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

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DoD 4145.26-MDOD Contractor’s Safety ManualFor Ammunition and ExplosivesMarch 13, 2008UNDER SECRETARY OF DEFENSEFOR ACQUISITION, TECHNOLOGY, AND LOGISTICS

DoD 4145.26-M, March 13, 2008This 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 afterthe reissue date. The prior DoD 4145.26-M (Reference (b)), dated September 16, 1997, ishereby rescinded and superseded, yet will remain applicable and effective for contractual actionsentered into on or after September 16, 1997 and before the reissue date. The Manual providessafety 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)) establishesthese AE safety standards and serves as the primary source document for this Manual. Theexplosives safety requirements included in this Manual are consistent with Reference (c) so thatAE 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. Thepurchasing activity may include additional AE or related safety requirements that are notinconsistent with this Manual as it deems necessary. The Manual should be incorporated intoAE procurement actions in order to legally bind the contractor to follow the provisions containedtherein.This revision removes the chapter on hazard component data statements and updates quantitydistance requirements and basic AE safety principles.Questions on interpretation of any requirement in this Manual by the contractor should besubmitted through the contractor’s assigned administrative contracting officer to the procuringcontracting 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, theDefense Agencies, the DoD Field Activities, and all other organizational entities in theDepartment 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 asspecified in Reference (a).2FOREWORD

DoD 4145.26-M, March 13, 2008Forward recommendations for change to this Manual to:ChairmanDepartment of Defense Explosives Safety BoardRoom 856C, Hoffman Building I2461 Eisenhower AvenueAlexandria, VA 22331-0600RELEASABILITY. UNLIMITED. This Manual is approved for public release. Copies may beobtained 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 ExplosivesSafety Board; Room 856C, Hoffman Building I; 2461 Eisenhower Avenue; Alexandria, VA22331-0600; telephone at 703-325-2525.3FOREWORD

DoD 4145.26-M, March 13, 2008TABLE OF CONTENTSFOREWORD2TABLE OF CONTENTS4ACRONYMS AND ABBREVIATIONS11REFERENCES14C1. CHAPTER 1 – 1.8.PurposeApplicabilityMandatory Requirements and Advisory GuidanceCompliance with Mandatory RequirementsPre-Award Safety SurveyPre-Operational Safety SurveyPost-Award Contractor ResponsibilitiesSite and Construction Plans1616161617181819C2. CHAPTER 2 - ACCIDENT INVESTIGATION AND rting CriteriaAccident Investigation RequirementsTelephone ReportWritten ReportTechnical Accident Investigation and Report212121222223C3. CHAPTER 3 – GENERAL SAFETY REQUIREMENTS24C3.1. GeneralC3.2. Personnel and Material LimitsC3.3. SOPsC3.4. Storage in Operating BuildingsC3.5. Housekeeping in Hazardous AreasC3.6. Explosives Waste in Operating AreasC3.7. Procedure Before Electrical StormsC3.8. Precautions for Maintenance and Repairs to AE Equipment and BuildingsC3.9. Safety Hand ToolsC3.10. Operational ShieldsC3.11. Protective ClothingC3.12. Material Handling Equipment421242424262727282930303131TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008C3.13.C3.14.C3.15.C3.16.C3.17.Ignition Sources in Hazardous AreasOperational Explosives ContainersIntraplant Rail TransportationIntraplant Motor Vehicle Transportation of AEInspection of AE Mixing Equipment3232323435C4. CHAPTER 4 - HAZARD CLASSIFICATION AND STORAGECOMPATIBILITY SYSTEMS37C4.1. Hazard ClassificationC4.2. Storage Compatibility3738C5. CHAPTER 5 – QD PRINCIPLES, CRITERIA, AND SITING REQUIREMENTSC5.1. GeneralC5.2. QD PrinciplesC5.3. Determining NEWQDC5.4. General QD RulesC5.5. Types of QDsC5.6. Explosion Effects, Expected Consequences, Exposure ControlsC5.7. Permissible ExposuresC5.8. Hazardous Fragment Distance (HFD)C5.9. IBD and PTRDC5.10. ILDC5.11. IMDC5.12. HD 1.2C5.13. HD 1.3C5.14. HD 1.4C5.15. HD 1.6C5.16. HD 6.1C5.17. Energetic LiquidsC5.18. Facilities Siting CriteriaC6. CHAPTER 6 - ELECTRICAL SAFETY REQUIREMENTSFOR AE ctrical InstallationsLightning ProtectionStatic Electricity and GroundingElectrical Test EquipmentHumidification and 8585878893935TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008C7. CHAPTER 7 - MANUFACTURING AND PROCESSINGPROPELLANTS94C7.1. GeneralC7.2. Properties of PropellantsC7.3. In-Process HazardsC7.4. Separation of Operations and BuildingC7.5. Equipment and FacilitiesC7.6. In-Process Quantities and StorageC7.7. Ingredients ProcessingC7.8. MixingC7.9. Casting and CuringC7.10. Extrusion ProcessesC7.11. Propellant Loaded AEC7.12. DisassemblyC7.13. Logistical Moves9494959697101101105105106106108108C8. CHAPTER 8 - SAFETY REQUIREMENTS FOR MANUFACTURING ANDPROCESSING PYROTECHNICSC8.1. GeneralC8.2. Properties of Pyrotechnic Material and MixturesC8.3. Process RequirementsC8.4. Spill ControlC8.5. Collection of Pyrotechnic WasteC8.6. Cleaning of Pyrotechnic Processing EquipmentC8.7. Personal Protective EquipmentC8.8. Additional ControlsC8.9. Reworking Pyrotechnic ComponentsC8.10. Fire ProtectionC9. CHAPTER 9 - AE ine Operational RegulationsStackingUnpackaged AE Items and Damaged ContainersMaintenance and Repairs to MagazinesOpen Storage (Outdoors)Storage of Bulk Initiating ExplosivesHazards of Long-Term StorageRockets and Rocket MotorsC10. CHAPTER 10 - FIRE PROTECTION120120120121121121121122122123C10.1. General1236TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008C10.2. Fire PlanC10.3. SmokingC10.4. Hot Work PermitsC10.5. Portable Fire ExtinguishersC10.6. Fire Hazard Identification SystemC10.7. Firefighting ProceduresC10.8. Automatic Sprinkler SystemC10.9. Deluge SystemsC10.10. Firebreaks123123123123124125128128129C11. CHAPTER 11 - RISK IDENTIFICATION AND MANAGEMENTC11.1.C11.2.C11.3.C11.4.GeneralRisk Management SystemAnalytical MethodsInformation for Analysis130130131132133C12. CHAPTER 12 - AE BUILDING DESIGN AND LAYOUTC12.1. GeneralC12.2. Building ExteriorsC12.3. Interiors, Walls, Roofs, and CeilingsC12.4. Floors and Work SurfacesC12.5. Substantial Dividing WallsC12.6. Exits and DoorsC12.7. Emergency EgressC12.8. PassagewaysC12.9. Roads and WalkwaysC12.10. Windows and SkylightsC12.11. Drains, Sumps, and SewersC12.12. HardwareC12.13. Ventilation SystemsC12.14. Steam for Heating and ProcessingC12.15. 37C13. CHAPTER 13 - SAFETY REQUIREMENTS FOR SPECIFIC AEAND AE 7.C13.8.130GeneralProperties of ExplosivesLaboratory OperationsHeat Conditioning of AESpray Painting Loaded AEDrying Freshly Painted Loaded AERework, Disassembly, Renovation, and MaintenanceAE Loading and Associated Operations7138138138140141142142143143TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008C14. CHAPTER 14 - TESTING REQUIREMENTS148C14.1. GeneralC14.2. Operating PrecautionsC14.3. Test HazardsC14.4. Test ClearanceC14.5. Warning and Communications SystemsC14.6. Specific Items for TestC14.7. MalfunctionsC14.8. Ammunition and Dud RecoveryC14.9. Personnel SheltersC14.10. Testing of Ammunition or Devices for Small ArmsC14.11. Velocity and Pressure Tests148148150150151151152153153156156C15. CHAPTER 15 - COLLECTION AND DESTRUCTION REQUIREMENTSFOR AEC15.1. GeneralC15.2. Protection During Disposal OperationsC15.3. Collection of AEC15.4. Design and Operation of Collection SystemsC15.5. Location of Collection ChambersC15.6. AE Awaiting DestructionC15.7. Containers for Waste ExplosivesC15.8. Destruction SitesC15.9. Destruction by BurningC15.10. Destruction by DetonationC15.11. Destruction by NeutralizationC15.12. Destruction Chambers and IncineratorsC15.13. Support in Disposal of Explosives Waste157157157157158160160161161164165166166167AP1 – APPENDIX 1 - GLOSSARY168AP2 – APPENDIX 2 - QD TABLES EXTRACTED FROM DOD 6055.9-STD177AP3 – APPENDIX 3 - ECM ORIENTATION FIGURES FROM DOD 6055.9-STDINCLUDED BY REFERENCE228TABLESC4.T1. Storage Compatibility Mixing ChartC7.T1. Control and Personnel Protection Requirements for Certain PropellantProcessing OperationsC10.T1. Fire Division MarkingsC10.T2. Emergency Withdrawal Distances for Nonessential Personnel842108124127TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008C11.T1. Risk Matrix Format ExampleC11.T2. Risk Assessment Definitions ExampleC14.T1. Separation of Firing Points and BombproofsC14.T2. Portable Bombproofs and UsesAP2.T1. HD 1.1 IBD and PTRDAP2.T2. HD 1.1 HFDAP2.T3. HFD for Open Stacks of Selected HD 1.1 AEAP2.T4. HD 1.1 ILD from ECMAP2.T5. HD 1.1 ILDAP2.T6. HD 1.1 IMD Hazard FactorsAP2.T7. QD For HD 1.1 AE For K 1.1, 1.25, 2, 2.75, 4.5, and 5AP2.T8. QD for HD 1.1 AE For K 6, 8, 9, 11, 18, 40AP2.T9. Summary of HD 1.2.1, 1.2.2, AND 1.2.3 QDAP2.T10. HD 1.2.1 QD (IBD, PTR, ILD) for AE With NEWQD 1.60 lbs [0.73 kg]AP2.T11. HDD for HD 1.2.1 AE Stored in Structures That Can Contribute tothe Debris HazardAP2.T12. HD 1.2.2 QD (IBD, PTR, ILD) For AE with NEWQD 1.60 lbs [0.73 kg]AP2.T13. HD 1.2.1, 1.2.2, AND 1.2.3 Mixing RulesAP2.T14. HD 1.3 QDAP2.T15. HD 1.4 QDAP2.T16. HD 1.6 QDAP2.T17. Hazard Classifications and Minimum QD for Energetic LiquidsAP2.T18. Factors to Use When Converting Energetic Liquid DensitiesAP2.T19. Energetic Liquid Explosive Equivalent Explosive WeightsAP2.T20. QD Criteria for OSHA/NFPA Class I – III Flammable and CombustibleEnergetic Liquids Storage in Detached Buildings or TanksAP2.T21. QD Criteria for Energetic Liquid Oxidizer (Excluding Liquid Oxygen)Storage in Detached Buildings or TanksAP2.T22. QD Criteria for Liquid Oxygen Storage in Detached Buildings or TanksAP2.T23. QD Criteria for Liquid Hydrogen and Bulk Quantities of HydrazinesAP2.T24. Default Maximum Case Fragment Distances For Intentional DetonationsAP2.T25. Maximum Case Fragment Distances for Selected Single Item GURESC5.F1. Determination of Barricade Height (Equal Height)C5.F2. Determination of Barricade Height (Unequal Height)C5.F3. Determination of Barricade LengthC10.F1. Fire Symbol MarkingsC14.F1. Emplacement of Bombproofs at Firing PointsAP3.F1. ECM Orientation Effects on IMD: Side-to-Side OrientationAP3.F2. ECM Orientation Effects on IMD: Side-to-Side OrientationAP3.F3. ECM Orientation Effects on IMD9848484125154228229229TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008AP3.F4.AP3.F5.AP3.F6.AP3.F7.ECM Orientation Effects on IMDECM Orientation Effects on IMD: Canted ECMECM Orientation Effects on IMD: ECM of Significantly Different LengthsECM Orientation Effects on Barricaded and Unbarricaded IMD and ILD10230230231232TABLE OF CONTENTS

DoD 4145.26-M, March 13, 2008ACRONYMS AND ABBREVIATIONSAEACOAGMAGSAGS (H)AGS (L)APASMEammunition and explosivesadministrative contracting officeraboveground magazineaboveground structure/siteaboveground structure, heavy wallaboveground structure, lightammonium perchlorateAmerican Society of Mechanical Engineers CCFRCGCOCOdegrees CelsiusCode of Federal Regulationscompatibility groupcontractor-owned, contractor-operateddDDCMADDESBDoDDOTloading density (used in formulae)minimum safe distance (used in formulae)Defense Contract Management AgencyDepartment of Defense Explosives Safety BoardDepartment of DefenseDepartment of TransportationECMEEDEIDSELCGESESDearth-covered magazineelectro-explosive deviceextremely insensitive detonating substancesEnergetic Liquid Compatibility Groupexposed siteelectrostatic discharge FFOFOEftdegrees Fahrenheitforeign objectforeign object eliminationfeetGOCOgovernment-owned, contractor-operatedHH/RHANHDHDDHEHEWHFDHMXheavy wallheavy wall/roofhydroxyl ammonium nitratehazard divisionhazardous debris distancehigh explosivehigh explosive weighthazardous fragment distanceoctogen, nitroamine high explosive11ACRONYMS AND ABBREVIATIONS

DoD 4145.26-M, March 13, 2008HPMhigh performance magazineIAWIBDILDIMDIRin accordance withinhabited building distanceintraline distanceintermagazine distanceinfraredJHCSJoint Hazard Classification SystemKkgkPakVfactor that is dependent upon the risk assumed or al logarithmpoundliquefied petroleum gasmMCEMIL-STDmsmetersmaximum credible eventmilitary standardmilli secondNAVFACNEWNEWQDNFPANGNPWNaval Facilities Engineering Commandnet explosive weightnet explosive weight for quantity distanceNational Fire Protection Associationnitroglycerinnet propellant weightOSHAOccupational Safety and Health rocuring contracting officerpotential explosion sitepentaerythritol tetranitratepersonal protective equipmentpounds per square inchpounds per square inch gaugepublic traffic routepublic traffic route distanceQQDnet explosive weight for quantity distance expressed in kilogramsquantity distance12ACRONYMS AND ABBREVIATIONS

DoD 4145.26-M, March 13, 2008RRDXRFrearcyclotrimethylenetrinitramineradio frequencySSGSOPsidesensitivity groupstandard operating procedureTBTEATNTTPtechnical bulletintriethyl aluminumtrinitrotoluenetechnical paperULUNUnderwriters LaboratoriesUnited NationsWW[Q]WPnet explosive weight for quantity distance expressed in poundsnet explosive weight for quantity distance in pounds [kilograms]white phosphorus13ACRONYMS AND ABBREVIATIONS

DoD 4145.26-M, March 13, (m)(n)(o)(p)DoD Instruction 4145.26, “DoD Contractor’s Safety Requirements for Ammunition andExplosives,” April 9, 2005DoD 4145.26-M, “DoD Contractors’ Safety Manual for Ammunition and Explosives,”September 16, 1997 (which is hereby rescinded and superseded, yet will remain applicableand effective for contractual actions entered into on or after September 16, 1997 and beforethe reissue date.)DoD 6055.9-STD, “DoD Ammunition and Explosives Safety Standards,”February 29, 2008Subpart 223.370 of the Defense Federal Acquisition Regulation Supplement, “SafetyPrecautions for Ammunition and Explosives.” December 9, 2005DoD Instruction 6055.7, “Accident Investigation, Reporting, and Record Keeping,”October 3, 2000Parts 1904 and 1910 of title 29, Code of Federal Regulations (CFR)Parts 100-199 of title 49, CFRMilitary Standard (MIL-STD)-398, “Shields, Operational for Ammunition Operations,Criteria for Design of and Tests for Acceptance,” November 5, 19761Technical Bulletin (TB) 700-2/Naval Sea Systems Command Instruction (NAVSEAINST)8020.8B/Technical Order (TO) 11A-1-47/Defense Logistics Agency Regulations (DLAR)8220.1, “Department of Defense Ammunition and Explosives Hazard ClassificationProcedures,” January 5, 19982National Fire Protection Association (NFPA) Manual 491M.5, “Hazardous ChemicalReactions,” current edition3Department of Defense Explosives Safety Board (DDESB) Technical Paper (TP) No. 13,“Prediction of Building Debris for Quantity-Distance Siting,” April 19912DDESB TP No. 16, “Methodologies for Calculating Primary Fragment Characteristics,”October 17, 20052DDESB TP No. 15, “Approved Protective Construction (Version 2.0),” June 20042Technical Manual (TM) 5-1300/Naval Facilities Engineering Command (NAVFAC) P397/Air Force Manual (AFM) 88-22, “Structures to Resist the Effects of AccidentalExplosions,” November 28, 19902DDESB TP No. 10, Change 3, “Methodology For Chemical Hazard Prediction," June19802American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section VIII,“Rules for Construction of Pressure Vessels,” Division 1/Division 2, current version41Defense Automated Printing, 700 Robbins Avenue, Philadelphia, PA 19111; Phone: 215-69721792Department of Defense Explosives Safety Board (DDESB), Room 856C, Hoffman Building I,2461 Eisenhower Avenue, Alexandria, VA 22331-0600; Phone: 703-325-0891; Fax: 703325-62273NFPA, 1 Batterymarch Park, Quincy, MA 02169-7471; Phone: 617-770-3000; Fax: 617-77007004ASME International, 22 Law Drive, Box 2900, Fairfield, NJ 07007-2900; Phone: 800-8432763; International: 973-882-1167; Fax: 973-882-171714REFERENCES

DoD 4145.26-M, March 13, 2008(q) NFPA 30, “Flammable and Combustible Liquids Code,” current version3(r) NFPA 70, “National Electric Code,” current version3(s) NFPA 91, “Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists, andNoncombustible Particulate Solids,” current version3(t) NFPA 780, “Standard for the Installation of Lightning Protection Systems,” currentversion3(u) NFPA 77, “Recommended Practice on Static Electricity,” current version3(v) NFPA 10, “Standard for Portable Fire Extinguishers,” current version3(w) NFPA 704, “Standard System for the Identification of the Hazards of Materials forEmergency Response,” current version3(x) NFPA 13, “Standard for the Installation of Sprinkler Systems,” current version3(y) NFPA 15, “Standard for Water Spray Fixed System for Fire Protection,” current edition3(z) MIL-STD-882D, “Standard Practice for System Safety,” February 10, 20001(aa) NFPA 101, “Life Safety Code,” current edition3(ab) NFPA 80, “Standard for Fire Doors and Other Opening Protectives,” current edition3(ac) NFPA 33, “Standard for Spray Application Using Flammable or Combustible Materials,”current version3(ad) Federal Aviation Administration Handbook5(ae) DDESB TP No. 18, “Minimum Qualifications for Unexploded Ordnance (UXO)Technicians and Personnel,” 20 December 20042(af) NFPA 430, “Code for the Storage of Liquid and Solid Oxidizers,” current version3(ag) Wilton, C., “Investigation of the Explosive Potential of the Hybrid Propellant CombinationsN2O4/PBAN and CTF/PBAN,” AFRPL-TR-67-124, 1967 (AD A003 595)6(ah) NFPA 251, “Standard Methods of Tests of Fire Resistance of Building Construction andMaterial,” current version3(ai) NFPA 55, “Standard for the Storage, Use, and Handling of Compressed Gases andCryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks,” currentversion3(aj) Zabetakis, M. G. and Burgess, D. S., “Research on the Hazards Associated With theProduction and Handling of Liquid Hydrogen,” U.S. Department of the Interior, Bureau ofMines Report 5707, 196175Available at dbk-006/HDBK006.pdfDefense Technical Information Center, Fort Belvoir, VA 22060; Phone: 800-225-38427Chemical Propulsion Information Agency, Accession Number 1964-0291, The Johns HopkinsUniversity, 10630 Little Patuxent Parkway, Suite 202, Columbia, MD 21044-3204; Phone:410-992-7300; Fax: 410-730-4969615REFERENCES

DoD 4145.26-M, March 13, 2008C1. CHAPTER 1INTRODUCTIONC1.1. PURPOSEC1.1.1. This Manual provides safety requirements, guidance and information to minimizepotential accidents that could interrupt Department of Defense (DoD) operations, delay DoDc

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.

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