DoD 4145.26-M DOD Contractor’s Safety Manual For Ammunition and Explosives March 13, 2008 UNDER SECRETARY OF DEFENSE FOR ACQUISITION, TECHNOLOGY, AND LOGISTICS DoD 4145.26-M, March 13, 2008 This Manual is reissued under the authority of and in accordance with DoD Instruction 4145.26 (Reference (a)) and, accordingly, is applicable to all contractual actions entered into on or after the reissue date. The prior DoD 4145.26-M (Reference (b)), dated September 16, 1997, is hereby rescinded and superseded, yet will remain applicable and effective for contractual actions entered into on or after September 16, 1997 and before the reissue date. The Manual provides safety standards common to DoD and private industry ammunition and explosives (AE), operations, and facilities performing AE work or AE services under DoD contracts, subcontracts, purchase orders, or other procurement methods. DoD 6055.9-STD (Reference (c)) establishes these AE safety standards and serves as the primary source document for this Manual. The explosives safety requirements included in this Manual are consistent with Reference (c) so that AE safety standards for DoD Components and DoD contractors are equivalent. Subpart 223.370 of the Defense Federal Acquisition Regulation Supplement (Reference (d)) requires contracting officers to incorporate this Manual in all AE procurement actions. The purchasing activity may include additional AE or related safety requirements that are not inconsistent with this Manual as it deems necessary. The Manual should be incorporated into AE procurement actions in order to legally bind the contractor to follow the provisions contained therein. This revision removes the chapter on hazard component data statements and updates quantity distance requirements and basic AE safety principles. Questions on interpretation of any requirement in this Manual by the contractor should be submitted through the contractor’s assigned administrative contracting officer to the procuring contracting officer for further review and resolution. This Manual applies to the Office of the Secretary of Defense (OSD), the Military Departments (including their Reserve Components), the Office of the Chairman of the Joint Chiefs of Staff, Combatant Commands, the Office of the Inspector General of the Department of Defense, the Defense Agencies, the DoD Field Activities, and all other organizational entities in the Department of Defense (hereafter referred to collectively as the “DoD Components”). This Manual is effective immediately, and is mandatory for use by all the DoD Components as specified in Reference (a). 2 FOREWORD DoD 4145.26-M, March 13, 2008 Forward recommendations for change to this Manual to: Chairman Department of Defense Explosives Safety Board Room 856C, Hoffman Building I 2461 Eisenhower Avenue Alexandria, VA 22331-0600 RELEASABILITY. UNLIMITED. This Manual is approved for public release. Copies may be obtained through the Internet from the DoD Issuances Web Site at http://www.dtic.mil/whs/directives. An electronic copy can also be obtained by contacting the Department of Defense Explosives Safety Board; Room 856C, Hoffman Building I; 2461 Eisenhower Avenue; Alexandria, VA 22331-0600; telephone at 703-325-2525. 3 FOREWORD DoD 4145.26-M, March 13, 2008 TABLE OF CONTENTS FOREWORD 2 TABLE OF CONTENTS 4 ACRONYMS AND ABBREVIATIONS 11 REFERENCES 14 C1. CHAPTER 1 – INTRODUCTION 16 C1.1. Purpose 16 C1.2. Applicability 16 C1.3. Mandatory Requirements and Advisory Guidance 16 C1.4. Compliance with Mandatory Requirements 16 C1.5. Pre-Award Safety Survey 17 C1.6. Pre-Operational Safety Survey 18 C1.7. Post-Award Contractor Responsibilities 18 C1.8. Site and Construction Plans 19 C2. CHAPTER 2 - ACCIDENT INVESTIGATION AND REPORTING 21 C2.1. General 21 C2.2. Reporting Criteria 21 C2.3. Accident Investigation Requirements 21 C2.4. Telephone Report 22 C2.5. Written Report 22 C2.6. Technical Accident Investigation and Report 23 C3. CHAPTER 3 – GENERAL SAFETY REQUIREMENTS 24 C3.1. General 24 C3.2. Personnel and Material Limits 24 C3.3. SOPs 24 C3.4. Storage in Operating Buildings 26 C3.5. Housekeeping in Hazardous Areas 27 C3.6. Explosives Waste in Operating Areas 27 C3.7. Procedure Before Electrical Storms 28 C3.8. Precautions for Maintenance and Repairs to AE Equipment and Buildings 29 C3.9. Safety Hand Tools 30 C3.10. Operational Shields 30 C3.11. Protective Clothing 31 C3.12. Material Handling Equipment 31 4 TABLE OF CONTENTS DoD 4145.26-M, March 13, 2008 C3.13. Ignition Sources in Hazardous Areas 32 C3.14. Operational Explosives Containers 32 C3.15. Intraplant Rail Transportation 32 C3.16. Intraplant Motor Vehicle Transportation of AE 34 C3.17. Inspection of AE Mixing Equipment 35 C4. CHAPTER 4 - HAZARD CLASSIFICATION AND STORAGE 37 COMPATIBILITY SYSTEMS C4.1. Hazard Classification 37 C4.2. Storage Compatibility 38 C5. CHAPTER 5 – QD PRINCIPLES, CRITERIA, AND SITING REQUIREMENTS 44 C5.1. General 44 C5.2. QD Principles 44 C5.3. Determining NEWQD 45 C5.4. General QD Rules 47 C5.5. Types of QDs 49 C5.6. Explosion Effects, Expected Consequences, Exposure Controls 50 C5.7. Permissible Exposures 54 C5.8. Hazardous Fragment Distance (HFD) 58 C5.9. IBD and PTRD 63 C5.10. ILD 64 C5.11. IMD 64 C5.12. HD 1.2 65 C5.13. HD 1.3 68 C5.14. HD 1.4 68 C5.15. HD 1.6 68 C5.16. HD 6.1 68 C5.17. Energetic Liquids 69 C5.18. Facilities Siting Criteria 75 C6. CHAPTER 6 - ELECTRICAL SAFETY REQUIREMENTS 85 FOR AE FACILITIES C6.1. General 85 C6.2. Electrical Installations 85 C6.3. Lightning Protection 87 C6.4. Static Electricity and Grounding 88 C6.5. Electrical Test Equipment 93 C6.6. Humidification and Ionization 93 5 TABLE OF CONTENTS DoD 4145.26-M, March 13, 2008 C7. CHAPTER 7 - MANUFACTURING AND PROCESSING 94 PROPELLANTS C7.1. General 94 C7.2. Properties of Propellants 94 C7.3. In-Process Hazards 95 C7.4. Separation of Operations and Building 96 C7.5. Equipment and Facilities 97 C7.6. In-Process Quantities and Storage 101 C7.7. Ingredients Processing 101 C7.8. Mixing 105 C7.9. Casting and Curing 105 C7.10. Extrusion Processes 106 C7.11. Propellant Loaded AE 106 C7.12. Disassembly 108 C7.13. Logistical Moves 108 C8. CHAPTER 8 - SAFETY REQUIREMENTS FOR MANUFACTURING AND 109 PROCESSING PYROTECHNICS C8.1. General 109 C8.2. Properties of Pyrotechnic Material and Mixtures 109 C8.3. Process Requirements 111 C8.4. Spill Control 117 C8.5. Collection of Pyrotechnic Waste 117 C8.6. Cleaning of Pyrotechnic Processing Equipment 117 C8.7. Personal Protective Equipment 118 C8.8. Additional Controls 119 C8.9. Reworking Pyrotechnic Components 119 C8.10. Fire Protection 119 C9. CHAPTER 9 - AE STORAGE 120 C9.1. General 120 C9.2. Magazine Operational Regulations 120 C9.3. Stacking 120 C9.4. Unpackaged AE Items and Damaged Containers 121 C9.5. Maintenance and Repairs to Magazines 121 C9.6. Open Storage (Outdoors) 121 C9.7. Storage of Bulk Initiating Explosives 121 C9.8. Hazards of Long-Term Storage 122 C9.9. Rockets and Rocket Motors 122 C10. CHAPTER 10 - FIRE PROTECTION 123 C10.1. General 123 6 TABLE OF CONTENTS DoD 4145.26-M, March 13, 2008 C10.2. Fire Plan 123 C10.3. Smoking 123 C10.4. Hot Work Permits 123 C10.5. Portable Fire Extinguishers 123 C10.6. Fire Hazard Identification System 124 C10.7. Firefighting Procedures 125 C10.8. Automatic Sprinkler System 128 C10.9. Deluge Systems 128 C10.10. Firebreaks 129 C11. CHAPTER 11 - RISK IDENTIFICATION AND MANAGEMENT 130 C11.1. General 130 C11.2. Risk Management System 130 C11.3. Analytical Methods 131 C11.4. Information for Analysis 132 C12. CHAPTER 12 - AE BUILDING DESIGN AND LAYOUT 133 C12.1. General 133 C12.2. Building Exteriors 133 C12.3. Interiors, Walls, Roofs, and Ceilings 133 C12.4. Floors and Work Surfaces 133 C12.5. Substantial Dividing Walls 134 C12.6. Exits and Doors 134 C12.7. Emergency Egress 134 C12.8. Passageways 134 C12.9. Roads and Walkways 135 C12.10. Windows and Skylights 135 C12.11. Drains, Sumps, and Sewers 135 C12.12. Hardware 136 C12.13. Ventilation Systems 136 C12.14. Steam for Heating and Processing 136 C12.15. Tunnels 137 C13. CHAPTER 13 - SAFETY REQUIREMENTS FOR SPECIFIC AE 138 AND AE OPERATIONS C13.1. General 138 C13.2. Properties of Explosives 138 C13.3. Laboratory Operations 140 C13.4. Heat Conditioning of AE 141 C13.5. Spray Painting Loaded AE 142 C13.6. Drying Freshly Painted Loaded AE 142 C13.7. Rework, Disassembly, Renovation, and Maintenance 143 C13.8. AE Loading and Associated Operations 143 7 TABLE OF CONTENTS DoD 4145.26-M, March 13, 2008 C14. CHAPTER 14 - TESTING REQUIREMENTS 148 C14.1. General 148 C14.2. Operating Precautions 148 C14.3. Test Hazards 150 C14.4. Test Clearance 150 C14.5. Warning and Communications Systems 151 C14.6. Specific Items for Test 151 C14.7. Malfunctions 152 C14.8. Ammunition and Dud Recovery 153 C14.9. Personnel Shelters 153 C14.10. Testing of Ammunition or Devices for Small Arms 156 C14.11. Velocity and Pressure Tests 156 C15. CHAPTER 15 - COLLECTION AND DESTRUCTION REQUIREMENTS 157 FOR AE C15.1. General 157 C15.2. Protection During Disposal Operations 157 C15.3. Collection of AE 157 C15.4. Design and Operation of Collection Systems 158 C15.5. Location of Collection Chambers 160 C15.6. AE Awaiting Destruction 160 C15.7. Containers for Waste Explosives 161 C15.8. Destruction Sites 161 C15.9. Destruction by Burning 164 C15.10. Destruction by Detonation 165 C15.11. Destruction by Neutralization 166 C15.12. Destruction Chambers and Incinerators 166 C15.13. Support in Disposal of Explosives Waste 167 AP1 – APPENDIX 1 - GLOSSARY 168 AP2 – APPENDIX 2 - QD TABLES EXTRACTED FROM DOD 6055.9-STD 177 AP3 – APPENDIX 3 - ECM ORIENTATION FIGURES FROM DOD 6055.9-STD 228 INCLUDED BY REFERENCE TABLES C4.T1.