
(2) Positive controls are provided to physically block or stop bowl
or blender head movement in case of hydraulic malfunction to assure
clearance at all times between mix bowl and blades.
(3) Mix blades and shaft shall be rigid and structurally strong to
ensure minimum flex from weight of the mix and speed of the shaft.
(4) Any mixer electrical fixtures shall be explosion-proof rated,
remotely located, or shrouded and pressurized with inert gas. Purged
systems automatically cut off if pressure is lost.
(5) Mix blade shaft should include adequate and compatible seals or
packing glands to prevent migration of mix or solvent vapor into
bearings. Submerged bearings and packing glands should be avoided. If
used, they shall be periodically tested for contamination and cleaned.
(6) A program shall be established whereby mix blade shaft and
bearings are monitored and changed before becoming worn and allowing
loose play in the blade shaft. Maintain a record of such checks, mixer
blade adjustments, and any damage to the mixer blades and bowls.
(7) Wet mixing shall not be started until adequate solvent is added
to preclude dry mixing.
(8) The operating procedures shall contain provisions to verify
acceptable blade/bowl clearance, bowl and shaft rigidity, and bearing
wear prior to introduction of materials.
(9) Electrical service to propellant mixers shall be interlocked
with fire protection system controls so that the mixer cannot start
when the fire protection system is inoperative.
Sec. 184.76 Pressing, extruding, and pelleting.
(a) Pressing operations shall be conducted with personnel protected
by substantial dividing walls, barricades, or operational shields; or
shall take place at intraline distance from the operator and other
operations. When it is necessary to repair, adjust, or otherwise clear
a jam on a press or extruder, the pyrotechnic material shall be removed
from the hopper and the bay or press room before such repairs or
adjustments are made. Only those adjustments of ram speed or conveyor
speed routinely controlled by the operator may proceed with material in
the bay. Under no circumstances shall repair or adjustment requiring
the use of tools be permitted with pyrotechnic material in the bay.
(b) The quantity of composition at the pressing location (behind
the barricade) shall not exceed that required for the components
undergoing the pressing operation. The quantity of composition in the
remainder of the building at any one time shall not exceed the minimum
required for a safe, efficient operation.
(c) Each individual press, extruder, or loading device shall be
located in a separate building, room, or cubicle, and be designed to
limit an incident to that area and protect operators. Multiple
installations may be permitted within a bay or cubicle, provided that
tests or hazard analysis demonstrate that facility and personnel
hazards are not increased. Adequate means of pressure relief shall be
built into each bay or cubicle.
Sec. 184.77 Assembly operations.
Individual assembly operations shall be adequately separated from
each other, and shall be located in a separate cubicle or building from
mixing, blending, and consolidation operations. Pyrotechnic composition
shall be kept in closed or covered containers at all times except
during processing. Surge, storage, and in-process transit between
operations shall also be accomplished with closed containers whenever
not absolutely prohibited by the operational configuration. Components
in any assembly room, bay, or building, shall be limited to the
smallest quantity necessary for safe and efficient operations.
Sec. 184.78 Granulation, grinding, and screening.
(a) Material to be reduced in particle size shall be processed over
a mechanical or magnetic separator to remove foreign materials before
grinding. Following grinding, the material should be re-screened or
passed over a magnetic separator.
(b) In the operation of ball mills, hammer mills, granulators, or
screeners, the operator shall be protected from the effects of a
potential incident by substantial dividing walls or operational
shields. Every effort shall be made to fill and discharge grinding,
granulating, and screening equipment remotely. Cleaning of such devices
shall also afford maximal operator protection.
(c) Working surfaces, containers, and hand tools shall be
appropriately bonded and grounded.
Sec. 184.79 Transportation.
Pyrotechnic compositions shall be moved in closed containers only.
Individual containers and the transport vehicle (hand cart, hand truck,
etc.) should be fabricated of the lightest materials compatible with
the composition and having the requisite strength. This shall minimize
fragment generation if an incident should occur. Transport vehicles
should be equipped with ``dead man'' brakes. On- and off-loading of
transport vehicles should be conducted only in weather-protected areas
designated for this purpose. Racks or other support, suited to the size
and shape of composition containers, should be provided to prevent them
from falling.
Sec. 184.80 Rebowling.
Rebowling operations transfer materials, typically sensitive and in
small quantities, from one container to another. They may be done to
recover remains of small quantities of materials, or to subdivide large
masses for processing. Operational shields shall be provided to protect
operators.
Sec. 184.81 Machining of pyrotechnic material.
(a) Machining of pyrotechnic materials shall be accomplished
remotely.
(b) General requirements. (1) When required, coolant shall be
compatible with the pyrotechnic composition. Positive automatic
interlocking devices shall ensure that the machine cannot be started
until the coolant is flowing. These controls shall also be capable of
stopping the machine should the flow of coolant be interrupted. When it
is essential to cut off the coolant to adjust machine tools, it shall
be restored, and all automatic controls operating, before machining
resumes. If a cutting edge overheats during machining, it is most
dangerous when continuous contact with the pyrotechnic material is
maintained after the machine has stopped. It is, therefore, essential
that coolant continue flowing until the cutter is removed from contact
with the pyrotechnic material.
(2) Sensors are recommended to detect tooling malfunctions or other
potentially hazardous conditions. Machine tool power-consumption
monitors, tool force gages, sound or noise detectors, temperature-
indicating devices, or IR detectors can be used in this regard.
(3) Cutting tools shall be chemically compatible with the
pyrotechnic material to be machined, capable of maintaining a sharp
cutting edge throughout the machine cycle.
(4) Control measures such as guides, bushings, and stops shall
limit depth, diameter, and contour of the cut. The lineal and
rotational speed of tools for the machining of pyrotechnic material
shall be the minimum necessary for safe and efficient operation.
Controls should be designed to prevent unintended operator adjustment.
(5) Drilling operations shall not impede the flow of chips and
coolant in the bore. The drilling of small holes (one-quarter inch or
less) and any size of multiple drilling operation shall be performed by
remote control, with operator protection, unless documented hazard
analysis or tests prove this unnecessary.
(6) Contoured cutting tools shall be removed from contact with the
pyrotechnic material being machined before personnel are permitted to
enter the machining area. Frequently cleaning machine tools during
operating hours shall prevent residues from accumulating; a thorough
cleaning shall conclude each work shift. Vacuum accumulator systems,
immersion in liquid coolant streams, or similar automatic means shall
remove the pyrotechnic waste products. Only low pressure (10 PSIG)
compressed air may be used as a coolant and only when the scattering of
pyrotechnic particles is contained by a vacuum collection system. The
coolant delivery tube shall have a metallic tip or nozzle grounded to
the machine to reduce static charges.
(c) Specific guidance for machining. (1) Drilling and facing
operations for colored smoke compositions containing organic dyes,
potassium chlorates, and sugars should be conducted at not more than
2475 lineal inches per minute, with the feed rate adjusted to enhance
the machinability of the composition. For red phosphorous compositions,
drilling and facing operations should be conducted at not more than
1100 lineal inches per minute with the feed adjusted to minimize
friction and heat buildup. For extruded candles composed of magnesium,
tetrafluoroethylene polymers, and fluoroelastomer binders, drilling and
machining operations shall be conducted at not more than 530 lineal
inches per minute.
(2) Hand trimming and cutting of pyrotechnic candles may be
permitted when supported by results of a hazard analysis specific to
that composition and candle configuration.
(3) Sawing operations require particular care, to prevent work from
plunging into the saw blade and to ensure that chips are removed from
sawteeth before their next cutting pass. Plunging can occur when thin
sections are force-fed into coarse-pitch saw blades. To prevent this, a
minimum of two saw teeth shall remain in contact with the work during
sawing, or the work feed shall be controlled. Chip accumulation in the
saw teeth is a function of the material being sawed, rate of feed,
blade speed, tooth design, and flushing arrangement. Additional chip
removal equipment such as blade-wiping brushes may be required.
Sec. 184.82 Spill control.
Spills of pyrotechnic composition and energetic ingredients pose
potential hazards. In case of accident, the responsible supervisor
should be notified before any action to clean or contain the spill.
Standard operating procedures (SOPs) for pyrotechnic operations shall
cover spill cleanup, either as part of the various operations detailed
or as a separate procedure. The procedures shall specify which actions
are to be taken by whom and in what order. The recovery of the spilled
material and decontamination of the area shall also be addressed.
Sec. 184.83 Collection of pyrotechnic wastes.
(a) Waste material and scraps shall be removed at regular intervals
from all operating areas. All waste material shall be segregated by
type and compatibility, and kept separate from common wastes.
Containers for these materials shall be distinguished by color and
labeled. Filled containers shall be placed at designated collection
points.
(b) Special care shall preclude the mixing of small quantities of
water with powdered or finely granulated metals. Pyrotechnic waste may
be maintained dry or submerged in water or oil, whichever is
appropriate for disposal. Plastic liners for waste containers
facilitate cleaning. Liners should be conductive when contents are
subject to initiation by static electrical discharge.
Sec. 184.84 Cleaning of pyrotechnic processing equipment.
(a) As pyrotechnic materials are sensitive to friction, impact, or
static discharge, cleaning this equipment poses hazards. Because
personnel shall be near the equipment being cleaned, risks may exceed
those of processing. Therefore, cleaning shall receive the same
planning and SOP coverage as production.
(b) Solvent solution flushing and cleaning by remote control is
required for slurry-type mixing operations. For other applications, the
process equipment shall be flushed with a compatible solvent and
drained, with the process repeated as often as necessary to remove the
pyrotechnic composition. High-pressure water wash may be used when
compatible with the pyrotechnic composition. Precautionary measures
shall be taken when a solvent represents a fire or toxicological
threat. Runoff from cleaning operations shall be controlled to preclude
the creation of a secondary hazard from the spread of contamination.
(c) When remote cleaning cannot be used, personal protective
equipment shall be designed and proven by test to afford operator
protection from the maximum quantity of material that could be present,
and its use shall be required.
Sec. 184.85 Personal protective equipment.
(a) Personal protective equipment shall not be relied upon as the
primary means of operator protection. The primary means should be by
reducing the quantities being handled to the minimum necessary or by
using operational shields. Supplemental operator protection should be
afforded by high-speed deluge systems designed and installed for such
purposes. The personal protective apparel prescribed in an SOP shall be
based upon the hazards associated with the operation.
(b) The minimum protective apparel for personnel exposed to open
containers of pyrotechnic or energetic raw materials shall consist of
the following:
(1) Cotton undergarments and socks.
(2) Conductive-soled safety shoes.
(3) Flame retardant coveralls.
(4) Hair coverings.
(c) All employees exposed to hazardous quantities of pyrotechnic
compositions shall wear the additional items described in Sec. 184.85
(c)(1) through (c)(3), or their equivalent. The definition of hazardous
quantities will depend on the composition's energy output and
sensitivity (as determined by hazard analysis or tests) and the nature
of the operation. Required levels of protective apparel shall be
specified in appropriate SOP steps.
(1) Aluminized, thermally protective suit with hood and face plate.
(2) Aluminized, thermally protective trousers.
(3) Aluminized, thermally protective gloves or equivalent.
(d) When the items described above are required, the design and
wearing shall ensure that no areas of the body are exposed. Appropriate
seals or joints shall be used to preclude flame intrusion where apparel
items overlap or are joined. Particular attention shall be given to
possible gaps in coverage provided by the hood in order to prevent
flame or hot gas impingement on the face, head, or neck.
Sec. 184.86 Additional controls.
(a) Many materials used to produce pyrotechnics are toxic,
represent fire hazards, or both. Operations shall provide protection
from these threats. Vapor-and dust-removal and collection systems shall
be provided where toxic or flammable dusts or gases are generated.
Design and installation of such equipment shall meet safety
requirements.
(b) Blankets should be provided in easily opened containers within
25 feet of operations where they could be required for wrapping burned
employees. Alternate means of achieving the same effect should be
provided when blankets are not.
(c) When required, conductive shoes shall be checked for
conductivity daily before the beginning of work, and retested upon
reentry into the building if the employee has walked over surfaces
(grass, mud, oil, paint, etc.) which could render the shoes
ineffective. A log of the testing shall be maintained.
Sec. 184.87 Reworking pyrotechnic components.
(a) All repair, reassembly, or similar operations on loaded
pyrotechnic compositions shall take place in a separate bay used only
for that purpose.
(b) Consolidated or extruded pyrotechnic compositions shall
normally be destroyed, not pulverized for reblending. While HC smoke
and such compositions are reusable, more sensitive materials, such as
IR flare compositions, are not.
Sec. 184.88 Fire protection.
When compatible with process materials, deluge systems may be used
for the protection of mixing and blending operations, screening,
granulation, drying, and pressing or extrusion operations. The response
time of the deluge system should be selected to minimize the damage to
process equipment and facilities. Hazard analysis of the operation may
dictate other applications.
Subpart I--Storage of Explosives and Ammunition
Sec. 184.90 General.
A properly sited segregated and separate storage area is preferred
for explosives storage. Earth-covered magazines (igloo or other
subsurface) offer the greatest protection to explosives. Such magazines
are preferred for the storage of all explosives. Earth-covered
magazines provide protection from weather and fire, and relatively
constant temperature control.
Sec. 184.91 Storage considerations.
Factors to consider when designating a structure for explosive
storage are:
(a) Magazine construction and location.
(b) Quantity and characteristics of explosives to be stored.
Sec. 184.92 Magazine operational regulations.
(a) No loose ammunition components, packing materials, conveyors,
skids, dunnage, empty boxes, or other such items shall be stored in
magazines containing ammunition or explosives.
(b) No crew shall work in a spot that requires passing a second
crew's work aisle or position to reach an exit in a magazine. The
number of crews should not exceed the number of exits. Doors shall
remain unlocked and permit rapid egress.
(c) Flammable liquids, except when used as the chemical filler of
ammunition, or as a prepackaged storable liquid propellant, shall not
be stored in magazines containing explosives.
Sec. 184.93 Stacking.
(a) Ammunition and explosives should be stored in original shipping
containers or equivalent. Explosives or ammunition in stacks should be
grouped and identified according to lots. General rules set forth in
Sec. 184.93 (b) and (c), shall be followed in the absence of applicable
storage drawings.
(b) Methods used for stacking shall provide for good ventilation to
all parts of the stack. Adequate dunnage shall be used for this
purpose.
(c) Aisles shall be maintained so that units in each stack may be
inspected, inventoried, and removed for shipment or surveillance tests.
Block storage is permitted, provided adequate ventilation of stacks
exists. Unobstructed aisles shall be maintained to permit rapid egress.
(d) Only one light box, pallet, or unit should be allowed per lot
in storage. Stacked light units should be readily visible and
immediately accessible.
Sec. 184.94 Loose rounds, damaged containers.
Loose rounds of ammunition, or single fiber containers with rounds
therein, shall not be stored in magazines containing ammunition items
packed in original shipping containers; however, they may be stored in
magazines set aside for their exclusive storage. Incomplete boxes of
ammunition and explosives may be stored in magazines containing
complete boxes packed in original shipping containers. Conspicuously
marked to identify contents and quantities, the incomplete boxes shall
be placed in designated locations. Explosives and ammunition in damaged
containers should not be stored in a magazine with ammunition in
serviceable containers. Such containers should be repaired or the
contents transferred to new or serviceable containers. Open containers
and containers with covers not securely fastened shall not be allowed
in magazines. Containers that have been opened shall be properly closed
before being restored. Stored containers should be free from loose dust
and grit.
Sec. 184.95 Repairs to magazines.
(a) Repairs should not be made to the interiors of magazines
containing bulk explosives. Repairs to roofs, ventilators, lightning
rods, doors and other parts of, or appendages to, the exteriors of
magazines containing bulk explosives shall not normally require
removing the explosives. Minor repairs may be made to the interiors of
magazines containing finished ammunition or ammunition components.
(b) The general safety requirements set forth in this part,
particularly the elimination of fire hazards, shall be followed when
magazines are repaired. When necessary, baffles and screens should be
used to confine sparks and flames to heating apparatus.
Sec. 184.96 Open storage (outdoors).
Open storage of A&E is prohibited.
Sec. 184.97 Storage of bulk initiating explosives.
Bulk initiating explosives shall not be stored dry nor exposed to
the direct rays of the sun. Containers of ample size to hold the double
bag of explosives are used for normal storage. Covers designed and
constructed to prevent friction and pinch points should be used. Covers
of shipping containers used for long-term storage shall be equipped
with a port for observing the level of the liquid contents. The viewing
port shall have a transparent plastic cover proven compatible with the
initiating explosives being stored. Bulk initiating explosives may, for
expediency, be stored in shipping containers without viewing ports,
provided they are stored in magazines that will prevent freezing; with
containers on end, only one tier high; with passageways for inspection
and handling. Bags of initiating explosives in storage containers shall
be under distilled water. Alcohol may be added to the distilled water
to prevent freezing.
Sec. 184.98 Rockets and rocket motors.
(a) In aboveground magazines, rockets and rocket motor items (in a
propulsive state) should be pointed in the direction least exposing
personnel and property in case of fire or explosion.
(b) Rockets should be stored in dry, cool magazines, out of the
direct rays of the sun. Prolonged exposure of rocket ammunition to
either high or low temperatures may increase the normal rate of
deterioration or render the motors more susceptible to ignition if
handled improperly later.
Subpart J--Fire Protection
Sec. 184.100 General.
This subpart provides general requirements for personnel developing
and effecting fire protection and prevention programs in A&E
environments.
Sec. 184.101 Fire plan.
A written fire plan shall be prepared. Although details may vary,
plans for all establishments shall itemize the emergency functions of
each department or outside agency, indicating responsible individuals
and alternates.
Sec. 184.102 Firefighting agreements.
Voluntary and mutual agreements with nearby municipalities or
industrial centers should include firefighting procedures as
established by the plant officials. Plant officials are responsible for
informing the assisting firefighters of particular procedures to be
followed. Outside firefighters should not assist in fires involving
A&E. If the practical need for their doing so can be anticipated, they
shall receive advance instruction in A&E firefighting procedures.
Outside firefighters shall never attack fires involving Hazard
Divisions 1.1 and 1.2.
Sec. 184.103 Smoking.
Smoking may take place only in safe, specifically designated and
posted ``smoking locations.''
(a) Cigarettes, tobacco, and matches shall be discarded in ash
receptacles only. They shall not be dropped into trash cans.
(b) Electric lighters with automatic pressure cutoffs shall be
fixed, ensuring against removal.
(c) At least one fire extinguisher shall be provided at smoking
locations.
(d) Persons wearing clothing contaminated with explosives or other
dangerous material should not be permitted in smoking areas.
Sec. 184.104 Hot work permits.
A written permit shall be required for the temporary use of heat-
producing equipment or devices when explosives or highly flammable
materials are involved.
Sec. 184.105 Portable fire extinguishers.
Hand extinguishers within buildings can squelch incipient fires
before major damage is done. Portable equipment may provide similarly
valuable outside aboveground magazines and other buildings with
explosives.
Sec. 184.106 Hazards in fighting fires involving ammunition and
explosives.
A fire hazard identification system shall be adopted. This shall
assess relative dangers, up to the most hazardous material stored.
(a) The following fire symbol system is provided as a guide:
(1) Fire divisions, numbered ``1'' through ``4,'' shall correspond
to Hazard Divisions 1.1 through 1.4.
(2) The lower the number, the greater the hazard:
------------------------------------------------------------------------
Fire division Hazard involved
------------------------------------------------------------------------
1.................................. Mass detonation.
2.................................. Explosion with fragment hazard.
3.................................. Mass fire.
4.................................. Moderate fire.
------------------------------------------------------------------------
(3) Distinctively shaped placards, instantly recognizable from a
distance, signify the different divisions. Each placard, or symbol,
shows the fire division number:
------------------------------------------------------------------------
Fire
Shape division
------------------------------------------------------------------------
Octagon...................................................... 1
Cross........................................................ 2
Inverted triangle............................................ 3
Diamond...................................................... 4
------------------------------------------------------------------------
(4) Black numbers appear on orange backgrounds as used by NATO,
UNO, IMO, and DOT. Relectorized or luminous symbols are preferred.
(b) Firefighting procedures. (1) General
(i) Fires should be immediately reported and may be fought without
specific authorization. However, personnel should evacuate and seek
safety if fires involve explosive materials or cannot be controlled by
equipment at hand. Training of operational personnel shall cover the
characteristics of explosive materials, including their reactions to
heat and fire, as well as what to do in case of fire.
(ii) Firefighters should be thoroughly informed of the specific
reactions of A&E exposed to heat or fire.
(iii) Firefighters should be briefed on conditions at the scene
before proceeding.
(iv) Ammunition contained both explosives and chemicals require
special precautionary measures. See Subpart K of this part.
(2) Specific. (i) Personnel shall not attempt to fight fires
involving A&E in Hazard Divisions 1.1 and 1.2. Because this material
detonates with a fragmentation hazard, personnel shall evacuate
immediately, using protective cover and activating deluge systems and
fire alarms while escaping. Individuals remain in danger until they
reach shelters, although reaching inhabited building distances in the
open affords some safety. During exit drills, employees shall be
advised of the safest escape routes.
(ii) If the fire in a Hazard Division 1.1 or 1.2 buildings involves
nonexplosive material and is small or in a segregated container, an
attempt may be made to extinguish the fire. After summoning
firefighters, responsible parties should attempt to meet them as they
approach to brief them. When 1.1 or 1.2 materials are directly
involved, firefighting forces should maintain inhabited building
distance from the fire. The safety of personnel fighting a 1.1 or 1.2
fire depends on the accuracy of the information made available to all
firefighting forces. No person shall reenter a burning building
containing 1.1 or 1.2 materials.
(iii) Personnel in the immediate vicinity of Hazard Division 1.3
explosives should activate deluge systems and alarms. Unless the fire
is minor, involves no explosive, and appears controllable, the
firefighting organization shall confine its efforts to preventing it
from spreading to other buildings. Fire in Hazard Division 1.3
materials creates a wide area of intense radiant heat, dangerous to
personnel and equipment. The firefighting organization should exercise
extreme caution.
(iv) Hazard Division 1.4 A&E present a moderate fire hazard. Fires
involving them shall be fought until extinguished.
Sec. 184.107 Automatic sprinkler systems.
Properly installed and maintained automatic sprinklers reduce fire
losses. They are particularly useful for load lines; explosives
manufacturing; receiving, shipping, inspection, and ammunition
workshops; and demilitarization.
Sec. 184.108 Clearance under sprinklers.
At least 18 inches shall separate sprinkler deflectors from store
materials piled 15 feet high or less; in all other cases, the clearance
shall be at least 36 inches. A minimum clearance of 36 inches shall be
maintained between sprinklers and extremely hazardous materials, and
between sprinklers and baled storage, regardless of height.
Sec. 184.109 Deluge systems.
(a) Deluge systems should supplement sprinklers when the hazards
are high, as in powder hoppers and cutters. Rate of rise, light-
actuating, ultraviolet, or other quick-action devices for automatic
control of deluge systems are recommended. Quick-acting manual controls
should serve as backup.
(b) To ensure immediate drenching of all parts of the machine, the
distribution outlets (nozzles, sprays, heads, etc.) should be as near
the explosive's exposed surface as permitted by the outlet discharge
pattern. When explosives are under tight hoods or covers inside
machines, distributing outlets belong inside the enclosed space.
(c) Nonmetallic, internally spring-held caps should protect outlets
exposed to explosive vapors, gases, or dust. Upon exertion of pressure
within the outlet, the cap shall pop immediately. Caps should be
attached to outlets to prevent their dropping into equipment during a
deluge.
(d) Required water flow and pressure should be determined for the
hazard.
(e) Periodic inspections of deluge systems shall ensure that they
are in proper operating condition.
(f) The deluge valve should allow for automatic and manual
activation. Manual activation devices shall be placed at exits in
explosives-operating buildings. They may also be located at the
operator stations when hazard analysis determines the risk to personnel
acceptable.
(g) National Fire Protection Association Standards No. 13,\7\
Installation of Sprinkler Systems, and No. 15,\8\ Water Spray Fixed
Systems, contain basic installation rules.
---------------------------------------------------------------------------
\7\Copies may be obtained from the National Fire Protection
Association, Batterymarch Park, Attn: National Fire Codes
Subscription--Service Department, Quincy, MA 02269.
\8\See footnote 6 to Sec. 184.109(g).
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Sec. 184.110 Hazards in fighting fires involving liquid propellants.
For safety's sake, firefighters shall know the burning
characteristics and specific hazards of liquid propellants. Burning
liquid propellants fumes are generally toxic, so firefighters should
remain on the upwind side. Protective clothing should include an
approved, self-contained breathing apparatus.
Sec. 184.111 Firebreaks.
The primary purpose of vegetation control is to limit the
probability of fires causing a hazard to ammunition and explosives
areas. Therefore, a firebreak, at least 50 feet wide in all directions,
shall be maintained around magazine areas, aboveground magazines and
explosives operating buildings/locations. Firebreaks need not be devoid
of vegetation but the growth shall be controlled to prevent rapid
transmission of fire. Maintenance of firebreaks around earth-covered
magazines is not required. However, combustible material and large
trees shall be removed. Vegetation around ventilators on earth-covered
magazines shall be controlled to prevent transmission of fire into the
magazine.
Subpart K--Specific Chemicals
Sec. 184.113 General.
This section covers specific chemicals used during explosives
manufacturing processing and provides basic guidance for the
establishment of local safety requirements. Publications listed below
are acceptable as guides in the formulation of safety requirements
except where they conflict with the requirements of this part:
(a) Chemical Data Sheets, National Safety Council.\9\
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\9\Copies may be obtained from the National Safety Council, P.O.
Box 558, Itasca, IL 60143-0558.
---------------------------------------------------------------------------
(b) Liquid Propellant Handling, Storage and Transportation, CPIA
publication No. 194,\10\ dated 1970.
---------------------------------------------------------------------------
\10\Copies may be obtained from Johns Hopkins University,
Chemical Propulsion Information Agency (CPIA), 10630 Little Patuxent
Parkway, Suite 202, Columbia, MD 21044-3200.
---------------------------------------------------------------------------
(c) Patty's Industrial Hygiene and Toxicology.\11\
---------------------------------------------------------------------------
\11\Copies may be obtained from Wiley Interscience, John Wiley &
Sons, Inc., 605 Third Avenue, New York, NY 10158-0012.
---------------------------------------------------------------------------
(d) Industrial Fire Hazards Handbook.\12\
---------------------------------------------------------------------------
\12\Copies may be obtained from the National Fire Protection
Association, Batterymarch Park, Attn: National Fire Codes
Subscription--Service Department, Quincy, MA 02269.
---------------------------------------------------------------------------
(e) Dangerous Properties of Industrial Materials.\13\
---------------------------------------------------------------------------
\13\Copies may be obtained from Van Nostrand Reinhold Company,
Inc., 135 West 50th Street, New York, NY 10020.
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Sec. 184.114 Repairs to acid equipment.
(a) Before a pipeline, pump, or other equipment exposed to acid is
dismantled for repairs, it should be drained and washed down with
water. All pressure shall be relieved; valves, switches, etc., shall be
tagged or locked to prevent the accidental application of pressure or
the introduction of acid into the line. Branch lines where pockets may
exist require particular attention. All pumping on the system connected
with parts under repair should cease, with starters tagged and locked,
unless blank flanges in the lines cut off the affected parts from the
pump. In breaking a flange, the bottom bolts should be loosened first
and the first line allowed to sag slightly, permitting the liquid to
run out by gravity. Spilled liquid shall be disposed of properly after
the repairs. Absent other information, chemical pipelines shall be
assumed to contain liquid.
(b) Repairing used-steel acid tanks presents two types of hazards.
Even a trace of weak acid or weak acid sludge shall violently react on
the metal, generating gases. These could cause an explosion if welding
is carried out on the tank. Personnel working inside the tank risk
serious poisoning from the gases. Therefore, before repairs start, the
tank shall be washed out, filled with water, then drained. If any acid
remains, it may be necessary to apply soda ash solution and steam, then
fill the tank with water, repeating the original procedure. Before
entering tanks, check that sufficient oxygen is present. When someone
is working inside the tank, an observer shall be present, with at least
one other person available for rescue work, should the worker in the
tank be overcome; such personnel shall receive training in tank rescue
work. Those entering tanks shall have respiratory protective equipment,
life belts, or harnesses and lifelines.
(c) Neutralizing spills. Slaked (hydrated) lime shall be available
to neutralize spilled acid. A 10 to 20 percent solution of sodium
bicarbonate shall remove acid from floors or equipment. Because
neutralization generates heat, care shall be taken in cleaning large
quantities of acid. Soda or other alkaline solutions shall neutralize
all places made slippery by acid, which shall then be flushed with
water.
(d) Mixing acid with water. The acid shall be added to the water,
never the water added to the acid, when significant amounts are being
diluted. Acid should be added slowly with agitation. Weak acid
replacing water as the diluting agent requires similar precautions.
Solutions shall be thoroughly mixed, particularly in steel tanks.
(e) Empty containers. Carboys that have contained acids shall be
thoroughly drained before being offered for transportation. They shall
be shipped in the same manner as full items.
Sec. 184.115 Mixed acids.
Mixed acids include mixtures of sulfuric and nitric acids used in
the nitration of various explosives constituents. The pressure of
liberated gases sometimes causes carboys of mixed acids to rupture
violently. Mixed acids can start fires, generate gases that cause
explosions, and emit poisonous oxides of nitrogen. Mixed acid
containing not less than 10 percent of nitric acid shall not freeze at
ordinary temperatures and shall not actively attack steel storage
tanks.
Sec. 184.116 Waste acids (spent acids).
Waste acids usually contain small amounts of nitrobodies, so
present the hazard of explosive material. Spent acid from the
manufacture of nitroglycerin and liquid esters are particularly
hazardous.
Sec. 184.117 Nitric acid.
Nitric acid forms explosive compounds with most organic materials.
With most oxidizable material, it forms flammable compounds, some of
which are subject to spontaneous ignition. Nitric acid fire creates
exceedingly toxic oxides of nitrogen. Buildings where nitric acid is
used shall have proper ventilation. Enough space shall separate them to
allow for firefighting forces; also, to prevent the accumulation of
acid ``fumes'' (sometimes colorless, at other times identifiable,
ranging from dark yellow to brown). The first symptoms of nitrous
poisoning are usually followed by a latent period, when the victim
feels comfortable though the poisoning continues. For this reason,
anyone with even mild symptoms of nitrous poisoning shall immediately
be made completely still and attended by a physician as soon as
possible.
Sec. 184.118 Sulfuric acid (oil of vitriol).
Concentrated sulfuric acid chars wood, cotton, and vegetable
fibers, usually without causing fire, but oleum (fuming sulfuric acid)
usually does cause fire in these materials. The addition of water may
create heat sufficient to cause a fire or explosion, and greatly
increases the corrosive properties of oleum. This does not preclude the
use of large quantities of water to dilute or dissipate small
quantities of acid. Sulfuric acid shall not be stored with nitric acid,
volatile or flammable liquids, or oxidizing agents. It may be stored in
carboys, drums, tanks, glass bottles, and in large outdoor tanks. All
precautions listed for sulfuric acid apply to oleum. In an emergency,
sand, earth, or other noncombustibles may be used to absorb oleum
spilled or leaking from storage containers. Once the crisis has passed,
the oleum-soaked mass can be neutralized with solid carbonates, such as
calcium carbonate.
Sec. 184.119 Oxidizing agents.
The following discussion is limited to the inorganic oxidizing
agents, because the organic agents, such as nitrobenzene, are often
violent explosives and should come with special storage and handling
instructions. Inorganic oxidizing agents include the chlorates,
perchlorates, peroxides, and nitrates of barium, sodium, potassium,
strontium, ammonium, etc. Their ability to furnish oxygen renders
oxiding agents hazardous, and violent explosions may occur when they
are mixed or contaminated with minute quantities of certain
carbonaceous and combustible materials such as wood, paper, metal
powders, sulfur, etc. The violence of reaction depends upon
subdivision, extent of contamination, degree of confinement, and type
of initiation. Shoes, clothing, and other combustible materials covered
with dust or solutions of oxidizing agents also represent dangers.
Intimate mixtures of finely divided oxidizers and fuels are very
sensitive to heat, friction, and impact.
Sec. 184.120 Handling oxidizing agents.
(a) Oxidizing agents shall be stored and processed only in fire-
resistive rooms or buildings. They shall be separated from fuels,
flammable materials, metal powders, and acids until processing.
(b) Equipment for processing oxidizing agents shall not be used for
fuels, flammable substances, metal powders, etc. It should be
constructed of non-combustible materials only.
(c) Solutions of oxidizing agents shall be placed in nonabsorbent,
non-combustible containers only.
(d) Damaged combustible containers shall not be repaired in the
storage building because of the risk of contamination and ignition.
Discarded containers shall serve no other purpose, but shall be burned
in the open. Combustible containers infused with oxidizing agents burn
fiercely if ignited, and may explode.
(e) Employees handling oxidizing agents should wear flame-resistant
clothing as minimal protection. Contaminated clothing should be stored
in metal cabinets until laundered.
(f) Spills of small quantities of oxidizing agents during
processing shall be cleaned up immediately. If large quantities are
spilled, the uppermost layers may be salvaged if free of contaminants.
Sec. 184.121 Chlorates.
(a) Chlorates mixed with sulfur, sulfides, or other readily
oxidizable material may cause spontaneous ignition. Sulfur presents a
greater hazard than sulfides. Adding phosphorus to a sulfur-chlorate
mixture increases the danger. Shellac, potassium, sodium nitrate with
petroleum derivatives, and powdered metals render chlorates sensitive;
mixtures of trinitrocresol or picric acid and chlorates should be
avoided since they are particularly sensitive. Chlorates shall never be
mixed with ammonium salts since the ammonium chlorate that could form
could spontaneously explode. Moisture of 0.5 percent or more in
mixtures containing chlorates is considered dangerous because of the
possible formation of chloric acid.
(b) Substituting sodium chlorate for potassium chlorate in any of
the above-described mixtures increases the hazard.
(c) Ammonium chlorate decomposes spontaneously. When mixed with
perchlorates it constitutes a major hazard.
(d) Barium chlorate is very toxic. In storage, it poses a greater
danger than potassium chlorate.
(e) Zinc chlorate, in contact with certain organic materials,
explodes under the influence of slight friction, percussion, or shock.
When involved in a fire, it is life-threatening.
(f) Storage of chlorates should preclude contact with other
combustible material, organic or inorganic. Broken or damaged
containers and spilled material should be promptly removed and
destroyed.
(g) Fires involving chlorates should be fought with solid streams
of water or with water fog. With solid streams, firefighters can
maintain a greater distance but steam explosion becomes a danger
requiring precautionary measures. Water fog offers the advantage of
quicker cooling. Its normal smothering action, however, is obviated by
the ability of chlorates to furnish oxygen to the fire.
Sec. 184.122 Perchlorates.
Perchlorates form slightly less sensitive mixtures than do
chlorates and should be substituted whenever possible. Advantages of
using perchlorates include this reduced sensitivity to impact and
friction, the nonformation of a free acid when moisture is present, and
greater safety in the event of accidental contact with the weak acids
that form the principal part of many gums used in binding pyrotechnic
mixtures.
(a) Ammonium perchlorate alone does not easily explode. It is
stable at ordinary temperatures, but decomposes at a maintained
temperature of 302 deg.F (150 deg.C). It has the same degree of
sensitivity to impact as picric acid. It becomes a high explosive when
mixed with flammable materials and metal powders.
(b) Containers for perchlorates and chlorates in storage include
lined wooden boxes, kegs, barrels, and iron drums. All damaged and
broken containers shall be removed from the storehouse and spilled
material swept up and destroyed promptly.
(c) Fires involving perchlorates alone may be fought with water.
Sec. 184.123 Peroxides.
(a) General. Solid peroxides decompose easily in the presence of
moisture and shall therefore be stored in a cool, dry place. They pose
a severe fire hazard, particularly when incorporated with combustible
materials. Sodium peroxide shall be protected from contact with water,
which renders it explosive. Hydrogen peroxide of approximately 30
percent strength is unstable, liberates oxygen, and resembles the solid
peroxides.
(b) High-strength hydrogen peroxide. (1) High-strength hydrogen
peroxide (90 percent or greater) is shipped in specially designed
containers with vents and stored only in containers vented to the
atmosphere, constructed so that foreign material shall not enter the
containers. It shall be stored in a cool, shaded location used only for
that purpose. Containers of hydrogen peroxide shall never exceed 15 or
20 above ambient temperatures. Larger increases in temperature may
indicate a decomposition of the hydrogen peroxide. Operators shall
report any undue heating of hydrogen peroxide drums to the person in
charge, and the area shall be evacuated immediately. A water spray
system, installed in every hydrogen peroxide storage location, shall be
turned on immediately upon observation of overheated storage drums. If
hydrogen peroxide is to be stored for long periods, high-purity
aluminum containers shall be used.
(2) All tanks, tubes, and fittings shall be thoroughly cleaned. The
recommended procedure involves immersing parts in a pickling solution
of 0.5 percent sodium hydroxide at room temperature for 1 hour, washing
with clear water, drying, immersing in a 5 percent solution of CP
sulfuric acid at room temperature for 1 hour; washing, drying, and
leaving in a 25 to 30 percent solution of hydrogen peroxide for at
least 24 hours, then draining off the solution. The part is then ready
for use.
(3) Hydrogen peroxide burns and discolors skin. All persons
handling this material should wear face shields, rubber gloves, and
rubber trousers on the outside of rubber boots. Running water shall be
available in the storage area; any part of the skin touched by hydrogen
peroxide shall be immediately washed with water. Spillages of hydrogen
peroxide shall be immediately washed away with water.
(4) Only the following materials should be used in equipment coming
in contact with high strength hydrogen peroxide: ``Pyrex'' glass, high-
purity aluminum, pure tin, ``Keroseal'' or equivalent. Stainless steel
types 304, 309, 310, 316, 321, and 347 are suitable for periods of 2
months or less.
(c) Fires. Fires involving peroxides, except sodium peroxide, may
be fought with water. Sodium peroxide fires shall be smothered with
sand, ashes, dirt, or rock dust.
Sec. 184.124 Nitrates.
(a) General. Many nitrates are not flammable in themselves, and are
usually stored in wooden boxes, kegs, or barrels. Ammonium nitrate,
however, is shipped in special waterproof bags or metal containers.
Barium nitrate is sometimes stored in iron drums. Regardless of the
type of container, it shall be moisture-proof. Nitrates shall be stored
in a dry place, since they cake in the presence of moisture.
(b) Ammonium nitrate. (1) Ammonium nitrate in confinement can
detonate with the violence of a high explosive, but this would require
a relatively heavy initiator. Under the effect of heating alone,
ammonium nitrate shall decompose. Contamination with chlorides, sulfur,
nitrobodies, charcoal, metallic nitrates, metal powders, petroleum
derivatives, and oxidizable carbonaceous materials sensitizes ammonium
nitrate, accelerates its decomposition, and increases the violence of
the reaction. Zinc or lead contamination lowers the decomposition
temperature to 200 deg.F. Galvanized metals and lead solder shall not,
therefore, be used in the vicinity of ammonium nitrate operations. The
burning of ammonium nitrate and combustible material such as wood or
paper containers, produces a gas mixture that under proper conditions
of pressure may detonate with sufficient force to initiate the
detonation of ammonium nitrate. Fires involving ammonium nitrate shall
be vented to the greatest practicable extent because air acts as a
diluent for the hazardous gases, minimizing the probability of
explosion.
(2) In high pan (evaporating) operations, deluge systems should be
provided over the pans for use in case of fire. Temperatures used to
heat the liquor may not exceed 317 deg.F (saturated steam at 100 psi).
High pan operations shall be located at class 1.1 distances from
adjacent structures other than the graining building. The graining
building, however, shall be protected from the high pans by a
barricade. The class 1.1 distances specified above may be based on the
maximum quantity of ammonium nitrate contained in any one high pan.
(3) Fires involving nitrate should be fought with large quantities
of water, never with steam. Solid hose streams enable the fire to be
fought from a greater distance but introduce the hazard of steam
explosion, particularly if the nitrate is molten; therefore, the hose
streams shall be directed from behind a protective barrier. Under some
circumstances, when the fire is in the incipient stage and accessible,
water fog may be used to an advantage but it shall have no smothering
action since the burning material provides its own oxygen.
(4) Storage of ammonium nitrate in explosives storage magazines is
preferred. When stored in an area where there is a possibility that
explosives may be projected into the nitrates, the requirements for
class 1.1 explosives are applicable. When stored in an area with fire
hazards only and separated by more than intraline distances from areas
containing ammunition, ammonium nitrate may be stored in accordance
with the requirements governing the storage of a class 1.3 solid
propellant.
(i) Buildings, other than earth-covered magazines, used for the
storage of ammonium nitrate, shall be of a type easily vented if fire
occurs, in order that the gases produced during combustion and
considered potential sources of explosion to the commodity are
dissipated. The floors of such buildings shall be of a type to prevent
hazardous impregnation by the nitrate.
(ii) Stacking within storage buildings other than earth-covered
magazines should anticipate stacks no larger than the 12 by 12 feet
plan dimension, and not higher than 7 feet. Aisles not less than 3 feet
wide shall be maintained around each stack and between the sides of the
building. The use of wood dunnage should be restricted to reduce the
quantity of combustible materials present.
(iii) Broken packages or containers shall be removed from the
building and the spilled material swept up and destroyed promptly.
Sec. 184.125 Powdered metals: aluminum, magnesium, and aluminum
alloys.
(a) Since a rise in the temperature of metal powders can result
from contact with water and ignition may ensue, precautions shall be
taken to prevent water from contacting the material. All buildings
where powdered metals are stored or processed shall be vented
adequately at the highest point of the room or building to prevent the
accumulation of evolved hydrogen gas that results from the reaction
between powdered metals and moisture, except when stored in watertight
containers.
(b) Exposed material that may be at a low temperature should be
brought to or near the room temperature under conditions of low
relative humidity before being placed in the operating room.
(c) Heating equipment shall be installed in service magazines, when
required, to bring the closed containers and contents to a temperature
approximately that of the operating building.
(d) Efforts should be made to maintain relative humidity between 50
and 55 percent in locations where metal powders are exposed, so as to
avoid the hazard of static electricity while preventing condensation.
(e) Operators should be cautioned to wear sweatbands on their
foreheads and take other precautions to prevent perspiration from
falling onto powdered metals.
(f) Care should be exercised in locating pipes, to prevent
condensation on cold pipes forming droplets of water and falling upon
hazardous material. Leaking water pipes can cause ignition.
(g) Powdered metals in metal containers with tight covers may be
stored in general warehouses, provided that they are remote from
oxidizing agents. The storage place shall be dry.
(h) When compounded with oxidizing agents, powdered metals present
a dangerous fire and explosion hazard.
(i) Very fine suspended dust from powdered metals is an explosion
hazard comparable to that of explosive gases and may be initiated
easily by discharges of static electricity.
(j) Powdered metals exposed to air are dangerous fire hazards and
burn with intense heat. Metallic oxide formed by the burning within
drums effectively blankets such fires, confining them, if undisturbed,
to the place of origin.
(k) Fires shall not be fought with ordinary streams of water
because of the danger of liberating large quantities of hydrogen gas, a
severe explosion hazard. Fires involving small quantities of powdered
metals may be combated with a fog nozzle or specially designed
commercial extinguishing powders gently applied to prevent the fire
from spreading. If large quantities of powdered metals become involved
in a fire and escape from their storage containers, firefighting
efforts shall be directed primarily to prevention of fire spreading to
other facilities. Where friction sensitivity is not a concern,
smothering fire with sand may be effective.
(l) Trained personnel shall repair or maintain buildings or
equipment where metallic powders are involved, and then only with the
following precautions: powder or dust shall be removed, nonsparking
tools shall be used, hammer impacts that could cause sparks shall be
avoided, flashlights shall be of approved type, equipment shall be
grounded, undue friction shall be prevented, and open flames shall not
be used.
(m) Zirconium powder can explode violently when in contact with
cupric oxide or lead oxide. Other metallic powders exhibit this
property under certain conditions. National Fire Prevention
Association, 491M,\14\ Hazardous Chemical Reactions, provides
information regarding reactions between metallic powders and other
chemicals.
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\14\Copies may be obtained from the National Fire Protection
Association, Batterymarch Park, Attn: National Fire Codes
Subscription--Service Department, Quincy, MA 02269.
---------------------------------------------------------------------------
Sec. 184.126 Charcoal.
(a) Charcoal is subject to spontaneous ignition in the presence of
moisture, although pit charcoal is less likely than the chemical
byproduct charcoal, and soft wood charcoal less so than hardwood
charcoal. The following conditions promote the spontaneous ignition of
charcoal: forced cooling after burning; drying after absorbing
moisture; and contact with alcohols and oils (particularly for charcoal
in which a fire has been extinguished). Pulverized charcoal is a
definite fire hazard. The gases from burning charcoal contain carbon
monoxide and are toxic.
(b) Permanent or reserve storage of large quantities of charcoal is
not recommended. Charcoal should be stored in airtight containers or in
bags piled in tiers with skeleton or gridwork floors between tiers to
provide ventilation. It should be isolated and remove from oxidizing
agents. Bulk storage of charcoal is prohibited.
Sec. 184.127 Sulfur.
(a) Sulfur compounded with chlorates and several other oxidizing
agents forms highly sensitive explosive mixtures. Sulfur presents a
spontaneous ignition hazard when mixed with carbon, lamp black, fats,
and oils. Burning sulfur produces toxic gases and fumes.
(b) Sulfur may be stored in wooden boxes, kegs, or barrels. Large
quantities may be stored in bulk. It should be isolated and remote from
oxidizing agents with which it forms highly sensitive explosive
mixtures.
Sec. 184.128 Flammable solids.
Guanidine nitrate, dinitrophenol, DNT, and dinitrobenzene are
examples of flammable solids. These materials may be stored in wooden
boxes or barrels lined with moisture-proof paper. They should be stored
in fire-resistant locations, preferably in magazines. When strongly
initiated they may act as explosives. Dinitrophenol may explode at
elevated temperatures.
Sec. 184.129 Volatile flammable liquids.
(a) Common examples of volatile flammable liquids are ether
acetone, gasoline, ethyl alcohol, methyl alcohol (wood alcohol),
benzene, toluene, xylene, and amyl acetate. These volatile liquids may,
if unconfined, evolve vapor in explosive concentrations. Ethyl and
isopropyl ethers tend to form explosive peroxides, especially when
anhydrous. Evaporation to near dryness shall be prevented. Volatile
flammable liquids shall not be used to wash or clean equipment or parts
of buildings except when specifically authorized as process
requirements.
(b) Some flammable liquids such as paints, varnishes, and enamels
may, under certain conditions, be subject to spontaneous ignition. They
shall therefore be isolated from sources of heat, in locations where
any heat produced shall readily dissipate. Only noncombustible sweeping
compounds should be used for cleaning up materials of this type.
Sec. 184.130 Calcium carbide.
Small quantities of calcium carbide may be stored in general
warehouses in airtight tin cans or iron drums. Large quantities should
be stored only in separate noncombustible buildings or detached
weatherproof sheds. The storage place should be dry and well
ventilated. Calcium carbide, in itself a slight fire hazard, reacts
violently with water, liberating large quantities of acetylene gas
which, with air, forms explosive mixtures.
Sec. 184.131 Sodium hydroxide (caustic soda) and potassium hydroxide.
These materials may be stored in general warehouses in airtight
iron drums. Permanent storage of large stocks is not recommended. These
chemical products may become a fire hazard when mixed with nitro
compounds or other materials. Their action is corrosive and caustic;
mixed with water, they create heat.
Sec. 184.132 Metallic sodium.
Metallic sodium may be stored in airtight steel drums and may be
stored under kerosene or nitrogen, but not under chlorinated
hydrocarbons. Its violent reaction with water liberates hydrogen and
causes heat, producing a serious fire and explosion hazard.
Sec. 184.133 Nitrocellulose and derivatives.
Nitrocellulose includes various types of nitrated cotton or wood
pulp, depending on the nitrogen content. When dry, it is extremely
sensitive to shock and friction and readily accumulates static charges.
It is highly flammable and explosive, burning rapidly and producing
very little smoke or residue. Impure, it is subject to spontaneous
ignition. Storage of dry nitrocellulose is not permitted as it
possesses all the hazards of a sensitive and easily ignited high
explosive. Nitrocellulose with 25 to 30 percent moisture content is
stored in zinc-lined boxes or metal drums and is substantially
nonexplosive when stored in an area where explosives or ammunition
cannot be projected into it.
Sec. 184.134 Red phosphorus.
Red phosphorus forms sensitive mixtures with oxidizing agents,
posing a dangerous fire hazard. It may be stored in general warehouses
in metal drums or metal containers included in wood boxes. Phosphine
gas may form in containers of red phosphorous; protective measures
should be used when opening these.
Sec. 184.135 Thermite (TH).
Thermite, a mixture of iron oxide, aluminum, and other substances,
is a dark gray granular mass. To burn, it requires an igniter. At 4300
deg.F, iron oxide reduces to molten iron, causing rapid burning.
Thermate is a mixture of thermite, grained aluminum, barium nitrate,
sulfur, and lubricating oil.
Sec. 184.136 Incendiary bombs.
Incendiary bombs may consist of a combustible body of magnesium
metal alloy containing an igniter composition such as thermate. When
ignited, the body of the bomb burns at about P3700 deg.F. Other types
(such as IM, NP, PTI) have steel cases filled with thickened fuel.
These operate by ejecting the burning fuel over a wide area. Incendiary
bombs are difficult to extinguish.
Sec. 184.137 Colored smoke mixtures.
These mixtures contain dye for smoke and some fuels. They do not
contain hexachloroethane (HC). Respiratory protection shall be worn for
protection against heavy concentrations of smoke.
Sec. 184.138 Smoke.
FM or FS in smoke form shall not usually produce effects requiring
treatment. Smoke in high concentrations from CN-DM, CN, and HC is
toxic, and anyone unprotected by a mask subjected to this should
receive medical attention. Corrosive on the skin, liquid FS or FM
should be immediately washed with copious quantities of water, then
flushed with mild sodium bicarbonate solution.
Sec. 184.139 Adamsite (DM).
DM is a greenish yellow to black solid, melting at 383 deg.F.
Smoke from the burning agent causes irritation in the nose and throat
even in minimal concentrations. Longer exposure causes tightness of the
chest, headache, sneezing, coughing, intense nausea, and weakness. The
symptoms increase in severity for some time after exposure, and
temptation to remove the mask should be resisted. Irritation produced
by this agent is so intense that an intolerable concentration is
reached long before it becomes dangerous to life. The effects may last
for several hours, but no permanent injury is caused. If DM is spilled,
it should not be swept or handled in any way so as to cause dust
formation: DM should be wet thoroughly before it is swept. For first
aid treatment, remove victim to fresh air and flush nose and throat
areas with bicarbonate of soda solution. Let victim breathe an alcohol,
chloroform, and ammonia mixture. Evacuate to hospital for medical
treatment.
Sec. 184.140 O-chlorobenzylidene malononitrile (CS).
(a) CS is a white crystalline powder similar to, but more powerful
than, CN. It has a minimum purity of 96 percent; insoluble in water and
ethanol, it is soluble in methylene chloride. CS1 is a micropulverized
powder. CS2 is a modified CS1, treated with liquid silicone to increase
fluidity and persistency.
(b) A protective mask; ordinary coveralls secured at the neck,
wrist, and ankles; and rubber gloves shall provide protection.
(c) Exposure incapacitates within 20 to 60 seconds and, after the
affected individual reaches fresh air, the effects continue for 5 to 10
minutes. Eyes burn, tear copiously, and involuntarily close. Exposure
also causes coughing, difficulty breathing, chest tightness, a stinging
sensation, a running nose, and dizziness or a swimming sensation in the
head. Heavy concentrations of CS, which has a pepper-like odor, shall
also cause nausea and vomiting. To prevent stinging and reddening of
the skin, personnel touched by CS dust or particles should not shower
for 6 hours. Individuals affected by CS should move to fresh air, face
the wind, and should not rub their eyes. To remove accidental gross
contamination, personnel should remove clothing and immediately flush
the body with copious amounts of water to remove most of the agent;
apply 5 percent sodium bisulfite solution to remove remainder (except
in or around eyes); then rinse the entire body.
(d) Area decontamination is required with CS, which settles as a
dust. Any such accumulation shall be removed, either by vacuuming or
washing down the area with detergent solution followed by a clear water
rinse.
Sec. 184.141 Sulfur trioxide-chlorosulfonic acid mixture (FS)
This is a heavy liquid acid with an acrid odor. It fumes strongly
in air, decomposes above 154 deg.F, and is used solely as a smoke-
producing agent. Exposure to heavy concentrations may cause severe
irritation to the skin, eyes, and respiratory tract. Inhalation of
concentrated fumes causes coughing and strangulation, a constricted
feeling around the chest, and a burning sensation in the nose and
throat. When the mixture comes in contact with moisture, it forms
hydrochloric and sulfuric acids, both of which corrode metals and
fabrics. Any FS on clothing or skin should be wiped off with a dry
cloth, and the contaminated area flushed with large amounts of water.
Itself nonflammable, FS may cause fires if spilled on flammable
material, particularly under damp conditions. Leaking munitions
containers should be removed from the magazine and contents poured on
the ground in a suitable area. Spillage can be removed with large
quantities of water. Small quantities of water added to FS react
violently.
Sec. 184.142 Titanium tetrachloride (FM).
Titanium tetrachloride is a heavy, colorless liquid acid with a
pungent odor. When it leaks it produces a massive amount of smoke. It
is used solely to produce smoke and has slight toxic effects. Liquid FM
shall burn the skin, however; and quantities of smoke cause a choking
sensation and difficulty breathing; a protective mask is required for
the comfort of the worker. In extremely heavy concentrations,
protective mask canisters may become clogged to such an extent as to
render breathing difficult; in enclosed places, serious injury can
result. Large quantities of water can remove liquid FM from the skin.
Leaking munitions containers should be removed from the magazine and
destroyed by pouring contents on the ground in a disposal area.
Spillage can be removed with large quantities of water.
Sec. 184.143 Hexachloroethane mixture (HC).
HC, a gray-colored powder without characteristic odor, consists
largely of a hexachloroethane, zinc oxide, and aluminum mixture. HC
reacts with water which can start it burning; it burns rather slowly
with the evolution of a dense cloud of smoke. Respiratory protection
shall be worn by personnel exposed to any concentration of HC smoke.
Sec. 184.144 Burning mixture (CN-DM).
CN-DM is a mixture of chloroacetophenone and diphenylamine
chloroarsine with pyrotechnic material. Respiratory protection is
required when this mixture burns.
Sec. 184.145 Phosphorus munitions agents.
(a) General. At present, white phosphorus (WP) and plasticized
white phosphorus (PWP) are the only two chemical agents in this group;
they have somewhat similar characteristics.
(b) White phosphorus. WP is a yellowish, wax-like substance,
melting at 110 deg.F. Its most characteristic property is that it
spontaneously ignites when exposed to air, burning with a yellow flame
and giving off a large volume of white smoke. Smoke in field
concentrations is not toxic, fumes are toxic. WP is intensely poisonous
when taken internally.
(c) Plasticized white phosphorus. PWP is finely divided WP
suspended in a gel of rubber and xylene.
Sec. 184.146 Storage for phosphorus munitions.
(a) General. Phosphorus munitions should be stored in fire-
resistive magazines with concrete floors or in earth-covered magazines
in a manner facilitating inspection.
(b) Temperature control. White phosphorus filling in munitions
becomes liquid at 111 deg.F. When exposed to air, WP shall ignite; in
cases when a burster is in the projectile, it may explode. Below 111
deg.F the filling is solid and shall not leak; for this reason, the
temperature shall be kept below 111 deg.F.
(c) Position of munitions. Where temperature is likely to reach 111
deg.F, WP munitions shall be stacked upright, sitting on their bases,
so that a subsequent drop in temperature shall not solidify the WP in a
position affecting the ballistics of the item.
Sec. 184.147 Special protective equipment for phosphorus munitions.
(a) General. Special equipment, including that required for first
aid, should be readily available to personnel working where phosphorus
munitions are stored, processed, or handled.
(b) Personal protective equipment. Personal protective equipment
consisting of flameproof gloves and coveralls and face shield,
sufficient in number to equip all personnel required to work with
phosphorus munitions, shall be centrally stored and maintained under
close supervision. These items shall be issued to personnel working
with WP- or PWP-filled items and shall be worn whenever munitions
containers leak.
Sec. 184.148 First aid for phosphorus burns.
Phosphorus buried in the flesh is absorbed and may result in
systemic poisoning. The tissues immediately around the burn are
particularly affected by the absorbed phosphorus. Untrained personnel
administering first aid should immediately plunge burned areas into
water, then wrap them in wet gauze.
Sec. 184.149 Leaking phosphorus munitions.
(a) General. White smoke immediately alerts observers to leaks in
WP munitions. Spontaneous ignition occurs when air contacts the WP.
Only prompt action can combat the great risk of fire posed by leaking
WP munitions.
(b) Immediate action on discovering leaking munitions. During
operations, the person discovering the leaking munitions shall, when
practicable, submerge the leaker in one of the tubs provided. (Rubber
protective equipment does not give adequate protection when exposed to
high temperatures such as produced by burning phosphorus. When burning
phosphorus adheres to gloves, the gloved hands should be dipped in
water.)
(c) Disposal of leaking munitions. After a single leaking item has
been immersed in water, it should be disposed of in an area where
fragmentation shall not be a hazard, smoke shall not create a nuisance,
and no dry vegetation could be ignited.
(1) An item that does not contain a fuze or burster shall be
removed to the demolition ground and destroyed by static firing. All
personnel shall retire to a safe distance before the projectile is
exploded.
(2) The fire shall be extinguished before a filled item with a fuze
or burster, not in a container, is handled or moved. This is extremely
hazardous, and shall be carried out under the direction of an expert in
demolition techniques, familiar with chemical munitions. After the
flames have been extinguished, the instructions given in
Sec. 184.149(c) shall be followed.
Sec. 184.150 Removal of phosphorus munitions.
(a) General. After leaked phosphorus has been doused and contained
by water, the water can evaporate, making it possible for the
phosphorus to reignite. Phosphorus that has self-extinguished by
forming a crust can reignite if the crust is broken.
(b) Procedures. Small amounts of phosphorus are best removed by
first scraping with a putty knife or other such implement, then
removing what remains with a blowtorch or similar appliance. This
method of removing phosphorus shall not be attempted until all loaded
munitions have been removed.
(c) Surveillance. The magazine should be kept under surveillance
for at least 2 weeks, as fire may recur. Any deep cracks or crevices in
the floor should be filled up with cement mortar before munitions are
returned in the magazine.
Sec. 184.151 Incendiary and smoke munitions.
Munitions in this group include incendiaries and signaling smokes.
Sec. 184.152 Special protective equipment for incendiary and smoke
munitions.
Boxed and unboxed incendiary and smoke munitions may be handled
without special protective equipment. Respiratory protection should be
available, however. Personnel exposed to burning munitions or bulk
chemicals should wear protective masks.
Sec. 184.153 First aid for incendiary and smoke munitions injuries.
No unusual first aid treatment is required for personal injuries
incurred handling incendiary-to-incendiary or smoke-to-smoke munitions.
Burns should be treated in the same manner as those caused by flame.
Persons exposed to high concentrations of smoke should be hospitalized.
Sec. 184.154 Leaking incendiary and smoke munitions.
Personnel handling leaking items need not generally wear protective
equipment, but masks should be worn during exposure to burning
munitions. Leaking munitions containing incendiary and smoke agents
shall be segregated.
Sec. 184.155 Fire in incendiary and smoke munitions magazines.
In magazines containing incendiary or smoke munitions, primary
firefighting efforts shall be confined to preventing fire from
spreading. Water is not used to fight fires of thermite or mixtures
containing fine metallic powders such as magnesium or aluminum.
Incipient fires may be smothered by spraying with dry chemical fire
extinguishers or covering with sand. Fire in magazines containing
incendiary-to-incendiary or smoke-to-smoke munitions shall be fought
with water only when large quantities of water can completely douse
relatively small quantities of munitions.
Subpart L--Safety Requirements for Explosives Facilities
Sec. 184.157 General.
This subpart contains minimum safety requirements for existing,
new, or modified explosives facilities and equipment. For facilities
primarily used for general industrial operations, the requirements of
this subpart shall apply in areas performing explosives work.
Sec. 184.158 Requirements.
Special properties of materials and operational hazards may require
that national, Federal, and local requirements be exceeded. In such
cases, requirements in this subpart shall apply.
Sec. 184.159 Requirements for buildings.
(a) Building exteriors. Exterior wall and roof coverings of
operating buildings should be noncombustible and, whenever possible,
frangible, of ``breakaway'' construction. The buildings should have no
basements and should not exceed one story, except to meet process
requirements.
(b) Interior walls, roofs, and ceilings. Interior wall surfaces and
ceilings of operating buildings which might house loose, finely divided
explosives materials shall be smooth, free from cracks and crevices,
fire resistive and, if painted, be covered with high-gloss paint, to
minimize dust accumulation and facilitate cleaning. As further
protection against dust, ledges should be avoided; any that exist shall
be beveled or kept clean. Wall joints and openings for wiring and
plumbing shall be sealed against dust. Roofs and walls should be as
light as practicable, constructed and supported to vent an internal
explosion with the formation of few large fragments. Firewalls and
dividing walls constitute exceptions. When class II hazard locations
exist as defined by the National Electric Code (NEC),
(National Fire Protection Association (NFPA) Standard No. 70,\15\
suspended ceilings and hollow walls are prohibited in explosives
facilities. Recommended practice is to install insulation and covering
directly on the underside of the roof deck.
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\15\Copies may be obtained from the National Fire Protection
Association, Batterymarch Park, Attn: National Fire Codes
Subscription--Service Department, Quincy, MA 02269.
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(c) Floors and work surfaces. Floors and work surfaces shall be
constructed to facilitate cleaning, with no cracks or crevices in which
explosives could lodge. Nonsparking floors and work surfaces are
required in all locations where exposed explosives or hazardous
concentrations of flammable vapor or gas are present. When grounding is
necessary, conductive floors (mats or similar static-dissipating floor
surfaces), tabletops, and other work surfaces shall be provided. Cove
bases at the junctions of walls and floors are preferred. No exposed
nails, screws, or bolts in work surfaces shall be permitted.
(d) Substantial dividing wall. (1) Substantial dividing walls,
constructed in accordance with the requirements of TM 5-1300,\16\
Structures to Resist the Effects of Accidental Explosions, separate
independent concentrations of high explosives so they do not need to be
added when determining Q/D requirements.
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\16\Copies may be obtained from Naval Publications and Forms
Center, 5801 Tabor Avenue, Philadelphia, PA 19120.
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(2) Openings in dividing walls for conveyors, pass-through boxes,
or other uses, should be avoided. However, in locations where
operationally necessary, the following apply:
(i) The opening(s) shall not be larger than the minimum needed for
the material's safe passage.
(ii) Closures shall have equivalent wall-strength characteristics
and fusible links.
(e) Exits and doors. No explosives hazard shall occupy space
between an operator and an exit. Exit doors in buildings containing
explosives, except storage magazines, should be casement-type and
glazed with non-shatterable plastic material. All interior doors should
open in the direction of the flow of material through the building and
should open onto unobstructed passageways.
(f) Emergency egress. When standard exits and fire escapes do not
provide for rapid enough egress from work levels above the ground
floor, other means of emergency egress (that is, safety chutes) shall
be provided.
(g) Passageways. Weather-protected passageways between buildings or
magazines should be of noncombustible construction and equipped with
fire stops to interrupt a fire's progress.
(h) Roads and walkways. Good all-weather roads should be provided.
Only roads serving a single magazine or explosives processing building
(including its service facilities) may dead end, and then, only at the
magazine or building. The road system should be designed to make it
unnecessary to pass through an explosives area to travel from one place
to another. Walkways and roads at the entrance to or between adjacent
buildings containing explosives should be boardwalks or hard surfaced,
preventing employees from tracking stones, grit, and other foreign
material into operating buildings.
(i) Windows and skylights. Non-shatterable glazing is preferred
where an explosion accompanied by falling or projected glass could
cause injury. When glazing with conventional glass is used, the hazard
may be reduced by covering it with properly fixed plastic or wire mesh
screening.
(j) Drains and sumps. (1) All drain lines handling explosive wastes
shall have sumps or basins of sufficient capacity for the removal of
explosives by settling. The drains shall be of adequate capacity; free
of pockets; and with slopes of at least one-quarter inch per foot to
prevent explosives settling-out in the drain line, rather than in the
sump or settling basin intended to collect them. Sumps shall be so
designed that suspended and settleable solid explosive material cannot
be carried beyond the sumps in the wash waters, and so overflow shall
not disturb any floating solids. The settling rate of the material and
the usual rate of flow shall be taken into account in determining the
sump's capacity. The design shall also permit easy removal of collected
explosives, and shall allow for retention of those that float on water
until they can be skimmed off. Bolted sump tanks or other types of
construction that permit the explosives to settle in obscure or hidden
spaces are prohibited.
(2) Care shall be taken to preclude deposition of explosives from
sump effluent due to drying, temperature changes, or interaction with
other industrial contaminations. Sweeping and other dry collecting
measures should be used to keep appreciably water soluble explosives
out of the drainage system.
(3) Drains between the source of explosive and the sump shall be
troughs with rounded bottoms and with removable ventilated covers to
facilitate inspection for accumulation of explosives. Waste liquids
shall not be run into close drains and sewers. Drains shall be
inspected periodically and necessary steps taken to prevent the buildup
of explosives deposits in them. Drains and sewers containing explosive
waste materials shall not be connected in a manner to empty such wastes
into the normal sewage systems carrying inert or sanitary wastes.
(k) Hardware: (1) Hardware in buildings containing exposed
explosive materials, explosive dusts, or vapors should be of
nonsparking material. Installation of hardware (piping and ducts)
should not be affixed to blowout panels or walls.
(2) Fasteners such as nuts and bolts which could accidentally drop
into explosives or explosive constituents shall be prevented from doing
so by being drilled and thonged or otherwise secured.
(l) Ventilation. Exhaust fans through which combustible dust or
flammable vapor pass shall be equipped with nonferrous blades, or the
casting shall be lined with nonferrous material. Motors shall be of the
proper National Electric Code (NEC) class for the hazard (National Fire
Protection Association Standard No. 70). Exhaust systems shall be
cleaned and serviced on a regular scheduled. The entire system shall be
bonded and grounded.
(m) Steam for processing and heating. Process steam is that which
is in direct contact with explosives, used directly in their
manufacture; or that which, in case of equipment failure, would exhaust
directly into contact with explosives or explosive fumes. Steam used
for heating operating buildings containing explosives should have a
maximum pressure of 5 psi (228 deg.F). When necessary, process steam
may exceed 5 psi, up to 15 psi. The exterior of stem or hot water pipes
in contact with wood, paper or other combustible materials shall not
exceed 160 deg.F. When steam temperature must exceed 228 deg.F in
hazardous locations, steam lines shall be covered and painted with an
impervious material or otherwise protected against contact with
explosives. Requirements for steam pressure exceeding 15 psi shall be
evaluated by the contracting officer on a case-by-case basis. When a
reducing valve is used, no relief valve shall be bypassed in a manner
permitting circumvention of the pressure reducing equipment. The
production of superheated steam caused by the throttling action of
reducing valves shall be prevented. Use of a ``water leg'' or water
column to control steam pressure of 5 pounds or less is recommended.
When close control of steam temperature is necessary, indicating and
recording pressure or temperature gauges shall be installed. Such
devices should be tested periodically and the test results recorded.
When electrical resistance to ground is high, steam lines shall be
properly grounded where they enter buildings.
(n) Tunnels. To prevent possible communication of an explosive,
shockwave and blast shall receive special consideration in designing
and constructing tunnels between buildings containing explosives.
Sec. 184.160 Electrical requirements.
The installation and use of electrical equipment within explosives
buildings, magazines, and explosives facilities shall comply with the
latest edition of the NEC (NFPA Standard 70), at a minimum, except as
otherwise specified herein. In planning electrical equipment for
special occupancies or for hazardous locations as defined in the NEC,
it is often possible to locate equipment in less hazardous or
nonhazardous areas, reducing the quantity of special equipment required
and decreasing the hazard.
(a) Hazardous locations. (1) Electrical equipment and installations
in hazardous locations (classes I, II, and III, as defined in the NEC
(NFPA Standard No. 70) shall in all cases comply with the requirements
of the code for division 1.
(2) When electrical equipment is installed in those areas that fall
into the categories of both class I and class II, the equipment shall
be of a type used in both locations. The installations shall be in
accordance with the requirements for division I hazardous locations.
(b) Alternate power source. In special processes and operations
requiring a continuous supply of power, provisions shall be made for an
alternate source.
(c) Electric power lines. To prevent broken wires from hitting the
building, the distance separating overhead transmission and service
lines from magazines and buildings containing explosives shall be
greater than that between the poles or towers supporting the lines,
unless an effective means is provided to ensure that energized lines on
breaking cannot come into contact with the facility or its
appurtenances; for example, cable trays and messenger lines. In no case
shall overhead transmission lines pass within 50 feet of magazines or
other explosives buildings. Service lines of all types shall, except
for local telephone connections and similar low-voltage intercom or
alarm systems, be run underground from a point at least 50 feet away
from the building. With regard to siting, electric transmission lines
(those carrying 69 KV or more) and the tower or poles supporting them
shall be located no closer to PES's than:
(1) Inhabited building distance if the line in question is part of
a grid system serving a large area off the establishment.
(2) Public traffic route distance if loss of the line shall not
create serious social or economic hardships. (Public traffic route an
inhabited building distances shall be based on airblast overpressure
only; fragment distances shall not be used.)
(3) Electric transmission lines which can be interrupted without
loss of power, i.e., power is rerouted through existing lines and/or
networks, shall be separated from explosives sites in accordance with
Sec. 184.160(c).
(d) Motors. Electric motors should not be installed in class I or
class II hazardous locations. They should be outside any such room or
building. They should be connected to the process building only through
mechanical glands or apertures adequately sealed against entrance of
hazardous materials into both the location where motors are positioned
and the motor enclosure itself.
(e) Motor controls, circuit breakers, and safety switches. (1)
Circuit breakers, safety switches, service entrance switches, and speed
controllers for hazardous locations should be installed on steel racks:
(i) In separate buildings connected only by electrical conduits
between the small building housing the control equipment and the
buildings containing the electrical equipment for hazardous locations.
Such conduits shall be provided with sealing fittings to prevent
communication of flame or arcs from the starters to the hazardous area.
(2) Limit switches, pressure switches, float switches and any other
control devices which for practical operating reasons cannot be located
outdoors shall bear the approval of the Underwriters' Laboratories,
Inc., or other nationally recognized testing agencies. Electrical
conduit connections to such equipment shall comply with the
requirements of the latest edition of the NEC (NFPA Standard No. 70)
for the specific hazard.
(3) The primary electric supply to an entire explosive area should
be so arranged that it can be cut off by switches located at one or
more central points away from the area.
(f) Flashlights and lanterns. Flashlights and hand lanterns powered
by low-voltage dry cell batteries and miners' cap lamps, approved as
``Permissible'' by the United States Bureau of Mines or, for class I
hazardous locations, by Underwriters' Laboratories, Inc., or other
nationally recognized testing agencies, may be used in both class I and
class II hazardous locations.
Sec. 184.161 Lightning protection.
When lightning protection systems are installed, the installation,
inspection, and maintenance shall be in accordance with the National
Fire Protection Association, Lightning Protection Code,\17\ at a
minimum.
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\17\See footnote 12 to Sec. 184.259.
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Sec. 184.162 Static electricity and grounding.
(a) Detailed discussions of the hazards of static electricity and
ways of reducing it are published by the National Fire Protection
Association, Underwriters' Laboratories, Inc., the United States
Department of Commerce, and the Bureau of Mines, U.S. Department of the
Interior. Where static spark discharge may be hazardous, NFPA Standard
No. 77,\18\ Static Electricity, shall apply except as otherwise
specified herein.
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\18\See footnote 12 to Sec. 184.259.3
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(b) Grounding of equipment. Bonding straps shall bridge contact
points where oil, paint, or rust could disrupt electrical continuity.
Permanent equipment in contact with conductive floors or tabletops is
not considered adequately grounded. Static grounds shall not be made to
gas, steam, or air lines, dry pipe sprinkler systems, or air terminals
of lightning protection systems. They may be made to water pipes,
ground cones, buried copper plates, driven ground rods, or to down-
conductors of lightning protection systems. All grounds shall be
interconnected if a structure is equipped with a lightning protection
system. Metallic bonding and grounding cables, straps, or clamps shall
be compatible with the explosives being processed.
(c) Belts. Conductive belting shall be used wherever static is a
hazard. Such belting shall have a resistance to ground not exceeding
600,000 ohms. Static combs shall not be used to drain off static
generated from belting or pulleys used in the presence of hazardous
concentrations of explosives dust or flammable vapors.
(d) Testing equipment grounds. Grounding systems shall be tested
for electrical resistance and continuity when installation has been
completed and, in the case of active equipment, at locally determined
intervals. The ground systems of equipment inactive longer than 1 month
shall be tested for resistance and continuity before reactivation. All
exposed explosive or hazardous materials shall be removed before
testing. All test records should be kept. In ground-resistance testing,
equipment should be considered as a unit. All conductive parts of
equipment shall be grounded so that resistance does not exceed 25 ohms,
unless 10 ohms is required for lightning protection. To ensure
compliance with ohmic requirements, resistance of the belting is to be
excluded in measuring the total resistance to ground for belt-drive
machinery. The rate of static generation should be considered before
changes in grounding systems are made.
(e) Conductive floors. Conductive floors and conductive shoes shall
be used for grounding personnel at operations with exposed explosives
with electrostatic sensitivity of 0.1 joule or less, such as primer,
initiator, detonator, igniter, tracer, and incendiary mixtures.
Materials sensitive to static sparks, easily ignited or detonated,
include lead styphnate, lead azide, mercury fulminate, tetrazene,
diazodinitrophenol, potassium chlorate-lead styphanate mixtures,
igniter compositions, grade B magnesium powder, and exposed layers of
black powder dust. Dust from solid propellants can be ignited from
spark energy, making conductive floors and shoes necessary where such
dust is present. Air and dust mixtures of ammonium picrate, tetryl,
tetrytol, and solid propellants are also sensitive to static
electricity discharge. Many flammable liquids and air mixtures tested
(ethyl ether, ethyl alcohol, ethyl acetate, acetone, and gasoline) can
be ignited by human static discharge. Therefore, areas where personnel
might come into contact with the kinds of explosives or mixtures
enumerated above shall be equipped with conductive floors, except when
the hazards of dust/air or flammable vapor/air mixtures are eliminated
by adequate housekeeping, dust collection, ventilation, or solvent
recovery methods.
(1) Conductive floors are also required when operations involve the
following:
(i) Exposed electro-explosive devices such as squibs, detonators,
primers, etc.
(ii) Electrically initiated items, such as rockets, with exposed
circuitry.
(iii) Hazardous materials that could be ignited by human static
discharge.
(2) When a hazard remains localized, conductive floors and footwear
are not required throughout an entire building or room. In such cases,
conductive mats or runners may be used. These mats and runners shall
meet all the specifications and test requirements that apply to
conductive floors.
(f) Conductive floor specifications. Conductive floors, made of
nonsparking materials such as lead, conductive rubber, or conductive
flooring compositions, shall meet the following requirements:
(1) The flooring and its grounding system shall provide for
electrical resistance not to exceed 1 million ohms.
(2) The surface of the installed floor shall be free from cracks
and reasonably smooth, and the material shall not slough off, wrinkle,
or buckle under operating conditions. Conductive tiles are not
recommended for areas where explosives dust can cause contamination,
because the large number of joints, and the tendency of tiles to
loosen, create areas where explosives dust can lodge, not amenable to
normal cleanup procedures. Where conductive floors and shoes are
required, the resistance of conductive shoes on a person plus the
resistance of floor to ground shall not exceed 1 million ohms total.
Tabletops used with exposed explosives or dusts should be covered with
a properly grounded conductive material meeting the same requirements
as those for the flooring. The conductive floors shall be compatible
with the particular materials to be processed.
(g) Initial tests of conductive floors shall be followed by others
at least semiannually. The test results shall be permanently recorded.
Testing shall proceed only when the room is free from exposed
explosives and flammable gas mixtures.
(1) The resistance of the floor shall be more than 5,000 ohms in
areas with 110 volts service and 10,000 ohms in areas with 220 volts
service, and less than 1 million ohms in all areas as measured between
a permanent ground connection and an electrode placed at any point on
the floor and also as measured between two electrodes placed 3 feet
apart at any points on the floor. Measurements shall be made at five or
more locations in each room and at least two of the points shall be
heavily trafficked areas. If the resistance during a measurement
changes appreciably with time, the value observed after the voltage has
been applied for about 5 seconds shall be considered to be the measured
value. These resistance values do not apply to metallic floors.
(2) The operation and maintenance of test instruments shall be
entrusted to competent personnel.
(h) Humidification. Humidification that maintains relative humidity
above 60 percent effectively prevents static electricity accumulations
and subsequent discharges. This technique involves pre-operational
checks and regular monitoring of the humidity levels throughout the
day. It cannot be used with metallic powders, some pyrotechnical
mixtures, and other materials susceptible to spontaneous ignition in
air with 60 percent relative humidity.
(i) Ionization. Ionization is electrical neutralization and serves
as an effective method of removing static charges from certain
processes and operations. Methods of application can be found in NFPA
Standard 77, Static Electricity.
(j) Neither ionization or humidification may be substituted for
conductive floors (where required).
Subpart M--Safety Requirements for Specific Explosive Materials and
Operations
Sec. 184.164 General.
This subpart provides the minimum safety requirements necessary for
the prevention of mishaps involving specific explosives materials and
operations that, unless properly controlled, make casualties to
personnel, material, equipment, and facilities highly probable. They
apply to similar operations and equipment, specifically addressed or
not. These requirements, to be used as a basis for developing local
program requirements, are in no way comprehensive. The contractor is
responsible for analyzing each operation and developing procedures to
control or eliminate actual or potential hazards.
Sec. 184.165 Properties of explosives.
Knowledge of properties of specific types of explosives is critical
to the establishment of proper hazard controls.
(a) Properties of initiating explosives. Initiating explosives
include lead azide, mercury fulminate, lead styphnate, and tetracene.
They manifest extreme sensitivity to friction, heat and impact. When
involved in a fire, they can be expected to detonate without burning.
In storage, initiating explosives shall be kept wet with water or
water/alcohol mixtures. Every effort shall be made to prevent the
liquid from freezing; frozen explosives material shall not be handled.
Emphasis shall be placed upon cleanliness and general housekeeping
since contamination of these explosives with foreign, particularly
gritty, material markedly increases their sensitivity. Water used for
storage shall be free of bacteria-forming impurities which could react
to form gases. Lead azide shall not be allowed contact with copper,
zinc, or alloys containing any concentration of such metals because of
the likely formation of other azides that are more sensitive than the
original lead azide. Likewise, mercury fulminate shall not be allowed
contact with aluminum, magnesium, zinc, brass, or bronze.
(b) Properties of boostering explosives. Explosives used for this
purpose include tetryl, RDX, PETN, and RDX with added ingredients.
These explosives have sensitivities between initiating explosives and
those of explosives used as bursting charges such as TNT. They may be
ignited by heat, friction, or impact and may detonate when burned in
large quantities or at too great a depth. Some of these materials are
toxic when taken internally or by skin contact and special precautions
are necessary to protect personnel. Local exhaust ventilation, enclosed
process systems, automatic handling systems, etc., should be used to
minimize dust in the employee's breathing zone.
(c) Properties of bursting explosives. Bursting explosives include
explosive D (ammonium picrate), amatol, picric acid, TNT, tritonal, RDX
compositions, HMX compositions, torpex, DBX, and HBX. In general, these
materials are less sensitive than initiating or boostering explosives.
Alkaline cleaning agents or other alkaline products should not be
permitted in buildings where large quantities of these explosives are
handled. Amatol forms sensitive compounds with copper and brass. Where
explosive D is processed, lead fusible links and solder-type sprinkler
heads should not be used. DBX is an aluminized explosive that is
somewhat hygroscopic and reacts with metals in the same manner as
amatol. HBX is also an aluminized explosive that outgasses when exposed
to water and may create internal pressure when loaded into ammunition.
HMX compositions usually result in a very powerful explosive with a
high degree of thermal stability. Pentolite tends to separate into its
ingredients (PETN and TNT) and should, therefore, be handled as
carefully as PETN. Picratol is a mixture of TNT and explosive D; the
precautions necessary when handling either shall be observed. Picric
acid is highly acidic, corrosive, and toxic; it shall be isolated from
lead and lead compounds. Tetrytol is a mixture of tetryl and TNT which
is stable in storage but exudes at 149 deg.F. Dry tetrytol slightly
corrodes magnesium and aluminum alloys, and wet tetrytol slightly
corrodes a copper, brass, aluminum, magnesium, mild steel, and cadmium-
plated mild steel. TNT is stable and does not form sensitive compounds
with metals. It shall, however, form sensitive compounds in the
presence of alkalies. It also exhibits well-recognized toxic
properties. Torpex is an aluminized explosive used mainly in underwater
ordnance. Non-hygroscopic and noncorrosive, it is stable in storage but
may outgas (hydrogen) and produce internal pressure when loaded into
ammunition. Tritonal is a mixture of TNT and aluminum powder and is
more sensitive to impact than TNT. Tritonal shall not be exposed to
water. Plastic bonded explosives are conventional high explosives with
plastic binders such as polystyrene, viton, estane, etc. Their
sensitivity varies with the composition. The series most frequently
encountered are identified by prefix PBX or LX and a number.
(d) Properties of other explosives. Other military explosives
frequently encountered include black powder and nitroglycerin. Black
powder is a mixture of potassium or sodium nitrate, charcoal, and
sulfur, highly sensitive to friction, heat, and impact. It deteriorates
rapidly on absorption of moisture but retains its explosive properties
indefinitely if kept dry. Nitroglycerin's extreme sensitivity to impact
and friction is such that it is manufactured only as needed. Frozen
nitroglycerin, while less sensitive than liquid, may undergo internal
changes upon thawing and, if enough heat is generated, may detonate.
(e) Research of additional properties. The foregoing does not
comprehensively catalog explosives and properties, but indicates how
significantly they can differ. For this reason, it is imperative that
contractors investigate pertinent properties before handling these or
other explosive materials. Contractors are responsible for
understanding all aspects of ammunition and explosives needed to
fulfill contractual obligations.
Sec. 184.166 Handling low-energy initiators.
Typical precautions, such as shielding and safety glasses, shall be
supplemented by the following measures, as appropriate, when
manufacturing, processing, using, or testing low-energy initiators
(initiated by 0.1 joule of energy or less).
(a) All metal parts of equipment shall be electrically bonded
together and grounded.
(b) Personnel shall wear clothing that prevents generation of
static electricity. Conductive shoes shall be tested with a resistance
meter before an operator enters an area where low-energy initiators are
being processed.
(c) When low-energy initiators are being handled, personnel shall
be directly grounded by wrist straps. The resistance reading, taken
once daily when the operator is wearing the strap, shall be between
250,000 and one million ohms when measured from opposite hand to
ground. Special contact creams may be used to decrease the resistance
to the required value.
(d) Glass, acrylic, or polycarbonate materials required for
transparent shielding shall be periodically coated with an anti-static
material to prevent buildup of static electricity.
(e) The sounding of a static electricity alarm, installed with the
setting best able to provide ample warning, signals that work shall
stop until the problem has been located and corrective action taken.
(f) Work shall not start in air-conditioned areas until relative
humidity and temperature have been checked (see Sec. 184.162(h)).
(g) No metal surface subjected to rubbing or friction shall be
painted. If a lubricant is necessary, it should be of a composition
that shall not increase the metal's surface resistance above 25 ohms.
(h) Work on or with initiators shall be performed in areas equipped
with conductive floors and table tops. Exceptions may be made with the
initiators are in their original packaging, or are in part of a
finished metallic end item affording them complete protection from
electromagnetic or electrostatic energy.
(i) Work shall not be done in the vicinity of actual or potential
electromagnetic or electrostatic fields. Sources of static electricity
and electromagnetic energy include radio transmission, electrical
storms, transformer stations, high voltage transmission lines,
improperly grounded electric circuitry, rotating equipment, belts, etc.
Adequate lightning protection and grounding and adequate resistances
for fixed sources of energy shall be established for locations with
low-energy initiator operations. These shall be shielded to afford
protection against local mobile radio transmission.
(j) Electrical equipment shall be located out of the range of an
operator working with a low-energy initiator. With soldering irons, it
may be advisable to ground and limit energy to levels below initiating
thresholds.
(k) When not part of an end item or end item subassembly,
initiators shall be transported only when packed according to the
latest packing specifications for low-energy initiators.
Sec. 184.167 Laboratory operations.
(a) Research and development laboratories and testing facilities
constitute a separate category involving guidance, restrictions, and
relief from certain requirements prescribed in this part.
(b) Each operation at facilities designed for blast and fragment
confinement shall be reviewed to ensure that the explosives limits are
within the laboratory or test area capability. Explosives limits and
safe separation distances shall be adjusted as the capability to
confine fragment and blast decreases.
(c) A total-confinement facility shall be inspected after a
detonation to ensure structural integrity, possibly reducing the
explosives limits to prevent future blasts from exceeding the retention
capability.
(d) Each proposed program for the laboratory or test facility shall
be reviewed to determine all potential hazards. Considerations shall
include:
(1) Structural limitations of the facility.
(2) Remote control viewing and operating equipment, if required.
(3) Special safety precautions for personnel elsewhere in the
building.
(4) Safe separation distances.
(5) Required deviations from other sections of this part.
(6) SOPs, which shall at a minimum include the following:
(i) Protective clothing.
(ii) Warning signals.
(iii) Fire and other emergency procedures.
(iv) Special testing of equipment needed before operations (such as
stray voltage and calibration checks).
(v) Removal of all explosives not needed for the operation.
(vi) Arrangements for overnight storage of necessary explosives.
(vii) Inspection and cleanup procedures after a test or detonation.
(e) Laboratories shall use no more explosives than absolutely
required for a given operation. Particularly hazardous laboratory
operations involving new or relatively unknown explosives should be
done by remote control. Operational shields shall be used in these
operations and in new or untested applications of explosives.
(f) When laboratories and testing facilities are shielded properly
to prevent the release of fragments, the minimum incremental safe
separation distances of Appendices A and B to this subpart shall apply
to operations, facilities, and personnel.
(g) If the proposed storage facilities will confine the blast and
fragments, or if the incremental safe separation distances are as
indicated in Sec. 184.167(f), up to 15 pounds of explosives, may be
stored without consideration of storage compatibility. However, the
operation shall be reviewed, as stated in Sec. 184.167(d).
Sec. 184.168 Electrical testing of ammunition and ammunition
components.
(a) Type of test equipment. Electrical and electronics test
equipment should use the weakest possible power source. Batteries shall
be preferred to 110-volt power sources. No Power source should be
capable of initiating the explosives item being tested. When exceptions
shall be made because more power is needed, steps shall be taken to
prevent delivery of power to the explosives item in quantities
sufficient to initiate. Safeguards shall be provided against the
possibility of human error.
(b) Layout of test equipment. Test equipment shall be placed in
hazardous atmospheres only when absolutely necessary. Unless the test
equipment is, under all circumstances, incapable of initiating the test
item, operational shields are required for personnel protection. The
most reliable way of attaining and retaining this initiation
incapability is by protecting the test equipment, including leads, from
electromagnetic induction and radiation fields and electrostatic
energy, and by providing the test equipment with a weak power source.
(c) Use of test equipment. Test equipment shall be used only as
intended by original design. The equipment shall be maintained by
qualified personnel, with operator adjustments limited to those
required for testing.
Sec. 184.169 Heat-conditioning of explosives and ammunition.
(a) All ovens, conditioning chambers, dry houses, and similar
devices and facilities shall be provided with dual independent fail-
safe heat controls. For devices or facilities heated by steam only, the
requirement for dual heat controls shall be satisfied if the steam
pressure is controlled by a reducing valve (maximum pressure of 5 psi,
unless otherwise authorized) on the main building steam supply, and a
thermostat.
(b) Heat-conditioning devices shall be able to discharge
overpressure from an internal explosion. Barriers or catching devices
shall restrain blowout panels, doors, and other venting apparatus, to
prevent excessive displacement during an accidental explosion.
(c) Heat-conditioning devices shall be vented to permit any gases
produced to escape.
(d) Steam should be used to heat conditioning devices; when
electric heating elements are unavoidable, they shall be located where
there is no possibility of contact with explosives or flammable
materials.
(e) The blades of a fan in a heat-conditioning device shall be of
non-sparking material; its electric motor shall be installed
externally. The air shall not recirculate if the heating surfaces
exceed 228 deg.F or if the air contains materials that could collect on
the heating coils.
(f) Electrical equipment and fixtures in or on a heat-conditioning
device used for explosives or flammable material shall be approved for
use in the hazardous atmosphere in question.
(g) The interior of a heat-conditioning device shall be free of
crevices, openings, and other protuberances not easily cleaned, where
dust or flammable material could lodge.
(h) All noncurrent-carrying metal parts of a heat-conditioning
device shall be interconnected and electronically grounded.
(i) Heat-conditioning devices should be installed in isolated
locations, set up to give personnel maximum protection from the effects
of an incident. When warranted, operational shields and other personnel
protection measures shall be used.
(j) Safe separation distances or protective construction shall
ensure against an explosives incident in one heat conditioning device
from propagating to others. No hazardous materials shall be placed in a
room or cubicle containing a heat-conditioning device, unless it can be
shown that an accident in the conditioning device would not involve the
other materials.
(k) Heat-conditioning device operating procedures require:
(1) Limiting the explosive materials in the device to the type and
quantity authorized for the specific device.
(2) Familiarity with the critical parameters of explosives
compositions before processing in a heat-conditioning device. The
device shall not exceed limits established for the hazardous
composition being conditioned.
(3) Checking heat-conditioning device temperatures at specified
intervals during operation.
(4) Cleaning the conditioning devices, ducts, vacuum lines, and
other parts of the equipment subject to contamination by hazardous
materials, before introducing a different item or composition for
conditioning.
Sec. 184.170 Spray painting.
(a) Loaded ammunition shall not be electrostatically spray painted.
(b) Water wash or dry filter-type spray booths shall be used for
loaded ammunition.
(c) Controls for ventilating fan motors for spray painting booths
shall be interlocked with the controls for the paint sprayer. With this
arrangement, failure of the ventilating system will shut off power to
the paint sprayer.
(d) High-voltage electrically powered paint-spraying equipment
shall be installed in accordance with the requirements of National Fire
Protection Association, Standard No. 33,\19\ Static Electricity, as
applicable.
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\19\Copies may be obtained from the National Fire Protection
Association, Batterymarch Park, Attn: National Fire Codes
Subscription--Service Department, Quincy, MA 02269.
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(e) Conventional equipment used for spray painting in standard
spray booths shall meet the requirements of NFPA Standard No. 33. The
nozzles of all spray guns shall be electrically grounded because of the
static electricity generated.
Sec. 184.171 Drying freshly painted loaded ammunition.
Ovens used in drying loaded ammunition shall comply with the
National Fire Codes. Other requirements include the following:
(a) Automatic thermostatic controls shall regulate temperatures
once they reach a maximum determined by the ammunition and explosives
involved. It is recommended that temperatures not exceed 170 deg.F.
(b) Automatic internal sprinkler systems shall equip each oven and
shall conform with NFPA Standard No. 13,\20\ Installation of Sprinkler
Systems. Automatic operation of the system may be accomplished by
approved electrical heat-actuated devices, installed as required for
NEC-defined class I, division 1, group D, hazardous locations. Refer to
NFPA Standard No. 70, National Electric Code.
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\20\See footnote 15 to Sec. 184.170.
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(c) Hot air or other means may supply heat, provided ammunition and
explosives are kept from contact with coils, radiators, and heating
elements.
(d) In case of power failure, the heat supply for any conveyor
system shall automatically stop.
(e) Electric drying units that are not approved for use in class I
hazardous locations should be designed so that solvent vapor
concentration in the oven is kept below 25 percent of its lower
explosive limit.
Sec. 184.172 Rework, disassembly, renovation, and maintenance.
(a) Rework and disassembly operations shall not usually be
conducted with other inert or explosives operations. However, when
concurrent scheduling cannot be avoided, operations shall be
sufficiently distanced from one another to protect adjacent personnel
and equipment, and prevent propagation to adjacent explosives. Such
separation may be accomplished with Q/D, operational shielding, or the
remote control of operations.
(b) The operator and all other personnel shall be fully protected
during rework and disassembly operations known or expected to use force
exceeding assembly specifications.
(c) If A&E items have been assembled normally, the same equipment,
tools, methods, and applied forces may be used to disassemble them. In
such cases, only that personnel protection required during the assembly
operations is also required during the rework or disassembly
operations. Care shall be taken, however, to ascertain that the
assembly was normal and that the surfaces to be separated are not
corroded and not sealed with metallic applicants.
(d) When renovation or maintenance not adequately addressed in the
contract is required, the contractor shall request specific safety
guidance through contract channels.
Sec. 184.173 Munitions loading and associated operations.
(a) Screening and blending high explosives. Bulk high explosives
intended for processing shall be screened or visually inspected and
passed over a magnetic separator to detect extraneous material for
removal. Screening equipment shall not subject explosives to pinching,
friction, or impact. Explosives screening units without exhaust
ventilation shall be thoroughly cleaned as often as necessary and after
every shift, to prevent hazardous accumulations of explosives dusts.
(b) Screening and blending initiating explosives. Suitable
operational shields shall be provided for screening and blending
operations involving initiating explosives, or operators shall be
located at intraline distance from screening and blending facilities.
(c) Explosives melting. (1) Temperatures used for melting
explosives and keeping explosives molten should not exceed 228 deg.F.
However, steam pressures up to 15 psi (250 deg.F) may be used to melt
composition B and similar binary explosives and to maintain a molten
state.
(2) Melt unit valves and melt mix draw-off or other lines carrying
molten explosives shall provide against friction or impact capable of
initiating the explosives. Diaphragm-type valves should be disassembled
and inspected regularly. Damaged or old diaphragms shall be replaced so
no cracks allowing metal-to-metal contact can develop. Draw-off lines
should be constructed to prevent exposure of threads, fastening screws,
and bolts, both outside and between the flanges. A sealing compound
should be used to prevent explosives seepage or vapor condensation on
the contacting surfaces of the bolts, flanges, screws, and nuts. Melt
mix kettle draw-off pipes should be electrically connected to items
being filled during draw-off operations. Items shall be individually
grounded unless tests show that grounding through contact surface is
adequate.
(3) Wet-type collectors effectively remove dust and vapors from
exhausted air, and are recommended for melt mix exhausting systems.
Water in the wet collector will not be recirculated unless the system
removes hazardous suspensions. Water retaining such explosives shall be
discharged to a sump designed to keep such explosives wet. The exhaust
and collecting equipment shall be regularly inspected and flushed of
explosives accumulations. When protective construction prevents
propagation of a detonation between melt kettles, a complete dust and
vapor collection system shall equip each kettle.
(d) Agitation. Agitation nitrators, washers, and other machines
which, because of the hazard of the process and the possibility of the
process material decomposing, are equipped with mechanical agitators,
shall have at least two means of agitation, each operating from an
independent power source to maintain agitation if one fails.
(e) Machining of explosives. (1) High explosives, cased or uncased,
that may be machined without special personnel protection and without
coolant, if no metal-to-metal contact is involved, include: Amatol,
Octol, TNT, composition B, explosive D, and RDX/TNT compositions
containing 60 percent or less RDX.
(2) High explosives, cased or uncased, that may be machined without
special personnel protection provided a coolant is directed on the tool
and explosives at their point of contact and no metal-to-metal contact
is involved, include: baratols, pentolite (50-50 and 10-90), tetrytol,
and cyclotols (composition B less than 60-40; that is, 70-30).
(3) When essential, other high explosives may be machined by remote
control, with the operator protected by a suitable operational shield;
however, initiating explosives should not be machined if desired shapes
or sizes can be obtained by other means, such as forming.
(4) When an unprotected operator is involved in drilling, only a
single drill, with a diameter greater than 1/4 inch, shall be used.
(5) Machining of cased explosives is permitted in an operation
requiring removal of metal before or after tool contact with the
explosives filler, provided that operators are protected by operational
shields and perform it by remote control.
(6) Where wet machining is to be performed, automatic interlocking
devices shall prevent machining from starting until coolant is flowing.
These controls shall also be capable of stopping the machining if the
coolant flow is interrupted. When coolant flow must stop for adjustment
of machining tools, positive means shall be devised to ensure that flow
of coolant is restored and all automatic control devices are operating
before machining can resume.
(7) The lineal and rotational speeds of tools used for the
machining of explosives shall be maintained at the minimum necessary to
perform the operation safely and efficiently. These shall not exceed
210 linear feet per minute nor 525 revolutions per minute. The rate of
feed should likewise be the lowest consistent with safety and
efficiency, based on the explosive materials being machined.
(8) Pneumatically or hydraulically driven machine tools are
preferred for all machining operations on high explosives. Control
mechanisms for hydraulic and pneumatic equipment shall prevent
unauthorized personnel from tampering with speeds.
(9) In all machining operations on cased or uncased high
explosives, procedures during tool adjustments shall prevent contact
between moving parts of the machining equipment and metallic parts of
the case or holding fixtures.
(10) Machining tools shall be compatible with the explosives being
processed. Dull or damaged tools shall not be used for machining high
explosives.
(11) The explosives products resulting from machining operations
shall be removed by an exhaust system meeting NEC requirements, or by
immersion in a stream of water flowing away from the operation. Refer
to NFPA Standard No. 70.
(12) Machining of explosives of questionable quality during an
ammunition and explosives demilitarization process shall be
accomplished by remote control, with operators protected by operational
shields.
(f) Assembly and crimping of complete rounds. Each assembly and
crimping operation shall be separated from other operations by
structures or shielding sufficient to contain any fragments produced.
(g) Pressing explosives. (1) Each pelleting operation involving
black powder, tetryl, TNT, or other explosives of similar sensitivity;
and each operation involving the pressing or reconsolidating of
explosives, shall be conducted in a separate room or cubicle having
walls of sufficient strength to withstand an explosion of all
explosives present.
(2) Pressing or reconsolidating explosives in small caliber rounds,
tracer bodies, tetryl lead-ins, detonators, and similar items shall be
performed on machines having consolidating stations designed to
preclude propagation between stations and provide adequate operator
protection. Operators shall be behind tested protective barriers during
such operations.
(3) Punches and dies shall be in matched sets that have passed
inspection. All punches and dies used in explosives pressing operations
shall undergo a rigid test, such as a magnaflux or X-ray, before use
and regularly thereafter. In a pelleting press, punches and dies shall
be replaced with matched sets checked and calibrated by a control
laboratory.
(h) Protection of primers. Equipment, transportation, and
operations shall be designed to protect loose primers or primers in
components from accidental impact or pressure. When feasible, a
protecting cap shall cover the primer.
(i) Explosives washout and flashing facilities. When washout
operations are placed in operating buildings or other locations, they
shall be separated from other operations by operational shields or
proper distances. Ammunition items subjected to washout operations
shall be subsequently inspected to ensure against residual explosives
contamination. When contamination is confirmed, decontamination shall
precede disposal. Decontamination of ammunition items by flashing
(exposure to flame) shall be performed at the explosives destruction
(burning) area or in approved incinerators.
(j) Heat sealing equipment. Electric heat sealing machines should
be separated from other operations. Temperature limits for heat sealing
equipment shall be established, with a safety factor below the ignition
temperature of explosives, propellants, or pyrotechnics involved.
(k) Rebowling operations. Rebowling operations involving lead azide
and primer mixes shall be performed by remote control, with the
operator protected by an operational shield.
(l) Thread cleaning. (1) Nonferrous picks shall be used for thread
cleaning. Stainless steel brushes may be used to clean threads of
explosives-loaded projectiles if a fuze seat liner separates the thread
cleaning operation from the explosive charge. Operators do not need
operational shields; however, thread cleaning operations should be
separated from unrelated operations.
(2) Power-actuated thread-chasing tools may be used to clean loaded
projectiles when threads are imperfect because of previously applied
sealers, provided the operation is performed within a separate cubicle
and by remote control. Hand-operated thread-chasing tools may be used
when no explosives are present in the threads.
(3) Neither correcting cross threads nor thread cutting shall be
performed on projectiles containing explosives. Straightening crossed
threads is considered thread cutting.
(m) Profile and alignment gaging operations. (1) Operational
shields shall enclose each profile and alignment gaging operation,
excluding small arms ammunition, to protect adjacent operations. The
layout of the equipment and the operational procedures shall be
developed to minimize personnel injury and property damage in case of
accident.
(2) During chamber gaging of high caliber fixed ammunition, the
gage should be pointed toward a dividing wall or other barrier and the
round inserted and removed by the same operator. In no case shall the
round be left in the gage. Rounds of mortar ammunition shall be gaged
before attaching propellant increments and, unless prohibited by the
design characteristics, before assembly of the ignition system.
Appendix A to Subpart M of Part 184.--Hazard Division 1.1--Laboratories
Q/D
------------------------------------------------------------------------
Quality (lbs) Distance (ft)\1\
------------------------------------------------------------------------
Inhabited Public
Over Not building traffic Intraline
over distance route
------------------------------------------------------------------------
0............................. 1 40 25 20
1............................. 2 50 30 25
2............................. 5 70 40 30
5............................. 10 90 55 35
10............................ 20 110 65 45
20............................ 30 125 75 50
30............................ 40 140 85 55
40............................ 50 150 90 60
------------------------------------------------------------------------
\1\The distance above may be used only when structures, blast mats, and
so forth, can completely contain fragments and debris. If fragments
cannot be contained or the quantity of high explosives exceeds 50
pounds, then the distances shall be obtained from the Q/D appendices
of Subpart F of this part.
Appendix B to Subpart M of Part 184.--Hazard Division 1.3--Laboratories
Q/D
------------------------------------------------------------------------
Quantity (lbs) Distance (ft)
------------------------------------------------------------------------
Inhabited Public
Over Not building traffic Intraline
over distance route
------------------------------------------------------------------------
0............................... 5 10 10 10
5............................... 10 15 15 15
10.............................. 20 20 20 20
20.............................. 30 25 25 25
30.............................. 50 30 30 30
50.............................. 80 35 35 35
80.............................. 100 40 40 40
100............................. 150 45 45 45
150............................. 200 50 50 50
------------------------------------------------------------------------
Subpart N--Testing Requirements
Sec. 184.175 Program requirements.
The contractor is responsible for the safety of testing programs
and shall designate an individual to be responsible for each program.
Technical information about the ammunition items, explosives, and
weapon systems shall be considered so that the required safety measures
may be engineered into the test plans.
Sec. 184.176 Operating precautions.
Special safety precautions to be considered during SOP development:
(a) Protection for percussion elements, i.e., primers, caps, etc.,
shall be provided in the design of equipment, transportation, and
operations to protect them from accidental initiation.
(b) Cartridges and projectiles larger than 60mm, when hand carried,
shall be handled one at a time.
(c) Fuzed projectiles shall not be handled by the fuzes alone.
(d) Powder charges shall be transported in closed containers to
prevent accidental ignition.
(e) Only trained personnel shall perform operations on explosives-
loaded ammunition components.
(f) No work, adjustment, or observation should be permitted on a
weapon system that is loaded and ready for firing, except to check and
adjust azimuth and elevation. In no case shall a lanyard be attached
until the piece is ready to be fired. No one shall step over the
lanyard once it is attached. On weapons equipped with safety locks, the
lock may be released after the lanyard has been attached. In the case
of small arms, the bolt shall be kept open at all times except where
actually firing.
(g) Ammunition and explosives material, except inert components,
shall not be delivered to machine shops or other locations not
specifically designated for this work or modification without the
approval by responsible contractor authority.
(h) The premature or improper mixing of fuels and oxidizers, as
associated with liquid propellants, shall be avoided. This applies
particularly at test stands and test facilities when transferring
liquid propellants.
(i) Remote control of mechanical devices shall replace manual
activation whenever possible.
(j) Guns operated by remote control shall be equipped with cease
fire devices for halting operations when a hazardous condition occurs.
These devices shall be independent of the regular controls so
operations can be stopped if the regular controls should fail.
Sec. 184.177 Test hazards.
(a) Inert-loaded or minimum-charged ammunition should be used in
lieu of explosives-loaded items when the test objectives are not
affected.
(b) When temperature-conditioning rooms or boxes are utilized, the
following shall apply:
(1) Firings from temperature-controlled facilities shall be on an
azimuth approved by the contractor's responsible representative. No
weapon shall be fired in an enclosed area unless the muzzle is located
outside the port opening. Destruction tests, excess pressure tests, and
tests of classes of guns known to be unsafe (where the possibility of
breech failures exists) shall be conducted with portable shields or
equivalents placed on each side of the breech and with a protective
plate to the rear of the mount, forming a barrier.
(2) All equipment used in the temperature conditioning of
explosives shall comply with Q/D requirements, unless in explosives
buildings.
(3) Hot temperature conditioning equipment shall have dual,
independent, automatic controls to prevent the desired testing
temperature from being exceeded. Controls shall be designed to fail in
the off position.
(c) No firing shall be permitted unless people in the area are
under adequate cover.
Sec. 184.178 Test clearance.
(a) Clearance, to be obtained before performing each test, shall be
granted only by responsible contractor personnel with jurisdiction in
the danger area where the test is to be performed. When reburied, air
space clearances shall be obtained in accordance with local and Federal
Aviation Administration Handbook\21\ requirements.
---------------------------------------------------------------------------
\21\Copies may be obtained from Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C. 20402.
---------------------------------------------------------------------------
(b) The contractor personnel responsible for the test areas where
the weapon system is located shall obtain the necessary coordination
and clearance from their counterparts when a test may encroach upon
other danger areas.
(c) To ensure that danger areas are clear of personnel and ships,
vessels, and other craft, clearance for impact and airburst danger
areas shall be obtained before firing on or over water.
Sec. 184.179 Warning and communication systems.
A warming system shall be established for each testing program,
comprising some combination of flags, lights, and sound signals. If
personnel authorized to enter a test area are not familiar with the
system, they shall be escorted by knowledgeable personnel. Test areas
should be equipped with adequate communication facilities, such as
telephone and radio.
Sec. 184.180 Specific items for test.
The safety requirements for testing specific items of ammunition
vary according to the type of ammunition, design features, explosives
characteristics, test facilities, climate and terrain environment, and
other related factors. These factors shall be considered and specific
test criteria included in the test plan.
(a) Recoilless weapons. (1) All personnel shall be protected
against breech blast and malfunction of the round. The danger area in
open range firing shall extend to the rear of the weapon: 300 feet for
calibers up to and including 75mm and 450 feet for all others. The
danger zone may be reduced only when effective barricades confine the
blast effect.
(2) The safety switch on a rifle shall not be advanced to the
firing position until the breechblock is closed and all preparations
for firing are completed.
(3) Because the blast from salvo firing can obscure a misfire,
ripple firing is preferred. When salvo firing cannot be avoided, a wait
of at least 2 minutes shall precede the opening of any breechblock
after a one-volley salvo.
(4) Unburned propellant from any test firing shall not accumulate
in the surrounding area. Safe methods shall be developed for cleanup,
decontamination, and disposal.
(b) Pyrotechnics. Shielded enclosures should be used when testing
pyrotechnic items inside a building. Enclosures should be vented to the
outside, preferably through the roof, to prevent exposure of personnel
to flame, toxic gases, and heat, and to prevent rupture of the
enclosures.
(c) Static tests of propellant motors and engines. Static test
stands are used for solid propellant motors and liquid propellant
engines in any combinations. Fire, blast, and fragments shall be
considered in establishing safe distances. Static test stands shall be
designed to restrain motors and engines undergoing tests.
Sec. 184.181 Malfunctions.
For the purposes of this part, malfunction applies to the
ammunition and the weapon systems or pieces involved.
(a) Cook-off. Automatic function, or cook-off, of a round left in a
hot gun for an extended period is possible in tests involving a high
rate of fire, particularly with machine guns and anti-aircraft guns.
This possibility largely depends upon the gun's rate of heat
dissipation. High air temperature, low wind velocity, low elevation of
the gun, and confinement of the gun are also factors. To prevent cook-
off, the barrel of the empty gun shall be frequently cooled. If a round
is retained or remains in a hot gun with the breech closed, people in
the vicinity shall remain under cover until the gun has cooled. If a
round jams and the breech fails to close, personnel in the danger zone
shall take cover and remain there until the gun has cooled.
(1) Adequate cooling periods are:
------------------------------------------------------------------------
Time
Type of cooling (minutes)
------------------------------------------------------------------------
Water....................................................... 5
Air (machine guns).......................................... 15
Air (other guns)............................................ 30
------------------------------------------------------------------------
(2) The danger zone for personnel in the vicinity of the gun firing
explosive ammunition shall be:
------------------------------------------------------------------------
Radius\1\
Type of gun (feet)
------------------------------------------------------------------------
Machine guns................................................ 600
Less than or equal to 75mm.................................. 1,200
Over 75mm through 105mm..................................... 1,800
Over 105mm.................................................. 2,400
------------------------------------------------------------------------
\1\Radii may be halved when ball ammunition or rounds with inert
projectiles are used. The use of barricades to confine blast effects
may also reduce the danger zone.
(3) The danger zone down range shall be maintained as for actual
firing until the danger of cook-off has passed.
(b) Premature burst. If a premature burst occurs, the test shall be
suspended or the lateral limits of the danger zone increased in
accordance with prescribed safety distances before the test continues.
The increased lateral limits shall be maintained until the particular
test is completed.
(c) Misfire. After a misfire, all persons shall stand clear of the
breech, in case the round functions and the gun recoils. All electrical
connections that could cause firing of the gun shall be disconnected.
The appropriate danger zone for the actual firing shall be maintained
during the waiting period, until the danger of cook-off has passed. The
removed round shall be immediately placed where subsequent detonation
could not cause injury or damage. In the case of misfires involving
small-caliber rockets and small-arms ammunition, the rounds should be
immersed in water (unless the results of prior analyses or
investigations preclude such practice). Misfire procedures shall be
established to include attempts to refire weapons, waiting periods,
cooling, operational precautions, and disposition of ammunition. Once
these procedures have been carried out, the firing pin and mechanism
shall be checked, and the barrel of the gun examined to ensure that it
is clear; then firing may resume. Appendices A through H of this
subpart provide general guidance on what to do when misfires occur.
(d) Hangfire. A hangfire is a delayed firing occurring as a short
time lag between the striking of the firing pin on the primer and the
ignition of the primer, igniter, or propellant. All hangfires shall be
immediately reported to responsible personnel. This is particularly
important for early detection of trends. In these cases, the firing of
a particular lot of ammunition shall be suspended unless responsible
authorities advise differently.
Sec. 184.182 Ammunition and dud recovery.
Open-air test area recovery requirements follow:
(a) Making. When projectiles or bombs with live fuzes, live
boosters, or high explosive are fired for impact on, or burst over, a
recovery field, observers stationed in a protected place shall record
the location of duds and exploded rounds. Before leaving a recovery
field or impact area, personnel in charge of cleaning the fields shall
mark duds and exploded rounds with the appropriate color-coded flag or
device. Where locations cannot be marked, fields shall be posted with
warning signs and entry shall be restricted.
(b) Policing. Personnel shall be prohibited from touching or in any
way disturbing dud ammunition. Unfuzed or inert-fuzed live ammunition
or ammunition components that have failed to function during a test
shall be recovered only in accordance with the SOP developed by the
contractor.
(c) Destruction. All types of ammunition and explosives shall be
disposed of in accordance with this part, contract requirements, or
instructions provided by the contracting officer.
Sec. 184.183 Personnel shelters.
(a) General. Responsible personnel shall require all within the
danger zone to take cover during tests where fragmentation might occur.
The person charged with attaching the lanyard shall be the last to
leave the gun emplacement, and shall advise the responsible person that
all personnel are clear before any firing.
(b) Portable bombproofs for fire observation. All portable
bombproofs used for fire observation shall be on the gun side of the
impact point; no closer than 200 yards from the impact point; and in
the sectors between compass headings 45 and 80 degrees and between 280
and 315 degrees (compass centered on impact point with 0 and 360
degrees at the firing point). When the impact will result in
fragmentation, the bombproof should be located behind the firing line
in the sectors between compass headings 100 and 135 degrees and between
225 and 260 degrees (compass centered on firing point with 0 and 360
degrees at the impact point). It should be so oriented with respect to
the impact that no wall surface is presented to fragmentation at an
angle greater than 60 degrees. This can usually be done by centering
one intersection of the walls of a square or U type bombproof, or
pointing the apex of a pointed V type, toward the impact point. Under
no circumstances shall the orientation expose the rear of the bombproof
to gunfire and fragmentation. Observations from bombproofs shall be
indirect, using mirrors, periscopes, or other suitable devices. Refer
to Appendix I to this subpart.
------------------------------------------------------------------------
Type Location and use Wall
------------------------------------------------------------------------
Portable reinforced At firing fronts when 12 inches.
concrete bombproof (open alongside or to rear of
back)\1\. gun and offset from line
of fire for any class of
fire.
Armored railway mounts..... At firing fronts when armorplate.
alongside or to rear of
gun and offset from line
of fire for any class of
fire.
Portable boiler-plate At firing fronts for inert \3/4\-inch
barrier. shrapnel or low explosive steel plate.
up to and including 155 mm
and all small-arms
ammunition.
Portable armor-plate At firing fronts when to 3-inch
barrier. rear and offset from line armorplate.
of fire for any classes
except high explosive or
plate firing.
Armorplate sheets.......... At firing fronts for \1/2\-inch
grenades, primer armorplate.
detonators, and ground
troop signals.
------------------------------------------------------------------------
\1\This type may be used for fire observation in the field, provided the
bombproof is offset from the line depending upon the caliber of guns
used, and in accordance with Sec. 184.182(c).
Sec. 184.184 Testing of ammunition or devices for small arms.
(a) Ammunition shall not be placed in any gun until it is in firing
position and ready to shoot.
(b) Safety devices on gun mounts and ranges shall be kept in
operating condition and tested before use. If a malfunction occurs,
test operations shall cease and a report made to the responsible
supervisors.
(c) Every weapon removed from a firing position, storage case, or
rack; or picked up by any operator, shall be inspected for the presence
of ammunition in the chamber, magazine, or feed mechanism, and for
obstruction in the bore.
(d) The chamber, magazine, and feed mechanism of all guns should be
open during handling and transportation. When practicable, a safety
block should be used in the chambers of weapons.
(e) Primers of misfired rounds may be hypersensitive; precautions
should be taken during their removal from the gun, handling, and
disposal.
(f) Firing on ballistic ranges, expect in function and casualty
tests, shall be from fixed rests.
(g) When sand butts are used to stop bullets, a reinforced concrete
wall should be constructed at sufficient distance behind the retaining
wall to permit inspection. This is necessary because bullets tend to
tunnel through the sand and penetrate the retaining wall after
continued firing. To discover any such penetration, the inner face of
the second wall should be inspected frequently. If terrain effectively
protects the rear of the range, no concrete wall is necessary.
(h) Because bullets tend to ricochet from a sand bank, the roofs of
enclosed ranges should be protected, to prevent penetration.
(i) When water traps are used to receive a fired bullet, interlocks
shall be provided to prevent firing of the test weapon if water
pressure failure occurs.
(j) Unburnt propellant from any test firing shall not accumulate in
the surrounding area. Safe methods shall be developed for cleanup,
decontamination and disposal.
Sec. 184.185 Velocity and pressure tests.
Special high pressure tests or tests of unknown pressure ammunition
shall be performed only when personnel are protected against injury
from gun failures. Operational shields or remote control firing of guns
serves this purpose.
Sec. 184.186 Primer drop tests.
(a) Cases continuing live primers shall be marked and separated
from those containing fired primers.
(b) The collecting tube and areas where primer dust could
accumulate shall be regularly inspected and cleaned.
BILLING CODE 5000-04-M
TP16DE94.005
TP16DE94.006
TP16DE94.007
TP16DE94.008
TP16DE94.009
TP16DE94.010
TP16DE94.011
TP16DE94.012
TP16DE94.013
BILLION CODE 5000-04-C
Subpart O--Collection and Destruction Requirements for Ammunition
and Explosives
Sec. 184.188 General.
This subpart provides safety requirements for the collection and
destruction of ammunition and explosives. At this writing, the
Environmental Protection Agency is developing rules which apply to each
contractor beyond the scope of this part. Explosive safety should not
be compromised while meeting environmental considerations.
Sec. 184.189 Protection during disposal operations.
(a) Operational shields and special clothing shall protect
personnel in facilities with explosives materials. Fragmentation
hazards require, at a minimum, overhead and frontal protection for
personnel. Shelters should be located at the inhabited building
distance appropriate for the quantity and type of materials being
detonated. Personnel shall use such protective measures when destroying
explosive materials by detonation and when burning explosive materials
that may detonate. Personnel shall not approach the burning site, but
shall wait until the fire is out.
(b) Personnel shall never work alone during disposal and
destruction operations. Warning sings or roadblocks shall restrict the
area. One person, available in an emergency, should observe from a safe
distance while another performs the operations.
Sec. 184.190 Collection of ammunition and explosives.
(a) Water-soluble materials. Enough water should be used in
neutralizing ammonium picrate (explosive D), black powder, and other
soluble materials to ensure their complete dissolution. As little
material as practicable should be dissolved at one time. Sweeping
floors before washing them down reduces the amount of dissolved
material in the wash water. When uncertainty exists concerning the
purity and composition of wash water, experts shall be consulted.
(b) Solid wastes. Explosive-contaminated solid waste material shall
be collected; placed in closed containers; and swiftly removed to
buildings for treatment or holding, or to the burning ground for
destruction.
(c) Explosives dusts. (1) High explosives dusts such as TNT,
tetryl, explosive D, composition B, and pentolite should be removed by
a vacuum system. A ``wet collector'' that moistens the dust near the
point of intake and keeps it wet until the dust is removed for disposal
is preferred for all but explosive D, which should be collected in a
dry system.
(2) More sensitive explosives such as black powder, lead azide,
mercury fulminate, tracer, igniter, incendiary compositions, and
pyrotechnic materials may be collected by vacuum, provided they are
kept wet close to the point of intake. Collect each type, representing
a different hazard, separately, so that black powder, for example,
cannot mix with lead azide. Provision should be made for releasing any
gases that form. The use of vacuum systems for collecting these more
sensitive materials should be confined to operations involving small
quantities of explosives, that is, operations with fuzes, detonators,
small-arms ammunition, and black powder igniters. To minimize the fire
and explosion hazard, collection of scrap pyrotechnic, tracer, flare,
and similar mixtures in No. 10 mineral motor oil or equivalent is
required. Materials collected in the dry state shall be placed in an
oil-containing receptacle available at each operation throughout the
shift. The oil level should be about 1 inch above the level of any
pyrotechnic mixture in the container. Containers of scrap explosive
shall be removed from the operating buildings for disposal at least
once per shift. Applicably rated class B firefighting equipment shall
be available when oil is used.
(d) Design and operation of collection systems. (1) Collection
systems and chambers shall be designed to prevent pinching thin layers
of explosives or explosive dust between metal parts. Pipes or ducts
used to convey dusts require flanged, welded, or rubber connections.
Threaded connections are prohibited. The system shall prevent
explosives dusts from accumulating in parts outside the collection
chamber. Pipes or ducts conveying high explosives shall have long
radius bends. Systems for propellant powder may use short radius bends
provided they are stainless steel, with polished interior. Vacuum
application points should be kept to a minimum. Each room requiring
vacuum collection should have a separate exhaust line to the primary
collection chamber; if this is not possible, no more than two bays
shall be serviced by a common header. Wet primary collectors are
preferred. The length of vacuum line from points of application of
vacuum to the wet collectors should be short. A single secondary
collector shall service as few primary collectors as possible. Not more
than two dry primary collectors shall be connected to a single
secondary collector (wet or dry type). If an operation does not create
a dust concentration potentially posing a severe health hazard, manual
operation of the suction hose to remove explosives dust is preferred,
since permanent attachment to the explosive dust-producing machine
increases the likelihood of propagation through the collection system
of a detonation at the machine. Manually operated hose connections to
explosive dust-producing machines should not interconnect.
(2) Two collection chambers shall be serially installed ahead of
the pump or exhauster to prevent explosives dust from entering the
vacuum producer in a dry vacuum collection system.
(3) Slide valves for vacuum collection systems are permitted;
however, there shall be no metal-to-metal contact. An aluminum slide
operating between two ebonite spacer bars or similar, compatible
materials will eliminate unacceptable metal-to-metal contact.
(4) Dry-type portable vacuum collectors, limited to five pounds of
explosives, shall be located in a separate cubicle having substantial
dividing walls, or outside the building; never in a bay or cubicle with
explosives. Wet-type portable vacuum collectors may be placed in
explosive operating bays or cubicles, provided the quantity of
explosives in the collector is limited in accordance with the
requirements of Sec. 184.190(e)(1) through (e)(3). For dry collection
of quantities in excess of five pounds or wet collection of quantities
in excess of 15 pounds, the provisions of Sec. 184.190(e)(1) through
(e)(3) also apply.
(5) The design of wet collectors shall provide for proper immersion
of explosives, breaking up air bubbles to release airborne particles;
and for removal of moisture from the air leaving the collector, to
prevent moistened particles of explosives from entering the small
piping between the collector and the exhauster or pump.
(6) At lease once every shift, explosives dust shall be removed
from the collection chamber to eliminate unnecessary and hazardous
concentrations of explosives. The entire system should be cleaned
weekly, with parts dismantled as necessary.
(7) The entire explosives dust collecting system shall be
electrically grounded. The grounding shall be tested on a locally
determined schedule.
(8) Small vacuum systems positioned close to work stations shall be
shielded.
(e) Location of collection chambers. (1) Whenever practicable, dry-
type explosives dust collection chambers, except portable units, shall
be located in the open, outside operating buildings, or in buildings
set aside for the purpose. To protect operating personnel from blast
and fragments from the collection chamber, a barricade or operational
shield appropriate for the hazardous quantities involved, shall be
provided between the operating building and the outside location or
separate building housing the collection chamber. At least 3 feet shall
separate the collection chamber from the barrier wall.
(2) When locating dry-type collection chambers outside the
operating building is not feasible, a separate room shall be set aside
for this purpose in the building. This room shall neither contain other
operations nor be used as a communicating corridor or passageway
between other operating locations when explosives are being collected.
Walls separating the room from other portions of the operating building
shall meet the requirements for operational shields for the quantity of
explosives in the collection chamber. If more than one collection
chamber is to be located in the room, the room shall be subdivided into
cubicles, with only one collection chamber per cubicle.
(3) Stationary and portable wet-type collectors may be placed in
explosives operating bays or cubicles, provided the quantity of
explosives in the collectors does not exceed five pounds. Placed in
separate cubicles, quantities may increase to 15 pounds. For wet
collectors containing more than 15 pounds, location requirements set
forth in Sec. 184.190 (e)(1) through (e)(2) apply.
(f) Explosives/munitions awaiting destruction. Material awaiting
destruction when stored in the open shall be inhabited building
distance from explosives being destroyed. Provided with adequate
frontal and overhead protection, material awaiting destruction may be
stored at intraline distance from the explosives being destroyed. All
such material shall be protected against accidental ignition or
explosion from ambient storage conditions or from fragments, grass
fires, burning embers, or blast originating in materials being
destroyed.
(g) Containers for waste explosives. Containers for these
explosives shall be the original closed packages or equivalent.
Closures shall prevent spillage or leakage of contents when handled or
overturned, and shall not pinch or rub explosives during closing and
opening. Containers shall be marked clearly to identify contents. No
containers constructed from spark-producing or easily ignited material
shall be used.
Sec. 184.191 Destruction sites.
(a) Site criteria. (1) Destruction of ammunition and explosives
shall occur as far as possible from magazines, inhabited buildings,
public highways, runways, taxiways, and operating buildings. Separation
distances shall be at least 1,250 feet or the applicable fragmentation
distance unless pits or similar aids limit the range of fragments.
Natural barricades should be used between the site and operating
buildings or magazines. The possibility that the explosives may
detonate when being burned requires use of appropriate protective
barriers or separation distances for the safety of personnel and
property. Explosives shall not be burned or detonated on concrete, nor
in areas having large stones or crevices.
(2) In all disposal and destruction activities, the number of A&E
units or the explosives quantity that may be destroyed safely at one
time shall be predetermined consistent with safe and efficient
operations. When tests or other substantiated documentation reveal that
fragments and debris are adequately controlled, appropriate inhabited
building distances may be used for separation of the destruction site
based on the maximum amount of explosives to be destroyed.
(3) Firefighting equipment should be available to extinguish grass
fires and to wet down the area between burnings and at the close of
operations.
(4) Ordinary combustible rubbish should not be disposed of near
areas where explosives and explosives-contaminated material are
destroyed.
(b) Material and equipment usage. (1) Detonation of ammunition or
explosives should be initiated by electric blasting caps, using
blasting machines or permanently installed electric circuits energized
by storage batteries or conventional power lines. When items to be
detonated are covered with earth, the initiating explosives should be
primed with enough primacord to allow connecting the blasting cap above
ground level.
(2) Special requirements for using electric blasting caps and
electric blasting circuits follow.
(i) The shunt shall not be removed from the lead wires of the
blasting cap until the moment of connection to the blasting circuit. If
the shunt shall be removed to test the blasting cap before priming the
charge, short circuit the lead wires again following the test by
twisting the bare ends of the wires together. The wires shall remain
short circuited in this manner until the moment of connection to the
blasting circuit.
(ii) When uncoiling the leads of blasting caps, the following shall
apply:
(A) No one shall hold the cap at its explosives end.
(B) The explosives end of a hand-held cap should be pointed down,
away from the body, to the rear.
(C) The wires shall be held carefully so that there is no tension
where it connects to the cap.
(iii) The lead wires of electric caps shall be straightened as
necessary by hand. These wires shall not be thrown, waived through the
air, or uncoiled by snapping as a whip.
(iv) Firing wires shall be twisted pairs. The connection between
blasting caps and the circuit firing wires shall not be made unless the
power ends of the circuit leads (firing wire) are shorted and grounded.
(v) Electric blasting or demolition operations and unshielded
electric blasting caps shall be at safe distances from radio frequency
energy transmitters.
(vi) The blasting circuit shall be tested for extraneous
electricity before electric blasting caps are connected to firing
wires. To do so, arrange a dummy test circuit similar to the actual
blasting circuit except that a radio pilot lamp of known good quality,
using no electricity, shall substitute for the blasting cap. If this
pilot lamp glows in the dark, indicating possibly dangerous amounts of
RF energy, blasting operations shall proceed with non-electric blasting
caps and safety fuses. Other instruments, such as the DuPont ``Detect-
A-Meter'' or ``Voltohmeter,'' may be substituted for the radio pilot
lamp used in testing.
(vii) If the exposure is to radar, television, or other microwave
transmitters, the actual blasting circuit, with blasting cap included
but without other explosives, shall be used to test for extraneous
electricity. Personnel performing such tests shall be protected from
the effects of an exploding blasting cap.
(viii) Blasting and demolition operations shall be suspended during
electrical storms, approaching as well as in progress. At first sign of
an electrical storm, cap wires and lead wires shall be short-circuited,
and all personnel removed from the demolition area to a safe location.
(ix) A galvanometer shall test the firing circuit for electrical
continuity before it connects with the blasting machine. Before
completing the circuit at the blasting machine or panel and signaling
for detonation, the individual assigned to make the connections shall
confirm that everyone in the vicinity is in a safe place. This
individual shall not leave the blasting machine or its actuating device
for any reason and, when using a panel, shall lock the switch in the
open position until ready to fire, retaining the only key.
(x) When transported by vehicles with two-way radios, and when in
areas presumed to have extraneous electricity, blasting caps shall be
in closed metal boxes.
(3) When conditions prevent the use of electrical initiators for
detonation, safety fuses shall be used. At the beginning of each day's
operation and whenever a new coil is used, the safety fuse's burning
rate shall be tested. The fuse shall be long enough for personnel to
retire to a safe distance. Under no circumstances shall the fuse length
be less than that required for a 2-minute burning time. Approved
crimpers shall be used to fix fuses to detonators. Only fuses small
enough in diameter to enter the blasting cap without forcing shall be
used. All personnel except the fuse-actuator shall retire to the
personnel shelter or leave the demolition area before ignition.
(c) Servicing of destruction site. (1) Vehicles transporting
explosive material to burning or demolition grounds shall meet the
requirements of this part. No more than two persons shall ride in the
cab. No one shall ride in the truck bed.
(2) Vehicles should be unloaded immediately and withdrawn from the
burning or demolition area until destruction operations are completed.
Containers of explosives shall not be opened before the vehicle has
departed.
(3) Containers of explosives or ammunition items to be destroyed at
the destruction site shall be spotted and opened at least 10 feet from
each other and from explosive material set out earlier, to prevent
rapid transmission of fire if premature should occur.
(4) Empty containers shall be closed and removed to prevent
charring or damage during burning of explosives. Delivery vehicles on
the return trip shall pick up empty containers.
Sec. 184.192 Destruction by burning.
(a) No mixing of an explosive with extraneous material, other
explosives, metal powder, detonators, or similar items shall occur
without authorization.
(b) Because of the danger of detonation, ammunition and explosives
shall not be burned in containers or in large masses, except as
directed by competent contractor authority.
(c) Beds for burning explosives shall be no more than 3 inches
deep. Wet explosives may require a thick bed of readily combustible
material underneath and beyond to ensure that all the explosives shall
be consumed upon ignition. An ignition train of combustible material
leading to the explosives shall be arranged so that both it and the
explosives burn against the wind. When wind velocity exceeds 15 miles
per hour, no disposal by burning shall take place. For direct ignition
of a combustible train, either a safety fuse long enough to permit
personnel to reach protective shelter or a black powder squib initiated
by an electric current controlled from a distance or protective
structure shall be used. Tying two or more squibs together may be
necessary to ensure ignition of the combustible train. Combustible
materials are not needed for burning solid propellants ignited by
squibs. The sites of misfires shall be evacuated for at least 30
minutes, after which two qualified persons shall approach the position
of the explosives: one shall examine the misfire; the other shall act
as backup. Watching the examination from a safe distance, with natural
or artificial barriers or other obstructions for protection, the backup
shall be prepared to rush to the examiner's aid should an accident
occur.
(1) Loose, dry explosives may be burned without being place on
combustible material if burning shall be complete, leaving the ground
uncontaminated. The ground shall be decontaminated often, for the
safety of personnel and operations. Volatile flammable liquids shall
not, at any stage, be poured over explosives or the underlying
combustible material to accelerate burning.
(2) Wet explosives shall always be burned on beds of nonexplosive
materials.
(3) RDX should be burned in wet form to prevent detonation.
(4) Pyrotechnic materials in oil containers shall be emptied into
shallow metal pans before burning. The open containers may be burned
with the explosives.
(d) Parallel beds of explosives prepared for burning shall be
separated by not less than 150 feet. In subsequent burning operations,
care shall be taken to prevent material being ignited from smoldering
residue or from heat retained in the ground from previous burning
operations. Unless a burned-overplot has been saturated with water,
then passed a safety inspection, 24 hours shall elapse before the next
burning.
Sec. 184.193 Destruction by detonation.
(a) Detonation of ammunition or explosives being destroyed should
occur in a pit not less than 4 feet deep and covered with not less than
2 feet of earth. The components should be placed on their sides or in
that position exposing the largest area to the influence of initiating
explosives. Demolition blocks shall be placed in intimate contact on
top of the item to be detonated, secured by earth packed over them.
Under certain circumstances, materials such as bangalore torpedoes and
bulk high explosives may be substituted for demolition blocks.
(b) Local regulations, atmosphere conditions, earth strata, etc.,
determine how many projectiles and explosives shall be destroyed at one
time, both in pits and open sites. Taking these variables into account,
the acceptable quantity shall be based on criteria in Subpart D of this
part. The procedure should be used for destruction of fragmentation
grenades, HE projectiles, mines, mortar shells, bombs, photoflash
munitions, and HE rocket heads that have been separated from motors.
When a demolition area is remote from inhabited buildings, boundaries,
work areas, and storage areas, detonation may be accomplished without
the aid of a pit, space permitting.
(c) After each detonation, the surrounding area shall be searched
for unexploded material and items.
(d) In cases of misfires, the procedures in Sec. 184.182(c) shall
apply.
Sec. 184.194 Destruction by neutralization.
Certain ammunition and explosives may be disposed of by
neutralization. Methods of neutralization include dissolving water-
soluble material and chemical decomposition. The contractor,
responsible for investigation which of these is most appropriate, shall
comply with all applicable local, State, and Federal requirements for
disposal and contamination operations.
Sec. 184.195 Destruction chambers and incinerators.
(a) General. Small, loaded ammunition components such as primers,
fuzes, boosters, detonators, activators, relays, delays and all types
of small-arms ammunition, should be destroyed in destruction chambers
and deactivation furnaces. Explosives scrap incinerators should be used
for burning tracer and igniter compositions, small quantities of solid
propellant, magnesium powder, sump cleanings, absorbent cleaning
materials, and similar materials. Destruction chambers and incinerators
should be equipped with suitable pollution-control devices, such as
multiple chamber incinerators with thermal incinerator afterburners.
The final incineration should take place at 1400 deg.F, minimum.
(b) Operation of incinerators. (1) The feeding conveyor shall not
be operated until the incinerator temperature is high enough to ensure
complete destruction. Temperature recording devices should be
installed.
(2) To remove accumulated residue, incinerators shall be shut down
and thoroughly cooled. Repairs shall be made only during shutdown.
Personnel entering the incinerator to clean it shall be provided with
respiratory protection, to prevent inhalation of toxic dusts or fumes,
such as mercury from tracers and lead from small-arms ammunition.
(c) Operation of destruction chambers and deactivation furnaces.
(1) Operation shall be by remote control.
(2) Operators shall not approach the unprotected side of the
concrete barricade to replenish fuel, adjust the oil flame, or for any
other reason, until enough time has elapsed for explosives in the
chamber to go off. To keep the feedpipe chute or conveyor obstruction-
free, regular inspections shall take place.
(3) Components shall be fed into the chamber a few at a time. The
exact number permitted at one time for each type of component shall be
posted in a place easily seen from the operator's working position.
(4) Guards shall be installed on conveyor-feeding mechanisms to
facilitate feeding and to prevent items from jamming or falling.
Sec. 184.196 Support in disposal of waste.
If Government-owned ammunition items or explosives are declared
excess or residual and the contract says nothing about disposition, the
contractor shall request instructions from the responsible Contract
Administration Office. A contractor having trouble safely disposing of
residual (scrap) ammunition items or explosives related to contractual
operations may request help from the Contract Administration Office.
Subpart P--Manufacturing and Processing Propellants
Sec. 184.198 General.
(a) These requirements are applicable to propellant manufacturing
and augment other requirements contained in this part.
(b) The safety precautions for fabrication of solid propellants,
propellant loaded items, gun ammunition, and rocket motors follow the
generally accepted principles used for many types of explosives and
energetic materials. Solid propellants can be divided into general
categories such as single, double, and triple base, castable composite,
and modified double base composite; e.g., castable composite propellant
modified with explosive plasticizer such as nitroglycerin.
(c) Although processing safety considerations for finished
propellant items and loaded rocket motors are similar, each propellant
type has its own characteristics for processing of raw materials,
intermediate compositions, and final processing. Hazards data testing
of intermediate and finished propellant shall be accomplished to define
the requirements that ensure safety in processing. Initiation
thresholds to such stimuli as impact, friction, heat, and electrostatic
discharge shall be known for specific processes and handling
situations. Response of the materials in terms of energy input
sensitivity and magnitude of energy release shall be considered to
evaluate and properly apply the guidelines in this subpart. Safety
precautions for ignition system fabrication shall follow the general
requirements for manufacturing and processing of pyrotechnics given in
subpart H of this part. (An exception to this requirement is the
processing of a propellant grain igniter which shall be the same as
motor propellant until grain is mated with the initiator assembly.)
(d) In addition to generally accepted safety precautions for
handling of explosives and other energetic materials, the following
paragraphs provide general guidance pertinent to the manufacturing of
solid propellants and loaded items and solid propellant rocket motors.
Sec. 184.199 In-process hazards.
(a) During scale up from research and development of new materials
to an existing solid propellant manufacturing process, determine the
chemical, physical, physiological and explosive hazards of raw
materials, intermediate compositions, processing aids, and final solid
propellant, both uncured and cured.
(b) Testing shall determine thermal stability, chemical
compatibility of ingredients, exothermic reactions, and sensitivity to
ignition or detonation from friction, impact, and electrostatic
discharge. Additionally, deflagration-to-detonation and card-gap test
data can be valuable. Applicable tests may be selected TB 700-2,
Explosives Hazard Classification Procedures.
(c) Minimum testing may satisfy the classification requirements for
several in-process operations. For example:
(1) If reliable data exists that indicate that the propellant
mixing operations are class/division 1.1 no testing would be needed to
adopt this classification.
(2) If testing shows that uncured propellant will detonate, the
casting and curing operations shall be considered exposed to class/
division 1.1 hazards.
(3) If detonation tests show that the cured propellant will
detonate, all operations with cured or curing propellant shall be
considered as exposed to class/division 1.1 hazards.
(d) Safety information for all materials used in the formulation
shall be available as required. Personnel shall be trained on the
hazards involved in propellant process situations.
Sec. 184.200 Quantity/distance (Q/D) requirements.
New manufacturing and support facilities for processing of solid
propellants and propellant loaded items shall be operated to conform to
the latest Q/D requirements for the class/division of the material in
the in-process condition.
Sec. 184.201 Separation of operations and buildings.
(a) Propellant and rocket motor manufacturing and processing shall
be done in special areas--operating lines--whose boundaries are
separated from all other areas outside the line in accordance with
appropriate Q/D criteria.
(b) Sequential operations on rocket motors can generally be treated
as one process operation in one building. Exception examples are shown
in Appendix A to this subpart.
(c) The required separation between buildings (sites, pads, or
other such locations), which form a single production or operating
line, shall be in accordance with quantity/distance criteria.
(d) When the hazard classification of a propellant has not been
established, classify the propellant during site and construction
planning as the most hazardous class/division that might possibly apply
during manufacturing and processing.
(e) Safety shelters, lunch rooms, convenience buildings, and
private vehicle parking for personnel working in an operating building
should be constructed and shall be sited in accordance with applicable
Q/D criteria.
Sec. 184.202 Equipment and facilities.
(a) Except as provided for in other applicable documentation, the
design, layout, and operation of facilities and equipment for solid
propellant operations shall follow the mandatory provisions. Where
guidance is not provided, operations should be governed by the results
of hazard tests and analyses performed and documented to address
specific operations. As some propellants can be sensitive to initiation
by static electricity, bonding and grounding of equipment, tooling, and
rocket motors along with other means of static elimination and control
should be given special consideration. Conductive work surfaces and
floors or floor mats shall be provided for assembly of igniters and
igniter subassemblies.
(b) Nonsparking and nonrusting materials, which are chemically
compatible with the propellant material, shall be used for equipment,
tooling, and machinery that will come in contact with propellant or
propellant ingredients.
(c) Certain solid propellant operations involve significant energy
input which enhances the possibility of ignition. Examples are rolling
mills, machining and drilling operations. In these situations, complete
hazard analysis and evaluation shall be conducted prior to starting the
operation.
(d) Space heating, air conditioning, and propellant hot air cure
oven equipment shall be designed and operated to prevent accumulation
of solvent vapors (whether flammable or nonflammable), explosive dusts,
and nitroglycerin vapors (or other nitroester vapors) that may present
an ignition, explosion, or personnel hazard. Ovens shall have dual or
redundant temperature controls.
(e) Exposed radiant surfaces in the form of S-shaped smooth pipe or
fin-type radiators, so positioned that they can be easily cleaned, are
considered suitable types of radiators because of the ease with which
they can be cleaned. Other types of radiators are acceptable, but are
less desirable because of cleaning difficulties.
(f) When mechanical ventilating equipment is used in operations
involving potential concentrations of solvent vapors, dusts, and
nitroester vapors, the electric motor and motor controls shall not be
located directly in the potentially contaminated air stream and the
system shall be provided with a suitable means of collecting
condensate.
(g) Air conditioning and cure oven air-circulating equipment of the
closed system type shall be designed to prevent contaminated air from
contacting the air motor and controls. Recirculated air shall be
monitored to ensure concentration of vapors and dusts do not reach
flammable (or explosive), or personnel threshold limits. Electric
motors and controls shall be dustproof and vaporproof electrical
equipment. Air mover blades should be nonmetallic.
(h) The equipment shall be rigidly fixed and stable during mixing
to preclude contact between fixed and movable parts. Any mix bowl lift-
mechanism (elevator) is to be designed so blade-to-blade and blade-to-
bowl clearances are assured during the complete operation cycle.
(i) Positive controls shall be provided to physically block or stop
bowl or mixer head movement in case of drive mechanism malfunction.
Assure blade-to-blade and blade-to-bowl clearance is maintained at all
times.
(j) Mix blades and shaft shall be rigid and structurally strong to
ensure minimum flex from viscosity of the mix and speed of the shaft.
(k) Electrical components of all mixers shall meet the appropriate
electrical classification, be remotely located, or shrouded and purged
with inert gas. Purged systems shall be designed to provide automatic
warning if gas pressure is lost.
(l) Mixer blade shafts shall be equipped with seals or packing
glands that prevent migration of liquids or solvent vapors into
bearings. Submerged bearings and packing glands should be avoided.
However, if used, they shall be periodically tested for contamination
and cleaned.
(m) A program shall be established to detect significant changes in
blade/shaft position relative to mixer head. Clearances between mix
blades and mixer bowls shall be checked at regular intervals based on
operating time and experience to make sure the clearance is adequate.
Maintain a record of such checks, mixer blade adjustments, and any
damage to the mixer blades and bowls.
(n) Mix bowl, blades, and drive unit are to be electrically bonded
and grounded.
(o) Inspect blades and other moving parts of new mixers and
replacement parts for old mixers. Inspect (magnaflux and/or X-ray) for
cracks, crevices, and other flaws.
(p) Electric service to propellant mixers shall be interlocked with
fire protection system controls so that the mixer cannot start when the
fire protection system is inoperative.
(q) All process equipment which applies energy to in-process
propellant should be checked regularly for wear and misalignment. A
record of these checks and maintenance performed should be maintained
for the process equipment.
(r) Equipment performing sequential operations on propellants, such
as extrusion and cutting, shall be controlled to prevent interference.
Sec. 184.203 In-process quantities and storage.
(a) Only the amount of propellant and loaded subassemblies needed
to ensure a safe and efficient workflow shall be present in an
operating building when operations are being conducted. This does not
preclude short-term storage of larger quantities in an operating
building when not in use for other operations.
(b) Operating buildings of standard construction may be used for
storage of completed assemblies with or without installed ignition
system. There shall be no other operation in progress and quantity/
distance shall be in compliance with requirements.
(c) Production igniters may be stored in designated areas within an
assembly/disassembly facility.
(d) Indoor storage is preferable for all types of explosives and is
mandatory for bulk high explosives, solid propellants, and
pyrotechnics. Priority of existing indoor storage should be given to
items requiring the most protection from the weather (based on the
method of packing). Solid propellant and propellant materials shall be
protected from overheating by exposure to direct sunlight when in
transit or on temporary hold.
(e) The propulsive characteristics and the ignition probability of
explosive items such as propellant loaded devices, rocket motors,
assist take-off units, and missiles shall be taken into consideration
during all logistical phases in order to obtain as much safety as
possible under the circumstances. Because of the great number of types
and sizes of propellant loaded devices and conditions of assembly
encountered, it is not feasible to present anything other than general
safety guidance in this part. Thus, every effort should be made to
prevent ignition of any units being manufactured, assembled,
disassembled, handled, stored, transported or deployed. Approved flight
restraining devices (tie-downs) shall be used to the maximum extent
possible and are required if probability of ignition is reasonably
high. When doubt exists as to whether a given item or configuration
(state of assembly) is propulsive or nonpropulsive, the item shall be
treated as propulsive until pertinent technical information can be
obtained.
Sec. 184.204 Ingredients processing.
(a) Weighing, measuring, and handling raw materials. (1) Scales for
weighing raw materials shall be electrically grounded, where needed, to
properly protect the operation. This grounding is especially important
where flammable or combustible materials are involved.
(2) Separate weight or measurement rooms, cubicles, or areas
(dependent upon the quantity and sensitivity of the materials handled)
shall be provided. Oxidizers and metallic powders weighing shall be
separated from each other and from other materials by physical barriers
rather than distance.
(3) It is important that containers, equipment, hand tools, scale
pans, etc., used for weighing processes are not mixed with those
weighing or measuring oxidizers and fuels, particularly where distance
rather than physical barriers separates these areas. Positive measures
shall be adopted to ensure the complete separation of such equipment
and tools.
(4) The designated use of space and equipment shall not be changed
without a thorough cleaning and inspection to make sure that all traces
of the previous material have been removed if any possibility exists
that materials are incompatible.
(b) Oxidizer processing. (1) Solid propellant oxidizing agents are
perchlorates, nitrates, nitroesters, and nitramines used in solid
rocket motor propellants.
(2) Avoid contaminating an oxidizer agent with any metal or
chemical (fuel) which may result in a more sensitive composition.
(3) Use closed systems as much as possible for dust, humidity, and
tramp material control.
(4) Flexible connections (socks) in pipes or duct systems which
convey oxidizer materials and dust socks in collectors or hoopers
should be fabricated of fire-retardant materials. These materials shall
be chemically compatible with the oxidizers to which they shall be
exposed.
(5) The pipes and duct systems shall be made electrically
continuous. Threaded joints and fittings in contact with oxidizer
should be avoided. Quick clamp neuter end pipe joints are preferred.
(6) Static control measures shall be used to dissipate static
charges to an acceptable level if oxidizer is transported by
fluidization.
(c) Oxidizer drying. (1) The safe temperature for drying each
material shall be established and shall not be exceeded at any point in
the drying apparatus or drying room.
(2) Use thermostatic controls to prevent the maximum safe
temperature from being exceeded in the drying process. Redundant
controls are required.
(3) Electrical heating elements that may contact the oxidizer or
oxidizer dust shall not be used.
(4) Dust should be held to a minimum in the drying process. A dust
collection system shall be used if dusting can create a potential
hazard.
(5) Care should be exercised to ensure incompatible materials are
not being dried simultaneously in the same drying process. An oven,
drying room, etc., used for processing flammable or other incompatible
materials should not be used for drying oxidizers until it has been
cleaned, inspected, and found to be free of any contaminating residual
materials.
(d) Screening oxidizers. (1) When screening for process purposes,
the screening equipment shall be constructed so oxidizer material is
not subjected to pinching, friction, or impact as a result of metal-to-
metal contact. Rooms in which screening units are operated shall be
kept thoroughly clean to eliminate hazardous accumulations of dust.
(2) Oxidizer screens shall be electrically grounded and bonded to
the receiving vessel.
(e) Blending oxidizers. (1) If gases are generated during blending
of oxidizer, a suitable means of gas pressure relief shall be designed
into the blender.
(2) The blender shall be electrically bonded throughout.
(3) Blending equipment shall be constructed so oxidizer material is
not subjected to pinching, friction, or impact between metal-to-metal
surfaces.
(4) When ammonium perchlorate is blended using powered mechanical
equipment, operating personnel shall be protected. Remote control of
mechanical blending is advisory.
(5) When powered mechanical methods are used for blending mass-
detonating materials (such as REDX or HMX), the operation shall be
remotely controlled and personnel protected (See Note 1 to Appendix A
to this subpart).
(f) Grinding oxidizers. (1) When impact-type mills are used, there
shall be sufficient clearance between stationary and moving parts to
prevent metal-to-metal contact. Clearances shall be checked as often as
needed to ensure they are adequate. Mill bearings should be wind swept
(purged) to prevent contamination. Impact-type grinders shall not be
used for mass-detoning materials.
(2) Oxidizer feed materials shall be passed through a screen mesh
with openings no greater than the clearance between hammer and plate.
Screen mesh size for ammonium nitrate should be the smallest that
allows free flow of the prills. Magnetic separations shall be used if
screening is not possible.
(3) Use only compatible lubricants in grinding equipment.
(4) Heat sensitive devices should be installed on the bearing
housing of grinding and conditioning equipment.
(5) Determine the cleaning cycle and method used for grinding
equipment and include in operating procedures.
(6) Grinding operations should be provided with wet dust-collection
systems, where appropriate.
(7) Pneumatic grinding operations shall be thoroughly grounded and
bonded to provide for electrostatic charge dissipation.
(g) Preparation of fuel compositions. (1) Sensitivity
characteristics of fuel compositions should be determined prior to
production mixing operations.
(2) Establish compatibility of materials. Develop procedures that
preclude the formation of highly sensitive compositions or hazardous
conditions during processing, such as, dry AP and powdered metal
mixtures.
(3) Equipment, piping, and vessels used in fuel preparation should
be bonded to form a continuous electrical path with each other and to
building ground. When metallic powder and flammable liquids are
transferred (poured) from one container to another, the containers
should be bonded together prior to transfer.
(4) Minimize the formation and accumulation of dust in all
preparation operations.
(5) Fume hoods, dust socks, closed systems, and dust/fume vacuum
exhaust hoses are to be used, as appropriate, to prevent vapors and
dust getting into the operating areas.
(h) Transfer operations. (1) Finely divided powdered ingredients
should be transferred by methods that control flow rate and minimize
electrostatic charge generation which would result from ``slug''
dumping.
(2) Flammable solvents should be transferred only after the
transfer and receiving vessels have been electrically bonded to
eliminate electrostatic potential differences.
Sec. 184.205 Mixing.
(a) Secure hardware and associated equipment to prevent loose items
falling into mixers.
(b) Liquids and powders to be added to the mix vessels shall first
pass through a screen or orifice with an opening(s) less than the
smallest clearance in the mixer. Smaller amounts of material may be
added directly, provided a positive means exists to ensure the material
does not contain any foreign material.
(c) Materials which cannot be screened and are opaque or not easily
inspected should be examined by other means, such as X-ray.
(d) When consistent with the process system and requirements, a
cover shall be placed over the mixer bowl after changing or mixing
operations are completed. This is to prevent the accidental
introduction of foreign objects into the mixer and also to preclude
sunlight impinging directly on the materials in the bowl.
(e) Use only nonsparking devices to scrape down the sides and
blades of mixtures by hand. Set up controls to prevent these and other
devices from being accidentally introduced into the mixer.
(f) Account for all loose tools and equipment before starting or
continuing mixing operations.
(g) Do not allow objects in the mixer operating area (such as
jewelry, pens, and coins) that may accidentally be introduced into
mixers. Suggest using pocketless coveralls.
(h) Direct and unobstructed routes shall be provided for personnel
egress from mixer buildings or bays.
(i) Personnel shall not attempt to fight propellant fires.
(j) Propellant mixers should be equipped, inside and outside of the
mixing vessel, with a high-speed deluge system.
Sec. 184.206 Casting and curing.
(a) Local attendance during cast operations is permitted provided a
thorough safety review of the operation is conducted.
(b) Multiple or production line type casting is permissible
provided provision is made to prevent propagation of an incident
between individual cast bells or pits.
(c) All cast piping and tooling in contact with propellant shall be
smooth for ease of cleaning and be free of cracks, pits, crevices, and
weld slag. Threaded joints should be avoided as much as possible.
Joints requiring disassembly as a process operation or for cleaning
should not be threaded type.
(d) Cast tooling and mandrel designs shall permit no metal-to-metal
friction or impact sites.
(e) Valves through which propellant flows shall be designed to
prevent propellant from being pinched or compressed between two metal
surfaces.
(f) Pressurized casting vessels shall be capable of withstanding at
least twice the maximum allowable working pressure.
(g) Lids shall be secured to pressurized casting vessels in such a
manner that they shall withstand the rated pressures of the vessels.
(h) Line pressure for pressurizing the casting vessel shall not
exceed the working pressure of the vessel. Pressure lines shall have a
relief valve downstream of the regulator.
(i) Equip each vessel with a blowout disk (burst diaphragm)
designed to blow out at less than 120 percent of the vessel's maximum
allowable working pressure. The design shall allow for the release of
the potential rapid rise of pressure in the vessel should the
propellant ignite.
(j) Pressure relief is to be provided when propellant is cured or
cast under pressure.
(k) Pressurization and depressurization for propellant cure shall
be done remotely.
(l) Casting vessels should be physically or electrically
disconnected from lifting devices during cast operations.
Sec. 184.207 Extrusion processes.
(a) Extrusion presses and compression molding equipment should be
designed to remove air from the propellant before compaction and
extrusion begin. Assure that procedures provide for checking operation
of the vacuum system and cleaning it of propellant residue and
condensed vapors such as those generated from nitroglycerin
volatization.
(b) Ramheads should be checked for alignment with the press bore to
preclude metal-to-metal contact. Flashing removal should be included in
the process procedures.
(c) Interlocks shall be provided to preclude press operation during
loading or other attendant operations.
Sec. 184.208 Propellant loaded items.
(a) When operations are performed on cured propellant contained in
pressure vessels or rocket motor cases and there is a significant risk
of ignition due to energy inputs (such as electrical check of
pyrotechnic devices), the unit should be secured in a fixture capable
of withstanding the rated thrust of the assembly times a factor 2.5,
minimum.
(b) When mechanically applied force is required to ``breakaway''
the mandrel or other tooling embedded in propellant, it should be
applied by remote control. However, see Appendix A to this subpart for
exceptions.
(c) Moving loaded motors with cores in place is, generally, not
recommended. If loaded motors containing cores shall be moved, however,
the core and motor case shall be supported by or suspended from a
common source or in some manner locked or tied together to prevent
independent movement of either.
(d) Hazard characteristics of individual propellants to be cut,
machined, or contoured, shall be evaluated and considered in
determining the safest method to use.
(e) Propellant machining equipment shall be designed:
(1) To prevent contact of cutting tools or blades with motor cases
and other metal objects.
(2) To minimize generation of heat.
(3) To facilitate removal of dust and chips, and to afford
personnel protection. The motor or grain should be X-rayed prior to
trim if there is a possibility that metal or other foreign objects may
be in the propellant.
(f) Propellant dust, chips and shavings shall be removed frequently
from the work area during machining and contouring.
(g) Rocket motors in final assembly process should be positioned to
permit ready access to all sides of the motor. Aisles and exit doors
are to be kept clear and unobstructed. All exit doors shall have quick-
release hardware.
(h) The number of items in the final assembly building shall be the
minimum consistent with a safe and efficient operation.
(i) Grounding of propellant loaded assemblies in storage is
optional and is to be reviewed on a case-by-case basis.
(j) If the process requires removing an igniter shorting clip, the
igniter shall remain shorted until immediately before insertion.
Igniter shall remain nonshorted for only the minimum time required for
the operation.
(k) Provide means for controlled dissipation of static electrical
charges during igniter insertion.
(l) Operations that involve electrical continuity checking/testing
of ignition systems installed in rocket motors are to be conducted
according to thoroughly reviewed and approved procedures. If review
indicates that an unacceptable potential for ignition exists, these
checks shall be conducted by remote control with the motor mounted in a
test stand designed to withstand the thrust of the motor times a factor
2.5, minimum.
Sec. 184.209 Disassembly.
(a) Process equipment and tooling that requires disassembly as a
process operation shall be designed as much as possible to avoid metal-
to-metal movement and trapping of explosive material.
(b) Sanitary, external clamp fittings should be used on pipe
assemblies for propellant transfer.
(c) Disassembly of equipment and tooling which is nonroutine, such
as necessary for equipment repair or for securing the process, should
not be started until evaluation of potential hazards from trapped
material or process residuals.
Appendix A to Subpart P of Part 184--Remote Control and Personnel
Protection Requirements for Certain Propellant Processing Operations
------------------------------------------------------------------------
Personnel
Operation Remote controls protected\1\
------------------------------------------------------------------------
Blending and screening of Advisory............ Advisory.
ammonium perchlorate.
Blending screening of nitramines Mandatory\2\........ Mandatory.\2\
and perchlorates other than
ammonium.
Grinding, and mechanized drying Mandatory........... Mandatory
of perchlorates and nitramines. (adequate
protective wall
for perchlorate
and intraline
distance for
nitramines).
Grinding, blending, screening, Advisory............ Advisory.
and mechanized drying of
ammonium nitrates.
Rotating blade propellant mixing Mandatory........... Mandatory.\4\
Power-driven cutting, machining, Mandatory\3\........ Mandatory.\3\
sawing, planing, drilling, or
other unconfined operations in
which rocket motors or
propellant of Q/D Hazard
Division 1.1 and 1.3 are
involved\2\.
Mandrel break away removal from Mandatory\3\........ Mandatory.\3\
cured propellant.
Pressing, extruding, pelletizing Mandatory........... Advisory at
or blending. intraline
distance
mandatory at
less than
intraline
distance.
Casting propellants............. Mandatory\3\........ Mandatory.\3\
------------------------------------------------------------------------
\1\Operating personnel shall be at Q/D or in a control room that will
limit overpressure to less than 2.3 psi.
\2\Attended screening of wet material may be permitted if shown
acceptable by hazard analysis.
\3\Attended operation permitted if shown to be acceptable by hazard
analysis.
\4\When the maximum credible event (MCE) is shown by hazard analysis to
be fire hazard only, non-attended operation is permitted.
Subpart Q--Hazardous Component Safety Data Statements (HCSDS)
[Reserved]
Subpart R--Bibliography
Sec. 184.230 List of Publications.
ANSI Z16.4, ``Uniform Record Keeping for Occupational Injuries and
Illnesses''
DoD Instruction 6055.2, ``Personal Protective Equipment,'' May 3,
1978--canceled by DoD Instruction 6055.1, ``DoD Occupational Safety
and Health Program,'' October 26, 1984
DoD Instruction 6055.5, ``Industrial Hygiene and Occupational
Health,'' January 10, 1989
DoD-STD 2105 (NAVY), ``Hazardous Assessments Tests for Navy Non-
Nuclear Ordnance,'' September 9, 1982
Joint Services Safety and Performance Manual, 1972
Military Standard (MIL-STD)-882B, ``Systems Safety Program for
Systems and Associated Subsystems and Equipment,'' 30 March 1984
NAVAIR 00-130-ASR-2-1, Joint Munitions Effectiveness Manual, ``Air-
to-Surface Joint Service Test Procedures for Bombs and Bomblets,''
December 1968
Subpart S--Glossary
Sec. 184.240 Terminology.
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.
Aboveground magazines. Any type of magazines above ground other
than standard or nonstandard earth-covered types of magazines.
Administration 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.
Aircraft parking area. Any area set aside for parking aircraft not
containing explosives.
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.
Ammunition and explosives aircraft cargo area. Any area
specifically designated for the following:
(1) Aircraft loading or unloading of transportation configured
ammunition and explosives.
(2) Parking aircraft loaded with transportation configured
ammunition and explosives.
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.
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 changehouses, paint and solvent lockers, and similar
facilities).
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.
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).
Blast overpressure. The pressure, exceeding the ambient pressure,
manifested in the shock wave of an explosion.
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.
Classification yard. A railroad yard used for the receiving,
dispatching, classifying, and switching of cars.
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.
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.
Demilitarize. To disarm, neutralize, and accomplish any other
action required to render ammunition and explosives innocuous or
ineffectual for military use.
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.
Dud. Explosive munition that is not armed as intended, or that has
failed to function after being armed.
Establishment. Any plant, works, facility, installation, or other
activity.
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.
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.
Explosives facility. Any structure or location containing
ammunition and explosives.
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.
Fire-resistive. Applies to generally combustible materials or
structures that have been treated or have surface coverings designed to
retard ignition or fire spread.
Firebrand. A projected burning or hot fragment from which thermal
energy is transferred to a receptor.
Firewall. A wall of 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.''
Flame-resistant. Applies to combustible materials, such as
clothing, which have been treated or coated to decrease their burning
characteristics.
Flammable. Combustible. A flammable material is one that is ignited
easily and burns readily.
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 thereof, or pieces of
equipment or buildings containing the items.
Hangfire. Temporary failure or delay in the action of a primer,
igniter, or propelling charge.
Hazard analysis. The logical, systematic examination of an item,
process, condition, facility, or system to identify and analyze the
probability, causes, and consequences of potential or real hazards.
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.
Holding yard. A location for groups of railcars, trucks, or
trailers used to hold ammunition and explosives for interim periods
before storage or shipment.
Hypergolic. The term used to describe the self-ignition of certain
fuels and oxidizers upon contact with each other.
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 customarily assemble, such as a
church, schoolhouse, railroad station and similar transportation
facilities, store, theater, or factory, inside or outside the
establishment.
Inhabited building distance. That separation between explosives
locations (PES) and non-associated locations (ES) requiring a high
degree of protection from an accidental explosion. Such exposed sites
include facility boundaries, wholly inert administrative facilities,
the public, etc.
Inspection station. A designated location at which trucks and
railcars containing ammunition and explosives are inspected.
Interchange yard. An area set aside for the exchange of railroad
cars or vehicles between the common carrier and establishment.
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.
Launch pads. The load-bearing base, apron, or platform upon which
the rocket, missile, or space vehicle and its launcher are positioned.
Liquid propellant(s). Liquid and gaseous substances (fuels,
oxidizers, or monopropellants) used for propulsion or operation of
missiles, rockets, and related devices (see Appendix A to Subpart G of
this part).
Loading docks. Facilities structure, or paved areas, designed and
installed for transferring ammunition and explosives.
Lunchrooms. Facilities where food is prepared or brought for
distribution by food service personnel. It may serve more than one PES.
A breakroom in an operating building may be used by personnel assigned
to the PES to eat meals.
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:
(1) Reinforced concrete, arch-type, earth-covered magazines whose
construction is at least equivalent in strength to the requirements of
The Office of Chief of Engineers (OCE), Department of the Army,
drawings 652-686 through 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 35-15-74.\22\
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\22\Copies available from U.S. Army, Chief of Engineers, Pulaski
Building, 20 Massachusetts Ave., NW., Washington, DC 20001.
---------------------------------------------------------------------------
(2) Magazines constructed according to Navy drawings 357428 through
357430, August 19, 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.\23\
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\23\Copies available from Commander, Naval Facilities
Engineering Command, 200 Stovall Street, Alexandria, VA 22332-2300.
---------------------------------------------------------------------------
(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
20 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.
(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 for new construction; however, existing magazines are
considered ``standard.'' For new 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.
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 subject 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
ammunition 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.
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 occurrence, 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.
Military pyrotechnics. Ammunition manufactured specifically for use
as signals, illuminants, and like items.
Misfire. Failure of a component to fire or explode as intended.
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.
NEW. Net Explosive Weight, expressed in pounds.
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.
Noncombustible. Not burnable.
Operting building. Any structure, except a magazine, in which
operations pertaining to manufacturing, processing, handling, loading,
or assembly of ammunition and explosives are performed.
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.
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 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:
(1) A 12-inch reinforced concrete wall (see definition
``substantial dividing wall'' of this subpart) 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 concrete walls may be used for operational shields for
protection from items containing not more than 6 pounds of high
explosives.
(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 (1) 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.
(3) A 36-inch reinforced concrete 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 (1) of this definition
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.
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.
Prohibited area. A specifically designated area at airfields,
seadromes, or heliports in which all ammunition and explosives
facilities are prohibited.
Propellant. Explosives compositions used for propelling projectiles
and rockets and to generate gases for powering auxiliary devices.
Public highway. Any street, road, or highway used by the general
public for any type of vehicular travel.
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.
Pyrotechnic material. The explosive or chemical ingredients,
including powdered metals, used in the manufacture of military
pyrotechnics.
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.
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 plants.
Restricted area. Any area, normally fenced, from which personnel,
aircraft, or vehicles, other than those required for operations, are
excluded for reasons of safety.
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.
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.
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.
Standard earth-covered magazines. These magazines are approved for
all quantities of explosives up to 500,000 lbs (226,798 kg) net
explosive weight.
Static test stand. Locations whereon liquid propellant engines or
solid propellant motors are tested in place.
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).
(1) Substantial dividing walls are one way of separating explosives
into smaller 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.
(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.
(3) Retaining walls filled with earth or sand shall be at least 5
feet wide, with earth or sand packed between concrete, masonry, or
wooden retaining walls.
Suspect truck and car site. A designated location for placing
trucks and railcars containing ammunition or explosives that are
suspected of being in hazardous condition. These sites also are used
for trucks and railcars that may be in a condition that is hazardous to
their content.
Taxiway/taxilane. Any surface designed as such in the basic
airfield clearance criteria specified by 14 CFR part 77, Objects
Affecting Navigable Airspace.\24\
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\24\Copies may be obtained from Superintendent of Documents,
U.S. Government Printing Office, Washington, DC 20402.
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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.
Waiver. Written authority that provides a temporary exception,
permitting deviation from mandatory requirements of this part. 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.
[FR Doc. 94-30503 Filed 12-15-94; 8:45 am]
BILLING CODE 5000-04-M