DOD 4145.26-M DOD Contractor’s Safety Manual For ...

1 DoD DOD Contractor's Safety Manual For ammunition and explosives March 13, 2008. UNDER SECRETARY OF DEFENSE. FOR ACQUISITION, TECHNOLOGY, AND LOGISTICS. DoD , March 13, 2008. This Manual is reissued under the authority of and in accordance with DoD Instruction (Reference (a)) and, accordingly, is applicable to all contractual actions entered into on or after the reissue date. The prior DoD (Reference (b)), dated September 16, 1997, is hereby rescinded and superseded, yet will remain applicable and effective for contractual actions entered into on or after September 16, 1997 and before the reissue date.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 (Reference (c)) establishes these AE Safety standards and serves as the primary source document for this Manual .

2 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 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.

3 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 , 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 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.

4 22331-0600; telephone at 703-325-2525. 3 FOREWORD. DoD , March 13, 2008. TABLE OF CONTENTS. FOREWORD 2. TABLE OF CONTENTS 4. ACRONYMS AND ABBREVIATIONS 11. REFERENCES 14. C1. CHAPTER 1 INTRODUCTION 16. Purpose 16. Applicability 16. Mandatory Requirements and Advisory Guidance 16. Compliance with Mandatory Requirements 16. Pre-Award Safety Survey 17. Pre-Operational Safety Survey 18. Post-Award Contractor Responsibilities 18. Site and Construction Plans 19. C2. CHAPTER 2 - ACCIDENT INVESTIGATION AND REPORTING 21. General 21. Reporting Criteria 21. Accident Investigation Requirements 21. Telephone Report 22. Written Report 22. Technical Accident Investigation and Report 23. C3. CHAPTER 3 GENERAL Safety REQUIREMENTS 24. General 24. Personnel and Material Limits 24. SOPs 24. Storage in Operating Buildings 26. Housekeeping in Hazardous Areas 27. explosives Waste in Operating Areas 27. Procedure Before Electrical Storms 28. Precautions for Maintenance and Repairs to AE Equipment and Buildings 29.

5 Safety Hand Tools 30. Operational Shields 30. Protective Clothing 31. Material Handling Equipment 31. 4 TABLE OF CONTENTS. DoD , March 13, 2008. Ignition Sources in Hazardous Areas 32. Operational explosives Containers 32. Intraplant Rail Transportation 32. Intraplant Motor Vehicle Transportation of AE 34. Inspection of AE Mixing Equipment 35. C4. CHAPTER 4 - HAZARD CLASSIFICATION AND STORAGE 37. COMPATIBILITY SYSTEMS. Hazard Classification 37. Storage Compatibility 38. C5. CHAPTER 5 QD PRINCIPLES, CRITERIA, AND SITING REQUIREMENTS 44. General 44. QD Principles 44. Determining NEWQD 45. General QD Rules 47. Types of QDs 49. Explosion Effects, Expected Consequences, Exposure Controls 50. Permissible Exposures 54. Hazardous Fragment Distance (HFD) 58. IBD and PTRD 63. ILD 64. IMD 64. HD 65. HD 68. HD 68. HD 68. HD 68. Energetic Liquids 69. Facilities Siting Criteria 75. C6. CHAPTER 6 - ELECTRICAL Safety REQUIREMENTS 85. FOR AE FACILITIES.

6 General 85. Electrical Installations 85. Lightning Protection 87. Static Electricity and Grounding 88. Electrical Test Equipment 93. Humidification and Ionization 93. 5 TABLE OF CONTENTS. DoD , March 13, 2008. C7. CHAPTER 7 - MANUFACTURING AND PROCESSING 94. PROPELLANTS. General 94. Properties of Propellants 94. In-Process Hazards 95. Separation of Operations and Building 96. Equipment and Facilities 97. In-Process Quantities and Storage 101. Ingredients Processing 101. Mixing 105. Casting and Curing 105. Extrusion Processes 106. Propellant Loaded AE 106. Disassembly 108. Logistical Moves 108. C8. CHAPTER 8 - Safety REQUIREMENTS FOR MANUFACTURING AND 109. PROCESSING PYROTECHNICS. General 109. Properties of Pyrotechnic Material and Mixtures 109. Process Requirements 111. Spill Control 117. Collection of Pyrotechnic Waste 117. Cleaning of Pyrotechnic Processing Equipment 117. Personal Protective Equipment 118. Additional Controls 119. Reworking Pyrotechnic Components 119.

7 Fire Protection 119. C9. CHAPTER 9 - AE STORAGE 120. General 120. Magazine Operational Regulations 120. Stacking 120. Unpackaged AE Items and Damaged Containers 121. Maintenance and Repairs to Magazines 121. Open Storage (Outdoors) 121. Storage of Bulk Initiating explosives 121. Hazards of Long-Term Storage 122. Rockets and Rocket Motors 122. C10. CHAPTER 10 - FIRE PROTECTION 123. General 123. 6 TABLE OF CONTENTS. DoD , March 13, 2008. Fire Plan 123. Smoking 123. Hot Work Permits 123. Portable Fire Extinguishers 123. Fire Hazard Identification System 124. Firefighting Procedures 125. Automatic Sprinkler System 128. Deluge Systems 128. Firebreaks 129. C11. CHAPTER 11 - RISK IDENTIFICATION AND MANAGEMENT 130. General 130. Risk Management System 130. Analytical Methods 131. Information for Analysis 132. C12. CHAPTER 12 - AE BUILDING DESIGN AND LAYOUT 133. General 133. Building Exteriors 133. Interiors, Walls, Roofs, and Ceilings 133. Floors and Work Surfaces 133.

8 Substantial Dividing Walls 134. Exits and Doors 134. Emergency Egress 134. Passageways 134. Roads and Walkways 135. Windows and Skylights 135. Drains, Sumps, and Sewers 135. Hardware 136. Ventilation Systems 136. Steam for Heating and Processing 136. Tunnels 137. C13. CHAPTER 13 - Safety REQUIREMENTS FOR SPECIFIC AE 138. AND AE OPERATIONS. General 138. Properties of explosives 138. Laboratory Operations 140. Heat Conditioning of AE 141. Spray Painting Loaded AE 142. Drying Freshly Painted Loaded AE 142. Rework, Disassembly, Renovation, and Maintenance 143. AE Loading and Associated Operations 143. 7 TABLE OF CONTENTS. DoD , March 13, 2008. C14. CHAPTER 14 - TESTING REQUIREMENTS 148. General 148. Operating Precautions 148. Test Hazards 150. Test Clearance 150. Warning and Communications Systems 151. Specific Items for Test 151. Malfunctions 152. ammunition and Dud Recovery 153. Personnel Shelters 153. Testing of ammunition or Devices for Small Arms 156.

9 Velocity and Pressure Tests 156. C15. CHAPTER 15 - COLLECTION AND DESTRUCTION REQUIREMENTS 157. FOR AE. General 157. Protection During Disposal Operations 157. Collection of AE 157. Design and Operation of Collection Systems 158. Location of Collection Chambers 160. AE Awaiting Destruction 160. Containers for Waste explosives 161. Destruction Sites 161. Destruction by Burning 164. Destruction by Detonation 165. Destruction by Neutralization 166. Destruction Chambers and Incinerators 166. Support in Disposal of explosives Waste 167. AP1 APPENDIX 1 - GLOSSARY 168. AP2 APPENDIX 2 - QD TABLES EXTRACTED FROM DOD 177. AP3 APPENDIX 3 - ECM ORIENTATION FIGURES FROM DOD 228. INCLUDED BY REFERENCE. TABLES. Storage Compatibility Mixing Chart 42. Control and Personnel Protection Requirements for Certain Propellant 108. Processing Operations Fire Division Markings 124. Emergency Withdrawal Distances for Nonessential Personnel 127. 8 TABLE OF CONTENTS.

10 DoD , March 13, 2008. Risk Matrix Format Example 131. Risk Assessment Definitions Example 131. Separation of Firing Points and Bombproofs 155. Portable Bombproofs and Uses 155. HD IBD and PTRD 178. HD HFD 181. HFD for Open Stacks of Selected HD AE 183. HD ILD from ECM 185. HD ILD 188. HD IMD Hazard Factors 191. QD For HD AE For K = , , 2, , , and 5 192. QD for HD AE For K = 6, 8, 9, 11, 18, 40 194. Summary of HD , , AND QD 196. HD QD (IBD, PTR, ILD) for AE With NEWQD > lbs [ kg] 198. HDD for HD AE Stored in Structures That Can Contribute to 201. the Debris Hazard HD QD (IBD, PTR, ILD) For AE with NEWQD < lbs [ kg] 203. HD , , AND Mixing Rules 205. HD QD 206. HD QD 209. HD QD 210. Hazard Classifications and Minimum QD for Energetic Liquids 212. Factors to Use When Converting Energetic Liquid Densities 214. Energetic Liquid Explosive Equivalent Explosive Weights 215. QD Criteria for OSHA/NFPA Class I III Flammable and Combustible 217. Energetic Liquids Storage in Detached Buildings or Tanks QD Criteria for Energetic Liquid Oxidizer (Excluding Liquid Oxygen) 218.