DOE Explosives Safety Manual Pantex Version M 440.1 1, Revision 8 Explosive

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DOE M 440.1-1 (Formerly DOE/EV/06194)
Revision 8
w/ Approved Changes through 5/19/98

DOE Explosives Safety Manual
Pantex Version
May 1998

U.S. Department of Energy

Battelle Pantex

Assistant Secretary for Environment,
Safety and Health
Office of Worker Safety and Health

Nuclear Explosives Safety Department
Explosives Safety Program

Revision 8

DOE M 440.1-1
w/ Approved Changes through 5/19/98

PREFACE

This document is not the official DOE publication of DOE M 440.1-1. It is an updated version that
includes all changes as approved by the DOE Explosives Safety Committee and is intended for Pantex
use only. It provides Pantex personnel with one reference for the latest requirements in DOE M 440.1-1
instead of requiring distribution of the individual DOE ESC meeting minutes. It is approved for use at
Pantex Plant. Any other use is not sanctioned by Pantex.
The chapter text is taken from DOE M 440.1-1, Revision 8, dated 3/29/96 and the errata sheet for
Revision 8 presented at the 35th DOE ESC Meeting. The approved changes from each semiannual
meeting of the DOE Explosives Safety Committee meetings have been added and annotated. This
document represents the up-to-date version of the DOE Explosives Safety Manual, current as of the date
above.
Formatting has been revised. Although the text in the Chapters is identical to the original DOE M
440.1-1, less approved changes, several formatting changes have been made. These include:
•
•
•
•
•
•
•
•

pagination has been set to continuous,
figures have been reproduced in an electronic format,
tables have been formatted consistently with lines and borders,
Table of Contents has been updated,
List of Figures and Tables has been updated,
a new Index has been generated,
an endnote section has been added to identify specific changes, and
paragraph formatting has been changed to automatically number paragraphs, chapters, tables,
and figures.

i

FOREWORDa
The Department of Energy (DOE) policy requires that all DOE activities be conducted in a manner that
protects the safety of the public and provides a safe and healthful workplace for employees.
DOE has also prescribed that all personnel be protected in any explosives operation undertaken. The
level of safety provided shall be at least equivalent to that of the best industrial practice. The risk of
death or serious injury shall be limited to the lowest practicable minimum.
DOE and contractors shall continually review their explosives operation with the aim of achieving
further refinements and improvement in safety practices and protective features.
This Manual describes the Department’s explosive safety requirements applicable to operations
involving the development, testing, handling, and processing of explosives or assemblies containing
explosives. It is intended to reflect the state-of-the-art in explosives safety. In addition, it is essential
that applicable criteria and requirements for implementing this policy be readily available and known to
those responsible for conducting DOE programs. This document shall be periodically reviewed and
updated to establish new requirements as appropriate. Users are requested to submit suggestions for this
Manual through their appropriate Operations Office to the Office of Occupational Safety.
This Manual is dedicated in the memory of the late Colonel Phillip Kelly, a former member of the DOE
Explosives Safety Committee, for his many contributions to the explosives safety program.

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TABLE OF CONTENTS
Section

Page

PREFACE . .. . . .. . .................................................................................................................................. i
FOREWORD . . .. . ................................................................................................................................. ii
LIST OF FIGURES................................................................................................................................ xi
LIST OF TABLES ................................................................................................................................ xi
ACRONYMS . . .. . ............................................................................................................................... xii
CHAPTER I - INTRODUCTION .......................................................................................................... 1
1.0 SCOPE, PURPOSE, AND JUSTIFICATION ................................................................................ 1
2.0 APPLICABILITY ........................................................................................................................... 1
3.0 EXEMPTIONS................................................................................................................................ 2
4.0 WAIVERS .. . ................................................................................................................................. 3
5.0 MANUAL ADMINISTRATION AND MANAGEMENT ............................................................ 3
5.1 DOE Explosives Safety Committee Organization ...................................................................... 4
5.2 DOE Explosives Safety Committee Functions ........................................................................... 4
6.0 DEFINITIONS ................................................................................................................................ 4
CHAPTER II - OPERATIONAL SAFETY ........................................................................................ 13
1.0 GENERAL OPERATIONS SAFETY GUIDELINES ................................................................. 13
1.1 Protection of Explosives ........................................................................................................... 13
1.2 Equipment Checks..................................................................................................................... 13
1.3 Inspection Frequency ................................................................................................................ 13
1.4 Laboratory Operations............................................................................................................... 13
1.5 Toxicity Hazards ....................................................................................................................... 13
1.6 Hazard Identification and Communication ............................................................................... 14
1.7 Process Hazard Analysis ........................................................................................................... 15
2.0 WORK ENVIRONMENT ............................................................................................................ 16
2.1 General Requirements ............................................................................................................... 16
2.2 Emergency Exit Requirements for Explosives Operations ....................................................... 16
2.2.1 Building or Structure Occupancy...................................................................................... 16
2.2.2 Hazard of Contents Classification..................................................................................... 17
2.2.3 Personnel Protective Restrictions and Requirements........................................................ 17
2.2.4 Requirements for Existing Facilities ................................................................................. 18
2.2.5 Requirements for New Facilities....................................................................................... 18
2.2.6 Single Exits ....................................................................................................................... 19
2.2.7 Blast-Resistant Doors........................................................................................................ 19
2.2.8 Slide Escapes..................................................................................................................... 20
3.0 BUILDING AND EQUIPMENT MAINTENANCE ................................................................... 21
3.1 Cleaning .................................................................................................................................... 21
3.2 Maintenance and Repair............................................................................................................ 21
3.3 Hot Work Permits ..................................................................................................................... 22

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Page

4.0 REMOTE OPERATIONS............................................................................................................. 23
4.1 Personnel Protection Criteria .................................................................................................... 23
4.2 Access and Equipment Controls ............................................................................................... 23
5.0 GENERAL EXPLOSIVES AREA CONTROLS ......................................................................... 24
5.1 Smoking, Matches, Lighters, Metal Articles............................................................................. 24
5.2 Cooking and Eating................................................................................................................... 24
5.3 Access to Explosives Areas....................................................................................................... 24
6.0 ELECTRICAL STORMS AND LIGHTNING PROTECTION................................................... 25
6.1 Assessment ................................................................................................................................ 25
6.2 Evacuation................................................................................................................................. 25
6.3 Shutdown of Operations............................................................................................................ 25
6.4 Lightning Protection.................................................................................................................. 26
7.0 STATIC ELECTRICITY .............................................................................................................. 27
7.1 General ...................................................................................................................................... 27
7.2 Bonding and Grounding of Equipment ..................................................................................... 27
7.3 Testing Bonded Equipment Grounds ........................................................................................ 27
7.4 Conductive Floors, Shoes, Mats and Wristbands...................................................................... 28
7.5 Conductive Floor, Work Surface, and Wristband Specifications ............................................. 28
7.6 Conductive Floor Tests ............................................................................................................. 30
7.7 Humidification .......................................................................................................................... 30
7.8 Ground Fault Circuit Interrupter ............................................................................................... 30
8.0 ELECTRICAL EQUIPMENT AND WIRING............................................................................. 31
8.1 Location/Operation Electrical Hazard Classification................................................................ 31
8.2 Electrical Supply System .......................................................................................................... 32
8.3 Building Electrical Service Entrance ........................................................................................ 33
8.4 Permanent Wiring and Equipment ............................................................................................ 33
8.5 Flexible Cords/Wiring............................................................................................................... 34
8.6 Electrical Equipment and Instrumentation................................................................................ 34
8.7 Electrical Requirements for Outdoor Test Areas ...................................................................... 35
8.8 Hand-held, Battery-Powered Lights and Instruments ............................................................... 36
8.9 Non-Rated Extension Lighting.................................................................................................. 36
8.10 Laboratories............................................................................................................................... 36
8.11 Modifications ............................................................................................................................ 37
9.0 VACUUM EQUIPMENT ............................................................................................................. 37
9.1 General ...................................................................................................................................... 37
9.2 Labeling..................................................................................................................................... 37
9.3 Disassembly .............................................................................................................................. 37
9.4 Traps or Filters .......................................................................................................................... 37
10.0 EXPLOSIVES DUST EXHAUST VENTILATION AND COLLECTION SYSTEMS ......... 38
10.1 General ...................................................................................................................................... 38
10.2 Exhaust Ventilation................................................................................................................... 38
10.3 Dust Collection Systems ........................................................................................................... 38
10.4 Dust Collection Location .......................................................................................................... 38
11.0 DRAINS AND SUMPS ............................................................................................................ 39
11.1 Collection .................................................................................................................................. 39
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11.2 Effluent...................................................................................................................................... 39
12.0 PROCESSING .......................................................................................................................... 40
12.1 Heating, Drying, and Thermal Conditioning ............................................................................ 40
12.1.1 General .............................................................................................................................. 40
12.1.2 Heating and Drying Equipment......................................................................................... 41
12.1.3 Heating and Drying Operations......................................................................................... 41
12.2 Pressing ..................................................................................................................................... 42
12.2.1 General .............................................................................................................................. 42
12.2.2 Isostatic/Hydrostatic Pressing ........................................................................................... 43
12.2.3 Punch and Die Pressing..................................................................................................... 44
12.3 Extruding................................................................................................................................... 44
12.4 Machining.................................................................................................................................. 44
12.4.1 Equipment Requirements .................................................................................................. 45
12.4.2 Contact or Remote Operations .......................................................................................... 45
12.4.3 Setup and Preparation........................................................................................................ 48
12.4.4 Operations Guidelines ....................................................................................................... 48
12.4.5 Specific Machining Operations......................................................................................... 49
12.5 Dry Screening............................................................................................................................ 50
12.6 Blending .................................................................................................................................... 51
12.7 Melting ...................................................................................................................................... 51
12.8 Assembly and Disassembly....................................................................................................... 51
12.8.1 Assembly Operations ........................................................................................................ 52
12.8.2 Loading Assemblies with Plastic or Extrudable Explosives............................................. 52
12.8.3 Disassembly Operations.................................................................................................... 52
12.8.4 Personnel Protection for Disassembly Operations ............................................................ 52
12.9 Inspection .................................................................................................................................. 53
12.10 Synthesis................................................................................................................................ 54
12.10.1 Laboratory-Scale Synthesis ............................................................................................ 54
12.10.2 Pilot- or Processing-Scale Synthesis............................................................................... 54
12.11 Formulation ........................................................................................................................... 55
12.11.1 General............................................................................................................................ 56
12.11.2 Mixing............................................................................................................................. 56
12.11.3 Ball or Jar Milling........................................................................................................... 56
12.11.4 Roll Milling..................................................................................................................... 57
12.12 Concurrent Contact Operations............................................................................................. 57
12.13 Contamination Prevention..................................................................................................... 57
12.14 Hand-Cutting and Finishing Operations ............................................................................... 58
12.15 Use of Low-Pressure Fluids .................................................................................................. 58

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13.0 TESTING . ............................................................................................................................... 59
13.1 General ...................................................................................................................................... 59
13.2 Test Planning............................................................................................................................. 59
13.2.1 Hazards Analysis............................................................................................................... 59
13.2.2 Firing Areas....................................................................................................................... 59
13.3 Test Firing ................................................................................................................................. 59
13.3.1 General Range Standards .................................................................................................. 59
13.3.2 Test Setup.......................................................................................................................... 61
13.3.3 Pin Switches and Other Non-initiating Circuits................................................................ 61
13.3.4 Lightning Storms............................................................................................................... 61
13.3.5 Low-Energy Electroexplosive Devices............................................................................. 62
13.3.6 Explosives Storage in Firing Areas................................................................................... 64
13.3.7 Warning Signals ................................................................................................................ 65
13.3.8 Grass Fires......................................................................................................................... 65
13.3.9 Firing Leads....................................................................................................................... 65
13.3.10 Unattended Test Assemblies........................................................................................... 65
13.3.11 Post-firing Controls......................................................................................................... 65
13.3.12 Contamination of Firing Areas ....................................................................................... 66
13.3.13 Test Range Firing Circuit Criteria .................................................................................. 66
13.4 Test Firing in Tanks or Chambers............................................................................................. 67
13.5 Gun Firings................................................................................................................................ 67
13.6 Ballistic, Environmental, Physical Property and Sensitivity Testing........................................ 68
13.6.1 Checkout of Dynamic Engineering Test Equipment for Explosive Assemblies .............. 68
13.6.2 Testing of Explosives and Hazardous Radioactive Materials........................................... 69
13.6.3 Heating of Explosives Test Specimens ............................................................................. 69
13.6.4 Instrumentation.................................................................................................................. 69
13.6.5 Explosives Limits.............................................................................................................. 70
13.6.6 Drop Testing...................................................................................................................... 70
13.7 Test Failures and Misfires ......................................................................................................... 70
13.7.1 Explosives Misfire ............................................................................................................ 70
13.7.2 Misfire of a Remotely Fired Gun ...................................................................................... 70
13.8 Electrical Instruments for Use with Explosives Systems.......................................................... 72
13.8.1 Classification..................................................................................................................... 72
13.8.2 Certification....................................................................................................................... 72
13.8.3 Electrical Instruments for Use with Initiating Electrical Circuits ..................................... 72
13.8.4 Electrical Instruments for Use with Non-initiating Electrical Circuits ............................. 73
14.0 MATERIALS HANDLING...................................................................................................... 73
14.1 General ...................................................................................................................................... 73
14.2 Manual Handling of Bare Consolidated Explosives ................................................................. 74
14.3 Carts or Hand Trucks ................................................................................................................ 75
14.4 Mechanical Handling Equipment.............................................................................................. 75

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15.0 MATERIALS RECEIPT........................................................................................................... 75
15.1 Motor Vehicles.......................................................................................................................... 75
15.2 Railcars...................................................................................................................................... 76
15.3 Damaged Shipments.................................................................................................................. 77
16.0 TRANSPORTATION ............................................................................................................... 77
16.1 Equipment ................................................................................................................................. 77
16.1.1 General .............................................................................................................................. 77
16.1.2 Motor Vehicles.................................................................................................................. 77
16.1.3 Railcars.............................................................................................................................. 79
16.1.4 Materials Handling Equipment ......................................................................................... 80
16.2 General Operation Guidelines................................................................................................... 80
16.3 Emergency Conditions .............................................................................................................. 81
17.0 EXPLOSIVES STORAGE ....................................................................................................... 82
17.1 Storage Magazine Facilities ...................................................................................................... 82
17.2 Storage Magazine Operations ................................................................................................... 83
17.3 Storage Review Program........................................................................................................... 85
17.4 Storage Compatibility ............................................................................................................... 86
17.5 Containers (On-site) .................................................................................................................. 91
17.6 Storage in Buildings Other Than Storage Magazines ............................................................... 92
17.6.1 Packing and Shipping Buildings ....................................................................................... 92
17.6.2 Service Magazines............................................................................................................. 93
17.6.3 Warehouses ....................................................................................................................... 93
17.6.4 Prepositioned Storage of Security Response Munitions ................................................... 94
18.0 DECONTAMINATION AND CLEANING ............................................................................ 94
18.1 General ...................................................................................................................................... 94
18.2 Cleaning Contaminated Equipment .......................................................................................... 95
18.3 Cleaning Screw Threads............................................................................................................ 95
18.4 Final Decontamination and Disposal of Equipment ................................................................. 95
18.5 Inspection .................................................................................................................................. 96
18.6 Identification and Control of Decontaminated Items................................................................ 96
18.7 Decontamination of Real Estate................................................................................................ 97
18.8 Decontamination and Cleaning References .............................................................................. 97
19.0 WASTE COLLECTION ........................................................................................................... 97
19.1 General ...................................................................................................................................... 97
19.2 Solid Wastes.............................................................................................................................. 97
19.3 Vacuum Collection of Explosives Dusts................................................................................... 98
19.4 Explosives Slurries.................................................................................................................... 99
19.5 Metal Scrap ............................................................................................................................... 99
19.6 Explosives Recovery and Reuse ............................................................................................... 99

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20.0 WASTE DISPOSAL............................................................................................................... 100
20.1 Preparation for Open Burning ................................................................................................. 100
20.2 Destruction by Burning or Flashing ........................................................................................ 101
20.3 Ignition System Malfunctions ................................................................................................. 101
20.4 Postburn Operations ................................................................................................................ 101
20.5 Disposal Area .......................................................................................................................... 101
20.6 Destruction by Detonation ...................................................................................................... 102
20.7 Use of Solvents........................................................................................................................ 102
21.0 LABORATORY OPERATIONS............................................................................................ 103
21.1 General .................................................................................................................................... 103
21.2 Safety Shields.......................................................................................................................... 103
21.3 Heating Operations.................................................................................................................. 105
21.4 Laboratory Setups ................................................................................................................... 105
21.5 Low Concentration of Explosives in Solution ........................................................................ 106
21.6 Explosives Sample Control ..................................................................................................... 106
22.0 EMERGENCY CONTROL .................................................................................................... 106
22.1 Placarding and Fire Symbols................................................................................................... 106
22.2 Explosives Emergency Control Plans ..................................................................................... 106
CHAPTER III - EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL ........................ 108
1.0 EXPLOSIVES LIMITS............................................................................................................... 108
2.0 PERSONNEL LIMITS ............................................................................................................... 108
3.0 LIMIT CONTROL...................................................................................................................... 108
3.1 Posting and Recording ............................................................................................................ 108
3.2 Limit Review and Approvals .................................................................................................. 109
3.3 Personnel Controls .................................................................................................................. 109
3.4 Explosives Control .................................................................................................................. 109
4.0 IHE LIMITS . ............................................................................................................................. 109
CHAPTER IV - PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT ........................ 110
1.0 CLOTHING AND PERSONAL EQUIPMENT ......................................................................... 110
1.1 Clothing................................................................................................................................... 110
1.2 Footwear.................................................................................................................................. 110
1.3 Respirators............................................................................................................................... 110
1.4 Eye Protection ......................................................................................................................... 110
1.5 Gloves...................................................................................................................................... 110
2.0 MAINTENANCE AND TESTING ............................................................................................ 110
2.1 Equipment Maintenance and Inspection ................................................................................. 110
2.2 Conductivity Testing ............................................................................................................... 111
2.3 Cleaning and Disinfecting....................................................................................................... 111
2.4 Contaminated Clothing ........................................................................................................... 111

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CHAPTER V - TRAINING................................................................................................................. 112
1.0
2.0
3.0
4.0
5.0

GENERAL .. . ............................................................................................................................. 112
SUPERVISORY RESPONSIBILITY......................................................................................... 112
TRAINING AND QUALIFICATION PROGRAMS................................................................. 112
UXO Training ............................................................................................................................. 113
References .. . ............................................................................................................................. 114

CHAPTER VI - QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION CRITERIA FOR
EXPLOSIVES ACTIVITIES............................................................................................................... 116
1.0 GENERAL .. . ............................................................................................................................. 116
2.0 APPLICABILITY OF CRITERIA.............................................................................................. 116
2.1 Specific Applications .............................................................................................................. 116
2.2 Explosives Limits.................................................................................................................... 116
2.3 Areas Where Criteria Are Not Applicable .............................................................................. 116
3.0 QUANTITY-DISTANCE CRITERIA........................................................................................ 117
3.1 Hazard Classes and Class Division ......................................................................................... 117
3.2 Establishing Quantity of Explosives and Distances................................................................ 119
3.2.1 General ............................................................................................................................ 119
3.2.2 Use of Metric System...................................................................................................... 119
3.2.3 Railcars and Transport Vehicles ..................................................................................... 119
3.2.4 Utilities Installations ....................................................................................................... 120
3.2.5 Petroleum Storage Tanks ................................................................................................ 121
4.0 LEVEL-OF-PROTECTION CRITERIA .................................................................................... 121
4.1 Hazard Classes ........................................................................................................................ 121
4.2 Required Level of Protection .................................................................................................. 122
4.2.1 Explosives Bay................................................................................................................ 122
4.2.2 Bays for Joint Explosives-Plutonium Activities ............................................................. 124
5.0 FIRE PROTECTION .................................................................................................................. 125
5.1 Vegetation Control .................................................................................................................. 125
5.2 Fire Protection Criteria............................................................................................................ 125
6.0 EXPLOSIVES FACILITY SITING AND DESIGN CRITERIA REFERENCES..................... 126

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CHAPTER VII - OPERATING PROCEDURES ............................................................................. 130
1.0 GENERAL .. . ............................................................................................................................. 130
1.1 Requirements........................................................................................................................... 130
1.2 Types of Procedures ................................................................................................................ 130
2.0 GUIDELINES130
2.1 Before Operation ..................................................................................................................... 130
2.2 Supervisory Responsibility ..................................................................................................... 131
2.3 Preparation .............................................................................................................................. 131
2.4 Approval.................................................................................................................................. 131
2.5 Control..................................................................................................................................... 131
2.6 Audits ...................................................................................................................................... 132
2.7 Reviews ................................................................................................................................... 132
2.8 Content of SOPs ...................................................................................................................... 132
2.8.1 General Operating Procedures ........................................................................................ 132
2.8.2 Unit Operating Procedures .............................................................................................. 133
2.9 Content of Special or Experimental Procedures ..................................................................... 134
3.0 Reference Documents ................................................................................................................. 134
CHAPTER VIII - FORMULATION SCALEUP.............................................................................. 136
1.0 EXPLOSIVES DEVELOPMENT PROGRAM.......................................................................... 136
1.1 Explosives Development Committee ...................................................................................... 136
1.2 Phase-by-Phase Approvals...................................................................................................... 136
1.3 Modified Formulations............................................................................................................ 136
1.4 Sensitivity Data from Another Laboratory.............................................................................. 136
2.0 DEVELOPMENT PROCEDURES ............................................................................................ 136
2.1 General .................................................................................................................................... 136
2.2 Synthesis Phase ....................................................................................................................... 138
2.3 Compatibility Testing.............................................................................................................. 138
2.4 Phase I - Preliminary Explosives Testing ............................................................................... 138
2.5 Phase II - Experimental Characterization and Development .................................................. 139
2.6 Phase III - Full-Scale Testing and Production ........................................................................ 139
CHAPTER IX - INSENSITIVE HIGH EXPLOSIVES QUALIFICATION ................................. 142
1.0 INSENSITIVE HIGH EXPLOSIVES (IHE) .............................................................................. 142
2.0 IHE SUBASSEMBLIES ............................................................................................................. 144
3.0 IHE WEAPONS.......................................................................................................................... 145
4.0 REFERENCE DOCUMENTS .................................................................................................... 146
Appendix A - References ................................................................................................................... A-1
Appendix B - Index............................................................................................................................ B-1
Appendix C - Approved Changes ...................................................................................................... C-1

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LIST OF FIGURES
Figure
Figure II-1.
Figure VI-1.

Page
Testing shoes on wearer .................................................................................................... 29
Application of Hazard Classification System ................................................................. 118

LIST OF TABLES
Table

Page

Table II-1.
Table II-2.

Minimum safe distances between RF transmitters and electric blasting operations......... 63
Minimum safe distances between TV and FM broadcasting transmitters and electric
blasting operations............................................................................................................. 63
Table II-3.
Minimum safe distances between mobile RF transmitters and electric blasting operations
........................................................................................................................................... 64
Table II-4.
Storage compatibility groups for explosives and explosive-containing devices............... 89
Table II-5.
Storage compatibility mixing chart ................................................................................... 91
Table II-6.
Safety shields for explosive laboratory operations ......................................................... 104
Table VI-1. Divisions of Class 1 ........................................................................................................ 117
Table VI-2. Quantity-distance separation for protection of underground service installations.......... 121
Table VI-3. Explosive facilities: protective design requirements by activity type............................ 128
Table VIII-1. Scaleup procedure guidelines for new explosives and formulations .............................. 137
Table IX-1. DOE qualification tests for IHE ...................................................................................... 143
Table IX-2. Approved IHEs................................................................................................................ 144
Table IX-3. DOE qualification tests for IHE Subassemblies ............................................................. 144
Table IX-4. Approved IHE Subassemblies......................................................................................... 145
Table IX-5. IHE Hazard Classification............................................................................................... 145

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ACRONYMS
ACGIH
ASTM
ASTI
BOE
DBA
DDESB
DoD
DOE
DOT
DSC
DTA
EBW
EDC
EED
EOD
FMECA
HAZOP
HE
HMX
IHE
LEL
LFL
MCE
MSDS
NEC
NEW
NEQ
NFPA
OSHA
PBX
PEL
PETN
RDX
SOP
SPMS
SSR
SST
TATB
TMAC
TNT
UL
UNO
UXO

American Conference of Government Industrial Hygienists
American Society for Testing and Materials
American National Standards Institute
Bureau of Explosives
design basis accident
Department of Defense Explosives Safety Board
Department of Defense
Department of Energy
Department of Transportation
differential scanning calorimetry
differential thermal analysis
exploding bridgewire
Explosives Development Committee
Electroexplosive device
Explosives Ordnance Disposal
Failure Modes, Effects, and Criticality Analysis
Hazard and Operability Study
high explosive
cyclotetramethylene tetranitramine
insensitive high explosive
lower explosive limit
lower flammable limit
maximum credible event
Material Safety Data Sheet
National Electric Code
net explosive weight
net explosive quantity
National Fire Protection Association
Occupational Safety and Health Administration
plastic bonded explosive
permissible explosive limit
pentaerythritol tetranitrate
cyclotrimethylene trinitramine
standard operating procedure
Safety Performance Measurement System
Safe Secure Railcar
Safe Secure Trailer
triamino trinitrobenzene
Toxic Materials Advisory Committee
trinitrotoluene
Underwriters Laboratory
United Nations Organization
Unexploded Ordnance
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CHAPTER I - INTRODUCTION
1.0 SCOPE, PURPOSE, AND JUSTIFICATION
This Manual prescribes the Department of Energy (DOE) safety standards and procedures used to
implement the DOE safety policy contained in DOE O 440.1, WORKER PROTECTION
MANAGEMENT FOR DOE FEDERAL AND CONTRACTOR EMPLOYEES, of 9-30-95, for
operations involving explosives, pyrotechnics, and propellants, or assemblies containing these materials.
With the exception of on-site explosives storage and transportation, this Manual does not apply to
commercial activities such as routine construction or routine tunnel blasting.
Explosives handling and processing operations by the DOE are an integral part of DOE weapons and
weapons-related development, manufacturing, and dismantlement activities. Safety in all operations
associated with weapons development is an ongoing, prime concern and must continually be given high
priority in all program direction and management. This Manual provides uniform guidance for all DOE
facilities and installations involved in explosives handling or processing. DOE will update the Manual
periodically to incorporate lessons learned, new technology, and suggestions for improvements. The
Assistant Secretary for Environment, Safety and Health (EH-1) is responsible for this task. b
Maintaining explosives safety in all operations within DOE is an ongoing process that, to be truly
effective, must be given high priority in all program direction, management, and line activities. Due to
the unique nature of DOE’s highly active role in research and development in new explosives
formulations, explosives synthesis, charge geometry, and explosives assemblies, as well as the proximity
of explosives to weapon components, it is necessary to maintain the level of explosives safety standards
commensurate with the risks.c
This Manual closes the considerable safety gap created by DOE’s unique activities by establishing safety
controls not found in existing DOE or non-DOE regulations to govern the DOE explosives safety
process and ensure that explosives safety is commensurate with the actual risk. However, Department
of Defense (DoD), Occupational Safety and Health Administration (OSHA), and other nationally
recognized standards, such as the National Fire Protection Association (NFPA) codes, provide the basic
framework. Specific requirements from these documents are applicable and pertinent as determined by
the "Authority Having Jurisdiction". Since the conception of the first DOE Explosives Safety Manual in
1978, and the formation of the expert DOE Explosives Safety Committee, no explosives-related
fatalities have occurred in DOE and explosives safety practices have significantly improved. Continued
maintenance of this Manual, combined with field adherence, will maintain the high level of explosives
safety evidenced within DOE over the past two decades.d
2.0 APPLICABILITY
This Manual applies to all DOE facilities engaged in developing, manufacturing, handling, storing,
transporting, processing, or testing explosives, pyrotechnics and propellants, or assemblies containing
these materials, and to the safe management of such operations. With the exception of explosives
storage and transportation, this Manual does not apply to commercial activities such as routine
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The design of all new explosives facilities shall conform to the requirements established in this Manual
and implemented DOE O 420.1, FACILITY SAFETY, of 9-30-95. It is not intended that existing
physical facilities be changed arbitrarily to comply with these provisions, except as required by law.
Existing facilities that do not comply with these standards may continue to be used for the balance of
their functional lives, as long as the current operation presents no significantly greater risk than that
assumed when the facility was originally designed, and it can be demonstrated clearly that a
modification to bring the facility into compliance is not feasible. However, in the case of a major
renovation, the facility must be brought into compliance with current standards.f
The requirements are presented as either mandatory or advisory. Mandatory requirements, denoted by
the words "shall," "must," or "will," must be followed unless an exemption is granted by facility
management. Advisory requirements denoted by "should" or "may," may be deviated from with a
written waiver granted by facility management.
3.0 EXEMPTIONS
An exemption is a written release from a mandatory requirement of this Manual that has been granted,
as applicable, by the DOE Assistant Secretary for Environment, Safety and Health (EH-1) or by the
Operations Office Manager. g
The DOE Operations Office Manager is permitted to grant exemptions from the mandatory requirements
of this Manual provided compliance is not feasible, and the facility operator has demonstrated that the
conditions, practices, means, methods, or processes to be used will not decrease the level of safety.
Requests for exemptions shall be submitted to the DOE Operations Office Manager for action. Each
such request shall contain the following information:
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•
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•
•
•

description of condition;
safety requirement necessitating deviation;
reason why compliance cannot be achieved;
steps taken to provide protection;
statement of whether equivalent safety is provided and, if not, assessment of the residual risk;
any proposed corrective action and schedule; and
duration of the exemption.

The DOE Director, Office of Worker Safety and Health (EH-5), shall be notified and sent copies of all
exemptions granted.h
The DOE Operations Office Manager shall submit to the DOE Office of Defense Programs all requests
for exemptions from a mandatory requirement for which equivalent protection of operating personnel,
the public, and property cannot be achieved. After review of the request for exemption, the DOE
Director, Office of Defense Programs, shall recommend to EH-1 whether to grant approval of the
exemption. EH-1 is responsible for final determination to grant or disapprove the exemption, and for
notification to the DOE Operations Office Manager. The DOE Operations Office Manager may grant a
temporary exemption for the period of time an exemption request is being processed at DOE
Headquarters.
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4.0 WAIVERS
If an activity, operation, or process is determined not to be in compliance with the Manual’s advisory
requirements, but the activity, operation, or process is determined to be safe and necessary, facility
management may grant written approval for an alternate solution. Waivers will be granted for the
minimum time necessary; those of an ongoing nature shall be updated every three years. Facility
management shall maintain a central file of active waivers and provide a copy of each waiver to the
local DOE contracting officer. Each waiver shall contain, as a minimum, the following information:i
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•

description of the condition;
safety standard requiring alternate solution;
reason why compliance is not achieved;
steps taken to provide alternate protection;
any proposed corrective actions and schedule; and
waiver duration or expiration date.

5.0 MANUAL ADMINISTRATION AND MANAGEMENT
This Manual shall be kept current. The Office of Environment, Safety and Health shall ensure that a
current version of this Manual is maintained by the DOE Directives On-Line Explorer system on the
Internet (the Explorer web-page address is http://www.explorer.doe.gov).j
The DOE Explosives Safety Committee, through the Office of Worker Safety and Health (EH-5), shall
administer and manage this Manual.k

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DOE Explosives Safety Committee Organization

The DOE Explosives Safety Committee is composed of a member from each of the following: l
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DOE Office of Worker Safety and Health (EH-5);m
DOE Office of Military Application and Stockpile Support (DP-24);
DOE Operations Office, Albuquerque;
DOE Operations Office, Oakland;
DOE Operations Office, Nevada;
DOE Kirtland Area Office;
DOE Operations Office, Idaho;
Los Alamos National Laboratory;
Lawrence Livermore National Laboratory;
Pantex Plant, Mason & Hanger Corporation;
Kansas City Plant, Allied-Signal Inc.;
Idaho National Engineering Laboratory, LITCO;
Nevada Test Site, Bechtel Nevada Corporation; and
Sandia National Laboratories.

The committee shall be chaired by the DOE Office of Worker Safety and Health (EH-5) Representative
and will report directly to the DOE Director, Office of Worker Safety and Health.n
5.2

DOE Explosives Safety Committee Functions

The DOE Explosives Safety Committee shall perform the following functions:
•
•
•

Review, evaluate, and act under authority delegated from the DOE Director, Office of
Worker Safety and Health, on proposed changes or revisions to this Manual.o
Evaluate and respond to requests for interpretations of the Manual.
Meet periodically, as appropriate, to review and evaluate Manual adequacy and existing
exemptions, and to initiate Manual changes as needed.

The DOE Explosive Safety Committee (at the local level its individual voting members) is (are) the
"Authority Having Jurisdiction" for DOE explosives safety matters. p
6.0 DEFINITIONS
For purposes of this Manual, the following terms are defined.
APPROVED. Complying with the provision(s) of this Manual and with instructions and details issued
by the authority having jurisdiction or with those of other approving agencies specified herein.
ARM. A general term that implies the energizing of electronic and electrical circuitry, which in turn
controls power sources or other components used to initiate explosives. The arming operation
completes all steps preparatory to electrical initiation of explosives except the actual fire signal.
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BARRICADE. An intervening approved 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
personnel.
BAY. A location (room, cubicle, cell, work area, etc.) containing a single type of explosives activity,
which affords the required protection specified for appropriate hazard classification of the activity
involved.
BLENDING. The mixing of solid materials (usually dry) by gravity flow, usually induced by vessel
rotation.
BONDED. The joining of metallic parts to form an electrically conductive path that will ensure
electrical continuity and the capacity to conduct safely any current likely to be imposed.q
BOOSTER. Explosives used in an explosive train to amplify the shock output of the initiating device
and cause detonation of the main explosive charge.r
CASUAL. A person other than an operator who intermittently visits an explosives operation for the
purpose of supervision, inspection, maintenance, etc.
COMBUSTIBLE MATERIAL. Any material that, when ignited, will sustain burning.
COMPATIBILITY. The chemical property of materials to coexist without adverse reaction for an
acceptable period of time. Compatibility in storage exists when storing materials together does not
increase the probability of an accident or, for a given quantity, the magnitude of the effects of such an
accident. Storage compatibility groups are assigned to provide for segregated storage.
CONCURRENT OPERATIONS. Operations performed simultaneously and in close enough proximity
that an incident with one operation could adversely influence the other.
CONTACT OPERATIONS. An operation in which an operator and an explosive item are both present
with no operational shield.
CONTROL POINT. The location used for personnel control and operation coordination in an
explosives operating or test area.
CORING. A machining operation that removes material in the form of a cylinder by cutting at the
circumference to create a hole or recover the material from the center of the cut.
CRITICAL TEMPERATURE. Temperature above which the self-heating of an explosive causes a
runaway reaction. It is dependent on mass, geometry, and thermal boundary conditions.
DANGER ZONE. That area around a test site where personnel could be in physical jeopardy due to
overpressure, fragments, or firebrands released during an explosive test.

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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.
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. When the material is located on or near the surface of the ground, a
detonation is normally characterized by a crater.
DIFFERENTIAL SCANNING CALORIMETRY (DSC). A technique in which the difference in
energy inputs into a substance and a reference material is measured as a function of temperature or time
while the substance and the reference material are subjected to a controlled temperature program, or are
held isothermally. The record is the DSC curve. The energy input is substituted for DT and is plotted in
the same manner as a normal DTA curve.
DIFFERENTIAL THERMAL ANALYSIS (DTA). A technique in which the temperature difference
between a substance and a reference material is measured as a function of temperature while the
substance and the reference material are subjected to a controlled temperature program. The record is
the differential thermal analysis or DTA curve.s
DRYING. The removal of volatiles from ingredients or mixtures.
DSC. See DIFFERENTIAL SCANNING CALORIMETRY.
DTA. See DIFFERENTIAL THERMAL ANALYSIS.
EBW. See EXPLODING BRIDGEWIRE.
EED. See ELECTROEXPLOSIVE DEVICE.
ELECTRICAL BONDING. Electrical connection between two conductive objects intended to prevent
development of an electrical potential between them.
ELECTROEXPLOSIVE DEVICE (EED). An EED is a device containing some reaction mixture
(explosive or pyrotechnic) that is electrically initiated. The output of the initiation is heat, shock, or
mechanical action. See also LOW-ENERGY EED.
EXPERIMENTAL OPERATING PROCEDURE. A procedure prepared for conducting a specific
experiment a limited number of times under close technical supervision.
EXPLODING BRIDGEWIRE (EBW). An EED that is initiated by the discharge of a high current
through the device bridgewire, causing the wire to explode and produce a shockwave. An EBW as
defined herein is a device containing no primary explosive.
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EXPLOSIVE. Any chemical compound or mechanical mixture which is designed to function as an
explosive, or chemical compound which functions through self-reaction as an explosive, and which,
when subjected to heat, impact, friction, shock, or other suitable initiation stimulus, 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. DOE
explosives may be dyed various colors except pink which is reserved for mock explosive.t
EXPLOSIVE DECONTAMINATION. The removal of hazardous explosive material.
EXTRUDING. Forcing a plastic-type material, under pressure, into a confined space or through a
confined opening to produce a desired configuration.
FACILITY. A group of buildings or equipment used for explosive operations at one geographic
location, generally owned by DOE.
FACILITY MANAGEMENT. Management staff of the facility operator (the contractor).
FACILITY OPERATOR. The organization having responsibility for conducting operations at a DOE
facility.
FIREBRAND. A projected burning or hot fragment whose thermal energy is transferred to a receptor.
FIRING PAD. The prepared site where explosive items are fired for test data acquisition.
FIRING SITE. Controlled access area where test firing of explosives is conducted.
FLAMMABLE LIQUID. Any liquid having a flash point below 60°C and a vapor pressure not
exceeding 280 kPa (41 psia) at 37.8°C. This is the definition as applied in this manual; it includes some
materials defined as combustible liquids by the Department of Transportation (DOT).
FLASH POINT. The temperature at which a liquid or volatile solid gives off a vapor sufficient to form
an ignitable mixture with air near the surface of the material or within the test vessel.
FORMULATION. (1) The operation of combining ingredients to produce a mixture of a final desired
composition possessing specific physical and explosive properties.(2) An explosives composition.u
GROUNDED. Connected to earth or to some conducting body that serves in place of the earth.v
HEATING LIMITS. The conditions established for safely heating an explosive system (maximum
temperature, heating time, heating rate, etc.). These limits are based on the estimated critical
temperature of the explosive system with a suitable margin of safety.
HIGH-ENERGY INITIATOR. Exploding bridge wire systems, slapper detonators, and EEDs with
similar energy requirements for initiation.
HIGH PRESSURE. Gas pressure greater than 3,000 psig (21 MPa gauge); liquid pressure greater than
5,000 psig (35 MPa gauge).

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HOLE. (as applied to machine explosives). Any cavity that is more than one-half diameter deep, being
cut by any tool with the direction of feed along the axis of rotation.
HOT WORK (thermal). Any operation requiring the use of a flame-producing device, an electrically
heated tool producing a temperature higher than 109°C, or a mechanical tool that can produce sparks or
heat explosives or explosives contamination to provide an initiation stimulus.
HYDROSTATIC PRESSING. The operation of compacting a material that is confined in a press by a
diaphragm by hydraulically applying pressure to the diaphragm.
IHE. See INSENSITIVE HIGH EXPLOSIVES.
IHE SUBASSEMBLIES. IHE hemispheres or spheres with booster charges, with or without
detonators, that pass the DOE qualification tests listed in Table IX-3.
IHE WEAPONS. Weapons listed in DOE-DNA TP 20-7, Nuclear Safety Criteria (for Warhead
Storage), as being exempt from storage and transportation limits are classified as IHE weapons when
stored or transported alone or in combination with each other. This classification is valid only if the
spacing between individual units is that provided by storage/shipping containers or, if not in containers,
by the spacing specified in TP 20-7.
INERT MATERIALS. Materials that shows no exothermic decomposition when tested by DSC or
DTA. Moreover, the inert material shall not show any incompatibility with energetic material with
which it may be combined when tested by recognized compatibility tests. Inert material shall neither
alter the onset of exotherm of the DSC or DTA trace of the energetic material nor increase the rate of
decomposition or gas evolution of the energetic material.
IN-PROCESS STORAGE MAGAZINE (facility, vault, rest house, etc.). See SERVICE MAGAZINE.
INHABITED BUILDING. A building or structure other than operating buildings, magazines, and
auxiliary buildings occupied in whole or in part as a habitation for people or where people are
accustomed to assemble, both within and outside DOE facilities. Land outside DOE facilities shall be
considered as sites for inhabited buildings.
INHABITED BUILDING DISTANCE. The minimum distance permitted between explosives
locations and inhabited buildings, administrative areas, site boundaries, main power stations, and other
facilities of vital or strategic nature.
INITIATION STIMULUS. Energy input to an explosive in a form potentially capable or initiating a
rapid decomposition reaction. Typical initiation stimuli are heat, friction, impact, electrical discharge,
and shock.
INITIATION, WITH ITS OWN MEANS. Explosives or ammunition having their normal initiating
device (e.g., detonators, squibs) assembled to them so that this device is considered to present a
significant risk of activation during storage.

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INITIATION, WITHOUT ITS OWN MEANS. Explosives or ammunition that (1) are not stored with
an initiating device assembled to them; or (2) have the initiating device assembled to them, but (a) safety
features preclude initiation of the explosives filler of the end item in the event of accidental functioning
of the initiating device, or (b) the initiating device does not contain any primary explosives and has a
high threshold of initiation (e.g., EBW or Slapper detonators). The power source for the initiator(s)
should not be present within the assembly or system. If the initiator(s) power source is present, two or
more management-certified safety devices connected in series shall be present to interrupt any flow of
energy from the power source to the initiator(s).
INSENSITIVE HIGH EXPLOSIVES (IHE). Explosive substances which, although mass detonating,
are so insensitive that there is negligible probability of accidental initiation or transition from burning to
detonation. The materials passing the DOE qualification tests in Table IX-1 are classified as IHE, and
are listed in Table IX-2.
INTERMEDIATE PRESSURE. Gas pressure from 150 to 3,000 psig (1 to 21 MPa gauge); liquid
pressure from 1,500 to 5,000 psig (10 to 35 MPa gauge).
INTRALINE DISTANCE. The minimum distance permitted between any two operating buildings or
sites within an operating line, at least one of which contains, or is designed to contain, explosives.w
INTRINSICALLY SAFE. An apparatus or system whose circuits are incapable of producing any spark
or thermal effect capable of causing ignition of a mixture of flammable or combustible material under
test conditions described in ANSI/UL 913.
ISOSTATIC PRESSING. The operation of compacting a material in a sealed flexible container. The
container is submerged in a pressure vessel, and the vessel is pressurized with liquid.
LABORATORY OPERATIONS. Experimental study, testing, and analysis of small quantities of
energetic materials. Manufacturing processes with small quantities of materials are not included.
LEL. See LOWER EXPLOSIVE LIMIT.
LFL. See LOWER FLAMMABLE LIMIT.
LOW-ENERGY EED. All EEDs except exploding bridgewire (EBW) detonators and slapper
detonators.
LOW PRESSURE. Gas less than 150 psig (1 MPa gauge); liquid less than 1,500 psig (10 MPa gauge).
LOWER EXPLOSIVE LIMIT (LEL). The concentration of vapor or dust in air below which an
explosion cannot occur.
LOWER FLAMMABLE LIMIT (LFL). The concentration of a vapor or dust in air below which a
burning reaction cannot be sustained.
MACHINING. A forming operation accomplished by removing material with a mechanically operated
cutting tool.

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MACHINING OVERTEST. A test to evaluate the susceptibility of an explosive material to initiation
during machining.
MAGAZINE. See SERVICE MAGAZINE or STORAGE MAGAZINE.
MAGAZINE DISTANCE. The minimum distance permitted between any two storage magazines. The
distance required is determined by the type(s) of magazine and also the type and quantity of explosives
stored therein.
MAXIMUM CREDIBLE EVENT (MCE). The MCE from a hypothesized accidental explosion or fire
is the worst single event that is likely to occur from a given quantity and disposition of
explosives/explosives devices. The event must be realistic with a reasonable probability of occurrence
considering the explosive propagation, burning rate characteristics, and physical protection give to the
items involved.
MELTING. Operations involving change in the physical state of explosives from solid to liquid.
MILLING. (1) Operations that either reduce solid material particle sized by attrition or apply high shear
mixing to incorporate solid materials into plastic binders; (2) a surface machining operation performed
on a mill.
MIXING. A mechanical operation that combines dissimilar materials.
MOCK EXPLOSIVE. Substances bearing similar physical properties (texture, density, cohesion, etc.)
to an explosive material. They are nondetonable; however some are exothermic materials and will burn.
Mock explosives are used to represent explosives for purposes such as dry run testing of equipment.
DOE mock explosives are normally pink in color.
NEW. Net explosive weight expressed in pounds.
NEW (OR EXPERIMENTAL) EXPLOSIVES. Explosive, explosive mixture, or explosive and binder
mixture that has not been characterized by the Explosives Development Committee.x
NON-DOE FACILITY PERSONNEL. Personnel of a contractor who does not have a continuing
contract with DOE at the facility concerned.y
OPERATIONAL SHIELD. A barricade constructed to protect personnel, material, or equipment from
the effects of a possible fire or explosion occurring at a particular operation.
PERSONNEL BARRIER. A device designed to limit or prevent personnel access to a building or an
area during hazardous operations.
PRESSING. The operation of increasing the density of explosive material by the application of
pressure.
PROPELLANT. Explosive composition used for propelling projectiles and rockets and to generate
gases for powering auxiliary devices.

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PUBLIC TRAFFIC ROUTE DISTANCE. The minimum distance permitted from a explosives facility
to any public street, road, highway, or passenger railroad (including roads on DOE-controlled land open
to public travel or navigable waterway).z
PUNCH AND DIE PRESSING. The operation of compacting a material confined by a die by forcing a
punch or punches into the die and against the material.
PYROTECHNIC MATERIAL. Physical mixtures of finely divided fuels and oxidizer powders; may
include various organic binders and color intensifiers. The material is intended to produce an effect by
heat, light, sound, gas or smoke, or a combination of these as the result of non-detonative, selfsustaining exothermic chemical reactions.
REMOTE OPERATION. An operation performed in a manner that will protect personnel in the event
of an accidental explosion. This can be accomplished by distance, shielding, barricades, or a
combination thereof.
RISK. A measure of the combination of the probability and consequences of the hazards of an
operation, expressed in qualitative or quantitative terms.
SAFETY ANALYSIS. A document prepared to systematically identify the hazards of a DOE operation;
describe and analyze the adequacy of measures taken to eliminate, control, or mitigate identified
hazards; and analyze and evaluate potential accidents and their associated risks.
SCREENING. An operation using screens to separate particles of differing sizes.
SERVICE MAGAZINE, REST HOUSE, ETC. An auxiliary building or suitable designated room
(vault) used for the intermediate storage of explosives materials not exceeding the minimum amount
necessary for safe and efficient operation.aa
SHUNT. An electrical interconnection of various portions of EED circuitry to prevent the development
of an electrical charge differential between the parts.
SLAPPER DETONATOR. An EED initiated by a rapid discharge of a high current through a metal
foil. The expansion of the metal vapor causes a plastic or metal covering to be propelled across an air
gap and detonate a high-density explosive pellet.
SMALL ARMS AMMUNITION. (1) Ammunition designed to be fired from a pistol, revolver, rifle, or
shotgun held by the hand or to the shoulder; (2) ammunition of caliber less than 20 mm with incendiary,
solid, inert, or empty projectiles (with or without tracers) designed to be fired from machine guns or
cannons; (3) blank cartridges.
SOP. See STANDARD (STANDING) OPERATING PROCEDURE.
SPECIAL OPERATING PROCEDURE. A procedure prepared for performance of a specific task on a
one-time basis, or for situations not encountered in normal operation.
STANDARD (STANDING) OPERATING PROCEDURE (SOP). A procedure prepared for operation
of a facility or performance of a task on a routine basis.
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STORAGE MAGAZINE. A structure designed or specifically designated for the long-term storage of
explosives or ammunition.
SUBSTANTIAL DIVIDING WALL. An interior wall designed to prevent the propagation of an
accidental detonation on one side of a wall to explosives on the other side.
SYNTHESIS. The chemical operation(s) required to produce a desired chemical compound.
TARGET. The area, structure, or material into which a projectile is fired.
TNT EQUIVALENT. A measure of the blast effects from explosion of a given quantity of material
expressed in terms of the weight of TNT that would produce the same blast effects when detonated.
TRANSIENT. Any person within inhabited building distance but not inside an explosives bay or other
occupied areas (offices, break areas, shops, etc.).
UNEXPLODED ORDNANCE (UXO). Explosive ordnance which has been primed, fuzed, armed, or
otherwise prepared for action, and which has been fired, dropped, launched, projected, or placed in such
a manner as to constitute a hazard to operations, installations, personnel, or material and remains
unexploded either by malfunction or design or for any other cause.bb
UNITED NATIONS ORGANIZATION (UNO) CLASS 1 EXPLOSIVES. (a) Explosive substances (a
substance that is not itself an explosive but that can form an explosive atmosphere of gas, vapor, or dust
is not included in Class 1), except those that are too dangerous to transport or those where the
predominant hazard is appropriate to another class; (b) Explosive articles, except devices containing
explosive substances in such quantity or of such a character that their inadvertent or accidental ignition
or initiation during transport shall not cause any effect external to the device either by projection, fire,
smoke, heat, or loud noise; and (c) Substances and articles not mentioned under (a) and (b) that are
manufactured with a view of producing a practical, explosive or pyrotechnic effect.

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1.0 GENERAL OPERATIONS SAFETY GUIDELINES
1.1

Protection of Explosives

Explosives are energetic materials that can react violently. Explosives should be protected from
abnormal stimuli or environments, including
•
•
•
•
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•
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1.2

friction forces;
excessive pressures and temperatures;
impact, shock, and pinching;
deformation;
electrical sparks, abrasive or welding sparks, and open flame;
contamination; and
contact with incompatible materials.

Equipment Checks

Before being used in the explosives process, and at established intervals, processing and test equipment
shall be checked for
•
•
•
•
•
•

proper design;
proper function;
specified clearances between parts in relative motion;
abnormal metal-to-metal rubbing of moving parts potentially contacting explosive materials;
cracks, voids, or screw threads where explosives may accumulate; and
contamination that is incompatible with the materials to be introduced.

This checkout may require the use of mock explosives in process or test conditions.
Explosive materials must not be pinched or confined between equipment lids or covers and their mating
surfaces. These surfaces shall be cleaned before cover placement. This includes pressing operations.
1.3

Inspection Frequency

When this Manual calls for an inspection, but the inspection interval is not specified, such inspection
interval shall be established by local facility management. Inspection intervals shall be modified when
experience dictates a need.
1.4

Laboratory Operations

The special safety guidelines applicable to general laboratory operations involving explosive materials
are contained in Section 21 of this chapter.
1.5

Toxicity Hazards
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Explosives materials, explosives components (additives or adhesives), and materials such as organic
solvents used in explosives processing can be toxic when inhaled, ingested or absorbed through the skin.
Skin contact with explosives materials, or with solvents and adhesives used in conjunction with
explosives operations, can result in a skin rash. This is the most frequently reported effect from working
with these materials. The following general precautions should be used to prevent overexposure to these
materials during explosives processing and handling:
a. Know the health hazard and controls before beginning operations.
b. Evaluate the operation during startup to assure that occupational exposure limits are not exceeded;
routine operations should be monitored periodically.
c. Handle in a well ventilated area; local exhaust ventilation is preferred.
d. Avoid skin contact; use appropriate protective clothing.
e. Practice good personal cleanliness; wash before eating, smoking, or using toilet facilities; end-ofshift showers may be required for some operators.
1.6

Hazard Identification and Communication

Before beginning explosives operations, managers shall ensure the following:
a. Identify and maintain a current list of explosives and other hazardous materials used in conjunction
with their operations.
b. Determine the hazardous properties and toxicity of these materials through the use of the
manufacturer’s Material Safety Data Sheets (MSDS) or other information sources and through
consultation with the facility Industrial Hygiene staff. For explosives without published
toxicological data, guidance can be obtained through the DOE Toxic Materials Advisory Committee
(TMAC). Health hazard information must be communicated to employees who work with or
generate hazardous materials.
c. Educate and train employees in the hazards and precautions required for handling explosives and
materials used in conjunction with explosives operation. This training should be a part of the
employee training and qualification program specified in Chapter V.

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Process Hazard Analysis

a. Before beginning any explosives synthesis, formulation, manufacturing, testing, or disposal
operation, a process hazard analysis shall be performed, as required by 29 CFR 1910.119. A single
process hazard analysis may be performed for similar processes performed in a single facility,
provided that the "worst-case" process is the basis for the hazard analysis. Selection criteria for the
worst-case process are:
•
•
•
•

sensitivity of materials;
quantity of materials;
number of personnel potentially affected; and
impact on other operations/activities.

b. The process hazard analysis shall be performed as a team effort. The team shall consist of a
minimum of three personnel and should not include more than seven personnel. The team shall
include at least one engineer and one operator, and should have the following makeup.
•
•
•

Team Leader, who is familiar with the analysis methodology used;
Technical Member(s), who is/are familiar with the process being analyzed; and
Scribe, who writes notes of meetings and interviews and drafts reports.

c. The analysis methodology used may be selected by either the facility manager or the team leader,
but should be one of the following:
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•

Preliminary Hazard Analysis;
Checklist (usually for similar batch operations);
What-if Analysis;
Hazard and Operability Study (HAZOP);
Failure Modes, Effects, and Criticality Analysis (FMECA);
Fault Tree Analysis; and
Event Tree Analysis.

d. The process hazard analysis shall be formally documented.
e. Employees and employee representatives shall be consulted on the process hazard analysis. The
result of the process hazard analysis shall be provided to employees involved in or affected by the
operation.
f. The process hazard analysis shall be updated and revalidated at least every 5 years by a team
meeting the above criteria.
g. The facility manager shall be responsible for establishing a system to address promptly the team’s
findings and recommendations. Corrective actions, schedules for corrective actions, and completion
of corrective actions shall be formally documented, and such documentation filed with the process
hazard analysis.

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h. Files containing process hazard analyses, updates, and corrective action statuses shall be maintained
for the life of the process.
2.0 WORK ENVIRONMENT
2.1

General Requirements

a. Adequate work space shall be provided to perform operations safely and efficiently.
b. Work shall be organized to eliminate clutter in the area while operations are being performed.
c. Walkways should be kept clear.
d. In work environments where solid, bare explosive pieces are handled, the floor should be cushioned,
and all hard objects that may be struck by explosives in a handling incident should be cushioned
where it is practical. Physical safety systems demonstrated to preclude the explosives from being
dropped or struck can meet these requirements.cc
e. An accounting procedure should be established for hand tools that may be inadvertently dropped into
an explosives processing operation, thus creating a hazard.
f. Personnel shall be assigned in such a manner that each worker’s presence is frequently monitored
and assistance can be provided or aid summoned in the event of an emergency.
g. Safety analysis of explosives facilities shall be performed. The safety analysis shall be performed
during the design of new explosives facilities or the redesign of existing facilities. Facility
management shall maintain readily available analyses documentation.
h. Noisy environments caused by explosives testing operations or process and handling equipment shall
be evaluated. Areas with noise above the allowable occupational exposure limits must be posted and
appropriate control measures instituted (e.g., engineering controls, protective equipment, and a
hearing conservation program).
2.2

Emergency Exit Requirements for Explosives Operations

Exit requirements for any building or structure containing explosives shall comply with the intent of the
Life Safety Code, NFPA 101, except as otherwise permitted in this section.
2.2.1

Building or Structure Occupancy

In determining occupancies:
a. explosives operating buildings shall be classified as industrial occupancies (NFPA 101, Chapter 28);
b. explosives storage or staging buildings or structures shall be classified as storage occupancies
(NFPA 101, Chapter 29).

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Hazard of Contents Classification

The hazard of contents classification of any explosives occupancy shall be determined using the
guidelines given in NFPA 101 and the following requirements:
a. High-hazard explosives contents are those which, because of form, character, or volume, are likely
to burn with extreme rapidity or from which poisonous fumes or explosions can be expected in the
event of a fire. The expectation of poisonous fumes or explosions is a relative matter to be
determined on a case-by-case basis. Operating buildings containing propellant, pyrotechnic, or
explosive powders shall be classified as high-hazard occupancies unless a reduced hazard
classification can be justified.
b. Reduced-hazard explosives contents are those that burn with moderate or less rapidity and will not
produce poisonous vapors. This criterion shall be documented by a hazard analysis.
2.2.3

Personnel Protective Restrictions and Requirements

DOE occupancies containing high explosives dictate personnel protection from blast overpressures and
fragments (and spread of plutonium in some occupancies) from an accidental detonation. This
accidental detonation of explosives is usually the result of stimuli other than a fire.
Non-compliance with some NFPA 101 provisions (such as those covering exit doors, exit travel
distance, number and location of exits, and common path of travel to exits), is authorized where required
to provide protection from blast overpressure and fragments. When NFPA 101 requirements are not met
the following additional personnel protective restrictions or requirements should be imposed:
a. The building and means of egress should be protected by supervised automatic sprinkler systems
connected to sound evacuation alarms. This requirement is not applicable to explosives storage
magazines, firing chambers, or rooms used as firing chambers, within explosives operating
buildings.
b. Explosives operating buildings and their means of egress should have automatic, early warning fire
detection systems connected to sound evacuation alarms where such early warning might reasonably
aid in prevention or mitigation of personnel injury. This requirement is not applicable to explosives
storage magazines, firing chambers, or rooms used as firing chambers within explosives operating
buildings.
c. Personnel limits within the explosives work area (bay, cell, etc.) shall be established and controlled.
These should not exceed 20 for reduced-hazard occupancies or 6 for high-hazard occupancies. The
need for personnel in numbers greater than these limits shall by documented in a hazards analysis
based on the criteria of paragraph 2.2.5 of this chapter.

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Requirements for Existing Facilities

Existing facilities may deviate from current NFPA 101 requirements in the following situations.
a. Current code requirements were not in effect when the building was constructed. The building,
however, is still required to meet the code of record.
b. Deviations were made to meet the level-of-protection and design criteria in Chapter VI, Section 6, of
this Manual.
c. Building construction predates both current and level-of-protection criteria, but a hazards analysis
has shown the risk of operations to be at an acceptable risk.
d. The risk from deviation has been analyzed and accepted by current hazards analysis.
Those facilities requiring hazards analysis to determine whether a deviation from the Life Safety Code is
acceptable shall follow the considerations and criteria described in paragraph 2.2.5 of this chapter.
2.2.5

Requirements for New Facilities

New facilities shall comply with the requirements of NFPA 101, except when deviation is necessary to
provide personnel protection from blast overpressure and fragments per Chapter VI of this Manual.
2.2.5.1
If deviations from NFPA 101 requirements are made, the Fire Hazards Analysis required by
Chapter VI of this Manual shall document the following aspects related to each explosives operation,
bay, and/or workroom where a deviation exists.
a. Clear pathway to exit in explosives bay or workroom.
b. Potential for sustained fire in work environments from the presence of combustible and flammable
materials and the presence of ignition sources.
c. Total time required to exit the bay or workroom.
2.2.5.2
The criteria considered acceptable for the components of the analysis in paragraph 2.2.5.1 of
this chapter are, respectively:
a. No obstruction shall limit the width of the pathway to less than 36 in.
b. Combustible and flammable material quantities shall be minimized, justified, documented, and
reviewed by site fire protection personnel and approved by line management. Ignition sources shall
be identified and eliminated where possible.
c. The total time for 6 people to exit the workroom or bay is 30 seconds or less, including the opening
of doors where necessary. The total time for 20 people to exit the workroom or bay is 90 seconds or
less. Noncompliance with this criterion shall be evaluated and justified during the conceptual design
review
.
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Single Exits

Where at least two exits are required by NFPA 101 and provisions for personnel protection from a blast
will not permit at least two exits from a room or structure, a single exit is acceptable, provided the
requirements of paragraphs 2.2.3 and 2.2.4 of this chapter and the following are met:
a. The path of exit travel shall be arranged so it is not through or toward a hazardous operation.
b. The room containing a high-hazard explosive occupancy shall not exceed 500 square feet, and the
occupant load of the room shall be restricted to two operators and two transients.
c. The room containing a reduced-hazard explosives occupancy shall not exceed 1,000 square feet.dd
Explosives storage magazines may have only single exits for the purpose of maintaining integrity of
design. The conditions of this section do not apply to these magazines.
2.2.7

Blast-Resistant Doors

Blast-resistant doors required for the purpose of personnel protection from the effects of an accidental
detonation may be located in the means of egress, provided the requirements of paragraphs 2.2.3 through
2.2.5 of this chapter and the following are met:
a. Where power-operated doors are required to accomplish unlatching and opening, they shall have
redundant features or be capable of being opened manually (to permit exit travel) or closed where
necessary to safeguard exits.ee
b. The time required to fully open or close a door shall be as short as reasonably possible.
c. A revolving door is acceptable if a secondary means of escape (with swinging doors) is provided at
the same location. The revolving door must also be prevented from rotating at too rapid a rate to
permit orderly exit of personnel.

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d. The following exceptions to NFPA 101 may be allowed when justified and documented. ff
•
•
•
•
•

•
2.2.8

Swinging doors may exceed 48 in. wide.
It is acceptable to omit the NFPA-required swinging doors adjacent to a revolving blast door.
Revolving blast doors need to collapse into book-fold position.
Where fire-rated doors are required, blast doors are considered to have the required fire
rating.
An airlock provided with two or more doors with the intended purpose of preventing
continuous and unobstructed passage by allowing the release of only one door at a time, shall
be permitted in a means of egress where there are provisions for continuous and unobstructed
travel during an emergency egress condition.
Panic hardware is not required on blast doors.

Slide Escapes

Slide escapes should be provided for elevated explosives operating locations from which rapid exit may
be vital and cannot be obtained by other means. Slide escapes should be located on opposite sides of the
explosives operation to reduce the likelihood of personnel being trapped by fire between them and a
single slide. Exits to slide escapes must open onto platforms that are not less than 3 feet square, and the
platforms must be equipped with guardrails. The slides shall begin at the outside edge of the platform,
not at the edge of the buildings. Slide escape landings shall be located at selected places leading directly
to escape routes that are free from tripping hazards, low guy lines, drains, ditches, or other obstructions.
Manually or automatically controlled devices (trips) that sound an alarm in the operating building shall
be installed at or near the entrances to slide escapes. These devices may also actuate deluge valves and
water curtains in the building or room affected.
Recommended slide escape specifications:
•
•
•
•

angle, 40 to 50 degrees horizontal;
slide depth, 24 in.;
radius at bottom of slide, 12 in.; and
height at lower end of slide, not over 24 in. above the landing.

If necessary, the end of the slide must have a horizontal run sufficient to prevent an employee injury
because of exit speed without the use of landing cushions, which are unsatisfactory in cold weather.
One foot of horizontal run is required for a 15-ft-long slide. One additional foot of horizontal run will
be provided for each additional 5 ft of slide length. The juncture of the two sections must be well
rounded. The metal sheets constructing the slide must overlap in the direction of travel.

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3.0 BUILDING AND EQUIPMENT MAINTENANCE
3.1

Cleaning

a. Structures containing explosives shall be kept clean and orderly.
b. Explosives and explosives dust shall not be allowed to accumulate on structural members, radiators,
heating coils, utility lines, equipment, or electrical fixtures.
c. To maintain safe conditions, there shall be a regular cleaning program for building interiors to
prevent explosives dust and waste accumulation. This program should not be conducted in any bay
where a hazardous operation is being conducted.
d. In buildings containing explosives, hot water or water-steam mix should be used wherever practical
for cleaning floors. Sweeping compounds that are non-abrasive and compatible with the explosives
involved may be used when the use of water-steam mix or hot water is not practical. Such
compounds may be combustible but must not be volatile (closed-cup flash point must not be lower
than 110 & 6ZHHSLQJFRPSRXQGVFRQWDLQLQJZD[VKDOOQRWEHXVHGRQFRQGXFWLYHIORRULQJ
Where nitrated organic explosives (which may form sensitive explosive compounds with some
alkalis) are involved, the use of cleaning agents containing those alkalis is prohibited.
e. Before beginning explosives decontamination activities that involve the use of large amounts of
organic solvents (generally over 1 L), provisions must be made for (a) adequate ventilation or
respiratory protection, (b) fire protection, and (c) adequate protective clothing.
3.2

Maintenance and Repair

a. Records shall be maintained for inspection, repair, and servicing of process and handling equipment
and fire protection systems.
b. Maintenance operations involving major repairs, changes, or the use of hazardous equipment should
not be performed within bays (rooms) while explosives are present. Before these operations,
explosives should be removed and the area prepared. An approval procedure shall be established to
ensure that the area has been inspected and is safe for these operations.
c. Maintenance or construction operations performed by non-DOE facility personnel shall be at least
intraline distance from any explosives operation and should be at least intraline distance from any
building containing explosives. This requirement does not apply to personnel (e.g. technical
representatives, architect-engineering surveyors, etc.) making job site inspections or equipment
repairs requiring less than eight hours. (Intraline distance separation may be satisfied by providing
equivalent protection.) Transportation of explosives is permitted on roadways at less than intraline
distance.gg

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d. For non-DOE facility personnel making job site inspections or equipment repairs requiring less than
8 hours, e.g., technical representatives, service representatives, architect-engineering surveyors, etc.,
facility management shall determine the minimum practicable distance from which such personnel
will be separated from explosives operations. Facility management shall control explosives
operations so that the chance of an explosion shall be kept to a minimum. Documentation showing
the rationale for establishing the minimum practicable distance and additional control measures
taken shall be maintained until operations have been completed and personnel have permanently
vacated the work site. All such personnel shall be informed of the risk of working at less than
intraline distance and agree to accept such risk.hh
e. New equipment or equipment subjected to major repair or modification shall be test-operated, and
handling equipment shall be tested before being returned to operations. The DOE HOISTING AND
RIGGING HANDBOOK (1090-95) may be used as a guide.
f. Maintenance work shall be performed by authorized personnel only.
g. Before resuming operations following maintenance, the area shall be cleaned and approved by the
operations supervisor.
3.3

Hot Work Permits

Where explosives are involved, a written permit shall be required for the temporary use of portable,
heat-producing equipment that generates temperatures higher than 109°C. Explosives decontamination
of the immediately affected work areas and explosives removal shall be required before hot work
operations. The permit should state the location, time, duration, purpose of use, details of safety, and
fire-fighting equipment required. The permit shall be kept at the named location for availability and
checkout by supervisory personnel.
a. Authorization of permits shall be by signature of personnel designated by the facility manager.
Designated personnel should be qualified by experience in explosives work, fire prevention, and
general safety precautions, particularly with regard to the purging of equipment, presence of
flammable mixtures, and the avoidance of electrical and mechanical hazards that could be incident to
repair work.
b. Designated personnel should represent supervision of the location where the work is being
performed, supervision of personnel performing the hot work, and a third group independent of the
first two (usually the safety and fire protection group).
c. Someone should remain at the site of a cutting or welding job for approximately 30 minutes after the
job has been completed to extinguish or report any fires that develop. Designated supervision should
inspect the job site before job initiation, during the job, and after job completion.

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4.0 REMOTE OPERATIONS
4.1

Personnel Protection Criteria

Explosives operations judged to present a high enough level of risk to be performed remotely shall be
conducted in facilities where the construction of the operating bay or the control room is capable of
affording sufficient protection to personnel to prevent serious injuries. Criteria for the prevention of
serious injuries are specified in Chapter VI, paragraph 4.2.1.d.
Prevention of serious injury from a remote operation applies to transient personnel as well as to
personnel involved in the operations.
4.2

Access and Equipment Controls

Control procedures and equipment shall be used to prevent personnel from entering the hazardous bay or
area in which a remote operation is occurring or to prevent the operation from proceeding when
personnel enter, as follows.
a. Roads shall be blocked at a minimum of the public-traffic route distance from buildings where
hazardous (remote) operations are being performed. Public traffic route separation may be satisfied
by providing equivalent protection.
b. Corridors leading to bays in which hazardous (remote) operations are being performed shall be
adequately marked to warn of the danger. Barriers shall also be set up.
c. Visual methods such as closed circuit television should be used to monitor remote operations and to
enable viewing the operating area conditions before entering. Remote audio monitoring and video
recording should also be considered.
d. Interlocking of remote operating equipment to access doors should be required for each remote
operation.
e. Buildings or bays in which remote operations are performed shall be conspicuously identified by
lights or similar warning devices to indicate when remote operations are under way.

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5.0 GENERAL EXPLOSIVES AREA CONTROLS
5.1

Smoking, Matches, Lighters, Metal Articles

a. There shall be no smoking in explosives storage, processing, or test areas, except in designated
locations.
b. No matches, lighters, other fire-, flame-, or spark-producing devices shall be taken into an explosives
control area except with written authorization. If authorized to be carried, matches shall be
contained in a metal carrying device too large to fit into pockets. Kitchen ("strike anywhere")
matches shall not be used.
c. In explosives processing areas, metal articles (keys, jewelry, knives, coins, etc.) should not be
carried by operating personnel where such items could constitute a hazard if dropped into the
process operation.
5.2

Cooking and Eating

a. There shall be no consumption of food or beverages in an explosives building, except in designated
areas.
b. There shall be no personal dishes or utensils in an explosives building, except in designated eating
areas.
c. Coffee pots, hot plates, ovens (including microwaves), and portable electric heaters shall not be
permitted in rooms where:
•
•
•
•
5.3

explosives may be present;
combustible vapors or dust may be present;
smoking or drinking is prohibited because there are toxic materials present; and
electrical classification of appliances is not compatible with the area.

Access to Explosives Areas

Access control procedures shall be established for entry to all explosives areas.

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6.0 ELECTRICAL STORMS AND LIGHTNING PROTECTION
6.1

Assessment

Whenever an electrical storm approaches, personnel shall exit any location wherein a hazard exists due
to explosives being initiated by lightning. The existence of such a hazard shall be determined based on
the assessment of the specific operation and facility or area lightning protection. Locations where
evacuation may be necessary are listed below:
•
•
•
6.2

All outdoor operations and operations in buildings that do not afford lightning protection, and
locations within inhabited-building distance of the hazard. (When an electrical storm is
imminent, explosives operations should not be initiated.)
Explosives-carrying vehicles and railroad cars and locations within magazine distance of the
hazard.
Locations (with or without lightning protection) where operations involving electrostaticsensitive bulk explosives or electroexplosive devices (EEDs) are being performed.

Evacuation

Evacuated personnel shall proceed to a suitable protective shelter. A suitable protective shelter is one
that will protect personnel from overpressures greater than 16 kPa (2.3 psi), structural collapse, and
missiles in the event of explosion of any adjacent facility containing explosives.
6.3

Shutdown of Operations

The following guidelines should be used for shutdown of an operation during an electrical storm:
a. Process equipment containing explosives should be stopped as soon as safety permits.
b. When buildings or bays containing explosives are evacuated during periods of electrical storms,
operations that cannot be shut down immediately should be manned by the minimum number of
personnel required for safe shutdown. When the operation has been brought to a safe condition so
that personnel can exit, remaining personnel should proceed.
c. Automatic emergency power equipment should be provided if electrical power is critical to an
explosives operation during a power shutdown or interruption.

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Lightning Protection

It is DOE policy to install lightning protection on all facilities used for storage, processing, and handling
of explosives materials where operations cannot be shut down during electrical storms and personnel
evacuated. Specific operations shall be assessed for the risk of initiation of process materials by
lightning. Assessment shall consider the need for protection factors outlined in NFPA 780, "Lightning
Protection Code," Appendix K ("Protection of Structures Housing Explosive Materials"). When risk is
high, as in operations with highly sensitive electrostatic materials or components, operations shall only
be conducted in lightning-protected facilities. Approved lightning protection systems must conform
with the requirements of NFPA 780, Appendix K. Examples of acceptable lightning protection systems
can be found in DOE 6055.9-STD, "DOD Ammunition and Explosives Safety Standards," Chapter 7.ii
a. Visual inspection of lightning protection systems should be conducted every seven months and shall
be conducted at least annually. A report shall be filed following each inspection. Any evidence of
corrosion, broken wires or connections, or any other problem which would negate the system’s
usefulness will be noted and repaired.
b. Electrical testing for lightning protection systems should be conducted every 14 months and shall be
conducted at least every 47 months to afford testing during all seasons and immediately following
any repairs or modifications. The testing shall be conducted only with instruments designed
specifically for earth-ground system testing. The instruments must be able to measure 10 ohms plus
or minus 10 percent for ground resistance testing, and 1 ohm plus or minus 10 percent for bonding
testing. Electrical resistance readings shall be recorded.
c. Inspection records shall contain the most recent electrical test report and any subsequent visual
inspection reports for each building.
See paragraph 8.3 of this chapter for additional requirements.

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7.0 STATIC ELECTRICITY
7.1

General

Positive steps must be taken to control or eliminate static electricity in areas where materials that are
ignitable by static spark discharge are processed or handled. This includes spark-sensitive explosives,
propellants, and pyrotechnics as well as solvent vapors, and flammable gases.
7.2

Bonding and Grounding of Equipment

Bonding straps can be used to bridge locations where electrical continuity may be broken by the
presence of oil on bearings, paint, or rust at any contact point. Permanent equipment in contact with
conductive floors or table tops is not considered to be adequately grounded by virtue of pressure contact
only. Static grounds shall not be made to gas, steam, or air lines, dry pipe sprinkler systems, or air
terminals of lightning protection systems. Static grounds can be made to water pipes, ground cones,
buried copper plates, or driven ground rods of lightning protection systems. If a structure is equipped
with a lightning protection system, all grounds shall be interconnected. Wires used as static ground
conductors should be at least No. 10 AWG or equivalent.jj
7.3

Testing Bonded Equipment Groundskk

Grounding systems shall be tested for electrical resistance and continuity when installation has been
completed and, in the case of active equipment, at intervals to be locally determined. The ground
system shall be visually inspected for continuity (before reactivation of the system) if the equipment has
been inactive for more than 1 month. All exposed explosives or hazardous materials shall be removed
before testing. When testing for resistance-to-ground, equipment should be considered as a unit except
in the case of an electrically isolated device or a belt-driven machine. In measuring the total resistanceto-ground for belt-driven machinery (to assure compliance with the paragraph below), resistance of the
belting is to be excluded. The maximum resistance-to-ground permitted for different types of equipment
is as follows:ll
Hazardous locations (operations where a static spark discharge may be dangerous). All conductive parts
of equipment shall be bonded; in the case of grounded equipment, bonding shall be such that resistance
to ground does not exceed 25 ohms, unless resistance is not to exceed 10 ohms because of the lightning
protection installation. For existing equipment, the rate of static generation should be considered before
changes in grounding systems are made. The resistance of conductive rubber hose should not exceed
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Conductive Floors, Shoes, Mats and Wristbands

a. Conductive floors and shoes should be used for grounding personnel in operations involving
explosives, propellants, pyrotechnics, etc., that are sensitive to initiation by the electrostatic spark
discharge from a person. These include lead azide, lead styphnate, mercury fulminate, CP, some
propellants, some pyrotechnics, etc. Many flammable liquids and air mixtures can be ignited by
static discharge from a person. When personnel come into the proximity of (possible contact with)
static-sensitive explosives or vapors, conductive floors shall be installed except where the hazards of
dust-air or flammable vapor-air mixtures are eliminated by adequate housekeeping, dust collection,
ventilation, or solvent recovery methods. Conductive floors may also be required where operations
are performed involving electroexplosive devices (EEDs) that contain a static-sensitive explosive.
b. Conductive floors are not required throughout an entire building or room if the hazard is localized.
In such cases, conductive mats or runners may be used where required. These mats or runners will
be subject to all the specifications and test requirements that apply to conductive floors. Conductive
wristbands may be substituted for conductive mats and footwear at fixed, grounded or bonded work
stations or outdoor locations.nn
7.5

Conductive Floor, Work Surface, and Wristband Specifications

Conductive floors must be made of non-sparking material such as conductive rubber or conductive
flooring composition and shall meet the following requirements:
a. The flooring and its grounding system must provide for electrical resistance not to exceed 1,000,000
ohms (measured as specified in paragraph 7.6 of this chapter).
b. The surface of the installed floor must be free from cracks and reasonably smooth. The material
must not slough off, wrinkle, or buckle under operating conditions. Conductive tiles are not
recommended for use in areas where contamination can be caused by explosive dust. The large
number of joints and the tendency of tiles to loosen provide areas where explosive dust can become
lodged that are not easy to clean with normal cleanup procedures.
(1)

Where conductive floors and shoes are required, resistance between the ground and the
wearer shall not exceed 1,000,000 ohms, (i.e., total resistance of conductive shoes on a
person, plus the resistance of floor to ground). (See Figure II-1 for testing method.)
Where conductive floors and shoes are required, table tops on which exposed explosives
or dusts are encountered should be covered with a properly grounded conductive material
that meets the same requirements as those for flooring.oo

c. Conductive floors must be compatible with the explosive materials to be processed.
d. Conductive wristbands shall not exceed a resistance between the wearer and ground or bonding point
of 1,200,000 ohms. This resistance shall be measured with a suitably calibrated ohmmeter.
Wristbands shall be of a design that maintains electrical contact with the wearer when used.pp

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Figure II-1. Testing shoes on wearer
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e. Table-top work surface mats that are not part of a total conductive system (paragraph 7.5.c) shall
have a resistance not to exceed 1,200,000 ohms. This resistance shall be measured by a method
similar to that outlined in paragraph 7.6 and records shall be maintained.
7.6

Conductive Floor Tests

a. Initial tests shall be made of all conductive floors, and subsequent tests shall be made at least
semiannually. Test results shall be permanently recorded and a copy filed in a central location.
Instruments used in making tests shall be used only when the room is free from exposed explosives
and flammable gas mixtures.
b. Maximum floor resistance shall be measured with a suitably calibrated ohmmeter that operates on a
normal open circuit output voltage of 500 volts DC and a short circuit current of 2.5 milliamperes
with an effective internal resistance of approximately 200,000 ohms. Minimum floor resistance will
be measured with an ohmmeter suitably calibrated for the task.
c. Each electrode shall weigh 2.3 kg and shall have a dry, flat, circular contact area 6.5 cm in diameter,
which shall comprise a surface of aluminum or tinfoil 1.3 to 2.5 mm thick, backed by a layer of
rubber 0.6 to 0.65 cm thick and measuring between 40 and 60 durometer hardness as determined
with a Shore Type A durometer (ASTM D-2240-68).
d. The floor shall be clean and dry. "Electrode jelly" such as brushless shaving soap or saline solution
shall not be used.
e. The resistance of the floor shall be more than 5,000 ohms in areas with 110 volt service and 10,000
ohms in areas with 220 volt service, and less than 1,000,000 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 ft apart at any points on the floor. Measurements shall be
made at five or more locations in each room. If the resistance changes appreciably with time during
a measurement, the value observed after the voltage has been applied for about five seconds shall be
considered as the measured value.
7.7

Humidification

Humidification for preventing static electricity accumulations and subsequent discharges is usually
effective if the relative humidity is above 60 percent. However, certain materials such as metallic
powders and some pyrotechnic mixtures cannot be exposed to air with 60 percent relative humidity due
to the possibility of spontaneous ignition. Where this technique is used to prevent static electricity
accumulations, a daily preoperational check of the humidity levels will be accomplished before work
starts.
7.8

Ground Fault Circuit Interrupter

Ground fault circuit interrupter protection shall be provided in static grounded areas where personnel
may come in contact with AC-powered electrical equipment.

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8.0 ELECTRICAL EQUIPMENT AND WIRING
8.1

Location/Operation Electrical Hazard Classification

The National Electric Code (NEC) does not specifically address explosives; however, Article 500,
"Hazardous (Classified) Locations," does establish requirements for the design and installation of
electrical equipment and wiring in locations containing combustible dusts and flammable liquids,
vapors, or gases that, in general, are comparably hazardous. Although explosives do not normally fit
these classifications, the atmosphere surrounding explosives is treated as Group D or Group G to restrict
ignition sources, such as sparks from electrical faults, and to control surface temperatures of electrical
equipment because explosives dusts or vapors may collect on electrical appliances in the vicinity.
Therefore, the NEC definitions of Class I and Class II hazardous locations are as modified and their
applications are implemented as follows for DOE explosives facilities.
a. Class I, Division 1 electrical hazardous location is one in which (1) ignitable concentrations of
flammable gases or vapors can exist under normal operating conditions; or (2) ignitable
concentrations of such gases or vapors may exist frequently because of repair or maintenance
operations or because of leakage; or (3) breakdown or faulty operation of equipment or process
might release ignitable concentrations of flammable gases or vapors, and might also cause
simultaneous failure of electrical equipment. Equipment and wiring approved for Class I locations
may not be acceptable in Class II locations. Operations involving solvents and explosives usually
require dual-rated (Class I/Class II) systems. See paragraph 8.1.d of this chapter.
b. Class II, Division 1 electrical hazardous locations are areas containing explosives dusts or explosives
that may, through handling or processing, produce dust capable of being dispersed in the
atmosphere. Explosives operations requiring this classification include, but are not limited to,
screening, grinding, blending, pressing, and dry machining explosives plus weighing of explosives
powders. All explosives operations not specified elsewhere are also included in this classification.
c. Class II, Division 2 electrical hazardous locations are areas that contain exposed explosives but
where no dust hazard exists. Explosives operations requiring this classification include, but are not
limited to, storage, inspection, assembly, and wet machining of explosives, plus heating of fully
encased explosives. Class II, Division 1 or dual-rated equipment and wiring can be substituted for
all explosives operations in this classification.
d. Dual-Rated (Class I, Division 1/Class II, Division 1) electrical hazardous locations are areas where
explosives are processed and sublimation may occur or where flammable gases or vapors may be
present in sufficient quantities to produce explosives or ignitable mixtures. Explosives operations
requiring this classification include, but are not limited to, synthesis, mixing, wet blending, and
casting explosives, and heating/drying of uncased explosives.

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e. General Purpose (Non-hazardous rated) electrical locations are areas where no special hazards exist
that might be influenced by the electrical wiring. Areas allowed in this classification include, but are
not limited to, offices, control rooms, halls, rest rooms, and mechanical equipment rooms in
explosives facilities. Explosives operations allowed in this classification include shipping and
receiving operations with fully encased explosives or explosives packaged in DOT/DoD-approved
shipping containers. General Purpose Areas may be established in Hazardous Locations if facility
management can determine, based on analysis of the processes involved, that the following can be
satisfied. Separation between the Class I or Class II operation and the General Purpose Area is
established and maintained such that:qq
•
•
8.2

Migration of explosives into the General Purpose Area from the classified area will not occur
under normal operating conditions;
Ignition energy that may be developed in the General Purpose Area will not be transferred to
the classified area, even under electrical fault conditions.

Electrical Supply System

Mutual hazards may exist where explosives facilities are located near electrical supply lines and
stepping equipment. To protect against these hazards, the NEC (NFPA 70) and the following
requirements apply to all new construction or major modifications, and should be considered for existing
facilities. Quantity distance requirements are based on air blast overpressure only, and fragment
distances are not considered.
a. Electric transmission lines (those carrying 69 kV or more) and the tower or poles supporting them
shall be located no closer to explosives facilities than:
•
•

inhabited-building distance if the line in question is part of a grid/system serving a large, offsite area;
public-traffic-route distance if loss of the line will not create serious social or economic
hardships to off-site areas.

b. Electric distribution lines (those carrying less than 69 kV) and the tower or poles supporting them
shall be located no closer to explosives facilities than public-traffic-route distance.
c. Aboveground, DOE-controlled electric service lines required to be in close proximity to a
combustible constructed or uncovered explosives facility shall be no closer to that facility than the
length of the lines between the poles or towers supporting the lines, unless an effective means is
provided to ensure that broken, energized lines cannot come into contact with the facility or its
appurtenances. Acceptable controls include, but are not limited to, geographic terrain features,
instantaneous circuit interrupters, cable trays and linking lines together. Equivalent underground
service lines shall be located as specified in Chapter VI, paragraph 3.2.4 and Table VI-2.rr
d. Electric lines serving explosives facilities shall be installed underground from a point not less than
50 ft away from such facilities.

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e. Unmanned privately owned or contractor-owned electrical substations (not to include building
transformers and associated switch gear) shall be no closer to explosives facilities than publictraffic-route distances.
f. Certain types of auxiliary power facilities, transformer stations, etc., present fire hazards to
explosives facilities. Transformers and associated electrical switching apparatus serving one
explosives facility or complex that do not present a fire hazard to the facility (i.e., dry-type, "less
flammable" oil-insulated, etc.) shall be located as specified by NFPA 70 and Factory Mutual Data
Sheet 5-4/14-18. Normal oil-insulated transformers shall be located at least 50 ft from an explosives
facility or as specified in DoD 6055.9-STD.
8.3

Building Electrical Service Entrance

Each electrical service entrance for explosives facilities should be provided with the following
protection.
a. Arrestors
•
•

An intermediate, valve-type lightning arrestor shall be provided on the primary side of the
transformer located in, on, or near the facility. See Section 6 of this chapter for additional
lightning protection guidance.
Surge arrestors and surge capacitors shall be provided on the supply side of the main service
disconnect.

b. Grounding
The lightning arrestor, surge arrestor, surge capacitors, service entrance ground, and building ground
shall be interconnected. This interconnection shall be made outside the building.
8.4

Permanent Wiring and Equipment

The NEC and this section are minimum requirements for DOE facilities containing explosives. (For
laboratories, see paragraph 8.10 of this chapter.)
a. Permanent facility wiring includes installed electrical wiring, communications wiring, security
systems wiring, and fire protection systems alarm and response wiring. Permanent equipment
includes the installed electrical fixtures and equipment associated with this wiring. Permanent
equipment also includes equipment such as (but is not limited to) HVAC, hoods, vacuum pumps,
hydraulic pumps, etc.
b. New Facilities and Renovations
(1)

All permanent equipment and wiring of a room shall conform to the NEC electrical
hazard class (see paragraph 8.1 of this chapter) required for the operations for which the
room is designed.

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(2)

To maintain maximum, long-term flexibility of use of facilities, facility management is
encouraged to consider installing dual-rated (i.e., Class I, Division 1 and Class II,
Division 1) permanent wiring and equipment in explosives operating rooms. As a
minimum, installation shall allow for easy conversion to dual-rated wiring and
equipment.

(3)

Explosives storage facilities shall meet Class II, Division 1 requirements.

(4)

Rated electrical fixtures shall not be painted.

c. Existing Facilities

8.5

(1)

Permanent wiring and equipment shall meet the requirements in effect at the time the
facility was built. The wiring and equipment shall be brought into conformance with
paragraph 8.4.b of this chapter if remodeling or renovation affect the wiring or
equipment.

(2)

As a minimum, the permanent wiring and equipment shall meet the requirements of
paragraph 8.1 of this chapter for the explosives operations performed.

(3)

Where equipment cannot meet the above requirements, the equipment should be located
outside the hazardous environment. Otherwise, the equipment shall be controlled as
specified for electrical equipment and instrumentation in paragraph 8.6 of this chapter.

Flexible Cords/Wiring

Wiring from the permanent premises wiring to process equipment or process instrumentation should be
rated for actual explosives operation being performed, per paragraph 8.1 of this chapter. As a minimum,
flexible cords shall be type SO hard service cord or rubber-covered heater cord type HSJ. Splices are
not allowed. In addition all flexible cords, receptacles, and attachment plugs must be equipped with
three prongs so that the third prong (green wire) acts as ground. The cord shall be supported so that
there is no tension on the terminal connections. Seals shall be provided where the cord enters explosionproof enclosures. For NEC Class I or Class II dual-rated operations, the cord shall also be equipped
with explosion-proof attachment plugs. Flexible cords shall not be used where fixed installed electrical
wiring is required by equipment design.
8.6

Electrical Equipment and Instrumentation

a. Non-permanent electrical equipment and instrumentation shall comply with the following.
(1)

Process instrumentation and process equipment should be rated for the actual
environment based on the explosives operation being performed as defined in paragraph
8.1 of this chapter.

(2)

If the properties of an explosive are such that NEC Class II, Group G equipment provides
inadequate surface temperature limits, special protection shall be provided, or the
equipment shall be excluded from the hazardous location.
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(3)

When NEC Class I or II, as applicable, equipment or instrumentation is not available, the
substitute equipment should be purged or pressurized in accordance with NFPA 496, or
be determined intrinsically safe (without regard to voltage) in accordance with NEC
Article 504/ANSI 913/NFPA 493 by facility management, or in NEC Class II locations
sealed to prevent explosives contamination. When the equipment is purged or sealed, the
surface temperature shall not exceed 120°C.

(4)

If the required NEC-rated equipment is not available or cannot be purged or sealed or is
not listed by a nationally recognized testing laboratory as intrinsically safe, facility
management shall evaluate the equipment or instrumentation as to their suitability for use
in the area. The following are suggested areas for evaluation:ss

•
•
•
•
•
•
•

Malfunction of electrical equipment or process instrumentation.
Breach of containment resulting in exposed explosives or spillage of explosives.
Ignition sources arising from physical damage to the wiring method used (e.g., crushing by
forklift or other material handling equipment, frayed cords, etc.).
Exposed electrical conductors or connectors that could make contact with leg wires or cables
of explosive devices during routine handling.
Exposed electrical conductors or connectors on which explosives dust or vapors could
collect.
Collection of explosives dust on or in the equipment.
Sensitivity to heat and spark, and thermal stability of explosives involved.

This equipment shall not have a surface temperature exceeding the lowest onset of the exotherm of the
explosive, as determined by the differential thermal analysis (DTA) test or the differential scanning
calorimetry (DSC) test in paragraph 12.1.1.c of this chapter and Chapter VIII, paragraph 2.2.d.
Approved instrumentation and equipment shall be administratively controlled and marked accordingly.
(5)

If the equipment is purged, the air flow shall be monitored per NFPA 496 and interlocked
to the equipment, or alarmed, if operator shutdown of the machine can be reliably
performed immediately upon receipt of that alarm.tt

(6)

A waiver is not required when the equipment or instrumentation meets the requirements
of either paragraphs 8.6.a.(3) or (4) of this chapter. If the equipment or instrumentation
cannot meet these criteria or has not been evaluated by facility management, it shall meet
the appropriate electrical hazard class requirements.

b. Watertight equipment (that would pass a NEMA 4 hose test) should be provided in those locations
where water-explosives mixtures may come in contact with the electrical equipment and wiring.
8.7

Electrical Requirements for Outdoor Test Areas

Requirements for outdoor test areas shall be contained in the specific test procedures.

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Hand-held, Battery-Powered Lights and Instruments

a. Flashlights and hand lanterns, powered by low-voltage dry cell batteries and "miners’ cap lamps"
approved as "Permissible" by the U.S. Bureau of Mines and by UL for NEC Class I hazardous
locations, are authorized for use in both Class I and Class II locations. Devices that provide "cold
light" through chemical action are acceptable for use in any location.
b. Hand-held instruments, watches, calculators, hearing aids, cameras, self-contained flashes, and
communication devices powered by low-voltage dry cell batteries are authorized for use in the
vicinity of NEC Class II, Division 2 rated hazardous operations and during setup of NEC Class I or
Class II, Division 1 hazardous operations. They shall be evaluated as to their intrinsic safety and
approved by facility management prior to use during NEC Class I or Class II, Division 1 hazardous
operations.
c. Hand-held, battery-operated equipment shall not come in direct or indirect contact with bare
explosives. Batteries shall not be removed or replaced in a NEC hazard rated area (paragraph 8.1 of
this chapter).
8.9

Non-Rated Extension Lighting

When it is necessary to use extension lights within 10 ft of exposed explosives, where no airborne dust
exists, the following requirements shall apply.
•
•
•
•
•
•
•
•
8.10

Lights shall be mounted on heavy tripod stands.
The lights shall be fitted with exterior globes to prevent the falling of hot sparks or particles
that might ignite the explosives.
The lights shall be fitted with adequate guards to protect the globes from physical damage.
The wire providing power to the lights shall be positioned so as to prevent vehicles and
personnel damaging the cord.
The flexible cord shall comply with paragraph 8.5 of this chapter.
The light stand shall be secured to prevent tipping.
Neither the light nor the power cord shall be allowed to come in direct or indirect contact
with the explosives.
Lights shall be positioned outside the fall-down distance to the explosives.

Laboratories

a. Permanent wiring and equipment for existing laboratory areas are not required to meet the
requirements of paragraph 8.4 of this chapter, except as noted in paragraph 8.4.c.(1)
b. Process equipment used for synthesis, heating, drying, mechanical mixing, and blending shall be
dual-rated. Weighing equipment shall be Class II, Division 1 or mechanical. These operations shall
be isolated from non-rated wiring, electrical equipment, and instrumentation in a manner that
prevents dust or vapors reaching an ignition source.
c. When laboratory equipment cannot meet the requirements of paragraph 8.10.b of this chapter, see
paragraph 8.6.a.(3) or (4) of this chapter.
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Modifications

Operating buildings and magazines are constructed to perform a specific function that dictates the
requirements for electrical installation. Procedures shall be established by each DOE facility to control
the use and modification of electrical equipment in explosives areas and ensure that uniform standards
are adhered to throughout the facility.
9.0 VACUUM EQUIPMENT
9.1

General

Precautions shall be taken to prevent explosives from entering any vacuum system not specifically
designed for the collection of explosives.
9.2

Labeling

All vacuum lines used for explosives operations should be labeled to warn maintenance personnel that
explosive residues may be present in these lines. One suggested label is:
DANGER, MAY CONTAIN EXPLOSIVES
9.3

Disassembly

Vacuum lines shall not be disassembled unless they are flanged or connected by elastomeric tubing.
Remote means shall be used to disassemble threaded connections that are potentially contaminated with
explosives. The design or installation of any new vacuum lines shall not employ any demountable,
internal screwed or threaded fittings or connections unless welded or fixed permanently in place. uu
9.4

Traps or Filters

Vacuum pumps used to evacuate processes for explosives operations shall be equipped with primary and
secondary intake line traps or filters to prevent contamination of the pump with explosives.

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10.0

EXPLOSIVES DUST EXHAUST VENTILATION AND COLLECTION SYSTEMS

10.1

General

Exhaust ventilation should be used to control explosives dust (or other hazardous materials used in or
resulting from explosives operations) that may create a hazard to operating personnel or contaminate the
operating area. When exhaust ventilation is used to remove explosives dust, an approved dust collection
system is required to prevent the release of the dust outside the building.
10.2

Exhaust Ventilation

Exhaust ventilation and collection systems for control of explosives dust and materials associated with
explosives production shall be designed to meet minimum requirements established in the ACGIH
Ventilation Manual (most current edition) and this Manual. The exhaust ventilation system should have
sufficient capture and adequate makeup air to reduce exposure to explosives dusts, or materials used in
conjunction with explosives, to as low as reasonably achievable. This is particularly important when
toxicity information and occupational exposure limits are not available for the explosives in use.
10.3

Dust Collection Systems

a. A "wet collector" that moistens the dust close to the point of origin and keeps it wet until the dust is
removed for disposal is preferred. A "dry type collector" is permitted when authorized by an SOP.
b. Dust collectors shall be designed to prevent explosives dust from reaching any mechanical power
source of the collection system.
c. All conductive portions of the collection system shall be grounded and bonded.
d. There shall be no screw threads, recesses, or cracks that may be exposed to explosives contamination
in a dust collection system.
e. Dust collection lines should be equipped with flanged connectors and inspection ports.
f. Pipes or ducts through which explosives are conveyed shall have long radius bends with a centerline
radius at least four times the diameter of the ducts or pipes.
g. Dust collectors shall be emptied and cleaned on a regular basis as warranted by system use and must
be inspected periodically.
10.4

Dust Collection Location

a. Wherever practical, dry-type explosives dust collection chambers should be located outside
operating buildings, in the open, or in buildings exclusively set aside for the purpose.
b. Stationary and portable wet-type collectors may be placed in the explosives operating bays or
cubicles, provided the quantity of explosives in the collectors does not exceed 2 kg.

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11.0

DRAINS AND SUMPS

11.1

Collection

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a. All drain lines handling explosive wastes shall be provided with sumps, clarifiers, weirs or basins of
adequate design and capacity for the removal of explosives by settling. The drains shall be of
adequate capacity, free of pockets, and have sufficient slope (at least 1/4 in/ft) to prevent the settling
out of explosives in the line until it reaches the sump, clarifier, weir or other settling basin.vv
b. Drain gutters within buildings may be constructed with a slope of 1/8 in/ft. However, a satisfactory
program of cleaning must be developed to assure that all hazardous material is removed from drain
gutters.
c. Sumps must be designed so that suspended and settleable solid explosive material cannot be carried
in the wash waters beyond the sumps. The design shall allow sufficient settling time on the basis of
the settling rate of the material and the usual flow rate. The sump shall be constructed so that the
overflow will not disturb any floating solids. The design must also permit easy removal of collected
explosives and retention of those explosives that float on water (until they can be skimmed off). If
settling basins are used to supplement sumps, they will be cleaned periodically and a log will be
maintained.
d. Explosives collection trays for sumps will be constructed of nonferrous metal. Hoisting equipment
used for lifting the trays will be designed to prevent the trays from binding on the sides of the sump.
Bolted sump tanks or other types of construction that permit the explosives to settle in obscure or
hidden spaces are prohibited.
e. Drains between the source of explosive and the sump shall be troughs with rounded bottoms and
removable ventilated covers to facilitate inspection for accumulation of explosives. This
requirement applies to all new construction and major modifications and should be considered for
existing facilities. Short sections of closed pipe or trough are permitted if they can be visually
inspected for blockage or explosives buildup. Explosives or explosives-contaminated waste liquids
shall not be run into closed drains and sewers.
f. Drains shall be inspected periodically and necessary steps taken to prevent the buildup of explosive
deposits in them.
11.2

Effluent

a. Drains containing explosive waste materials must not be connected in a manner that allows such
wastes to empty into the normal sewage systems carrying inert or sanitary wastes.
b. Care must be taken to avoid the possibility of deposition of explosives from sump effluent due to
drying, temperature changes, or interaction with other industrial contaminations. When explosives
that are appreciably soluble in water are handled, sweeping and other dry collecting measures shall
be used to keep them out of the drainage system.
c. The combination of sumps, settling ponds, etc. must remove explosives so that outflows meet
environmental standards.
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12.0

PROCESSING

12.1

Heating, Drying, and Thermal Conditioning

12.1.1 General
a. Heating explosives is potentially dangerous for several reasons:
•
•
•
•
•

Elevated temperature can increase the sensitivity of an explosive to other stimuli such as
impact, shock, friction and static electricity.
At or above the critical temperature of the system, (see definition in Chapter I, Section 6) a
runaway chemical reaction may occur that can produce an explosion or fire.
Elevated temperature of an explosive in a sealed container can cause gas generation and
pressure rupture of the containment at temperatures below the critical temperature.
Chemically incompatible or reactive materials, which may be present as accidental
contaminants, as components of the formulation, or in external contact with the explosive,
can intensify the preceding dangers or cause them to occur at lower temperatures.
Nonuniform heating can cause excessively hot regions in the explosives. Causes may
include inadequate agitation of fluid explosives, nonuniform heaters, and nonuniform heat
conduction.

b.
The critical temperature is a system property that depends on a combination of the chemical
decomposition reactions of the explosive, its mass and shape, the heat transfer and other thermal
characteristics of the system, and the confinement or pressure of decomposition products, especially
gases. The determination or estimation of the critical temperature can be accomplished by several
different methods of thermal analysis, but the process is typically quite complex because of the
complexity of chemical reactions that normally occur. For operational safety, a conservative estimate
(i.e., lower limit) of the critical temperature for a heating operation shall be made (uncertainties of 10 to
25°C being common). Analogy of one explosive or system to another similar system with a reliable
thermal analysis may be used to determine safe heating temperatures and heating times (heating limits).
c.
The DTA, DSC, or other comparable techniques can be used to measure the temperature of the
onset of an exothermic reaction in an explosive. The result of this test can be used to rank the thermal
stability of explosives and as part of a thermal analysis. Because of the complexity of chemical
decomposition, however, the DTA/DSC exotherm has no systematic relationship to the critical
temperature and is unreliable for estimating safe heating limits. The exotherm temperature is always
considerably above the critical temperature and usually increases with the heating rate of the test.
Where the DTA/DSC exotherm is specified as a standard for control of temperature, the test heating rate
shall not exceed 10°C per minute. The DTA/DSC shall not be used alone (except as specified in
paragraph 8.6.a.(4) of this chapter) for establishing heating limits.

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d.
Each facility shall conduct or obtain a thermal analysis of any explosives system before the
explosive is heated in a contact operation or in association with hazardous radioactive materials as
described in paragraph 13.6.2. of this chapter. A heating limit for the explosives system shall be
established from this analysis and shall be approved by the EDC. All factors in paragraphs a and b,
above, shall be considered. Any significant change in the geometry or an increase in mass should be
considered a new explosives system. For a contact operation, the maximum temperature should be set at
least 10°C below the critical temperature. For heating explosives in association with hazardous
radioactive materials, the maximum temperature should be set at least 20°C below the critical
temperature. Heating to a temperature greater than the above specifications may be approved by facility
management if a documented analysis of the explosive’s thermal characteristics indicates that an
acceptable time or temperature safety factor is still present for a specific operation. These operations
shall be conducted remotely.
e.
Heating controls for each operation shall be established and specified in the written operating
procedures. The specified condition should be set at the lowest temperatures and heating times to do the
job efficiently and should not exceed the heating limit for the explosives system. When establishing
heating controls, consider the heating limit and the accuracy of the estimated critical temperature, the
accuracy of the temperature control equipment, and the likelihood of incompatible chemical
contamination along with other operational parameters.
12.1.2 Heating and Drying Equipment
a. Heat should be supplied by steam, hot water, friction air, or electrically heated transfer fluid.
Temperatures shall be limited by redundant, automatic heat controls.
b. In systems heated by steam only, the requirements for redundant, automatic heat controls shall be
satisfied if the steam pressure is controlled by a pressure-reducing valve, pressure relief valve, and
thermostatic valve on the system.
c. In systems heated by electricity, a manual reset secondary over temperature system consisting of a
controller, fail-safe sensor, and an interrupting device shall be provided to interrupt the heat supply
source in the event of primary system failure. The secondary interrupter shall be separate from the
primary interrupter. The upper limit of the primary controller is determined by the desired operating
temperature limit. The secondary (override) controller is set at a higher temperature but should not
exceed the maximum temperature determined by the heating limit specified for the explosives
system as determined in 12.1.1.d of this chapter.
d. Visual and/or audible alarms should be provided to alert operating personnel to abnormal
temperature conditions. The heating of explosives should be monitored at all times.
e. The air or gas used to condition exposed explosives shall not be recirculated if directly heated by
electrical resistance elements.
f. Drying or heating ovens should be vented to a safe location outdoors. Water wash or filtration of the
exhaust may be required. If exhaust fans are used, they shall be interlocked with the heat source.
12.1.3 Heating and Drying Operations
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a. Heating and drying shall be performed under the mildest set of conditions that will accomplish the
task safely and efficiently. A thermal analysis shall be made and a written procedure prepared
consistent with paragraph 12.1.1. The procedure shall include controls on the mass and geometry
(thickness of the layer, etc.) of the material that may be heated.
b. Except as described in 12.1.3.c, below, drying shall be achieved by circulating a warm, dry gas -either air or inert -- over or through the material.
c. Small samples may be dried by placement in desiccators or by subjecting them to vacuum. Vacuum
drying of larger items should be preceded by drying at atmospheric pressure to remove quantities of
moisture or solvent before vacuum is applied to remove the final traces of moisture or solvent.
Explosives having a vapor pressure exceeding 1 x 10-4 mm Hg at the drying temperature shall not
be subjected to vacuum drying. A cold trap shall be used for vacuum drying where the vapor
pressure of the explosives is unknown.
d. Formation of a vapor-air mixture within explosive concentration limits shall be avoided. This can be
accomplished by providing sufficient airflow to maintain a vapor concentration well below the lower
flammability limit or by using an inert atmosphere. For inert atmosphere, positive purge shall be
used to preclude oxygen leakage into the unit. If vapor concentrations approaching a flammable
level are anticipated, they shall be monitored. Airflow shall be controlled to prevent dusting.
e. When heating explosives whose vapor pressure may cause undesired condensation of explosives on
parts of the equipment, heating shall be conducted in a manner to control condensation of the
explosive material. This control should be accomplished by heating the exhaust system or by
circulating the air at a rate that will keep the explosives concentration below the level at which
condensation could occur.
f. The proper operation of heater controls shall be verified on a regular schedule established by site
management.
12.2

Pressing

Explosives pressing operations are those in which explosives are subjected to high pressures to achieve a
physical change. Pressing of explosives formulations is done routinely to consolidate explosive
materials into configurations required for test assemblies or weapon systems. Two types of pressing
operations commonly performed are isostatic/hydrostatic and punch and die. The following safety
guidelines apply to these types of pressing operations.
12.2.1 General
a. Explosives pressing operations shall be conducted as remote operations.
b. The correct functioning of press interlock systems shall be verified at regular intervals.

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c. Pressing mandrels, punches and dies used in explosives operations shall be examined regularly
during periods of use for evidence of structural failure. Examination shall be performed by suitable
nondestructive test methods. Intervals between inspections shall be established by site management
for each tooling design before committing the tooling to use. The inspection interval and updating
should be dictated by experience with similar tooling designs and configurations. All new or
modified mandrels, punches and dies shall be inspected before their first use. At least one pressing
cycle should be completed with mock explosives before proceeding to explosives.
d. Pressure controllers and indicators shall be calibrated periodically to ensure accurate control and
monitoring of pressing operations.
e. Press parts that contact explosive materials shall be thoroughly cleaned of residual explosives before
they are used with a different explosive formulation.
f. Temperature control for heated presses and dies shall comply with the requirements of paragraphs
12.1.2.a and b of this chapter.
g. All pressing assemblies shall be designed or procedural controls established so that the extrusion of
explosives between two mating metal surfaces will be minimized or eliminated during the pressing
operation.
h. Operations with explosive powders should be performed in a manner that reduces the liberation of
explosive dust in order to reduce operator exposure and general room contamination. For operations
involving large amounts of powders, local exhaust ventilation with a dust collection system should
be provided. Respiratory protection to prevent inhalation of explosives dust may be required when
adequate ventilation is not available.
12.2.2 Isostatic/Hydrostatic Pressing
a. Before an elastomeric container or mandrel constructed of a new material is introduced into a
pressing operation (where it will contact explosives), the material shall be evaluated for
compatibility with the explosives.
b. All pressing vessels shall be examined for evidence of cracking or other signs of incipient structural
failure at regular use intervals by suitable nondestructive test methods. Examination intervals shall
be established by local management.
c. Before large-scale pressings of new explosives or explosives formulations are made, these materials
shall be evaluated for thermal stability (see scaleup procedures, Chapter VIII). "New explosives or
explosives formulations" refer to those that are "new" to large-scale pressing. Stability test results
shall be used to assist in establishing safe pressing conditions for the specific pressing size.
d. For isostatic pressing, procedural controls shall be established to ensure that:
•
•

an acceptable vacuum on the mandrel assembly can be obtained to prevent adiabatic heating
during pressing; and
air is bled out of the press before pressurization.
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e. Consideration should be given to the use of fire-resistant hydraulic fluids. The compatibility of any
new fluids must be checked with the explosives used.
12.2.3 Punch and Die Pressing
a. All pressing punches and dies shall be visually inspected for damage, deformation and cleanliness
before installation on a press. Any questionable condition shall be resolved before the pressing
proceeds to ensure that the operation’s safety is not compromised.
b. All punches, dies and press attachment fixtures shall be designed to minimize the possibility of the
punch being misaligned with the die (resulting in gouging of a die surface during pressing). Press
setup procedures shall provide for operator verification of proper alignment before pressing.
c. Punches and dies should be maintained in matched sets and shall be controlled by the responsible
user or a gaging section capable of performing the necessary measurements. A group other than the
user should check critical punch and die dimensions before initial use and at suitable intervals
thereafter. Suitable check intervals for each punch and die design should be determined as in
12.2.1.c of this chapter.
12.3

Extruding

Extrusion operations involve the flow of plastic explosives material under pressure into a cavity in a
component of an assembly. The following general safety guidelines are given for this type of extrusion
operation.
a. Extrusion operations shall be conducted remotely. Contact extrusion may be performed only when
nonexplosive or mock materials are to be extruded or when hand-extruding small quantities with no
metal-to-metal contact. Precautions shall be taken to prevent personnel from being injured by the
rupture of pressurized equipment.
b. The explosive shall be protected against extrusion beyond the tooling cavity. Precautions shall be
taken to prevent foreign material from entering the explosives.
c. New designs and significant design changes in equipment, tooling or components shall be tested by
mock explosives extrusion before actual explosives extrusion.
d. Pressure controllers and indicators shall be periodically calibrated to ensure that proper sealing and
extrusion pressures are being maintained.
e. Extrusion press parts shall be thoroughly cleaned of residual explosives remaining from the previous
operation before the press is loaded with a different explosive formulation.
f. Hand-loading of extrudable explosives is covered in paragraph 12.8.2 of this chapter.
12.4

Machining

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Explosives machining is a class of operation that involves cutting of the explosive material, often in
conjunction with harder inert materials. There is a possibility that thermal initiation of the explosive
substance due to heat buildup from friction at the cutting surface can occur. Precautions must be taken
to limit this buildup and to facilitate the dissipation of thermal energy.
12.4.1 Equipment Requirements
a. Interlocks shall be provided for wet machining operations to ensure coolant flow before machine
operation. The coolant flow shall be monitored and the equipment automatically and safely shut
down if loss-of-coolant flow is detected. The interlocks shall be protected from tampering and
unauthorized disabling by physical means, or supervisory control.
b. The vacuum on vacuum chuck holding fixtures shall be monitored and interlocked with the
equipment for automatic shutdown of machining in the event of vacuum loss.
c. Tool path controls (stops, limits, design patterns, etc.) shall be provided to prevent the unplanned
travel path of a tool or workpiece. Equipment speed and feed rates shall be controlled and limited by
positive means or secondary verification.
d. Pressure-relief devices should be installed on pneumatically or hydraulically powered equipment
when necessary to ensure safe operation.
e. Metal chip waste from machining operations should be kept separate from explosives waste. When
this is not possible, mixed explosives and metal waste should be completely segregated from
unmixed waste and held for separate disposal.
f. Dull or damaged tools shall not be used. A cutting tool inspection and control program shall be
established for explosives machining operations.
g. Consideration will be given to using additional safety control devices (i.e., design patterns, safety
templates, chip thickness sensors, tool pressure sensors, etc.), depending on the type of machining
operations, size of explosives pieces, types of explosives, etc.
h. The "machining overtest" shall be considered a testing operation (see paragraph 12.4.4.e of this
chapter) and shall be exempt from equipment requirements.
12.4.2 Contact or Remote Operations
a. The following explosives may be contact machined if a compatible, nontoxic, noncombustible
coolant is used. Explosives not listed below shall be machined remotely.
•
•
•
•
•
•

Amatol
Baratol
Boracitol
Explosive D
Octol with no more than 75% HMX
Pentolite with no more than 50% PETN
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RDX/TNT compositions with no more than 75% RDX. These compositions include:
Composition B, Composition B-3, 75/25 Cyclotol.
TATB and TATB compositions with an inert plastic binder
TNT.

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b. Explosive assemblies composed of any combination of explosives listed in the above paragraph and
the following nonexplosive materials may be contact machined if a compatible, nontoxic,
noncombustible coolant is used. If an assembly contains an explosive not listed in the above
paragraph or a nonexplosive material not listed below, the assembly shall be machined remotely:
•
•
•
•
•
•

foamed plastics,
solid plastics,
adhesives,
amorphous graphite,
calcium sulfate casting powder, or
explosives mockup.

c. On any explosive, with certain exceptions for IHE and for those explosives being machined by fluid
jet (see paragraph 12.4.2.e of this chapter), the following operations shall be performed remotely:
•
•
•
•
•
•

drilling of holes smaller than 5 cm in diameter, except for IHE, where drilling of holes
smaller than 5 mm shall be done remotely;
coring operations (except contact operations on those explosives listed in 12.4.2.a of this
chapter, when the requirements of paragraph 12.4.5.b of this chapter are met and a coolant is
used);
machining of any metal/explosives interface;
machining IHE subassemblies with Hazard Class/Division 1.1 boosters installed;
dry machining, except that IHE booster pellets may be contact machined provided a dust
collection system (see Section 10 of this chapter) is used; and
machining of explosives in Phase II or earlier stage of scaleup (see Chapter VIII).

d. Machining of primary explosives shall be avoided. Alternative methods, such as forming or pressing
to final dimensions, should be used to achieve the desired shape.
e. The machining of IHE, PBX 9404, and LX-10 may be performed contact by high-pressure fluid jet.
The fluid-jet system pressure shall not exceed 20,000 psig. The velocity of the fluid jet shall not
exceed 520 meters per second (theoretical). The jet nozzle orifice diameter shall not exceed 0.010
in. The system machining fluid shall be water and shall not contain any abrasives. See paragraph
12.15 of this chapter for use of low-pressure fluids.
f. Concurrent contact machining operations should not be permitted in the same bay. However,
concurrent IHE contact machining is permitted when other explosives are not present.
g. Provisions shall be made for visual monitoring of remote machining operations. Consideration
should be given to video recording and audio monitoring.

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12.4.3 Setup and Preparation
The following precautions are provided for preparation and setup before beginning the machining
operation.
a. Before setting up the explosive work piece, the equipment shall be checked for proper function and
the absence of interference between stationary and moving parts. A mock explosive bearing similar
physical properties should be used for testing equipment function.ww
b. The explosive component to be machined shall be inspected by radiography methods for cracks,
voids, and high density foreign objects. The component shall also be checked for proper size.
c. Caution shall be exercised during setup and adjustment to avoid pinching, dropping, crushing, or
otherwise applying abnormal forces to explosives present. Special care must be given to mounting
and centering a part on a vacuum chuck. Special attention must be given to the proper functioning
of the vacuum system and its surface holding area.
d. Limits on machine speed, depth of cut, and feed rate shall be set before the machine is activated.
e. Interlocks shall be functional before the machine is used to machine explosives. They should be
tested once per shift.
12.4.4 Operations Guidelines
a. The minimum tool speed necessary for safe and efficient operation should be maintained. The
following maximums shall apply:
(1)

the relative velocity between the explosives surface and the cutting tool shall not exceed
65 m per minute;

(2)

work pieces or cutting tools shall not be rotated at speeds exceeding 525 rpm; and

(3)

the feed rate of the cutting tool or workpiece shall not exceed 1 mm per revolution.

b. the work piece, fixture, cutting tools, equipment, floor, troughs, drains, etc., should be cleaned
frequently to prevent accumulation of explosive wastes.
(1)

Approved measures should be taken to prevent rust and minimize deterioration of
precision surfaces.

(2)

All tools, equipment, fixtures, and parts should be cleaned before being removed from the
work area for storage.

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c. For contact machining operations, coolant shall be used to aid in removal of heat and cutting waste.
Coolant should be used for remote operations when practical.
(1)

Coolant should be used on explosives/inert assemblies. When the explosives portion is
included in the cut, coolant shall be used for contact machining. Coolant is not required
if the explosives portion of the assembly is contained (no bare explosives) and is not
included in the cut, or the machining is conducted remotely.

(2)

Spray mist coolant may be used during machining of the explosive-containing assemblies
if the explosives portion is not included in the cut.

d. All visible explosives shall be removed from the machine before maintenance or repairs are
performed. No safeguards or interlocks of any kind shall be removed or made inoperative, except by
authorized personnel.
e. Before submitting an explosive for contact machining approval, a machining overtest program shall
be conducted to identify the machinability and associated hazards. These HE qualification tests
should be performed in facilities set aside for these purposes.
(1)

Machining overtests shall be conducted remotely.

(2)

Operations performed during sample preparation may include gaging and assembly, but
shall not include any contact cutting, scraping, or other material-removing operations on
the explosives specimens.

12.4.5 Specific Machining Operations
a. Drilling
(1)

Drilling operations should be set up to maximize the ease of achieving and maintaining
proper alignment and to facilitate removal of explosives chips, fines, and powder.

(2)

Length of fluting on the drill bit shall exceed the depth of the hole to be drilled by a
minimum of 1.3 cm or one hole diameter, whichever is greater.

(3)

The depth of a hole shall not be extended more than 1.5 times the hole diameter (up to a
maximum of 2 cm) during a single insertion of the drill into the material. After each
insertion, it may be advisable to withdraw the drill completely and remove loose
explosives from the cavity and drill bit before reinserting.

(4)

Coolant flow (when used) shall be directed to the explosives/cutting edge interface. Drill
bits having coolant channels to the tip of the drill should be used. Pulsating pressure
types of coolant supplies are recommended for drills of 6 mm diameter or less to remove
drill fines.xx

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b. Coring
(1)

Coolant flow (when used) shall be directed at the explosives/cutting edge interface.

(2)

The coring will be accomplished in increments if the hole is not positioned to provide
continuous breakout. When done in increments, no more than 1.5 times the diameter of
the hole shall be cored at one time. Before the maximum distance has been cored, the
tool shall be totally retracted from the hole and cleaned. The hole shall be flushed with
coolant.

c. Sawing

12.5

(1)

The feed rate of the saw blade or work piece shall not exceed 7.5 cm per minute.

(2)

For band saws, coolant flow should be directed onto the saw blade at the cutting
interface, guide rollers, and the drive wheel/saw blade interface. For circular saws, the
coolant flow should be directed at the explosives/cutting edge interface.

Dry Screening

Screening of dry explosives is often required for size classification or to remove extraneous objects.
Use of magnetic separators is often advisable for removal of ferrous materials that may have passed
through the screens. The following guidelines shall be observed for screening operations and
equipment:
a. Screening operations using mechanical screens shall be performed by remote operations. Equipment
shall be designed and operations performed to avoid subjecting explosive materials to pinching,
friction, or impact.
b. Screening small samples may be performed as a contact operation if approved by written procedures.
c. Equipment shall be electrically bonded and grounded. Resistance-to-ground shall be 10 ohms or less
and shall be inspected on a regular basis. Equipment used to transfer electrostatic-sensitive
explosives to or from screens shall be conductive and electrically bonded to the screen during
transfer.
d. Operations and equipment shall be set up to minimize and control dust generation.
e. The operating area and equipment therein shall be cleaned frequently to avoid accumulation of
explosives dust.
f. Precautions shall be taken to prevent metal-to-metal rubbing during vibration of the screens.
Particular attention shall be paid to frequent inspection of vibrating equipment for development of
cracks subject to contamination by explosives.

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Blending

a. Dry blending of explosives shall be performed remotely. However, dry, hand blending of small
samples may be performed as a contact operation when approved by facility management.
b. Equipment should be designed and operations performed to minimize generation and dispersion of
explosives dust.
c. Equipment shall be electrically bonded to provide a continuous path-to-ground. Resistance-toground shall be 10 ohms or less and shall be inspected on a regular basis. Equipment used to
transfer electrostatic-sensitive explosives to or from blenders shall be conductive and electrically
bonded to the blender during transfer.
12.7

Melting

a. The heat for melting explosives shall be supplied by saturated steam, hot water, or other
temperature-controlled medium. The steam pressure shall be controlled in accordance with
paragraph 12.1.2.b. of this chapter.
b. Temperatures used for contact melting of TNT-based explosives (except those containing PETN,
e.g., pentolite) and keeping them molten shall not exceed 121°C. The temperature limit for TNT
explosives containing PETN shall be 109°C.
c. Feeding of the melt kettle and the melting operation shall be controlled or regulated to prevent the
formation of large chunks of explosives.
d. Alarms shall be provided on the melt temperature and on melt kettle agitation when the operation
will be left unattended. Alarms shall sound if the temperature exceeds the specifications of
paragraph 12.7.b., above, or if agitation ceases.
e. Wherever possible, valves, piping, and threaded bolts and fasteners should be eliminated from
melted explosives handling systems.
f. Provisions should be made for emergency emptying of melt kettles in the event of temperature
control problems or power failures.
g. Melt kettle construction materials shall be corrosion resistant. Construction shall not contain blind
holes, threads, or cracks in areas exposed to melted explosives. Welds shall be inspected and found
free of cracks and porosity.
12.8

Assembly and Disassembly

During assembly and disassembly operations, hand tools and electrical and pneumatic tools that may
subject the explosives to abnormal frictional forces, pinching, or excessive pressure, or cause significant
deformation, shall not be used. They may, however, be used on nonexplosive components.

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12.8.1 Assembly Operations
During assembly operations, the operator should be alert for mismating parts and misalignment of
components. Hard surfaces contacting explosives shall be precisely machined to mate with the
explosives or lined with cushioning material, or other methods shall be used to keep sharp corners or
projections from being forced into explosives.
12.8.2 Loading Assemblies with Plastic or Extrudable Explosives
a. The workability and plasticity of plastic and extrudable explosives improves with an increase in
temperature. Plastic explosive Compositions C-3 and C-4 may be softened by warming to between
21°C and 38°C before working. Extrudable explosives LX-13 and Extex should be kept as cool as
practical to prevent premature curing.
b. Contamination of these explosives with abrasive or foreign substances shall be avoided.
c. The assembly shall be loaded with small increments of the explosive and may be tamped with
suitable nonmetallic tools to eliminate air voids.
12.8.3 Disassembly Operations
a. Before beginning disassembly, the condition of the device shall be assessed to determine if it can be
safely handled.
b. The disassembly operation shall be planned before actual disassembly. Possible problem areas
caused by method of construction or physical condition shall be considered. A safety procedure for
all disassembly shall be written and reviewed.
c. Pressurized units shall be thoroughly depressurized before beginning disassembly if disassembly
would normally cause release of the pressure or if there is a credible hazard of the pressure causing
components to fly apart.
d. If approved for use, compressed air shall be applied cautiously during disassembly operations to
avoid causing components to fly apart. This may require remote operation. Use hydraulic pressure
if possible.
12.8.4 Personnel Protection for Disassembly Operations
a. The operator and all other personnel shall be provided complete protection from disassembly
operations involving conditions that are known or expected to require the use of abnormal force.
This requires either remote operation or the use of an operational shield. The shielding shall be
designed to protect personnel at any other operation or location from blast and missiles arising from
a possible explosion.

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b. When disassembly is required to be performed with the operator protected by an operational shield,
disassembly shall be defined as complete separation (threads or other connections) of component
parts. For example, parts shall not be loosened while the operator is properly protected and then
separated without the same protection.
12.9

Inspection

This section deals with the following types of explosives inspection operations: (1) inspection of
incoming explosives raw materials and pressed explosive billets for foreign bodies or cracks that could
cause operating or safety problems in processing operations; and (2) measurement of physical
parameters of explosive pieces and assemblies.
a. To enhance the safety of process operations, positive steps shall be taken to assure that explosives
used are properly identified and that foreign material is kept from entering the operation via the
explosives raw materials or via materials in process (i.e., pressed explosive billets). Some of the
means by which this can be accomplished include:
•
•
•
•
•

screening,
visual inspection,
magnetic separation,
radiographic inspection, and
chemical analysis.

b. In the design and operation of explosives inspection equipment, the following principles shall be
followed.
(1)

Pinch points shall be eliminated or steps taken to preclude explosives contamination of
pinch points.

(2)

Threaded fasteners or threads of measuring equipment shall be protected from explosives
contamination. Care shall be taken to prevent any parts of the measuring or handling
equipment from becoming loose and getting into the explosives.

(3)

Where inspection fixtures are used, they shall be designed to hold the explosives piece or
assembly securely to prevent toppling, rolling, or dropping during measurement
operations. This is especially critical if the explosives assembly is in motion (i.e.,
spinning, vibrating, etc.) during measurement.

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12.10 Synthesis
Synthesis and other chemical processing of new explosives compounds are ongoing activities at DOE
weapons facilities. Synthesis operations are conducted both on laboratory and pilot scales, and new
operations and materials will be approved by the Explosives Development Committee (EDC, Chapter
VIII). In the laboratory, the new material will initially be prepared on a small scale and characterized as
to sensitivity, physical, and explosive properties. Also, the laboratory will develop processing
techniques for the material. If the explosive is of continuing interest as a result of the laboratory studies,
it may be advanced to the Pilot Plant where processing techniques will be refined and scaled up. The
Pilot Plant will produce sufficient material for larger scale physical, explosive, and sensitivity
characterizations.
12.10.1Laboratory-Scale Synthesis
a. Before initiation of work, the professional staff member who is directing or conducting the synthesis
work shall analyze each experiment involving explosives or potential explosives for type and
magnitude of hazards. This staff member shall be responsible for planning the proper selection of
conditions, quantity of explosives, and safety devices to be employed.
b. Experiments should be designed to minimize the amounts of explosives involved and to use the
mildest conditions that will yield the desired information.
c. New explosives materials shall be afforded extra protection against impact, pinching, friction,
pressure, sparks, contamination, and deterioration. If it is necessary to subject explosives to any of
these conditions, the operation shall be conducted remotely or adequate personnel shielding shall be
provided.
12.10.2Pilot- or Processing-Scale Synthesis
a. When operations are conducted using flammable or toxic liquids or gases, local ventilation shall be
provided to preclude the formation of hazardous vapor concentrations in the work area.
b. Alarms should be provided for coolant flow to the reactor, for reaction vessel agitation, and for
reactor temperature. These alarms should be energized whenever coolant supply or agitation is
critical to prevent a runaway reaction. Also, if agitation is critical, the reactor should be equipped
with at least two sources of power to maintain agitation in the event of failure. For example, a
reactor might employ an air or inert gas bubble tube as a backup for a mechanical agitator.
c. The reaction vessel should be equipped with an emergency system. Upon activation, it will
automatically cool the vessel or, open or close a vessel dump valve as required by the process.
Contact operations should be conducted with a manual means of activating the emergency system.yy
d. The building exhaust ventilation system shall be operating during all synthesis operations involving
flammable liquids.
e. An alarm or monitor should be provided for the critical exhaust ventilation system to warn operating
personnel if air flow rates drop below a predetermined level.
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f. Emergency plans shall be established for the synthesis area, specifying action to be taken in the
event an alarm sounds.
g. Before operating, all equipment shall be set up and checked for proper function. Any new
equipment, or equipment that is not used frequently, shall be tested in a "dry run" before being used
with any hazardous material.
h. All explosives synthesis process equipment shall be inspected and maintained on a routine basis.
Equipment found to have any defects that could affect safe operations shall be tagged to prevent its
use until repairs are completed.
i. Before any process operation is started, the transfer lines to be used should be properly labeled and
their function specified in the operating procedure.
j. Transfer hoses and portable equipment not involved in the process shall be removed from the work
area and stored in their proper places.
k. All control valves shall be correctly identified according to function.
l. Safety equipment and clothing shall be worn as defined in the operating procedures.
m. Agitator blades on reactors and mixers shall be inspected for proper clearance at regular intervals.
This is to ensure that there are no pinch points or metal-to-metal contact. The inspection schedule
shall be set up and approved by local facility management.
n. Explosives warning signs shall be conspicuously displayed on any processing vessel in which
explosive materials are to be left overnight.
o. Any vessel that can be sealed and that can operate above atmospheric pressure shall be equipped
with overpressure protection.
p. All closed vessels should be purged with inert gas before introducing flammable liquids.
q. Inert gas pressure should be used for transferring flammable liquids when gravity flow or pumping
are not practical.
12.11 Formulation
Formulation operations considered in this section are those involving the combining of compounds or
mixtures when one or more of the ingredients being combined is an explosive. This combining of
ingredients is commonly accomplished at DOE explosives handling facilities to obtain some desired
physical property, combination of properties, or reaction parameters.

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12.11.1General
a. Explosives may be loaded as a contact operation (operator attended) into mixers, mills, and
deaerators. However, the starting, operating, and stopping of such equipment with explosives
present shall be accomplished remotely. Exception: mixing-type operations involving a low energy
transfer may be allowed as a contact operation. Examples: slurry coating and melt agitation.
b. Equipment used for explosives formulation shall be checked for proper operation before adding
explosives. In particular, equipment shall be examined for proper clearances and for metal-to-metal
rubbing of moving parts potentially contacting explosives. Bearings should be sealed to preclude
contamination with explosives.
c. Fast-action deluge systems shall be considered for equipment (e.g., mixers, mills, and deaerators)
used for easily ignitable explosives formulations.
d. Hot or cold water, or steam, can be applied to mixers and mills, but heating fluid temperatures shall
not exceed known safe operating temperatures for the particular explosives involved. In the case of
roll milling, allowance shall also be made for viscous shear heating of the explosives during
working. Heated systems shall comply with the requirements of paragraphs 12.1.2.a and b of this
chapter.
12.11.2Mixing
a. Mixer seals and gaskets shall be checked on a regular schedule and cleaned or replaced as required.
b. Checks should be made to ensure that maximum particle sizes of ingredients or hard agglomerates of
proposed mixes are less than the blade-to-blade or blade-to-bowl clearances.
c. Initial cleaning with solvents used for dissolving or suspending the explosives residues shall be done
remotely (other than melt-mix or slurry coating vessels).
d. Explosive powders and plastic-bonded explosives formulations may be mixed wet in a contact
operation. This can be accomplished if the wet mixture cannot be initiated with energy sources
available and the viscosity is kept low and the possibility of isolated portions of the mix becoming
dry is precluded.
12.11.3Ball or Jar Milling
a. Balls that are porous or contain cavities shall not be permitted in mills for grinding explosives.
b. Grinding media contaminated with explosives slurry shall be protected from excessive impact during
emptying of the mill.
c. After grinding, a careful inspection shall be made to ensure that the explosive is free of grinding
media. Dispose of any explosives contaminated with broken media.

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d. After separation of the explosive, the grinding media shall be thoroughly cleaned and inspected
before reuse or disposal.
12.11.4Roll Milling
a. Positive stops should be installed on roll mills to prevent rolls from rubbing each other.
b. Before a milling operation is started on a roll mill, the contact of the scraper blade with the roll
should be adjusted to the minimum pressure necessary to perform the operation.
c. Roll gaps should be set as wide as possible while still allowing adequate working of the material.
Minimum gap setting shall be 0.1 mm.
d. Roll rpm should be held at the minimum required to process the material adequately.
e. All roll mills that may be contact operated (e.g., with nonexplosive materials) shall be equipped with
emergency stop devices (breaker bar, chain) within easy reach of the operator.
12.12 Concurrent Contact Operations
Arranging explosives operations so that each operation is performed in a separate location to preclude
any adverse operation interaction is preferred. Since such an arrangement is frequently impractical,
concurrent operations may be permitted if the following conditions exist:
a. Potential equipment-operator interactions between the two operations have been analyzed and the
risk is not appreciably greater than that for both operations considered separately.
b. Explosive materials in either operation are not exposed to stress conditions such as elevated
temperature (melting or heat conditioning), elevated pressures (pressing or extruding), or
deformation/shear (machining or cutting).
c. Mixing of materials in the concurrent operations will not create compatibility problems.
d. Each operator is aware at all times of concurrent operations in their area.
12.13 Contamination Prevention
a. When two or more incompatible explosives or materials are handled on a line or within a building or
room, precautions shall be taken to avoid mutual contamination. This includes vacuum systems and
explosives scrap collection. Inadvertent mixing of incompatible explosives materials can be
hazardous not only to manufacturing facilities and personnel but also to the user if such materials are
loaded into explosives devices.
b. When two or more explosives are used in a line or within a building and mixing is not intended, the
materials shall be segregated in separate locations. The containers shall be clearly marked with the
weight and contents identification. Care shall be exercised to properly segregate material in service
magazines as well as in operating buildings.
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c. When a different explosive is to be used in process equipment, the equipment shall be thoroughly
cleaned, and excess explosive from the previous job should be removed from the bay. This
eliminates the hazards caused by mixing materials.
d. In any explosives operation, all permanent service lines shall be labeled as to contents. All valves
and switches on service lines whose operation can result in a hazardous situation shall be labeled as
to function.
12.14 Hand-Cutting and Finishing Operations
Hand-cutting finishing may include cutting, trimming, coring, and lapping (surface polishing) explosive
materials. Hand operations shall be performed using the mildest energy input that will accomplish the
task safely and efficiently. The safety of hand-cutting and finishing operations shall be reviewed by the
facility’s EDC, approved and incorporated into an operating procedure prior to performing the operation.
12.15 Use of Low-Pressure Fluids
Low-pressure fluids (liquid pressure less than 1,500 psig) may be handled as in a contact operation to
aid in explosives dissolution, rinsing, system flushing and similar operations under the following
conditions:
a. The fluid system shall have a pressure relief device installed to prevent the system from being over
pressurized.
b. Low-pressure fluid operations may be used with those explosives that have impact sensitivity
properties less sensitive than PETN. Such operations may be used on other explosives only after
analysis of energies involved.
c. Solvents must be compatible with the explosive material. Controls for their use must be specified in
operating procedures.
d. See paragraph 12.4.2.e of this chapter for use of pressures above 1,500 psig.

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TESTING

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This section covers the following types of testing operations.
a. Explosives test shots, gun firings (both small arms and large caliber), and environmental, physicalproperty, and sensitivity testing of explosives specimens.
b. Explosives-related experiments or tests for which the explosive material is used to provide desired
results such as a seismic yield, overpressure effects, pulse energy, or other special applications.
13.2

Test Planning

13.2.1 Hazards Analysis
a. Every proposed testing program shall be examined for all foreseeable hazards involved in the test.
This shall be done with a knowledge of the construction and operation of all standard and
nonstandard equipment to be used, as well as the type of explosives involved.
b. Those tests that are unique in their application or pose obvious hazards shall adhere to the
requirements contained in Chapter VII, Section 2.1.
c. In the case of large-scale tests that have the potential for propelling missiles off Government land, a
formal risk analysis of worst-case conditions for each different test type shall be performed. Such
analysis shall address both the probability of a hazard occurring and the potential severity of the
hazard with respect to injury and property damage.
13.2.2 Firing Areas
a. A secured firing area (danger zone) shall be established for each test to ensure that personnel are not
exposed to hazardous blast overpressure, firebrands, fragments, or projectiles from an explosives
shot or gun firing. The danger zone can be determined by the application of the principles outlined
in DoD 6055.9 Chapter 5, Section E.4.zz
b. Firing areas shall be selected so as to minimize adverse effects to the environment and potential for
causing secondary fires.aaa
13.3

Test Firing

13.3.1 General Range Standards
a. Procedures shall be established at each DOE explosives test site to ensure that no site personnel or
transients are exposed to firebrands, fragments, or excessive blast overpressure from a test shot. In
establishing these procedures, the following guidelines shall be considered.

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b. Personnel access to each test site shall be controlled during actual testing operations. If unattended
roadblocks, gates or doors are used to prevent personnel from entering the danger zone during a test,
they should be interlocked or locked with specially controlled keys.
c. All firing site personnel and visitors shall be accounted for and in a safe place before test firing.
d. A visual inspection of the danger zone shall be performed immediately before each test shot or series
of shots as applicable, to ensure that no transients are present.
e. The danger zone shall be free of service personnel (such as telephone repairmen, surveyors, road
maintenance crews, etc.) during test operations. The control point shall notify service personnel of
the specific requirements under which they may safely work when testing is not in progress. In
addition, the control point shall notify firing site personnel of the presence and location of service
personnel in their areas.
f. Clearance for a test or test series shall be coordinated with all test sites and other areas potentially
affected. A warning shall be provided to every affected area immediately before each firing.
g. Detonation of very large explosive shots, numerous smaller shots, or gun firings may result in
hearing damage and may exceed the DOE allowable limits for impulse noise. Perform a noise
evaluation of these activities to ensure that adequate hearing protection is provided to those
involved.
h. During test operations, all personnel assigned to the test area shall be continuously alert for
movement of personnel, vehicles and aircraft.
i. Test firings often create hazardous conditions for aircraft operating in the airspace near the danger
zone. If this airspace is periodically subject to air traffic, precautions shall be taken to ensure that
the airspace will be clear of traffic at the time of firing.
j. Each firing site shall establish personnel limits based on the number of people actually needed to
conduct an operation and the number of transients that should be present. These personnel limits
shall be enforced by the responsible person at the firing site.
k. Testing of explosives can result in personnel exposure to toxic decomposition products such as
carbon monoxide, hydrogen chloride, hydrogen fluoride, hydrogen cyanide, and nitrogen oxides. It
is good practice to allow the detonation cloud to disperse before leaving protective bunkers.
Fragment-danger-zone distances are normally adequate to allow cloud dispersal and protect outside
personnel from excessive exposure.
l. If the nature of a proposed test is such that hazardous conditions of abnormally long duration may
exist following the test, the procedure shall require a suitable waiting period before personnel leave
their shelter or safe haven area.

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13.3.2 Test Setup
In setting up a test, all work should be done that can be done before receipt of the explosives. Such
work includes the following items.
a. All firing site safety devices shall be checked at regular intervals. Such safety devices include
warning lights, door and gate firing circuit interlocks, emergency firing circuit cutoff switches,
grounding, etc. (including those that are remote from the firing bunker).
b. All firing pad and shot stand setup work that requires power tools or other potential spark-producing
devices should be completed. The firing pad shall be cleared of all unnecessary gear. Special
precautions and procedures will be developed and implemented if power tools or other sparkproducing devices are needed after the explosive has been received at the firing pad.
c. If a special structure is required, as much work as possible should be accomplished on the structure,
including assembly of all materials.
d. When possible, all diagnostic equipment shall be set up, checked, and dry runs performed.
13.3.3 Pin Switches and Other Non-initiating Circuits
Whenever pin switches and other non-initiating circuits are to be checked (such as for charging current
or leakage) and are in contact with or close proximity to explosives, the check should be performed
remotely. Other non-initiating electrical circuits include strain gauges, pressure transducers,
thermocouples, etc., that may be affixed to or close to the explosives within an assembly. If a
continuity-only (resistance) check is desired, this may be accomplished as a contact operation with an
electrical instrument approved for use with the particular explosive device. When low-firing-current
actuators are involved, it may be advisable to conduct these tests remotely (see paragraph 13.8 of this
chapter).
13.3.4 Lightning Storms
All operations in open, test-firing areas shall be discontinued during lightning storms when explosives
are present. Completion of a test after receipt of a lightning alert may be allowed only if test preparation
has progressed to the extent that discontinuance of testing would represent a greater personnel exposure
than completion of testing.

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13.3.5 Low-Energy Electroexplosive Devices
When using hot-wire or low-energy electroexplosive devices (EEDs) for a test firing, apply the
following requirements:
a. Procedures shall be established to ensure that RF, FM, and television transmitters that have sufficient
output energy to initiate an EED at the test site are either restricted to a safe distance from the site or
not operated. Tables II-1, II-2, and II-3 specify minimum safe distances for the various types of
transmitters at several output power levels.
b. Blasting caps and other low-firing-current igniters or detonators shall be kept separate from
explosives at all times, except during actual test charge assembly and setup.
c. The entire wiring system of the explosive charge and of any low-firing-current initiators shall be
kept insulated at all times from every possible source of extraneous current except for weapon
components that have an exposed electrical ground by design. Connections that are made using
weapon wiring connectors and/or cables are acceptable without further modification. Shunts shall be
left on all low-energy initiators or lead wires until actual connections are to be made. Connections
shall be taped or otherwise insulated.
d. Test units containing low-firing-current actuators or detonators shall be clearly marked. No contact
operations involving electrical testing shall be permitted on this type of unit unless an electrical
meter for the specific application is used.

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Table II-1. Minimum safe distances between RF transmitters and electric blasting
operations.
Minimum safe distances (feet)
Transmitter power
(watts)

a

b

Commercial AM
broadcast transmitters

HF transmitters other
than AM broadcast

100

750

750

500

750

1,700

1,000

750

2,400

4,000

750

4,800

5,000

850

5,500

10,000

1,300

7,600

25,000

2,000

12,000

50,000a

2,800

17,000

100,000

3,900

24,000

500,000b

8,800

55,000

Present maximum power of U.S. broadcast transmitters in commercial AM Broadcast Frequency Range
(0.535 to 1.605 MHz).
Present maximum for International Broadcast.

Table II-2. Minimum safe distances between TV and FM broadcasting transmitters and
electric blasting operations
Minimum safe distances (feet)
Effective radiative
power (watts)
Up to 1,000
10,000

c

UHF

1,000

750

600

1,800

1,300

600

100,000

3,200

2,300

1,100

316,000

b

4,300

3,000

1,450

5,800

4,000

2,000

5,000,000

9,000

6,200

3,500

10,000,000

10,200

7,400

6,000

100,000,000

-----

-----

-----

c

b

Channels 7-13

a

1,000,000

a

Channels 2-6 and FM

Present maximum power, Channel 2 to 6 and FM.
Present maximum power, Channel 7 to 13.
Present maximum power, Channel 14 to 83.

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Table II-3. Minimum safe distances between mobile RF transmitters and electric
blasting operations
Minimum safe distances (feet)
Transmitter power
(watts)
5b

e
f
g

UHFa

----

----

10

40

100

40

15

10

50

90

220

90

35

20

125

310

130

50

30

180

----

----

----

65

40

250

200

490

205

75

45

d

----

----

209

----

----

600e

300

760

315

115

70

f

400

980

410

150

90

10,000g

1,200

----

1,300

----

----

1,000

d

VHF(2) a

----

500

c

VHF(1) a

----

c

b

HFa

----

100

a

MFa

MF
HF
VHF(1)

1.6 to 3.4 MHz
Industrial
28 to 29.7 MHz
Amateur
35 to 44 MHz
Public Use
50 to 54 MHz
Amateur
VHF(2)
144 to 148 MHz
Amateur
150.8 to 161.6 MHz
Public Use
UHF
450 to 460 MHz
Public Use
Citizens band radio (walkie-talkie), 26.96 to 27.23 MHz and cellular telephones, 3 watts power, 825 to 845
MHz; minimum safe distance; five feet.
Maximum power for 2-way mobile units in VHF, 150.8 to 161.6 MHz range, and for 2-way mobile and fixedstation units in UHF, 450 to 460 MHz range.
Maximum power for major VHF 2-way mobile and fixed-station units in 35 to 44 MHz range.
Maximum power for 2-way fixed-station units in VHF, 150.8 to 161.6 MHz range.
Maximum power for amateur radio mobile units.
Maximum power for some base stations in 42 to 44 MHz band and 1.6 to 1.8 MHz band.

13.3.6 Explosives Storage in Firing Areas
a. Explosives or ammunition storage at a firing area shall be located such that ignition, explosion, or
detonation is improbable in case of a fire, unplanned explosion, or detonation in the area.
b. Those tests that require explosives or ammunition to be stored at the firing site beyond a day’s event
shall conform to the requirements of Section 17 of this chapter.

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13.3.7 Warning Signals
Each DOE explosives testing facility shall use standard audible signals to warn personnel of any
impending firing in a test area. Signals shall be established by each facility and approved by facility
management.
13.3.8 Grass Fires
Evaluation shall be made before a test shot at outside firing pads to determine the necessity to control
any grass fires that may be initiated by the test.
13.3.9 Firing Leads
All detonator lead wires shall be electrically insulated. Firing leads or cables of low-energy detonators
for explosive assemblies shall be kept properly shorted during setup on the firing point.
13.3.10Unattended Test Assemblies
If necessary, a test assembly may be left unattended on the firing pad during off-shift hours under the
following minimum conditions:
a. If explosives are present, appropriate safety warning signs shall be displayed at all entrances to the
firing pad.
b. Protective services and fire department personnel shall be notified of the explosives location. This
location must be in a controlled-access or secured area.
c. If low-energy detonators are present on the assembly, their leads or cables shall be shorted.
13.3.11Post-firing Controls
a. If the firing appears to be normal, a suitable waiting period shall be observed before test personnel
leave the protective shelter. The waiting period shall be sufficient to assure adequate dissipation of
smoke and dust and shall be specified by the test procedure. In some cases, it may be helpful to
develop and analyze the diagnostic film for misfires.
b. During the waiting period, all power to the firing units shall be turned off or disconnected.
Whenever possible, detonator cables should be disconnected from the firing units and shunted and
grounded, and the firing unit capacitor grounded.
c. After the waiting period, one qualified person shall inspect the firing pad in person or by remote TV
to determine the results of the shot before other personnel leave the shelter.
d. If the inspecting person is certain that safe conditions exist, the lead person shall signal "all clear."
e. After any test misfire, suspected misfire, or partial detonation, the firing area shall be inspected for
unreacted explosives after the minimum waiting period (see Section 13.7 of this chapter).
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f. Recovered explosives from a destructive test shall be placed in an explosives storage magazine as
Storage Compatibility Group L unless a documented determination is made that the explosives do
not present a special risk.bbb
13.3.12Contamination of Firing Areas
Most test firing areas are subject to explosives contamination due to incomplete detonations or to
detonation failures when the explosives are subjected to varying forms of energy input. Most, but not
all, of this contamination will be cleaned up in the post-shot inspection of the test sites. The following
steps shall be taken to reduce the hazards from residual explosives contamination:
a. The contamination zone for each firing area shall be established and permanently annotated on
facility site plans.
b. Personnel access to explosives-contaminated areas shall be controlled.
c. Service personnel shall not work in the area without the permission of testing-area management and
only when supervised by a person approved by management.
13.3.13Test Range Firing Circuit Criteria
The following criteria are guidelines for the design of electrical circuits that are used to arm and initiate
squibs, igniters, detonators and similar electroexplosive devices (EEDs) during test firing activities.
a. The fire control circuit shall include both an ARM switch and a FIRE switch. In the case of lowfiring-current initiators, the safe mode of the arming circuit should not only interrupt the firing
circuit, but also short-circuit and ground the EED terminals. Manual shorting and grounding is
permitted.
b. Every electrical ARM and FIRE circuit on a test range shall include an interlock device consisting of
a safety plug or a key-operated switch to prevent inadvertent energization.
c. The safety plug design and configuration shall be unique for its application and used to prevent
unauthorized or accidental activation of a firing circuit. Key-operated switches for ARM and FIRE
circuits shall be designed to lock in the safe (OFF) position when the control key is removed.
Duplicate keys or safety plugs shall not be permitted in any one test area.
d. During shot-preparation operations, the key or safety plug for a firing site shall be in the control of
the lead operator at all times.
e. All FIRE control circuits in test operation areas shall be properly documented for operational control
purposes. Documentation shall include complete wiring diagrams, electrical schematics, and cable
function lists. All changes or modifications to FIRE control circuits shall be reviewed for safety and
approved by other appropriate departments before being incorporated into the circuits.
f. Each FIRE control circuit shall be adequately isolated from all other circuits. A shielded, twisted
pair of wires with an outer insulating jacket or coaxial cable should be employed for each circuit.
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g. All programmers (sequential timers) used in firing circuits shall be "fail-safe." That is, failure of a
component or circuit must not energize the firing circuit.
h. Test current from the electrical instruments used to perform resistance checks shall not exceed 10 %
of the no-fire rating of the EED in the circuit.
i. Firing circuits shall be clearly marked or otherwise identified in a distinctive manner, and shall be
installed so as to prevent their inadvertent energization by other circuits.
13.4

Test Firing in Tanks or Chambers

Small quantities of explosives may be detonated in cubicles or in pressure vessels. The following
requirements apply to such vessels.
a. The firing vessel and flanges shall be capable of withstanding and confining the effects of the
explosion and properly safeguarding personnel. When new firing chambers are designed and put
into service, a safety factor to their operational weight limit must be included during certification
testing. This overtest load should be based on a percentage of the operational explosives weight
limit. For example, a certification test should be performed with an appropriate explosive material
weighing 125 percent TNT equivalency of the intended operating limit.ccc
b. The firing circuit should be interlocked with the vessel access door latch in such a manner that the
door must be closed and latched before the explosive can be fired.
c. Inspections of the vessel by qualified engineering personnel shall be made periodically to ensure that
structural integrity is maintained after repeated detonations.
d. Test firing is often conducted inside large containment vessels that allow personnel entry but provide
a confined working space and limited egress. The requirements for ventilating and evaluating the
atmosphere of the tank or chamber before personnel entry must be included in the SOP.
13.5

Gun Firings

a. No work, adjustment, or observation shall be permitted on any gun while a live round is in the firing
chamber. The only exception is to check azimuth and elevation.
b. Precautions shall be taken to protect against errors in assembly or preparation of equipment and
ammunition that may create hazards to personnel or equipment. In particular, the following areas
shall be checked.
•
•
•

Adequate filling of hydraulic recoil mechanisms
Safe function of the firing mechanism. (Firing mechanisms shall be tested before use,
particularly in the case of electric firing mechanisms, to ensure that mere insertion of the
round or closing of the breech will not result in firing.)
Absence of obstructions in the bore.

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c. With the exception of manually-fired small arms, test weapons should be equipped for remote
control of the safety and for remote cocking. The safety shall not be advanced to the fire position
and the weapon shall not be cocked until all personnel are in a safe location.
d. Guns used to fire projectiles at explosives targets shall meet the following criteria.
(1)

The gun shall be rigidly mounted in such a way that the impact area is defined and
controlled.

(2)

The target shall have an adequate backstop.

(3)

Provision should be made for remotely moving the gun, remotely removing the
propelling charge, or removing the explosives from the line of fire in the event of a gun
misfire.

(4)

Provisions shall be made for the collection and removal of undetonated explosives from
the chamber or area.

e. When hydrogen gas is used in the firing of a light gas gun, the operation shall be remote while
hydrogen is present in the gun pressure tanks or in the gun barrel and catch tank after firing. The
hydrogen shall be purged from the entire system with inert gas and the atmosphere checked before
personnel are allowed to reenter the gun bay.
13.6

Ballistic, Environmental, Physical Property and Sensitivity Testing

13.6.1 Checkout of Dynamic Engineering Test Equipment for Explosive Assemblies
a. To minimize the possibility of an incident during dynamic testing of explosive assemblies, loadbearing members of the test equipment or the explosive assembly should be proof-tested and
examined if:
(1)

the test equipment is new or has undergone a design modification;

(2)

existing test equipment is to be used under unusually severe test conditions (i.e.,
conditions of velocity, vibration, pressure, load, etc.); or

(3)

a new or modified explosive assembly is to be tested that affects the loading
characteristics of the equipment.

b. Proof-testing of the explosive assembly or test equipment should be conducted before running tests
involving actual systems with explosives.
c. As a minimum, proof-testing should consist of the following sequence of checkouts:
(1)

Check out load-bearing members (lifting devices, hold-down mechanisms, fixtures,
vehicle cases) to at least 125% of rated load using simulated loads (see Section 14.4 of
this chapter).
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"Dry run" tests of actual systems with mock materials in place of explosives and
hazardous radioactive materials.

d. In the event of a part failure in either of the two checkout tests given above, no tests involving
explosives or radioactive material shall be run until additional checkout tests have demonstrated that
the failure cause has been eliminated.
13.6.2 Testing of Explosives and Hazardous Radioactive Materials
Explosives and hazardous radioactive materials (i.e., plutonium, enriched uranium, etc. - depleted
uranium and natural thorium are not considered hazardous radioactive materials for this purpose) shall
not be included in the same test or operation if the test or operation is not contained and involves:
a. Application of high-energy stimuli (i.e., high shock, impact, or friction levels) to the explosive.
b. Heating the explosive to within 10°C of the heating limit determined for the explosive system
without hazardous radioactive materials consistent with paragraph 12.1.1.d of this chapter.
c. Intimate contact of incompatible material with the explosive as determined by compatibility testing.
d. Unacceptably high risk of accidental application of stimuli listed in a, b, or c above.
13.6.3 Heating of Explosives Test Specimens
a. Heating of an explosive shall be preceded by a thermal analysis and preparation of a written
procedure consistent with paragraph 12.1.1 of this chapter. See paragraph 12.1.2 of this chapter for
requirements on heating equipment.
b. Contact operations on explosives specimens undergoing thermal conditioning may be permitted if
(1) the specimen will not be subjected to excessive friction, impact, or spark stimuli during normal
operations or during a credible accident scenario, and (2) the explosive involved has satisfied
appropriate scaleup sensitivity and stability criteria (see Chapter VIII) and has sufficient handling
history to reveal any special characteristics affecting its safe use.
c. If an explosives test specimen in a contact operation is discovered to have exceeded the established
heating limit for the explosive system, the test shall be terminated and the specimen cooled to
ambient temperature. A procedure should be prepared and approved for the required corrective
action (i.e., disassembly or disposal).
13.6.4 Instrumentation
a. Instrumentation directly applied to explosives in a test specimen shall be physically disconnected,
isolated, or grounded before personnel may enter the test cell. Only those instrumentation channels
that contain devices that limit the current below the level capable of initiating the explosive are
exempt.

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b. Environmental control transducer leads, not attached to the test specimen and permanently installed
in an approved control system, do not need to be grounded or disconnected.
13.6.5 Explosives Limits
Explosives specimens shall not be permitted to accumulate in a test cell beyond the number required to
sustain the test. For short-term testing (less than one day), specimens present shall not exceed a 4-hour
supply.
13.6.6 Drop Testing
After an explosives drop test, personnel shall wait a minimum of 5 minutes before leaving the control
bunker to inspect the test pad. If smoke or flame is observed at the drop test area, entry shall not be
permitted until at least 30 minutes after all visual signs have disappeared.
13.7

Test Failures and Misfires

13.7.1 Explosives Misfire
a. If no audible detonation is heard after once pulsing the firing circuit, the firing circuitry and
detonator(s) may be checked for continuity. This checking shall be accomplished from within the
control bunker or from a protected location. If the firing circuits and detonators appear operative,
one or more attempts to fire may be made.
b. If the shot still does not fire, the following precautions shall be taken:
(1)

Disconnect and de-energize all electrical power sources connected to the shot.

(2)

Ensure that all personnel in the danger zone are aware that a misfire has occurred and that
they must remain under cover until notified otherwise.

(3)

Before any personnel are permitted to leave the cover of the bunker, a preestablished
waiting period shall be observed. It is advisable in most situations to establish this
waiting period at 30 minutes minimum.

(4)

A carefully prepared review of the situation, in consultation with another knowledgeable
person, should be initiated.

(5)

Before other personnel are permitted to leave cover of the bunker and after an agreement
has been reached, one qualified person should carefully approach and examine the setup
to verify that it is safe.

13.7.2 Misfire of a Remotely Fired Gun
a. When a misfire occurs, several more attempts to fire the gun may be made. If these subsequent
attempts are also unsuccessful, the following precautions should be taken.
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(1)

Disconnect all electrical circuitry to the gun to ensure that the firing system cannot be
energized.

(2)

If the gun is light-gas driven, ensure that it is in a safe condition by venting all pressure in
the gun breech before approaching the gun. To reduce the risk of a gas explosion in the
case where the driving gas is flammable, the gun breech shall be purged with inert gas
after venting.

(3)

An appropriate waiting period shall be observed before approach to the gun is permitted.
In no case shall the waiting period be less than 10 minutes.

(4)

If there is any indication that powder is burning when the gun is approached, personnel
shall return to a safe area and observe an additional waiting period of at least 20 minutes.

(5)

The gun shall not be approached within the known recoil distance behind the breech or
from the front. Approach to and work on the gun shall be from the sides.

(6)

If the gun is a separate loading type (i.e., propellant charge is loaded separate from
projectiles), the propellant igniter shall be disconnected from the firing mechanism and
removed from the gun before any other gun operations.

(7)

If possible, the powder chamber of the gun shall be checked for the presence of pressure
and vented to the atmosphere before opening the chamber.

b. If an unforeseen failure situation arises (the explosive projectile is stuck in the bore, for example), an
emergency procedure shall be prepared and followed to resolve the situation.

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Electrical Instruments for Use with Explosives Systems (except those covered by DOE O
5610.11, NUCLEAR EXPLOSIVE SAFETY)

13.8.1 Classification
Test instruments shall be assigned to categories on the basis of electrical characteristics that affect their
safe use with explosives systems. Specifically, the instrument categories shall be established so that
each category can be safely applied to one or more of the following classes of explosives systems: (a)
low-energy or hot-wire initiators (blasting caps, actuators, squibs, etc.); (b) high-energy initiators
(exploding bridgewires, slappers, etc.); and (c) non-initiating electrical circuits.
Test instruments that do not meet the safety criteria may only be used on an explosive system if the
activity is considered a remote operation and adequate personnel shielding or separation distance is
provided.
13.8.2 Certification
a. Each DOE facility engaged in the use of electrical test instruments on explosives systems shall
establish a formal system for the purpose of reviewing and certifying these instruments. Procedures
for marking instruments to show their approved use and restrictions on their use should also be
established.
b. Every individual test instrument designated for use on explosives systems shall be certified and
prominently labeled with its approved use and with a warning if there is a restriction on its use.
c. Inspection and calibration of certified instruments shall be required at prescribed intervals or
whenever the instrument is opened for servicing or repair. Access to internal circuitry of certified
instruments shall be controlled to prevent unauthorized repairs, maintenance, or alteration.
d. Records of all instrument types certified shall be maintained by each DOE facility using electrical
instruments to test explosives systems. These records should include type, manufacturer, model,
electrical specifications, wiring diagrams, and failure mode analyses. The Explosives Safety
Committee chairperson shall be notified in writing by DOE facilities management when they
approve new electrical instruments for use with initiating systems. The chairperson shall
disseminate this information to all committee members.
13.8.3 Electrical Instruments for Use with Initiating Electrical Circuits
Instruments in this category are used with electrical initiation circuits connected to electroexplosive
devices. Instruments may be further categorized for use with either low-energy initiators or high-energy
initiators. All test instruments used for this purpose shall be current-limited. Before being used on
initiating circuits, every individual instrument wiring diagram and internal circuitry design shall be
analyzed, examined, and certified for the following:

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a. The output current through a resistance equivalent to that of the minimum resistance initiator of the
class should not exceed 1% and shall not exceed 10% of the no-fire rating for the most sensitive
initiator of the class. The current-limiting features of the test instrument shall be internal to the
instrument and shall not depend on test circuit load characteristics.
b. The internal circuitry shall ensure isolation features that require, as a minimum, two independent
failure modes before the specified output current can be exceeded.
c. A comprehensive (point-to-point, if possible) wiring check should be made to ensure that the wiring
corresponds to the diagram and that all components are functioning properly and within
specifications.
13.8.4 Electrical Instruments for Use with Non-initiating Electrical Circuits
Instruments in this category are used with electrical circuits connected to strain gauges, pin switches,
pressure transducers, thermocouples, electrical components, etc. that are affixed to or within an
assembly with explosives. These instruments shall meet the following requirements:
a. Each specific use of the instrument shall be analyzed to ensure that there is no credible scenario
whereby the normal test energy from the instrument can ignite explosives charges or initiators in the
test. Guidance on operational requirements is contained in paragraphs 13.3.3 and 13.6.4 of this
chapter.
b. Where an instrument is used to make measurements on sensors directly applied to explosives, for
example, bonded strain gauges or pin switches, the instrument shall be certified and have met the
requirements of paragraph 13.8.3.
c. Instruments used with non-initiating electrical circuits shall be prominently marked with the
restriction on use. Many of these instruments do not meet the requirements for use with initiating
systems and must be marked to prevent their use on this type of circuit.
14.0

MATERIALS HANDLING

14.1

General

a. The distance that explosive materials can fall, if accidentally dropped during handling, shall be
maintained at a minimum.
b. Hard surfaces and edges of equipment that could be struck by accidentally dropped, consolidated
explosives, should be padded with cushioning mats or coverings whenever possible and needed.
(Protective padding includes both sheet material on work surfaces and on equipment and approved
floor coverings.)
c. Explosives handling shall be permitted only where handling areas are free of obstructions and where
the walkway surfaces provide positive footing with no slipping or tripping hazards (for example,
explosives shall not be handled on walkways coated with snow or ice).
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d. Explosives and materials that are not compatible shall not be handled together.
e. Detonators, actuators, EEDs, and other items that would normally be shipped as Hazard
Class/Division 1.4 explosives, should be kept in non-propagating trays or containers unless handled
individually.
f. Dry explosive materials that generate dust shall be transported in closed containers.
g. Containers of explosives or explosive assemblies shall be labeled for contents identification during
handling, storage, and transportation.
h. Any explosives items that cannot be identified and labeled shall be stored as Hazard Class/ Division,
Storage Compatibility Group 1.1L material and analysis performed to identify the material
adequately for return to inventory or for disposal in accordance with regulatory requirements.ddd
i. Those components or devices that contain explosives should not be labeled/marked "inert" or
"dummy". Upon discovery, any nonconforming items shall be labeled/tagged indicating that they
contain explosives. Effective January 1, 1999, no new components or devices containing explosives
shall be labeled/marked "inert" or "dummy".eee
14.2

Manual Handling of Bare Consolidated Explosives

a. Manual handling shall be minimized as follows:
(1)

One person may lift or carry up to 25 kg of explosive (if it can be securely gripped).

(2)

Two people may lift or carry 50 kg of explosive (if manual lifting and handling tooling is
provided).

(3)

Any explosive item over 50 kg in weight or that cannot be securely gripped should not be
manually handled.

b. Explosives should not be carried up or down stairs except when in protective containers.
c. Operations shall be arranged to minimize the handling distance in all manual explosives handling
situations.

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Carts or Hand Trucks

a. Explosives that cannot be manually handled shall be handled only on suitable carts or hand trucks.
Carts used for bare explosives handling shall be provided with a padded surface to support the
explosives. These carts shall be equipped with either a lip, sides of sufficient height, or tiedown
straps to prevent the explosives from sliding or rolling off the cart. The cart-explosive load
combination shall have a center of gravity low enough to prevent tipping in the event of a sudden
stop caused by a wheel contacting an obstruction.
b. Explosives handling carts or hand trucks should be provided with brakes. Carts containing
explosives shall be positively secured (e.g., setting wheel brakes or chocking) when the cart is
stationary.
14.4

Mechanical Handling Equipment

a. All items of mechanical handling equipment (i.e., cranes, hoists, slings, etc.) used to lift and move
explosives or assemblies containing explosives shall be initially proof-tested, periodically inspected,
and maintained in first-class working condition. The DOE Hoisting and Rigging Handbook (109095) may be used as a guide for testing, inspection, and maintenance.
b. Equipment for vacuum lifting of consolidated explosives must comply with the following
requirements:

15.0

(1)

The lifting equipment shall be designed so that jerks or other irregular motions in the
hoisting apparatus or bumping of other equipment will not dislodge explosives from the
vacuum head.

(2)

Equipment shall be designed to monitor the available vacuum and to control loss of
vacuum in the event of a power failure or vacuum-source failure.

(3)

Any handling where a loss of vacuum would allow the explosive to drop an excessive
distance shall incorporate some safety device (collar, net, strap) to prevent dropping.
"Excessive distance" shall be defined as a distance greater than the minimum drop height
giving drop-skid initiation for the explosive being handled. "Initiation" in the drop-skid
test is used here to refer to any indication of sample decomposition. An alternative
method of protection can be the use of a cushioning surface under and over all items that
may be struck by the falling explosives.

MATERIALS RECEIPT

The following guidelines shall apply to the inspection, receipt, and unloading of explosives materials.
15.1

Motor Vehicles

a. Incoming motor vehicles loaded with explosives shall be carefully inspected by a competent person
using an approved checklist at a designated inspection station.

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(1)

When an inspection reveals that an incoming tractor is in an unsatisfactory condition, the
tractor should be disconnected from the trailer at the inspection station and moved to a
position where it will not endanger any other explosives.

(2)

When inspection reveals that a trailer or its load is in an unsatisfactory condition, the
trailer shall be moved to a location that is at least inhabited-building distance for the
particular material involved from inert and administration areas, hazardous locations, and
the facility boundary. At this location, correction of unsatisfactory conditions shall be
accomplished before moving the vehicle to its destination within the facility. When
moving from the inspection station to the isolated locations, the route should be as far
away as possible from built-up areas and areas where personnel concentrations are high.

(3)

Vehicles that cannot be immediately dispatched to points where they are to be unloaded
may be moved to a holding yard that shall be sited in accordance with Chapter VI,
paragraph 3.2.3.

(4)

Incoming or outgoing explosives loaded trailers that cannot be exchanged directly
between the carrier and DOE facilities may be moved to an interchange yard. Quantitydistance provisions do not apply if the trailers are moved expeditiously.

b. Vehicles shall not be backed up to a dock where explosives are resting and could be damaged if the
dock were struck.
c. The building doors at the receiving facility should be closed while the motor vehicle is in motion or
the engine is running. This requirement does not apply if the vehicle is equipped with a spark
arrestor or no exposed explosives are present.fff
d. Once the vehicle is in position, the engine shall be shut off, the brakes set, and the wheels chocked.
e. After unloading, the vehicle shall be inspected for loose explosives materials, and any spilled
material shall be cleaned up after the inspection. If a spill involves liquid explosives or explosives in
solution, the spill shall be reported immediately to the building supervisor and appropriate cleanup
procedures shall be used.
15.2

Railcars

Railcars containing explosives and ammunition entering a DOE facility must be inspected. This
inspection comprises the examination of the outside and underside of each car for damage such as
defective brakes, couplings, wheel flanges, etc.; for unauthorized and suspicious articles; and for
correctness of the individual car numbers and seal numbers against bills of lading.
a. Cars of ammunition or explosives showing a defect that could affect the facility or contents of the
car should be removed to the suspect car spur for additional inspection (Chapter VI, paragraph
3.2.3.b).

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b. Cars that satisfactorily pass the inspection outlined above may be considered reasonably safe, but
care must be exercised in breaking car seals and opening car doors because of possible damage or
shifting lading, leaking containers, etc. Interior inspection should be accomplished after the cars
have been spotted at the unloading point.
15.3

Damaged Shipments

a. Explosives shipments shall be inspected for damage before storage.
b. Contents of a damaged or broken container shall be removed to another container. Any spilled
materials shall be cleaned up before continuing with loading or unloading.
c. Any shipment received in damaged condition as a result of inadequate or improper blocking and
bracing or as a result of not being loaded in accordance with appropriate DOT requirements shall not
be reshipped until the damage is corrected.
16.0

TRANSPORTATION

16.1

Equipment

16.1.1 General
a. Explosives shipped on common carriers shall be packaged and shipped in accordance with DOT
regulations.
b. Explosives-containing items transported by weapons couriers in a Safe Secure Trailer (SST) or Safe
Secure Railcar (SSR) are exempt from the equipment requirements given below.
c. Security and authorized emergency vehicles carrying approved quantities of explosives in support of
approved contingency plans are not considered "in transportation," as defined by 49 CFR Part 171.8.
16.1.2 Motor Vehicles
a. Motor vehicle shipments on public highways are governed by DOT regulations. All motor vehicle
shipments from a DOE installation shall comply in full with the applicable portions of DOT
regulations, and with state and municipal regulations, except as provided for in these regulations.
Any motor vehicle that may be loaded with explosives (Hazard Class/Division 1.1, 1.2, and 1.3) and
is designated for movement over public highways must be inspected and approved by a qualified
inspector for compliance with an approved checklist. After loading, the lading must be inspected
and approved. Driver selection, training, etc., for intraplant shipping and for operation of
government-owned trucks on public highways shall be in accordance with pertinent requirements 49
CFR, Parts 390-397.
b. Before motor vehicles loaded with explosive materials leave a DOE facility, drivers shall be
informed as to the nature of their cargo and methods of fighting fires involving the vehicle or its
cargo.
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c. Cargo-type trucks and truck-tractor drawn semitrailers are the preferred types of equipment for
transporting explosives. Flat-bed semitrailers or trailers may also be used to transport large items in
special containers for such movement. For transfer movement within facilities, open- body vehicles
(other than flat-bed types) must have sides and tailgates or rear doors that are strong and securely
fastened so that explosives are safely retained. Vehicles (including flat-bed types) partly or
completely loaded shall have the lading blocked, braced, chocked, tied down, or otherwise secured
to prevent shifting during transit.
d. All DOE explosives-carrying vehicles for on-site transportation should be equipped with the
following.
•
•
•
•
•
•
•

Explosives placards plainly visible from all directions (except for vehicles transporting
Hazard Class/Division 1.4 items).
Tiedown bolts, rings, and straps with which to securely fasten the explosives items and which
are adequate for the load.
On trucks, a cargo area with no sharp projections. (Non-sparking lining is desirable when
hauling explosives in transfer containers that are not DOT approved.)
Chock blocks.
A quick-disconnect switch on the battery if explosives are left on the vehicle overnight.
Rear-view mirrors on both sides of the vehicle.
Two fire extinguishers with a minimum rating of 2A:10BC, one of which should be mounted
outside the vehicle. Vehicles for transportation of Hazard Class/Division 1.4 explosives need
just one extinguisher.

e. Precautions must be taken to avoid ignition of explosives material by the exhausts of motor vehicles.
When a motor vehicle approaches within 25 feet of the doors of a structure through which a
shipment is to be moved, the doors must be kept closed until the motor has been turned off unless the
exhaust system is equipped with a spark arrestor or no exposed explosives are present. Exposed
explosives exclude finished items and explosives packaged for shipment in DOT or DOT-equivalent
containers. No explosives shall be loaded into or unloaded from motor vehicles while their motors
are running except when required to provide power to vehicle accessories used in loading or
unloading and the vehicle exhaust is equipped with a spark arrestor.

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(1)

Security patrol and response vehicles are authorized to transport the minimum quantity of
munitions needed to support approved contingency plans and to execute their security
duties. Whenever possible, support munitions required for defense against hostile forces
should be prepositioned in readily accessible magazines. Security vehicles armed with a
combination of up to 25 pounds net explosives weight of Hazard Class/Division 1.1 and
1.2 munitions shall be exempt from explosives quantity-distance requirements when
executing approved contingency plans or security duties. Vehicles so armed will not be
used for administrative purposes and will be separated from inhabited facilities and
property lines by a minimum of 125 feet when temporarily out of security service, and
shall be downloaded into properly sited magazines or approved facilities when parked for
periods in excess of 4 hours. Operation of vehicles loaded with explosives will be
restricted to on-site locations and transported explosives must be secured within the
vehicle. Smoking in explosives loaded vehicles is prohibited. These vehicles shall be
downloaded into properly sited magazines or approved facilities prior to repair or
maintenance, except under emergency response conditions.

(2)

Security force personnel shall be allowed to transport on their person Hazard
Class/Division 1.1 and 1.2 munitions issued to them for personal use in the execution of
approved contingency plans and security duties without regard to explosives quantitydistance requirements. Appropriate safety precautions for the handling of ammunition
shall be observed and the munitions shall be placed in an approved location if temporarily
removed from the uniform/load bearing equipment worn to carry such items.

16.1.3 Railcars
a. A railcar must not be loaded with any Hazard Class/Division 1.1 and 1.2 explosives unless it has
been thoroughly inspected by a qualified employee of the carrier who certifies that the railcar’s
condition conforms to DOT regulations. After a certified car has been furnished by the carrier, the
shipper or an authorized employee of the shipper must, before starting to load any such car, inspect
the interior thereof and, after loading, certify its proper condition. A certificate will be completed
and signed where applicable. Shipments of Hazard Class/Division 1.3 explosives may be loaded in a
closed car or container car in good condition (i.e., sparks cannot enter the car and the roof does not
have unprotected decayed wood that constitutes a fire hazard). Wooden-floored cars must be
equipped with spark shields. Such cars do not require a car certificate, but they must have a placard
in accordance with DOT regulations.
b. The railcar certificate, printed on strong tag board measuring 7 by 7 in. or 6 by 8 in., must be
executed in triplicate. The original copy must be filed by the carrier in a separate file at the
forwarding station, and the other two must be attached to the car, one to each outer side on a fixed
placard board or as otherwise provided.

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16.1.4 Materials Handling Equipment
a. Gasoline-powered materials-handling equipment (forklifts, etc.) may be used only in areas where all
explosives are properly packaged and only if equipped in the following manner.
•
•
•
•
•
•

Backfire deflectors shall be securely attached on the throat of the carburetor and shall be the
oil-bath or screen type (certain types of air cleaners will serve the purpose).
A tight-fitting cap, properly vented, shall be in place on the gasoline fill pipe at all times
(except during refueling).
A flame arrestor shall be installed in the fill pipe.
If necessary, a deflector plate shall be installed to prevent any gasoline tank overflow from
reaching the motor or the exhaust pipe.
On gravity feed systems or on pump systems where siphoning might occur, a shutoff valve
shall be installed at the fuel tank or in the feed line to permit shutting off the flow of gasoline
in the event of an emergency or a break in the fuel line or carburetor.
Provisions shall be made to prevent vibrational rupture of the fuel lines.

b. Diesel-powered equipment may be used if all the precautions for gasoline-powered equipment (as
specified above) are followed.
c. Battery-powered equipment for handling explosive material shall comply with the criteria listed
below.

16.2

(1)

Battery-powered equipment and its use in hazardous locations shall comply with OSHA
standards. All equipment shall be appropriately labeled for ready identification.

(2)

Types E, EE, ES, and EX rated, battery powered equipment are satisfactory for handling
all classes of properly packaged ammunition and explosives. Types EE and ES batterypowered equipment may be used for handling packaged explosives or explosive
components in corridors or ramps connecting hazardous operations, provided the ramps
and corridors are not Class I or II, Division 1, hazardous locations (NEC). Type EE
equipment is authorized for use in Class II, Division 2, Group G hazardous locations, and
Type ES equipment may be authorized on approval of facility management (see NFPA
505, Powered Industrial Trucks).

(3)

Type EX equipment is the only equipment approved for use in specifically named Class
I, Division 1, Group D or Class II, Division 1, Group G hazardous locations. At this
time, EX equipment does not carry a dual rating and shall only be used in hazardous
areas for which it is specifically rated.

General Operation Guidelines

a. Explosives-containing items transported by weapons couriers in SSTs or SSRs are exempt from the
operation guidelines given below.
b. Drivers shall be given special training that emphasizes caution, road courtesy, and defensive driving.
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c. The operator of an explosives-carrying vehicle shall have proper training in the general safety
precautions for explosives handling.
d. Congested areas should be avoided.
e. Road vehicles shall stop at all railroad crossings.
f. No personnel shall ride in the cargo area. There shall not be any loose items (e.g., handling gear) in
the cargo compartment.
g. No smoking is allowed in or within 25 ft of any vehicle containing explosives. Matches, lighters, or
other fire-, flame-, or spark-producing devices shall not be in the vehicle or carried by personnel in
the vehicle.
h. The vehicle shall be subjected to regular maintenance checks.
i. Before shipment, explosives materials being transported by commercial carrier shall be classified by
testing or analogy in accordance with DOT regulations.
j. Other than when opened for inspection, containers of explosives shall not be opened or repaired on
any transportation vehicle.
k. Except for emergency situations, fueling or maintenance of vehicles containing explosives is
forbidden.
l. Each facility shall have a special set of traffic rules governing the operation of explosives-carrying
vehicles and the operation of other on-site vehicles in the vicinity of explosives-carrying vehicles.
m. Industrial trucks shall not be used in locations where high concentrations of dusts or sublimation of
explosives may result in contaminated surfaces (e.g., screening buildings, pouring bays, melt-pour
units, drilling bays, consolidating bays, and explosive washout facilities).
16.3

Emergency Conditions

a. Explosives should not be transported when hazardous conditions (such as storms, icy roads, or poor
visibility) prevail, unless an emergency plan is in effect that provides instruction and guidelines
while an explosives-carrying vehicle is in transit. The plan should address the following issues: ggg
•
•
•
•

parking the vehicle;
safeguarding the vehicle from other traffic;
notifying appropriate authorities of the emergency situation; and
leaving the vehicle unattended.

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b. A plan shall be prepared to provide for an explosives-carrying vehicle that has a mechanical
breakdown. The plan shall address the following issues:
•
•
•
•
•

removing the vehicle from the road as far as practical;
posting emergency reflectors, signals, etc. (carrying flares on the vehicle is not permitted);
reporting the problem;
maintaining surveillance of the vehicle; and
if necessary, removing the vehicle load to facilitate repair of the vehicle.

c. If an explosives-carrying vehicle is involved in an accident, the following steps should be taken:
(1)

Inspect the load for evidence of fire.

(2)

If there is a fire, but the explosives material is not presently or imminently involved,
attempt to prevent the fire from spreading to the load. The fire may be fought using the
vehicle’s fire extinguishers. If explosives items are removed from the vehicle, ensure
their security..

(3)

If there is a fire that presently or imminently involves the explosives load, evacuate all
personnel to a preestablished safe distance. Block or divert other traffic from the vicinity
of the accident. Evacuate any potentially affected area residents.

(4)

Unless the explosive cargo is imminently involved in fire, direct the operator to stay with
the vehicle until proper disposition of the cargo is accomplished.

(5)

Immediately notify the fire department or fire brigade of the accident and inform them of
the general type and approximate quantity of explosives involved.

(6)

Inform proper authorities of the accident.

17.0

EXPLOSIVES STORAGE

17.1

Storage Magazine Facilities

a. All new storage or service magazines should be constructed in accordance with the guidance
provided with in one of the following references:
•
•
•
•

DoD 6055.9-STD - suggested for high security or large volume operations
27 CFR 55.206 - suggested for sites that need flexibility due to unique operations
DOE 6430.1A - suggested for sites that utilize service-type magazines
29 CFR 1910.109 - suggested for sites with normalized operations

b. Placard(s) shall be posted on or near each door of the magazine, specifying explosive and personnel
limits and general safety precautions that should be observed during work in the magazine.
c. Vegetation around storage magazines should be controlled to minimize potential damage to the
magazine (see Chapter VI, paragraph 5.1).
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d. At least two fire extinguishers, minimum rating 2A:10BC and winterized where necessary, should be
provided and maintained for immediate use by personnel working around a magazine. These
extinguishers may be permanently located in the area or available on an explosives transportation
vehicle. The extinguishers are for the purpose of fighting small external fires or magazine fires
where explosives are not involved.
e. Suitably rated telephone or other forms of emergency communication equipment should be provided
in magazine storage areas. All communication equipment located outdoors should be protected from
the weather.
f. Temperature Control

17.2

(1)

In general, storage magazines should not be provided with heat. An exception shall be
made in the case where heating may be necessary to prevent damage caused by sudden
changes in temperature or where dimensional changes of components are undesirable.

(2)

Magazines requiring heat should be heated with steam, hot water, or electrically heated
hot water. Some magazines with tight temperature controls may require both heating and
air conditioning. Electrical systems with forced air through ducts may be allowed if the
systems are located exterior to any explosive hazard.

(3)

Heating coils shall be arranged so that explosives material cannot come in contact with
the coils. They shall be equipped with covers designed to prevent the storage of materials
on top of the coils.

(4)

In all magazines where heat is supplied, maximum and minimum temperature monitors
should be provided.

Storage Magazine Operations

a. Explosives items shall be properly packaged and stored in either DOT-approved manufacturers’
container/packages or in specified on-site containers (see paragraph 17.5 of this chapter).
b. Explosives may be stored on magazine shelves, where provided. The bottom of the container should
not be more than 2 m off the floor, except as permitted by paragraph 17.2.c of this chapter.
c. Explosives and explosives containers in storage shall be safely and securely positioned. If
explosives containers must be stacked, they shall be placed in stable arrays.
d. Permissible loading of all shelving should be determined for all magazines containing explosives. If
there is a possibility of overloading, the loading conditions shall be posted.
e. Materials shall not be left suspended by booms, cranes, or hoists in any explosives storage facility.
f. Explosives in storage should be segregated by lot designation. Stacks of explosives should be
arranged so that air freely circulates to all parts of the stack. In order to prevent the accumulation of
moisture, pallets or appropriate dunnage shall be used to ensure that containers are not stacked
directly on the magazine floor.hhh
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g. Aisles shall be wide enough to accommodate inspection, inventory, sampling, and materials
handling operations on the stored explosives containers.
h. A crew shall not be permitted to work in a position that requires passing the work aisle or the
position of a second crew to reach the exit. Unobstructed aisles shall be maintained to permit rapid
exit of personnel.
i. Each crew working in a magazine must have its own exit route that does not interfere with exit
routes for other crews.
j. Magazines shall be locked at all times except when permissible operations are in progress or when a
magazine is opened for ventilation. Personnel shall be present while the magazine is open for
ventilation. All exit doors shall be unlocked and open when personnel are working in the magazine.
k. An inventory of each magazine shall be taken at least annually to determine the total weight of
explosives present (to assure this weight conforms to allowable quantity-distance constraints) and to
remove and destroy materials that are not properly identified or labeled.
l. The liquid level in storage containers for wet explosives shall be checked and replenished if
necessary at least once a year, and a log of the checks shall be maintained.
m. Empty containers, tools, conveyors, lift trucks, skids, and other similar equipment should not be
stored in a magazine containing explosives.
n. Combustible materials such as excess dunnage, packing material, and boxes shall not be stored in a
magazine containing explosives. Flammable liquids shall not be stored or used in explosives
magazines unless the liquid is an explosive, is needed as an explosives-wetting agent, or is an
integral part of an explosives device.
o. Operations in and around magazines shall be prohibited when an electrical storm is in progress and
minimized when it is evident that such a storm is approaching. Explosives-handling operations shall
not be performed when magazine entranceways are ice-covered or, for any other reason, do not
provide adequate footing.
p. Unless excepted, no operation in which hazardous materials are involved shall be permitted in any
magazine. The following exceptions are recognized.
(1)

Those operations incident to storage or removal from storage.

(2)

Inspection and surveillance sampling of compatibility Group D materials, and Group C
materials consisting of bulk propellants and IHE, provided that each storage container
sampled is in good condition (i.e., the container is not leaking, no evidence exists of
explosives contamination at the closure or of seal failure, and the closure is mechanically
sound and free of excessive corrosion, etc.). Only one container of explosives shall be
opened at one time in a magazine.iii

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Liquid addition to adjust the liquid composition level in which a Group D explosive is
stored. (Water and alcohol mixtures may be used as the liquid. If only water is added to
the explosive, the water should be distilled or deionized. Bacteria present in untreated
water may produce gas during storage.)

Storage Review Program

Each facility shall have a program to review the explosive materials stored at that facility. In
recognition of the fact that explosives may degrade during prolonged storage and the hazards of
handling or using degraded explosives may increase significantly, the following procedure is provided
as an example.
a. A storage review date should be assigned to every bulk explosive placed in storage. The storage
review date should be shown on or adjacent to the identification tag or sticker attached to every
container or package of explosive in storage or should be listed in the inventory records.
b. Storage review intervals should be based, whenever possible, on stability data. A safe storage
interval should be considered as that time period, at maximum anticipated storage temperature,
during which an explosive material can be conservatively expected to show an acceptable level of
decomposition.
c. A storage review committee should be designated or created by facility management to establish and
approve storage review intervals for all explosives stored at the DOE facility. Also, the committee
should prescribe for each explosive appropriate tests to permit an evaluation of the safety of
handling and processing the material once it has exceeded its storage review interval. These tests
may be referred to as "stability tests," although sensitivity, or other types of testing, may be included
in the material evaluation program. In some cases, the review committee may simply require
periodic stability testing of the material rather than establish a storage review interval (i.e.,
nitrocellulose, single- and double-base propellants, etc.).
d. To store a new explosive, to increase (or decrease) the review interval for a previously approved
material, or to use different stability test data for an explosive, the following procedure should be
observed:
(1)

A responsible person should communicate the request to the storage-review committee.

(2)

If the request concerns storage of a new explosive, the individual should recommend a
storage-review interval and stability-evaluation testing.

(3)

Supporting data should be supplied with the recommended review interval and with the
proposed stability tests for the explosive.

(4)

The storage review committee should review the request and supporting data and then
prescribe a storage review interval and/or stability tests.

e. A new explosive should be assigned an interim storage review and stability test interval before Phase
II scaleup (see Chapter VIII).
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f. The following general guidelines are offered to assist the storage-review committee in establishing
review intervals in cases where there is insufficient stability information to predict storage life.
(1)

If there is no available information on a new material relative to storage stability, a
review interval of 90 days or less should be assigned.

(2)

A new formulation should be assigned a storage review interval not exceeding that of its
least stable component.

(3)

If the compound or formulation is new to DOE but DoD agencies have extensive
experience with it, the DoD information should be used conservatively.

(4)

If a manufacturer has an assigned shelf life for a formulation or ingredient, a review
interval that exceeds the recommended shelf life should not be assigned unless additional
DOE tests indicate such storage is warranted.

g. A storage review interval of up to 20 years should be permissible for an explosive if a conservative
evaluation of stability data indicates that such an interval is justified.
17.4

Storage Compatibility

a. Explosives shall not be stored with materials or items that increase the risk of initiation or
decomposition of the explosives. Examples are mixed storage of explosives with flammable or
combustible materials, acids, or corrosives.
b. Different types of explosives may be stored in the same magazine if they are compatible. Explosives
shall be assigned to a storage compatibility group when they can be stored together without
significantly increasing either the probability of an accident or, for a given quantity of explosive, the
magnitude of the effects of such an accident.
c. Each type of explosive shall be assigned to an appropriate storage compatibility group (A through G,
L, and S) for the purpose of storage at DOE facilities. The nine groups are defined in the following
paragraphs. These definitions and Table II-5 Storage Compatibility Mixing Chart, are in accordance
with the principles and tables in DoD 6055.9-STD, "DoD Ammunition and Explosives Safety
Standards." Table II-4 presents some examples of commonly used materials that are assigned to
each storage compatibility group. This list does not enumerate all materials that may be included in
each group.
(1)

Group A - Initiating explosives. Bulk initiating explosives that have the necessary
sensitivity to friction, heat, or shock to make them suitable for use as initiating elements
in an explosives train. Examples are lead azide, lead styphnate, mercury fulminate, and
tetracene.

(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 explosives train. Examples are detonators (all
types, excluding EBWs and slappers), blasting caps, small arms primers, and fuzes.
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(3)

Group C - Bulk propellants, propellant charges, and devices containing propellant with or
without their own means of initiation. Items that will deflagrate, explode, or detonate
upon initiation. Examples are single-, double-, triple-base, and composite propellants,
rocket motors (solid propellant), and ammunition with inert projectiles.

(4)

Group D - High explosives (HE) and devices containing explosives without their own
means of initiation and without a propelling charge, or articles containing a primary
explosives substance and containing two or more effective protective features. This
group shall include explosives and ammunition that can be expected to explode or
detonate when any given item or component thereof is initiated.

(5)

Group E - Explosives devices without their own means of initiation1 and with propelling
charge (other than one containing a flammable or hypergolic liquid). Examples are
artillery ammunition and rockets.

(6)

Group F - Explosives devices with their own means of initiation and with or without
propelling charge.1

(7)

Group G - Pyrotechnic materials and devices containing pyrotechnic materials.
Examples are devices that when functioning, result in an incendiary, illumination,
lachrymatory, smoke, or sound effect.

(8)

Group H - Ammunition containing both explosives and WP or other pyrophoric material.
Ammunition in this group contains fillers which are spontaneously flammable when
exposed to the atmosphere. Examples are WP, plasticized white phosphorus (PWP), or
other ammunition containing pyrophoric material.jjj

(9)

Group J - Ammunition containing both explosives and flammable liquids or gels.
Ammunition in this group contain flammable liquids or gels other than those which are
spontaneously flammable when exposed to water or the atmosphere. Examples are liquid
or gel filled incendiary ammunition, fuel-air explosive (FAE) devices, flammable liquid
fueled missiles, and torpedoes.kkk

(10)

Group K - Ammunition containing both explosives and toxic chemical agents.
Ammunition in this group contain 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.lll

See definitions of Initiation, Chapter I, Section 6.

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(11)

Group L - Explosives or ammunition not included in other compatibility groups which
present a special risk, requiring isolation of each type. This group shall include
explosives or ammunition having characteristics which do not permit storage with other
similar or dissimilar materials. Examples are damaged explosives, suspect explosives,
and explosives, explosive devices or containers that have undergone severe testing unless
documented determination is made that these items do not present a special risk; fuel/air
explosive devices, and water-activated devices. Also included are experimental
explosives, explosives of temporary interest, newly synthesized compounds, new
mixtures and salvaged explosives until they have been established to be compatible with
the original materials. Types presenting similar hazards may be stored together.mmm

(12)

Group N - Hazard Division 1.6 ammunition containing only extremely insensitive
detonating substances (EIDS). Examples are bombs and warheads. If dissimilar 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.nnn

(13)

Group S - Explosives, explosive devices, or ammunition presenting no significant hazard.
Explosives or ammunition so designed or packed that, when in storage, 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 be communicated to other packs.

d. Newly synthesized compounds and mixtures shall be stored in Group L storage facilities. After
more complete evaluation, those compounds or mixtures of continuing interest shall be assigned by
the Explosives Development Committee (see Chapter VIII, Section 1.1) to the appropriate
compatibility group, and stored according to the following considerations:
(1)

The material’s sensitivity to initiating stimuli (i.e., friction, impact, spark, shock, and
thermal) is similar to that of other explosives in the group.

(2)

The material’s reactions and the effects of these reactions, in the event of application of
initiating stimuli, are similar to other members of the group.

(3)

The material is chemically compatible with other members of the group. Sensitivity and
compatibility testing is described in Chapter VIII.

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Table II-4. Storage compatibility groups for explosives and explosive-containing
devicesooo
Group A.
Initiating explosives.
•
CP (5-Cyanotetrazolpentaamine Cobalt III Perchlorate)
•
HMX (Cyclotetramethylene tetranitramine) (dry)
•
Lead Azide
•
Lead styphnate
•
Mercury fulminate

•
•
•
•
•

Nitrocellulose (dry)
PETN (Pentaerythritol tetranitrate) (dry)
RDX (Cyclotrimethylene trinitamine) (dry)
TATNB (Triaziodotrinitrobenzene)
Tetracene

Group B.
Detonators and similar initiating devices.
•
Blasting caps
•
Detonators excluding EBWs and slappers
•
Explosive bolts
•
Fragmenting actuators
•
Igniters

•
•
•
•

MDF (mild detonating fuse) detonator assemblies
Pressure cartridges
Primers
Squibs

Group C.
Bulk propellant, propellant charges, and devices containing propellants with or without their own means of
initiation. This Group also includes some IHEs.
•
TATB (Wet)
•
Smokeless powder
•
LX-17
•
Pistol and rifle powder
•
PBX-9502
•
Rocket-motor solid propellants
Group D.
High explosives (HE) and devices containing explosives without their own means of initiation and without a
propelling charge or articles containing a primary explosive substance and containing two or more effective protective features.
•
HMX (Cyclotetramethylene tetranitramine) (wet)
•
Ammonium picrate
•
HMX/wax (formulated with at least 1% wax)
•
Baratol
•
HNS (Hexanitrostilbene)
•
Black Powder
•
Linear-shaped charge
•
Boracitol
•
Methyl dinitorpentanoate
•
Compositions A, B, and C (all types)
•
Nitrocellulose (wet)
•
Cyclotols (not to exceed a maximum of 85% RDX)
•
Nitroguanidine
•
DATB (diaminotrinitrobenzene)
•
Octol
•
Detasheet
•
Pentolite
•
Detonating cord (primacord or mild detonating fuse)
•
PETN (Pentaerythritol tetranitrate) (wet)
•
Bis-Dinitropropyl adipate
•
PETN/extrudable binder
•
Bis-Dinitropropyl glutarate
•
Plastic Bonded Explosives, PBX (a Group D explosive
•
Bis-Dinitropropyl maleate
formulated with a desensitizing plastic binder)
•
Dinitropropane
•
Potassium picrate
•
Dinitropropanol
•
RDX (Cyclotrimethylene trinitramine) (wet)
•
Dinitropropyl acrylate monomer (DNPA)
•
TATB (Triamino trinitrobenzene)(dry)
•
Dinitropropyl acrylate polymer (PDNPA)
•
TATB/DATB mixtures
•
EBW and slapper detonators
•
Tetryl
•
Elastomeric plastic bonded explosives
•
TNT (Trinitrotoluene)
•
Explosive D
Group E.
Explosives devices with their own means of initiation and with or without propelling charge.
•
Artillery ammunition
•
Rockets (e.g., 66 millimeter LAW)
Group F.

Explosives devices with their own means of initiation and with or without propelling charge.

Group G.
Pyrotechnic material and devices that produce an incendiary, illumination, lachrymatory, smoke, or sound
effect.
•
Smoke pots
•
Incendiary ammunition
•
Flares

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Table II-4. (Continued)

Group L.
Explosives or ammunition not included in other compatibility groups that present a special risk requiring
isolation of each type.
•
Damaged or suspect explosives, explosive devices or containers.
•
Experimental explosives, explosives of temporary interest, newly synthesized compounds, new mixtures, and some
salvaged explosives.
Group S.
Explosives, explosives devices, or ammunition presenting no significant hazard. Propellant cartridge
actuated devices (that yield nonfragmenting, nonflame-producing controlled reaction). Examples include the following:
•
Safety fuze
•
Cable cutters
•
Small arms ammunition
•
Cartridge actuated valves
•
Thermal batteries
•
Linear actuators (e.g., dimple, piston, bellows motors)
When near explosives, these materials become Group D, unless otherwise indicated.
•
FEFO/SOL (35 wt% or less FEFO in ethyl acetate)
•
FEFO/solution
•
Group D explosives in inert solvents (explosive concentration not exceeding 25 wt%)
•
Nitrates; treat as Group C when with other explosives
•
Perchlorates; treat as Group C when with other explosives
•
Small arms ammunition classified for shipment by DOT as ORM-D (Other Regulated Material Class D) rather than Hazard
Class/Division 1.4 explosives. Normally consists of ammunition not exceeding 50 caliber for handguns and rifles and 8
gauge for shotguns.

e. Mixing of Storage Compatibility Groups may be permitted as indicated in Table II-5. Items from
Storage Compatibility Groups B, C, D, E, F, G, and S may be combined in storage if the net quantity
of explosives in the items (or in bulk) does not exceed 1,000 lb and if the items are in approved
containers. Each article of Storage Compatibility Groups B and F shall be segregated in storage
from those of other compatibility groups by means that will prevent propagation of those articles.
f. As an alternate to Tables II-4and II-5, samples of explosives up to 2 kg total, may be stored in the
same cubicle if the cubicle walls are designed to prevent propagation. The material shall be stored in
separate cubicles in one of the following categories:
•
•
•
•

high explosives;
propellants;
detonators, actuators, and similar devices; or
primary and static-sensitive explosives.

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Table II-5. Storage compatibility mixing chartppp

Groups

A

B

C

D

E

F

G

A

x

z

B

z

x

z

z

z

z

C

z

x

x

x

D

z

x

x

E

z

x

F

z

G

z

N

S

z

x

x

z

z

x

x

x

z

z

x

x

x

x

z

z

x

x

z

z

z

x

z

x

x

z

z

z

z

x

x

x

H

H

J

K

L

x

J

x
x

K

x
z

L
N

x

x

x

x

x

x

S

x

x

x

x

x

x

x

x

x

x

x

NOTES:
•
•
•
•
•

An "x" in a block of the above chart indicates that these groups may be combined in storage. Otherwise, mixing is either
prohibited or restricted according to the following paragraphs.
A "z" in a block of the above chart indicates that when warranted by operational considerations or magazine availability,
and when safety is not sacrificed, these groups may be combined in storage. Combinations that violate the principles of
paragraph 17.4b in Chapter II require justification by an exemption.
No mark in a block indicates that combined storage is not permitted. L compatibility group types presenting similar
hazards may be stored together but not mixed with other groups.
K compatibility group requires not only separate storage from other groups, but also may require separate storage within
the group.
Refer to DOE DNA TP 20-7 for warhead storage compatibility and hazard class.

17.5

Containers (On-site)

a. Explosives containers shall be designed and constructed so they will not leak and will protect their
contents from excessive movement, external stimuli, contamination, or spillage during handling,
transportation (including transportation to disposal sites), and storage. Container closures shall
prevent spilling or leakage of contents if the container is overturned. Screw-type container closures
should not be used.

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b. Explosives containers should be constructed of, or lined with, nonabsorbent materials that are
compatible with the explosive contents. Use of glass containers is discouraged, except for small
samples, and shall be used only when the explosive reacts with other materials or when a high
degree of purity is required.
c. Metal containers for materials that are potential dust producers shall be constructed without seams or
rivet heads. Seams or rivet heads can provide locations for dust accumulation.
d. Containers for cast or pressed explosives pieces that are larger than 0.3 meter at their greatest
dimension or weigh more than 5 kg loaded should be provided with handles or some other type of
handhold. If the loaded container weighs more than 50 kg, provisions should be made to allow
handling by mechanical handling equipment.
e. Containers shall be labeled with the applicable UNO hazard classification code and marked in a
manner that clearly identifies its contents.qqq
f. Whenever possible, explosive pellets and items containing small quantities of explosives (e.g.,
detonators) shall be packaged in containers constructed so the functioning of one item will not
propagate to the remaining items in the container. When a nonpropagating array is not possible, the
pellets or detonators shall be stored inside a closed container and shall be labeled to indicate the total
weight of the explosive contents.
g. Container closures shall be the type that will not apply excessive pinching or rubbing forces to
explosives during closing and opening. The closures and surfaces of container openings shall be
kept thoroughly clean of explosives contamination to minimize any hazard during closing and
opening.
h. Explosives and ammunition in damaged containers shall not be stored in a magazine with other
explosives and ammunition. Damaged containers shall be repaired, or the contents transferred to
new or undamaged containers, or the container plus contents moved to a Group L storage magazine.
i. Open containers and containers with covers not securely fastened shall not be stored in magazines.
Containers that have been opened shall be properly reclosed before being returned to storage.
17.6

Storage in Buildings Other Than Storage Magazines

17.6.1 Packing and Shipping Buildings
In buildings specifically designated for packing and shipping, explosives may be stored subject to the
following rules.
a. Incoming shipments shall not be allowed to accumulate and shall be distributed as soon after receipt
as practical.
b. Items for outgoing shipments should not be accumulated before receipt of orders covering each
specific shipment.

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c. Separate rooms shall be provided for the temporary storage of explosives awaiting shipment and for
their preparation for shipment (i.e., assembling, crating, marking, etc.). The rooms shall be divided
by walls or separated from each other so an explosion in the preparation area will not propagate to
the temporary storage area.
d. The combined total amount of explosives permitted in shipping/receiving buildings, platforms, and
transportation vehicles shall be based on quantity-distance constraints. If there is an adequate
barricade (sufficient to prevent sympathetic detonation) between transportation vehicles and the
adjoining building or platform, the quantities on each side of the barricade may be considered
individually to determine quantity-distance requirements.
e. If required by operational necessity, explosives and pyrotechnics which are part of the work in
process within the building may be stored during non-operational hours in operating buildings
provided: 1) explosives limits are not exceeded, 2) containers of bulk explosives or pyrotechnics are
properly secured and covered, and 3) processing equipment, such as hoppers and pipelines, is empty.
17.6.2 Service Magazines
The guidelines presented above in paragraphs 17.1 through 17.5 of this chapter for storage magazines
shall also apply to service magazines, except as modified below:
a. An explosives item should be stored for no longer than necessary in a service magazine (with a
maximum of 180 days).
b. The inventory of each service magazine should be reviewed every 3 months. Any material that has
been in the service magazine for a period approaching 180 days and is not expected to be used
immediately should be disposed of or removed to an appropriate storage magazine.
c. When practical, explosives stored in service magazines shall be in containers. Unpackaged
explosives-containing devices and unsealed bulk explosives containers may be present in a service
magazine. However, these items and unsealed containers shall be stored in a manner that renders
them stable and unlikely to be dropped or spilled.
d. Minimum/maximum temperature monitors are not normally required for service magazines.
17.6.3 Warehouses
a. Hazard Class 1.4 materials (see Chapter VI, Section 3.1) packaged as Hazard Class/Division 1.4,
Storage Compatibility Group S, may be stored in warehouses if they are placed in segregated and
specifically designated areas.
b. Articles in Hazard Class/Division 1.4 and Storage Compatibility Group S are considered inert for
storage purposes and not subject to quantity-distance requirements as long as they are stored with
inert items or other Hazard Class/Division 1.4S items only. This applies only if Hazard
Class/Division 1.4 and Storage Compatibility Group S articles remain in their original packaging
container or are proven to be self-contained. When stored with items in a Storage Compatibility
Group other than S, normal quantity-distance requirements must be observed.
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17.6.4 Prepositioned Storage of Security Response Munitions
a. When required for defense against hostile forces, and in support of response and contingency plans,
limited quantities of authorized response force munitions may be prepositioned at locations other
than bulk-storage magazine areas. Compliance with Quantity-Distance and compatibility criteria is
not required during the heightened security condition. Munitions will be kept in their original
shipping containers unless operational necessity dictates otherwise.
b. Personnel charged with the responsibility of overseeing storage of munitions at guard stations and
contingency deployment sites shall be trained in explosives storage and transportation, as required in
Chapter V of this Manual.
c. In the event Hazard Class/Division 1.2 is stored inside or at less than inhabited-building distance
from inhabited buildings, fragment barriers will be provided. Any of the following are minimally
acceptable fragment barriers: 0.25 in. of mild steel plate, one layer of sand bags, 12 in. of loose sand
or dirt, or other equivalent protection.
18.0

DECONTAMINATION AND CLEANING

18.1

General

a. Operating procedures shall be prepared to specifically cover decontamination procedures. These
procedures should cover methods, inspection, marking, control, dismantling, maintenance, final
disposition, etc.
b. Hot water or steam may be used to clean up explosives or remove explosives contamination from
equipment. Solvents that have been tested for and are compatible with explosives can be used if
necessary. Controls for their use must be specified in operating procedures. Only clean cloth rags,
paper wipes, and approved non-metallic brushes or scrapers should be used in conjunction with hot
water, steam and solvents, to clean or remove explosives material from equipment, work surfaces,
and floors.
c. The disposal of waste generated during decontamination shall be coordinated with site
environmental/waste management personnel.

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Cleaning Contaminated Equipment

a. Items to cleaned should be positioned so that water and residue will drain directly into an approved
collection system. See Sections 19 and 20 of this chapter for guidance concerning waste collection
and waste disposal.
b. Personal protective equipment as required shall be used by personnel decontaminating facilities and
equipment. Emergency shower and eyewash shall be provided where needed.
c. Exhaust ventilation may be required to remove toxic explosives fumes or vapors and/or steam from
the decontamination area.
18.3

Cleaning Screw Threads

a. To avoid the necessity of cleaning explosives from threads, explosives processing techniques shall
be designed to avoid the deposition of explosives on threaded fasteners. When it is necessary to use
screw threads, some type of covering or protection (i.e., RTV cement) over the exposed threads
should be provided.
b. Threads should be cleaned by judicious use of approved non-metal "picks," solvent, or hot water, or
steam. Soaking in solvents and the application of a penetrating oil may be useful.
c. After decontamination of threads of screws, bolts, pipe, etc., it may still be advisable to provide
operator protection to facilitate their disassembly.
18.4

Final Decontamination and Disposal of Equipment

a. If the item to be decontaminated has only smooth, flat surfaces (i.e., no cracks, seams, voids, or other
places where explosive residue may be inaccessible), hot water, steam, or solvents may be employed
to effect total decontamination. Any explosives contamination of concern will be visible to the
unaided eye and will have dimensions (length, width, and depth).
b. If the item to be decontaminated has tight places where explosives may remain lodged following
normal cleaning procedures, the item shall be subjected to final decontamination techniques. To
facilitate cleanup, some items may have to be partially disassembled during the decontamination
operation.
(1)

Final decontamination by thermal techniques shall be done by subjecting the item to
sustained heating at a temperature at least 60°C higher than required for decomposition of
the most thermally stable explosive substance present. The item shall be kept at that
temperature for a sufficient period of time to ensure that all parts have reached the
temperature and all explosives material is decomposed. This is usually done by placing
the item(s) to be decontaminated in a high-temperature sustained fire (see TB 700-4,
"Decontamination of Facilities and Equipment"). This operation shall be conducted
remotely or with operator protection.

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(2)

Final decontamination may also be accomplished by immersing the item in a chemical
cleaning agent. The period of immersion shall be of sufficient duration to ensure that all
explosive material is chemically decomposed. The chemical cleaning agent shall be one
which is approved for use by the Department of Army TM 9-1300-214, "Military
Explosives." Chemical cleaning agents for decontamination or destruction of explosives
should not be used for more than about one oz. (or about 28 g) of explosives. Reference
U.S. Department of the Army TM 9-1300-214 for decontaminating chemicals for
explosives and for color tests for identification of energetic materials.

(3)

Before subjecting the item to final decontamination by thermal or chemical techniques, as
much explosive as possible shall be removed by the approved means (hot water, steam,
and approved solvents in conjunction with cloth or paper wipes and non-metallic brushes
or scrapers).

Inspection

After decontamination procedures are complete and before transfer to a nonexplosive area, the item shall
be inspected. The degree of decontamination shall be determined/documented and the item shall be
labeled to indicate its decontaminated state. Inspection should be accomplished by representatives of at
least two departments, such as the operating department and the safety department.
18.6

Identification and Control of Decontaminated Items

a. Decontaminated items shall be marked to indicate the degree of decontamination and stored
separately from non-contaminated items until final disposition is made.
b. Degrees of decontamination shall be designated and items shall be tagged and/or marked with this
designation.
c. Guidelines for establishing a system for designation degrees of decontamination are provided below.
(1)

X - A single X indicates the facilities or equipment have been partially decontaminated.
Further decontamination processes are required before facilities or equipment are moved
or any maintenance, repair, etc. is performed. This degree would generally be applied to
facilities or equipment that have been subjected to routine decontamination performed by
an operator on a piece of equipment, room, bay, or building at the close of the workday.

(2)

XXX - Three Xs indicate the equipment or facilities have been examined and
decontaminated by approved procedures and no contamination can be detected by
appropriate instrumentation, test solutions, or by visual inspection on easily accessible
surfaces or in concealed housings, etc. and are considered safe for the intended use.
Items decontaminated to this degree cannot be furnished to qualified DOE, DoD, or
industry users or be subjected directly to open flame (cutting, welding, high temperature
heating devices), or operations which generate extreme heat, such as drilling and
machining unless the following two conditions are met:rrr
(a) It is determined that decontamination to the XXXXX level will destroy the usefulness of
the item; and,
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(b) Decontamination to a degree less than XXXXX in combination with administrative and
technical safeguards will eliminate risk of injury. As a minimum, an approved SOP
(setting forth the specific operational limitations, precautions to be observed, and
monitoring necessary to assure safety) will be available and decontamination will be
performed under the direction of the inspector(s) who will certify decontamination.
(3)

XXXXX - Five Xs indicate the equipment or facilities have been completely
decontaminated, are free of hazard and may be released for general use or to the general
public.

(4)

O - A zero indicates the item, although located in a contaminated area, was never directly
exposed to contamination.

d. Reference U.S. Department of the Army TB 700-4, "Decontamination of Facilities and Equipment"
for decontamination methods and marking.
18.7

Decontamination of Real Estate

For decontamination of real estate reference DoD 6055.9-STD.
18.8

Decontamination and Cleaning References

In addition to this Manual, the following are reference sources for decontamination and cleaning.
•
•
•

DoD 6055.9-STD, "Department of Defense Ammunition and Explosives Safety Standard,"
Assistant Secretary of Defense (Force Management and Personnel), Chairman Department of
Defense Explosives Safety Board, 2461 Eisenhower Avenue, Alexandria, VA 22331.
Department of the Army Technical Bulletin TB 700-4, "Decontamination of Facilities and
Equipment," Army AG Publications Center, St. Louis, MO.
Department of the Army Technical Manual TM 9-1300-214, "Military Explosives," Army
AG Publications Center, St. Louis, MO.

19.0

WASTE COLLECTION

19.1

General

a. Provision shall be made for removal of explosives waste from any area in which explosive waste is
generated. Removal of explosives waste may be accomplished by collecting dust/fines in a wet or
dry vacuum system, collecting dust/fines or chips in a slurry of water or nonflammable solvent, or by
collecting solid waste in receptacles (See also Chapter II, Sections 9, 10, and 11).
b. Explosives waste shall be collected and maintained separately from conventional waste.
c. Mixing of incompatible explosives shall be avoided. Receptacles shall be clearly labeled to indicate
the type of waste permissible.
19.2

Solid Wastes
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a. Each explosives area in which solid explosives wastes are generated that are not removed by vacuum
or liquid systems shall be equipped with a seamless or lined receptacle in which explosives wastes
can be collected. The receptacle should never be more than half full.
b. Explosives waste shall be removed from the collection point on a regular basis, frequently enough to
keep the aggregate explosives levels within the explosive weight limits.
c. Rubbish not contaminated by explosives or containing noncombustible materials shall not be placed
in an explosives waste receptacle.
d. Rubbish contaminated by explosives shall be placed in separate waste containers and also segregated
as combustibles and noncombustibles.
e. Before being transported, explosives waste shall be packaged to prevent spillage, leakage, or
exposure to initiation stimuli. Incompatible materials shall not be packaged together. All packages
of explosives waste shall be clearly labeled to indicate the nature and approximate quantity of
contents.
19.3

Vacuum Collection of Explosives Dusts

a. Explosives dusts should be collected by a vacuum system, preferably the wet type. When using a
wet vacuum system, the dust should be maintained in a wet form using a wetting agent that is kept
close to the point of origin; the dust should also be kept wet in the collection system until removed
for disposal. Water-soluble explosives such as Explosive D should be collected dry.
b. Storage compatibility Group A explosives may be collected by a vacuum system, provided they are
maintained in a wet form using a wetting agent that is kept close to the point of intake. Use of
vacuum system for collecting these more sensitive materials should be confined to operations
involving small quantities of explosives.
c. Dry-type dust collection chambers, except portable units, should be located in the open and outside
operating buildings, or may be inside if adequate shielding is provided. The quantity of explosives
collected shall not exceed the capacity of the shielding to protect operating personnel. This limit
shall be determined by the degree of barricading and the appropriate intraline distance.
d. If dry dust collection outside the building is not practical, a separate room or shielded area within the
building shall be designated for this purpose. This room or shielded area shall not contain other
operations, nor shall it be used as a communicating corridor or passageway between other operating
locations within the building when explosives are being collected.
e. Stationary and portable wet-type collectors may be placed in the explosives operating bays or
cubicles if the quantity of explosives in the collectors does not exceed 2 kg. If placed in separate
cubicles, the explosive weight limits may be increased by an amount determined by the extent of the
cubicle walls’ capabilities to serve as operational shields.
f. Collection systems and chambers shall be designed to prevent explosives from being pinched
between metal parts. See Sections 9 and 10 of this chapter for additional design information.
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g. Two collection chambers shall be installed in series ahead of the pump or exhauster to prevent
explosives dust from entering the vacuum producer in dry vacuum collection systems. In addition,
non-sparking fans and dust-tight motors shall be used.
h. Dry-type portable vacuum collectors shall not be located in a bay or cubicle where explosives are
present or in enclosed ramps, but may be positioned outside the building or in a separate cubicle.
The building or cubicle walls shall provide adequate shielding for at least 2 kg of explosives and the
explosives limits shall be defined by shielding and quantity-distance constraints.
i. Explosives dust shall be removed periodically from the collection chamber to eliminate unnecessary
and hazardous explosives concentrations. The entire system should be cleaned periodically,
dismantling the parts if necessary. A cleaning schedule for the collection chamber and the entire
system shall be established using the operating hours as a basis.
j. The entire explosives-dust collecting system shall be electrically bonded and grounded with
resistance-to-ground not exceeding 10 ohms. The grounds shall be tested periodically.
19.4

Explosives Slurries

a. Machine tools shall be fitted with wet boxes to catch and direct water and explosives fines to an
explosives waste gutter system.
b. Wastewater that might contain explosives materials shall be kept from contaminating potable water
or conventional wastewater systems.
c. Settling tanks shall be regularly inspected to monitor the accumulation of waste. Records shall be
kept of waste removals.
d. If pumping is involved in removing the settled explosives from a slurry settling tank, the operation
shall be arranged to preclude exposure of the explosive material to any pinching in the operation.
e. Explosives materials in the settling basins shall be kept wet until removed and the materials shall be
maintained wet until spread out for disposal. Explosives materials containing powdered metals shall
be kept sufficiently wet to prevent a dangerous temperature rise resulting from a reaction of the
metal with water. The possibility of hydrogen generation in this situation must be anticipated.
19.5

Metal Scrap

a. Metal scrap shall be inspected to detect explosives-contaminated items and shall be certified by
qualified responsible personnel to be free from explosives before disposition.
b. If the scrap is found to be contaminated with explosives, it shall be decontaminated in accordance
with final decontamination procedures (see Section 18.4 of this chapter).
19.6

Explosives Recovery and Reuse

a. Salvaged explosives materials shall be thoroughly inspected by operating supervisors and reused,
screened, reprocessed, or destroyed as the situation warrants.
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b. Salvaged explosives materials shall be classified as Storage Compatibility Group L until they have
been established to be compatible with the original material.
20.0

WASTE DISPOSAL

20.1

Preparation for Open Burning

a. Preparations for burning explosives waste on a pad or in a pit, or for placing explosives waste shall
not begin until 24 hours after the previous burn at the same burning point. The only exception is if
the burning area has been thoroughly soaked with water and inspected by qualified personnel to
assure the safety of personnel during subsequent burning operations. In any case, the burning point
shall be inspected for residual embers or hot spots before loading with explosives.
b. Before beginning preparations, firing controls shall be disconnected from the power source and the
circuit shunted and grounded.
c. Incompatible explosives materials shall not be in the same pit or on the same pad at the same time.
d. Containers of explosives materials shall not be opened less than 3 m from each other.
e. Empty explosives waste containers that are to be reused shall be situated an adequate distance from
the burning point to prevent charring or damage during the destruction operation.
f. A layer of excelsior or similar material should be placed on the bottom of the pit or pad for
placement of the explosives waste.
g. Explosives in powdered, granular, or slurry form should be placed in a layer not more than 8 cm
thick. Water-wet initiating explosives (storage compatibility Group A) shall not be allowed to
become completely dry.
h. Wood, heating oil, LPG, or natural gas are authorized for use as an aid to ensure complete
combustion of the explosives waste material.sss
i. The ignition train should be set up to burn upwind.
j. The firing circuit shall require a key for completion. Only one copy of the firing key shall exist, and
it shall be in the lead operator’s possession.
k. Radio transmitters in the control shelter and vehicles at the burning site shall be turned off during
setup and firing to protect against radio frequency currents.
l. Precautions shall be taken to ensure that the firing system will not be unintentionally activated by
extraneous electrical currents from any source.
m. Priming of the burn shall be accomplished after all other preparation work is complete and with a
minimum number of personnel present.
n. Ignition shall be accomplished remotely.
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Destruction by Burning or Flashing

a. Explosives waste may be destroyed by burning (remotely) if it can be done with little chance of
detonation. Explosives-contaminated waste may be burned remotely in a wire cage.
b. An open furnace or burning area for explosives should be used for destruction of wet-machining
cuttings and classified parts. The furnace or burning area may also be used for flashing casings after
washout of an explosive charge.
c. Explosives should not be burned in closed containers or casings, nor in large pieces likely to
detonate. Special attention should be given to the placement and orientation of large items and those
in closed containers or casings. Approved incinerators may be used to destroy small devices such as
detonators, actuators, etc.
d. Concurrent burning operations shall not be conducted within 45 m of each other.
e. When several pads are burned, the downwind pad shall be ignited first, followed by the others in
succession to the upwind pad.
20.3

Ignition System Malfunctions

a. If the ignition system fails to fire, check the circuit’s continuity and refire if no open circuits are
detected.
b. If the squibs did fire but failed to ignite the ignition train, survey the area by remote means, and wait
at least 30 minutes. If it then appears safe to emerge from the control shelter, disconnect, shunt, and
ground the firing circuit, and inspect the squibs, firing system, or ignition train.
20.4

Postburn Operations

a. No entry shall be allowed into the pit area until at least 8 hours have elapsed following an open burn.
b. The squib firing lines shall be disconnected, shunted, and grounded before the burn area is entered.
c. Unburned or partially burned explosives materials remaining in the pit shall not be raked or
otherwise disturbed. The burning operation shall be repeated to destroy any remaining explosives
waste.
d. At least 24 hours shall elapse before ashes are collected and the pit prepared for another burn.
20.5

Disposal Area

a. Explosives waste destruction operations shall be separated from magazines, inhabited buildings,
public traffic routes, and occupied operating buildings to ensure that personnel and facilities are not
exposed to hazardous blast overpressure, fire brands, fragments, or projectiles from burning or
detonation of explosives. The following separation distances shall apply:ttt

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(1)

Destruction by open burning or flashing shall not be performed within 730 m (2395 feet),
unless carried out in pits or with other aids for limiting the range of fragments and debris
in event of an accidental detonation. In no case may the pit be located at less than 204 m
(669 feet) for weights of 45 kg (99 pounds) or less and 381 m (1250 feet) for weights
exceeding 45 kg (99 pounds). Sites should be located in relation to the direction of the
prevailing winds so that sparks will not be blown toward explosives locations.uuu

(2)

The size of the danger zone for destruction by open detonation shall be determined by the
formula D(m) = 131 Q1/3 [D(ft) = 328 W1/3]. The minimum separation distance shall be:
Non-fragmenting explosive materials

381 m

Fragmenting explosive materials

762 m

Bombs/projectiles with 5 in. caliber or greater

1220 m

If known, the maximum fragment (debris) throw distances with an applicable safety factor
may be used to replace the 762 m and 1220 m minimum separation distances but not below
381 m.
(3)

Self-contained destruction facilities fully analyzed for the intended net explosives weight
(NEW) are exempt from the above requirements.

b. The maximum quantity of explosives that may be destroyed at one time shall be determined by
starting with a small quantity, gradually increasing until an optimum amount, consistent with safe
and efficient operation, is achieved.
c. Explosives waste and ordinary rubbish shall not be destroyed in the same destruction area at the
same time.
d. When destruction operations are being carried out, the area within 60 m of the destruction point shall
be kept clear of dry grass, leaves, and other extraneous combustible material. This clearance may be
reduced to fire brand distance if aids for limiting the range of fragments and debris are provided for
all the destruction points used within the disposal area.
e. Explosive waste awaiting destruction shall be stored at least intraline distance from the explosives
being destroyed.
f. Provisions for emergency fire fighting shall be readily available at the waste disposal area.
20.6

Destruction by Detonation

a. Cased explosives should be removed from the case and burned or the cased item destroyed by
detonation. Detonators, primary explosives, and other explosives that might detonate if burned
should also be destroyed by detonation.
b. The detonation should be initiated by a high-energy detonator (e.g., an EBW).
20.7

Use of Solvents
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a. Small quantities of explosives and explosive detonators may be prepared for destruction by solvent
immersion.
b. The items to be destroyed shall be soaked in a suitable, compatible solvent until all the explosives
material is dissolved. Saturated solvent solutions shall not be reused.
c. The solvent-explosives mixture shall be destroyed by burning.vvv
21.0

LABORATORY OPERATIONS

21.1

General

a. The safety guidelines presented in this section are applicable to general laboratory operations
involving explosive materials. Laboratory operations shall be conducted in a manner that maintains
employee exposures to hazardous chemicals at or below the permissible exposure limits (PELs) and
complies with the facility chemical hygiene plan.
b. Laboratory work involving explosives materials shall be performed only in accordance with the
provisions of written operating procedures (see Chapter VII). Laboratory operations shall comply
with the requirements of NFPA 45, "Fire Protection for Laboratories Using Chemicals," including
the requirements for electrical equipment and wiring.
c. The quantity of explosives present in the laboratory shall be the minimum required for the operations
and should be at or below assigned limits. Storage of material not in process is allowed provided it is
secured when the laboratory is not occupied. The material shall be configured in a manner to
preclude exceeding the Maximum Credible Event (MCE).www
d. Open flames shall be prohibited in laboratories where explosives or flammable solvent vapors are or
may be present unless allowed by approved hazards assessment or procedure.xxx
e. Disposal of explosives through laboratory drains shall be forbidden unless the drain plumbing has no
traps and is designed to handle explosives (i.e., is provided with a sump or other device for the
collection of solids). Even if a drain is designed to handle explosives, deliberate disposal of
explosives in these drains should be avoided. These drains should be used only for the purpose of
cleaning up explosives spills. Special care should be exercised to prevent entrance of compounds
into drains that may react with iron or rust to form sensitive salts (e.g., picrates and picric acid).
f. Solvents or other substances that are flammable shall be protected against electrical sparks, heat, and
open flames.
g. Suitable guards shall be provided for all glass or fragile equipment that must withstand reduced or
elevated pressure.
21.2

Safety Shields

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a. If a laboratory operation involves an explosion hazard, personnel should be protected by safety
shields or the operation should be performed by remote control. Table II-6 lists shields that have
been tested and found acceptable for the indicated quantities of explosive. Shields listed in this table
were not tested for metal-fragment penetration (unless specifically indicated) and thus may not offer
effective protection when the explosive is closely confined in a heavy-walled metal container.
("Heavy-walled" is defined here as wall thickness to diameter ratio greater than 0.01.)
b. If an experiment presents a metal-fragment hazard (as opposed to a glass-fragment hazard) and the
experiment cannot be conducted remotely, the proposed shield should be tested and approved under
conditions simulating an explosion in the experimental setup but with at least 125% of the
anticipated explosive content.
c. The shield shall be anchored to the hood frame or bench top when it is being used for protection
against more than 5 grams of TNT equivalent.
d. Other shields may be used after successfully passing a test of 125% of the rated explosive charge
and being approved.
e. For confined areas, a blast vent having less strength than the shield should be provided.
f. When explosives operations require personnel to reach around a shield to manipulate equipment,
exposure shall be minimized.
Table II-6. Safety shields for explosive laboratory operations*yyy
Shield

Minimum distance from
explosive (cm)

Explosives limit

Leather gloves, jackets, or coats, and
plastic face shields

----

50 mg

3 mm tempered glass

8

50 mg

7 mm Lucite/equivalent material

15

2.5 g

20 mm Lucite/equivalent material

15

10 g

15 mm laminated resistant glass

20

20 g

25.4 mm Lexan/Lexguard

30

50 g

2 units each of 25.4 mm plate glass
laminated with 12.4 mm polycarbonate
with a 9.5 mm air gap between units
(glass sides facing the explosive)

30

50 g
(steel confined)

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Recent blast testing has shown that laminated tempered glass is superior to monolithic tempered glass, and
polycarbonate is superior to acrylic plastics, such as Lucite. Laminated tempered glass is recommended
instead of monolithic tempered glass and polycarbonate is recommended in lieu of acrylic. The shields are
recommended to be of equal or greater thickness than those listed in the table. Proof testing is highly
recommended. When designing and/or replacing a safety shield with a polycarbonate, it should be UV
stabilized, treated for abrasion resistance, and have met Mil Spec P-46144C. When designing and/or
replacing a safety shield with laminated glass, it should be coated with a 0.1 mm fragment-resistant film on
the viewer’s side to minimize spalling. The shield, shield frame, and anchoring system shall be designed to
resist maximum credible overpressure and fragments.

21.3

Heating Operations

a. During synthesis, formulation, or experimental work, heat may be applied to initiate or maintain
reaction, to increase solubility, etc., if the principles below are followed:
(1)

Heat shall be applied indirectly using steam, a water bath, oil bath, or an approved
laboratory electrical heating device such as a mantle.

(2)

Utmost caution shall be exercised to ensure that reactive material does not come in direct
contact with the heating elements.

(3)

If an experiment must be conducted behind a shield, any heating device shall be mounted
so that temperature can be controlled from the operator side of the shield. The heating
device should be mounted so it can be quickly separated from the reaction vessel without
operator exposure. Consideration should be given during design of the experiment to
providing emergency cooling for the reaction vessel or its contents.

(4)

Heating of explosives with devices without proper controls shall be monitored at all
times, and if the operator must leave for any reason, the heating device should be turned
off. Heating systems that will be operated unattended shall have dual controls, an
override shutoff, or some other protection against failure of the primary heating control.
Systems capable of total containment of the effects of an explosion may be exempted
from this requirement.

b. Periodic checks should be made to ensure that an experiment is proceeding satisfactorily and that the
apparatus is not boiling dry, malfunctioning, or the like. in the case of remotely controlled
operations, provisions shall be made for such observation, using such equipment as mirrors,
television monitors, etc.
21.4

Laboratory Setups

Good workmanship and laboratory practice shall be exercised in making and operating laboratory
setups. In particular, cognizance must be taken of the following points:
a. Equipment and apparatus shall be clean, in good condition, and in good working order.
b. All glassware and apparatus shall be inspected for cracks, defects, etc., before use. Defective or
damaged equipment shall be removed from service.
c. Setups shall be geometrically and structurally stable.
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d. Work areas should be as neat and uncluttered as circumstances will permit.
21.5

Low Concentration of Explosives in Solution

a. After explosives are in dilute solution (less than 33% explosives by weight), the primary hazard shall
be considered as that associated with the solvent and not with the explosive.
b. Until the explosive is in solution, or if for any reason the explosive recrystallizes or precipitates out
of solution, the safety guidelines for pure explosives shall apply.
21.6

Explosives Sample Control

a. Samples shall be delivered to the laboratory only at specific designated locations.
b. Each sample shall be properly identified and labeled.
c. Upon completion of the required tests or analyses, the sample should be removed from the
laboratory.
d. All samples of new experimental explosive material submitted to a laboratory for analysis should be
accompanied by an information sheet giving available safety information.
22.0

EMERGENCY CONTROL

22.1

Placarding and Fire Symbols

Buildings and areas shall be placarded to warn of potential hazards from explosives and to provide
information crucial to dealing with emergency situations. This includes the use of appropriate fire
symbols as specified in DoD 6055.9-STD or the NFPA 704 Standard, provided placarding is applied
consistently throughout the entire facility.
22.2

Explosives Emergency Control Plans

a. Each installation shall have a written plan, prepared specifically for that installation (it may be
necessary to break it down for each operating area), for the control of emergencies involving
explosives. The explosives emergency control plan may be part of the overall emergency control
plan for the facility. All facility personnel shall be trained in the content of the plan applicable to
their area. The plan shall be available to all personnel for ready reference.
b. Emergency situations that should be covered, as applicable to the facility, are as follows:
(1)

fires and explosions;

(2)

floods;

(3)

extreme weather conditions;

(4)

conditions resulting in environmental disturbances;
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(5)

civil disturbance;

(6)

threats and bomb scares;

(7)

enemy attack; and

(8)

any other emergencies which require rapid mobilization of personnel and equipment to
minimize death and injury to personnel or to prevent the spread of damage and
destruction.

c. Subjects that should be addressed by the plan include:
(1)

reporting an emergency;

(2)

decision to activate the emergency plan;

(3)

authority and responsibility for administration and execution of the plan;

(4)

mobilization of personnel to combat the emergency or disaster;

(5)

roles of operating personnel in combatting the emergency;

(6)

procedures for combatting the emergency or disaster;

(7)

accounting for evacuation of personnel; and

(8)

plant and document security.

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CHAPTER III - EXPLOSIVES AND PERSONNEL LIMITS
AND CONTROL
1.0 EXPLOSIVES LIMITS
The quantity of explosives at an operating location shall be the minimum necessary to carry out the
operation in a safe and efficient manner. When practical, this quantity shall be subdivided and
adequately separated to prevent propagation of detonation. Supplies exceeding this minimum quantity
shall be removed from the operating area.
In no case shall the quantity of explosives permitted in an operating building exceed the maximum
permitted by the quantity-distance criteria. Quantity-distance criteria and guidelines for application of
these criteria are presented in Chapter VI of this Manual.
2.0 PERSONNEL LIMITS
The number of personnel at an operating location shall be the minimum consistent with safe and
efficient operation. In establishing personnel limits, the following principles shall be followed:
a. Jobs not necessary to the performance of a hazardous explosives operation should not be performed
in the same location as the hazardous operation. Personnel not needed for the hazardous operations
will not be allowed in hazardous locations.
b. Personnel limits shall allow for necessary casuals.
c. Sufficient personnel shall be available to perform a hazardous operation safely and, in the event of
accident, to obtain help and aid the injured.
d. No person shall work alone performing explosives activities that have a high risk of serious injury.
Prompt and easy communications with other employees shall be provided. Facility management
shall specify which explosives activities may be performed alone.
3.0 LIMIT CONTROL
3.1

Posting and Recording

All rooms, bays, and buildings containing explosives shall have posted in a conspicuous place a
standardized placard stating the maximum amount of explosives and the maximum number of workers
and casuals permitted in the control unit at any one time.
Maximum explosives and personnel limits for all buildings and bays for each explosives area shall be
recorded and maintained on file.

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Limit Review and Approvals

Management personnel with authority and jurisdiction over an operating bay or building shall
periodically review explosives and personnel limits for each location and recommend changes as
required. If the use of a location changes, personnel and explosives weight limits shall be reviewed at
the time of use change and limits reestablished as required.
Changes in explosives and personnel limits shall be reviewed and approved in the same manner as
operating procedures (see Chapter VII).
A procedure shall be established for the approval of temporary changes in explosives and personnel
limits for an operating location.
3.3

Personnel Controls

A system shall be established to control the presence of personnel within explosive operating areas.
3.4

Explosives Controlzzz

A system shall be established to control the amount of explosives present in an explosives facility and
shall be verifiable.aaaa
4.0 IHE LIMITS
When no other explosives are present, IHE weight limitations shall be based on separation distances for
Hazard Class 1.3 explosives (see Chapter VI, Section 3.1) or equivalent protection provided by facility
design features. The quantity of IHE at an operating location shall be the minimum necessary to carry
out the operation in a safe and efficient manner.bbbb
IHE limits for pressing, dry blending, dry milling, dry screening, and certain machining operations (see
Chapter II-12.4.2c), should be the same as those established for HE operations.cccc

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CHAPTER IV - PERSONAL PROTECTIVE CLOTHING AND
EQUIPMENT
1.0 CLOTHING AND PERSONAL EQUIPMENT
1.1

Clothing

Each operation shall be analyzed to determine when personnel working with explosives and toxic
materials must wear approved coveralls or laboratory coats to prevent contact with these materials and
to prevent contaminating personal apparel. Flame-retardant coveralls may be desired for certain
explosives operations where the possibility of flash fire exists. These coveralls shall not have cuffs and
should not have metallic fasteners. Written procedures shall include protective clothing and equipment
requirements.
Cotton (or other antistatic material) outer and undergarments, including socks, should be worn where
generation of static electricity would create a hazard.
1.2

Footwear

Personnel working in a building or area where electrostatic-sensitive explosive powders or materials are
handled shall wear conductive, nonsparking footwear. Exception: personnel working on electrical or
electronic equipment shall not wear conductive footwear unless protected by insulated mats, ground
fault circuit interrupters (GFCI), etc. Personnel working in other areas where explosives contamination
may be present shall wear nonsparking footwear or bootie shoe coverings.
1.3

Respirators

Appropriate, approved respiratory protection shall be used when exhaust ventilation is not available, or
does not adequately control airborne particulate, gases, or vapors liberated during explosives operations.
The employee must have current approval to wear respiratory protection (medical exam, respirator
fitting, and training).
1.4

Eye Protection

Suitable eye protection devices must be worn by all personnel when working or visiting in eye hazard
areas, particularly when electroexplosive devices are handled. The type of explosive operation shall be
evaluated for eye hazard risks. Contact lenses shall not be considered as an appropriate eye protection.
1.5

Gloves

Skin contact with some explosives, and with some materials used in conjunction with explosives, can
result in dermatitis or absorption across the skin barrier. Each type of operation using these materials
must be evaluated for the potential skin contact hazard and the need for the proper type of glove.
2.0 MAINTENANCE AND TESTING
2.1

Equipment Maintenance and Inspection
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Personal protective equipment shall be properly maintained; the operator’s life may depend on the proper
functioning of the equipment. An appropriate inspection schedule shall be established.
2.2

Conductivity Testing

When conductive footwear is required, the conductivity shall be tested initially and regularly thereafter
to ensure continued conductivity from person to ground.
2.3

Cleaning and Disinfecting

Provision shall be made for the laundering and disinfecting of protective garments and devices.
Attention to cleaning and disinfecting is especially important for equipment worn about the face.
Because laundering affects the flame-retardant properties of fabric, flame-retardant coveralls should be
tested to establish the maximum number of laundering cycles permitted.
2.4

Contaminated Clothing

If clothing becomes contaminated, as much contaminant as possible should be removed by wiping or
dusting; compressed air shall not be used for this purpose. If obvious contamination remains, clothing
shall be changed.

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CHAPTER V - TRAINING
1.0 GENERAL
Personnel shall be properly trained before they are assigned to any explosives operation or operate any
explosives-carrying vehicle. The training for explosives work, which serves to assist in conducting
work safely and developing safety awareness, shall insure that personnel:
•
•
•
•
•

develop and maintain a safe attitude towards work with explosives;
define and understand the potential hazards involved;
learn correct skills for safe performance of the task;
are prepared for unexpected hazardous conditions; and
read and understand the appropriate operating procedures.

2.0 SUPERVISORY RESPONSIBILITY
The supervisor shall be responsible for the following:
•
•
•
•
•

determining the training required for the worker (or researcher);
verifying that the worker is adequately trained to perform the task safely and efficiently;
ensuring that the worker can perform required emergency duties;
providing on-the-job training for the worker; and
continually updating worker training.

3.0 TRAINING AND QUALIFICATION PROGRAMS
Each organization shall have a training and qualification program. The following is an example.
a. After successfully completing training for an assignment, the worker should be qualified for that task
for a specific period of time. Maintenance of qualification should be governed by the following
items:
(1)

At the end of the initial qualification period, qualification may be extended for
subsequent specific time periods if:
•
•

the worker has successfully performed the task during the preceding six months and
has read and understands the current operating procedures; or
the worker receives refresher training and is again determined to be qualified by
his/her supervisor.

(2)

Retraining in the specific area of weakness should be required of workers who do not
demonstrate job proficiency or who subsequently violate safe practices.

(3)

If an operating procedure is modified substantially, all personnel using that procedure
should be retrained in the use of the new procedure.

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A person should not be permitted to continue working with explosives if the supervisor,
with counsel from medical personnel, determines that the person is unable to perform the
task safely. Possible reasons include:
•
•
•

(5)

Records should be maintained for each worker, including:
•
•
•
•
•

(6)

physical injury or illness;
disease; and
mental or emotional disturbances.

description and dates of training received;
description and dates of refresher training;
a signed "statement of understanding" for operating procedures;
attendance at safety meetings and participation on safety committees; and
qualification review by supervisor.

The supervisor may temporarily authorize an employee who has not completed the
required training to perform the task if the following conditions are satisfied:
•
•

the supervisor determines that the employee has a working knowledge adequate to
perform the task safely.
the work is directly supervised by qualified person.

b. Employee hazardous materials information and training programs are required for personnel
working with explosives and hazardous materials used in conjunction with explosives operation.
Training should include:
•
•
•
•

information on the physical and health hazards;
the purpose and proper use of engineering controls, work practice controls and protective
equipment;
labeling systems and Material Safety Data Sheet terms; and
detection methods for the presence or release of a hazardous material in the work area.

4.0 UXO Trainingdddd
a. Personnel in charge of UXO removal/disposal should be US citizens and shall have successfully
completed training at a United States Military Explosives Ordnance Disposal (EOD) school.
Personnel shall have documentation of completion [completed training] and have a minimum of 18
months operational EOD experience. All personnel engaged in operations shall be thoroughly
trained in UXO recognition and explosives safety applicable to the operation.
b. Personnel performing UXO removal/disposal shall have completed training at a US Military EOD
school or have equivalent training and/or experience. All other personnel engaged in operations
shall be thoroughly trained in UXO recognition and explosives safety applicable to the operation.

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c. Personnel who are not involved in UXO operations, but require access to areas known or suspected
to contain UXOs shall be required to have completed UXO awareness training and shall be escorted
by personnel qualified under (a) or (b) above. An UXO High Explosives Awareness video (EPL
122) is recommended for the awareness training.
5.0 Referenceseeee
-

OT-525, Personnel Qualifications, Commanding Officer, Naval Explosive Ordnance Disposal
Technology Division, 2008 Stump Neck Road, Indian Head, MD 20640-5070

-

UXO High Explosives Awareness video (EPL 122), Sandia National Laboratories/New Mexico
Environmental Restoration Program

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CHAPTER VI - QUANTITY-DISTANCE AND LEVEL-OFPROTECTION CRITERIA FOR EXPLOSIVES ACTIVITIES
1.0 GENERAL
This chapter establishes quantity-distance and level-of- protection criteria for all DOE operations
involving explosives. The purpose of these criteria is to provide specific levels of protection from the
effects of potential fires and explosions for personnel and property within and outside of DOE
installations.
The cardinal principle to be observed at any location or in any operation involving explosives,
ammunition, severe fire hazards, or toxic materials is to limit, in a manner consistent with safe and
efficient operation, the exposure to a minimum number of personnel, for a minimum time, and to a
minimum amount of the hazardous material.
2.0 APPLICABILITY OF CRITERIA
2.1

Specific Applications

The criteria presented in this chapter shall be applied to the following activities:
a. establishing maximum explosives limits for explosives facilities and operations;
b. planning explosives activities to be performed in existing facilities; and
c. designing and siting new explosives facilities and operations and siting other facilities and
operations in the explosives area.
2.2

Explosives Limits

When defining working explosives limits, those limits shall never exceed the minimum required for
efficient, safe operation (see Chapter III).
2.3

Areas Where Criteria Are Not Applicable

The quantity-distance and level-of-protection criteria in Section 4 of this chapter are not applicable to
portable buildings used at specified nuclear test shot locations.

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3.0 QUANTITY-DISTANCE CRITERIA
Quantity-distance criteria must account for the types and severity of hazards presented by each explosive
material, the construction and orientation of facilities to which the criteria are applied, and the degree of
protection desired for facilities and personnel adjacent to the explosives operations. The hazard
classification system recommended by the United Nations Organization (UNO) defines types and
severities of hazards for explosives. The guidelines presented below specify minimum degrees of
protection for various categories of facilities. These guidelines also describe how the quantity-distance
tables are to be applied to facilities of various construction and orientation with respect to adjacent
facilities.
3.1

Hazard Classes and Class Division

Explosives shall be classified on the basis of their reactions to specific initiating influences. The hazard
classification system recommended by the UNO shall be used for DOE explosives classification. The
UNO system consists of nine classes for dangerous goods, with explosives included in Class 1. The
explosives hazard class is further subdivided into "divisions," which are based on the character and
predominance of the associated hazards and on the potential for causing personnel casualties or property
damage. Table VI-1 lists the six divisions of Class I.
Table VI-1. Divisions of Class 1
Hazard class and division designators

Hazards

1.1

Mass detonating

1.2

Non-mass explosion, fragment producing

1.3

Mass fire, minor blast or fragment

1.4

Moderate fire, no blast or fragment

1.5

Explosive substance, very insensitive (with a
mass explosion hazard)

1.6

Explosive article, extremely insensitive

When required to properly describe the hazard, a numerical figure in parenthesis shall be placed to the
left of the division designators 1.1 through 1.3 [e.g., (18) 1.1, (08) 1.2, and (06) 1.3]; this number
indicates the minimum separation distance (in hundreds of feet) for specified levels of protection from
explosive items for inhabited buildings, public traffic routes, and personnel in the open. A minimum
distance number shall be used for all items in Class 1, Division 2, as shown in the applicable tables.
Figure VI-1 illustrates the use of the UNO hazards classification system. Also, this figure lists the
storage compatibility group opposite each hazard class. The listed compatibility group is typical for the
expected compatibility to hazard class relationships. Note however, that the two classification systems
apply to different concerns.

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Figure VI-1. Application of Hazard Classification System
•
•

Compatibility groupings define which explosives may be safely stored together without
increasing the risk of initiation.
Hazard classifications indicate the initiation effects of the various explosives.

Classification tests (described by TB 700-2, "Explosives Hazard Classification Procedures") and/or
additional tests (as desired), including United Nations ST/SG/AC.10/1 and ST/SG/AC/10/11, shall be
used in the assignment of energetic materials to the appropriate compatibility group and hazard division.
These tests may be supplemented by other tests to characterize material hazards more fully if material
properties or anticipated material environment are expected to significantly influence the explosives
classification.
Though DOT Hazard classifications require the use of the Bureau of Explosives’ (BOE) Impact
Apparatus to determine impact sensitivity, other impact apparatus may be used, providing:
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a. test results for at least two reference explosives are compared to results for the reference explosives
on the BOE Impact Apparatus; and
b. a minimum of ten trials each is run for the reference explosives and the explosives being classified.
3.2

Establishing Quantity of Explosives and Distances

3.2.1

General

The principles and tables presented in DoD 6055.9-STD, "DoD Ammunition and Explosives Safety
Standards," shall be used to determine the following:
a. The total quantities of explosives in adjacent magazines, operating buildings, or other explosives
facilities that must be applied to quantity distance tables.
b. When the levels of protection required by Section 4 of this chapter for different types of facilities
differ from the requirements of DoD 6055.9-STD, Section 4 shall take precedence.
c. The minimum separation distances required for the facilities are based on the desired level of
protection and total quantities of explosives.
d. The total quantity of explosives is determined by defining and examining the maximum credible
event (MCE). If an explosives event occurs, the maximum credible explosives event is the largest
credible amount of explosives that could be involved in the event (not necessarily the total quantity
of explosives present).
3.2.2

Use of Metric System

Throughout DoD 6055.9-STD, the net explosive weight (NEW) is used to calculate distance by means
of a formula of the type D=KW1/3, when D is the distance in feet, K is a factor depending upon the risk
assumed or permitted, and W is the NEW in pounds. When metric units are used, the symbol Q denotes
net explosive quantity (NEQ) expressed in kilograms. In the formula D=KQ1/3, the distance D is
expressed in meters. Thus, the respective units of K are ft/lb1/3 and m/kg1/3 in the two systems. The
value of K in English units is approximately 2.5 times its value in metric units [e.g., if D(m)=6Q1/3,
then D(ft)=15W1/3].
3.2.3

Railcars and Transport Vehicles

Explosives-loaded railcars, motor vehicles, or any other transport vehicles in holding yards are
considered as aboveground magazines for quantity-distance purposes. These railcars, motor vehicles, or
other transport vehicles shall be kept in groups, and each group shall be limited to a maximum of
250,000 lb of high explosives.
a. When a railcar receiving yard or point is provided for the interchange of cars containing explosives
between the common carrier and the facility rail system, quantity-distance provisions do not apply,
provided that the cars are moved expeditiously to a suitable location.
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b. When inspection of a railcar of explosives indicates that it may be in a hazardous condition, the
railcar should be moved at once to a suspect car spur track or an isolated section of track. This spur
or section of track should be accessible directly from the inspection point. The distance between the
spur or track and facility boundaries, classification yards, inhabited buildings, administration areas,
operating buildings, magazines, inert storage locations, and public traffic routes should be the
inhabited-building distance, which is based on the maximum quantity of explosives that the facility
can receive in one railcar. Only one car is permitted at this location at any time.
c. Incoming explosives-laden motor vehicles shall be inspected at a station located remotely from
hazardous and populated areas.
3.2.4

Utilities Installations

a. Permanent DOE-controlled underground utilities installations (excluding building service lines)
should be separated from explosives locations containing Hazard Class/Division 1.1 materials (see
Table VI-2). Privately owned or operated utilities installations (aboveground and underground) shall
be separated from explosives locations by at least public-traffic- route distances. If these
installations include structures, they should be separated from explosives facilities by inhabitedbuilding distance.ffff
b. Certain type of auxiliary power facilities, transformer stations, etc., present fire hazards to explosives
facilities. Transformers and associated electrical switching apparatus serving one explosives facility
or complex that do not present a fire hazard to the facility (i.e., dry-type, "less flammable" oilinsulated, etc.) shall be located as specified in NFPA 70 and FM Data Sheet 5-4/14-18. Normal oilinsulated transformers shall be located at least 50 ft from an explosives facility or as specified in
DoD 6055.9-STD.

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Petroleum Storage Tanks

Above ground tanks containing 500 gal or less of petroleum that serve equipment (such as oil heaters or
diesel generators) located in or near explosives buildings shall be located a minimum of 50 ft from
explosives locations and comply with NFPA 30. Tanks located near intentional detonation areas should
be barricaded. Similar underground tanks complying with NFPA 30 do not require separation from
explosives facilities. In both cases, the tanks shall be equipped with an antisiphoning device, unless the
tank is installed such that siphoning is impossible.
Table VI-2. Quantity-distance separation for protection of underground service
installationsgggg
Quantity of explosives
(maximum pounds)

Distance
Meters

Feet

100

26

80

200

26

80

500

26

80

1,000

26

80

2,000

26

80

5,000

26

80

10,000

26

80

20,000

28

85

50,000

36

110

100,000

46

140

250,000

62

190

Note: If the potential donor building is designed to contain the effects of an explosion, the formula D=3.0 W1/3
can be used to determine separation distances for less than 20,000 pounds.

4.0 LEVEL-OF-PROTECTION CRITERIA
4.1

Hazard Classes

The level of protection required for any specific explosives activity shall be based on the hazard class
(accident potential) for the explosives activity involved. These four hazard classes are defined for
explosives activities as follows:

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a. Class I. Class I consists of those explosives activities that involve a high accident potential; any
personnel exposure is unacceptable for Class I activities, and they thus require remote operations. In
general, Class I would include activities where energies that may interface with the explosives are
approaching the upper safety limits, or the loss of control of the interfacing energy is likely to exceed
the safety limits for the explosives involved. This category includes those research and development
activities where the safety implications have not been fully characterized. Examples of Class I
activities are screening, blending, pressing, extrusion, drilling of holes, dry machining, machining
explosives and metal in combination, some environmental testing, new explosives development and
processes, explosives disposal, and destructive testing. hhhh
b. Class II. Class II consists of those explosives activities that involve a moderate accident potential
because of the explosives type, the condition of the explosives, or the nature of the operations
involved. This category consists of activities where the accident potential is greater than for Class
III, but the exposure of personnel performing contact operations is acceptable. Class II includes
activities where the energies that do or may interface with the explosives are normally well within
the safety boundaries for the explosives involved, but where the loss of control of these energies
might approach the safety limits of the explosives. Examples of Class II activities are weighing,
some wet machining, assembly and disassembly, some environmental testing, and some packaging
operations.iiii
c. Class III. Class III consists of those explosives activities that represent a low accident potential.
Class III includes explosives activities during storage and operations incidental to storage or removal
from storage.
d. Class IV. Class IV consists of those explosives activities with IHE or IHE subassemblies. Although
mass detonating, this explosive type is so insensitive that a negligible probability exists for
accidental initiation or transition from burning to detonation. IHE explosions will be limited to
pressure ruptures of containers heated in a fire. Most processing and storage activities with IHE and
IHE subassemblies are Class IV. However, the following examples of explosives activities with IHE
and IHE subassemblies will remain Class I:jjjj
•
•
•
•
•
4.2

pressing;
some machining (see Chapter II, paragraph 12.4.2.c);
dry blending;
dry milling; and
dry screening.

Required Level of Protection

Each bay (i.e., storage, handling, or processing building) housing an explosives activity shall have levels
of protection that are based on the hazard class determined for the activity. The levels of protection may
be accomplished by equipment design, structural design, operation separation, or provision of
operational shields. The levels of protection required for each hazard class are as follows and shall be
required for all new facilities or redesign of any existing facilities where changes in activities will result
in a change to a more hazardous class.
4.2.1

Explosives Bay
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a. Class IV. Bays for Class IV (negligible probability of accidental initiation) activities shall provide
protection from fire hazards effects. This protection may be achieved by Hazard Class/Division 1.3
aboveground-magazine distance separation or by a design that contains the effects of an accident.
Because accidental detonation is not considered credible, Class IV bays shall be sited and designed
as acceptors rather than donors for the effects of blast overpressure, structural collapse, and missiles
(hazardous fragments).
b. Class III. Bays for Class III (low accident potential) activities shall provide protection from
explosion propagation from bay to bay within buildings and between buildings that are located at
intraline or magazine distance. If intermediate storage of explosives is within an operating building
containing Class II or Class I operations, the intermediate storage or staging bay will require Class II
level of protection. Examples of Class II activities are weighing, some wet machining, assembly and
disassembly, some environmental testing, and some packaging operations. Minimum separation
distances may be reduced when explosives bays are designed to adequately contain the effects of an
accident (blast pressures and missiles).
c. Class II. Bays for Class II (moderate accident potential) activities shall, in addition to complying
with the requirements for Class III bays, provide protection to prevent fatalities and severe injury to
personnel in all occupied areas other than the bay of occurrence. (For the purpose of this Class II
Category, access ramps and plant roads are not considered occupied areas.) Prevention of fatalities
and severe injuries is satisfied where personnel in occupied areas other than the bay of occurrence
will not be exposed to the following:kkkk
•
•

•

Overpressures greater than 100 kPa (15 psig) maximal effective pressure.
Structural collapse resulting from overpressure or debris impact - structural collapse is the
failure of a structural component as a direct result of loss of structural integrity of the facility
being subjected to various loadings (judged in accordance with the ability of the structure to
remain intact so that explosion propagation, fatalities, or severe injuries will not occur).
Missiles (hazardous fragments) generated in acceptor-occupied areas - hazardous fragments
that can cause fatalities and severe injuries are defined as those having greater than 58 ft-lb
impact energy. These values are taken from Chapter I of TM 5-1300. The threshold pressure
for eardrum rupture is 34 kPa; one-half of the threshold pressure for lung damage is 100 kPa.

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d. Class I. Bays for Class I (high accident potential) activities shall, in addition to complying with the
requirements for Class II bays, provide protection to prevent serious injuries to all personnel,
including personnel performing the activity, personnel in other occupied areas, and all transient
personnel. This protection may be achieved by controlling blast and debris through suppression,
containment, or establishment of an exclusion area with positive access control. Prevention of
serious injuries is satisfied where personnel will not be exposed to:
•
•

•
•
4.2.2

Overpressures greater than 34 kPa (5 psi) maximal effective pressure, and should not exceed
16 kPa (2.3 psi) peak positive incident pressure 2;
Structural collapse of the building from overpressure or debris impact - structural collapse is
the failure of a structural component as a direct result of loss of structural integrity of the
facility being subjected to various loadings (judged in accordance with the ability of the
structure to remain intact so that explosion propagation and serious injury to personnel will
not occur.);
Missiles (hazardous fragments) - hazardous fragments that can cause serious injuries are
defined as those having greater than 11 ft-lb impact energy; and
Thermal fluxes greater than 0.3 cal/cm sq/sec3.

Bays for Joint Explosives-Plutonium Activities

Bays for joint explosives-plutonium activities shall comply with the requirements of 4.2.1 of this chapter
for the class of explosives activity involved and DOE DNA TP 20-7. In addition, because of the
plutonium contamination potential, they shall comply with the following.
a. Bays for Uncased Explosives - Plutonium Activities. Where it is necessary to store, handle, or
process uncased explosives components in the same bay with plutonium, the enclosing structure and
its associated ventilation, electrical, fire protection, and utility system shall be designed to assure
that, in the event all the explosives present should detonate, radiation exposures shall comply with
DOE O 420.1," from the standpoint of hypothesized accidental releases. The quantity of plutonium
allowed in such a bay will be governed by the safety analysis report. Activities may be performed in
Class IV bays if IHE, IHE subassemblies, or IHE weapons are present; however, the quantity of
plutonium allowed will be governed by criticality considerations.
b. Bays for Cased Explosives - Plutonium Activities. Where it is necessary to handle or process cased
high-explosive components that contain plutonium, the enclosing structure shall be designed as a
Class II explosives bay. Storage shall conform to Class III requirements. The limit of plutonium
shall be 25 kg per bay. The plutonium limits for magazines are specified in DOE DNA TP 20-7.
Activities may be performed in Class IV bays if only IHE, IHE subassemblies, or IHE weapons are
present; however, the quantity of plutonium allowed will be governed by criticality considerations.

2.

This value is specified in DoD 6055.9-STD as required protection for all personnel exposed to remote operations (16kPa
is also the overpressure for public-traffic-route distance).

3.

This value is specified in DoD 6055.9-STD, Chapter 4, paragraph D, as required protection for all personnel assigned to
perform remote operations

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5.0 FIRE PROTECTION
5.1

Vegetation Control

Vegetation around storage magazines and explosives operating facilities should be controlled to
minimize potential damage to the magazine or facility from grass, brush, or forest fires, or from erosion.
A firebreak at least 15 m wide and free from combustible material should be maintained around each
aboveground magazine or facility processing or containing explosives. If the aboveground magazine or
explosive facility exterior is fire resistant, the firebreak need not be devoid of vegetation, but the growth
must be controlled by mowing to prevent rapid transmission of fire to the magazine or facility. The
maintenance of firebreaks around earth-covered magazines and the cutting of grass covering these
structures are not normally required, except around ventilators to prevent transmission of a fire into a
structure.
5.2

Fire Protection Criteria

These fire protection criteria shall be required for all new facilities or for redesign of any existing
facilities where changes in activities will result in a change to a more hazardous class.
a. Automatic fire suppression systems shall be installed in all buildings containing high explosives and
plutonium, with the exception of storage magazines.
b. For buildings containing explosives, but no plutonium, the need for fire suppression systems shall be
determined by the facility management, on the basis of maximum fire loss criteria and program
mission interruptions and delays as outlined in DOE O 420.1, FACILITY SAFETY; DOE O 430.1,
LIFE-CYCLE ASSET MANAGEMENT; and DOE O 440.1, WORKER PROTECTION
MANAGEMENT FOR DOE FEDERAL AND CONTRACTOR EMPLOYEES.
c. Where fire suppression is required, each explosives bay shall have an individual feed with its
controls protected outside the bay and located so as to remain operable in the event of a detonation in
any bay.
d. Transmitted fire alarms shall distinguish between explosives and nonexplosives areas through the
use of annunciator panels at safe locations; small non-high explosives areas are exempt from having
separately transmitted alarms.

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6.0 EXPLOSIVES FACILITY SITING AND DESIGN CRITERIA REFERENCES
Permanent explosives facilities shall comply fully with TM 5-1300, "Structures to Resist the Effects of
Accidental Explosions," and DOE/TIC-11268, "A Manual for the Prediction of Blast and Fragment
Loading of Structures." Portable magazines should be water resistant, fire resistant, theft resistant, and
ventilated. They can be made of any material that meets these guidelines. (Portable facilities that
comply with 27 CFR 55.206, "Bureau of Alcohol, Tobacco and Firearms" (BATF) meet this criteria.)
Portable magazines shall be sited per DoD 6055.9-STD as above ground magazines.llll
Blast-resistant design for personnel and facility protection shall be based on the TNT equivalency of the
maximum quantity of explosives and propellants. In accordance with TM 5-1300, the TNT equivalency
shall be increased by 20% for design purposes.
For an unproven facility design, either a validated model or full-scale test is required to ensure structural
adequacy unless a high degree of confidence can be provided by calculations or other means. The
contract administrator (Head of Field Organization) with competent engineering review shall concur in
any determination regarding test requirements.
The design of all new facilities, or those with major modifications, shall conform to the DOE explosives
safety requirements. For a tabular summary of the types of protective design established by these
criteria, see Table VI-2. Protective construction design features are specified in TM 5-1300 and
DOE/TIC-11268.
Studies necessary to provide the technical basis for location, engineering, design, and operation [under
normal and potential design basis accident (DBA) conditions] of the buildings shall follow the stricter of
this Manual and DoD 6055.9-STD, DoD Ammunition and Explosives Safety Standards, for establishing
explosives quantity-distance separation.
DoD 6055.9 requires that the minimum distance for protection from hazardous fragments to facility
boundaries, critical facility, and inhabited structures shall be 1,250 ft for explosives quantities of 101 to
20,000 lb and 670 ft for 100 lb or less of Hazard Class/Division 1.1 explosives, unless it can be shown
that there will be no hazardous fragments or debris at lesser distances. The methods of calculation
presented in the Department of Defense Explosives Safety Board (DDESB) Technical Paper No. 13 may
be used to establish a smaller fragment exclusion zone. It is not intended that these minimum fragment
distances be applied to operating facilities or dedicated support functions within an operating line. For
these exposures, the DOE criteria presented in this Manual, for Class I, II, III, or IV activities with
appropriate quantity-distance separations are the required protection levels.
In addition to this Manual, the following are resource documents for the siting and design of explosives
facilities:
•

DOE O 420.1, FACILITY SAFETY, 10-13-95, U.S. Department of Energy, Washington, D.C.
20545.

•

DOE O 430.1, LIFE-CYCLE ASSET MANAGEMENT, 8-24-95, Office of Project and Facilities
Management, U.S. Department of Energy, Washington, D.C. 20545.
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•

10 CFR 830, Nuclear Safety Management.

•

TM 5-1300, NAVFAC P-397, AFM 88-22, "Structures to Resist the Effects of Accidental
Explosions," Departments of the Army, the Navy, and the Air Force, Chairman, Department of
Defense Explosives Safety Board, 2461 Eisenhower Avenue, Alexandria, VA 22331.

•

DOE/TIC-11268, "A Manual for the Prediction of Blast and Fragment Loading of Structures," U.S.
Department of Energy, Albuquerque Operations, Amarillo Area Office, Facilities and Maintenance
Branch, P.O. Box 30030, Amarillo, TX 79210.

•

DoD 6055.9-STD, "Department of Defense Ammunition and Explosives Safety Standards,"
Assistant Secretary of Defense (Manpower, Installations, and Logistics), Chairman, Department of
Defense Explosives Safety Board, 2461 Eisenhower Avenue, Alexandria, VA 22331.

•

DDESB, Technical Paper No. 13, "Prediction of Building Debris for Quantity-Distance Siting,"
April 1991, Chairman, Department of Defense Explosives Safety Board, 2461 Eisenhower Avenue,
Alexandria, VA 22331.

•

AMC-R-385-100, AMC Safety Manual, Headquarters, United States Army Materiel Command,
5001 Eisenhower Avenue, Alexandria, VA 22333.

•

TR-828, "Blast Environment from Fully and Partially Vented Explosions in Cubicles," W.A. Keenan
and J.E. Tancreto, Civil Engineering Laboratory, Naval Construction Battalion Center, Port
Hueneme, CA 93043.

•

AD 411445, "Industrial Engineering Study to Establish Safety Design Criteria for Use in
Engineering of Explosives Facilities and Operations," Process Engineering Branch, APMED
Picatinny Arsenal, Dover, NJ; Defense Technical Information Center, Defense Logistics Agency,
Cameron Station, Alexandria, VA 22314.

•

AFWL-TR-74-102, "The Air Force Manual for Design and Analysis of Hardened Structures," Air
Force Weapons Laboratory, Air Force Systems Command, Kirtland Air Force Base, NM 87117; AD
B004152, Defense Technical Information Center, Defense Logistics Agency, Cameron Station,
Alexandria, VA 22314.

•

HNDM-1110-1-2 , "Suppressive Shields, Structural Design and Analysis Handbook," U.S. Army
Corps of Engineers, Huntsville Division, HNDED-CS, P.O. Box 1600, Huntsville, AL 35807.

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Type of Activity

DOE M 440.1-1
Operational
Requirement for
Activity Involved

Explosion
Protection for
Personnel in
Other Occupied
Areas Including
Adjacent Bay

Explosion
Protection for All
Personnel
(Remote
Operation)

Control of
Plutonium in
Event of
Explosion

Class I Activities
Explosives Only

X

X

High-Level
Protection from
Natural
Phenomena

Normal
Protection from
Natural
1
Phenomena

Radiological
Considerations

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Table VI-3. Explosive facilities: protective design requirements by activity typemmmm

2

X

X

HE-Pu Cased
HE-Pu Uncased
Class II Activities
Explosives Only

X

X

HE-Pu Cased

X

X

HE-Pu Uncased

X

X

X
X

X

X

129

Class III Activities
Explosives Only

X

X
NOT
PERMITTED

HE-Pu Uncased

NOT
PERMITTED
Class IV Activities
X

3

X

X

3

X

X

HE-Pu Uncased

X

3

X

X

Support Area

X

X

Explosives Only
HE-Pu Cased

1

These facilities need only be designed to provide protection acceptable with normal DOE loss criteria.
Class I activities with either cased or uncased HE-Pu are not permitted, except where such activities are justified from a nuclear explosives safety study
performed in accordance with DOE O 5610.10, NUCLEAR EXPLOSIVE AND WEAPON SAFETY PROGRAM, 10-10-90.
3
Class IV bays need only be sited and designed to withstand the effects of blast overpressure, structural collapse and missiles (hazardous fragments) from an
adjacent bay.
Definitions of explosives hazard classes by activity are in the glossary.
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CHAPTER VII - OPERATING PROCEDURES
1.0 GENERAL
1.1

Requirements

This section establishes requirements for preparing and controlling all procedures used for operations
involving explosives at DOE installations. These requirements for procedures minimize the chances of
an incident resulting from operations using outdated, inapplicable, or incomplete procedures, or from
operations performed in violation of established practices.
This section also specifies that procedures must be generated for all explosives operations because the
step-by-step reasoning process that is used in developing the procedure will identify many safety-related
problem areas that might be overlooked otherwise. In addition, the approval system for new or revised
procedures also provides other viewpoints and knowledge that may not be available to the originator and
may need incorporation into the procedure.
1.2

Types of Procedures

Two general types of operating procedures are described in this chapter: (1) standard operating
procedures (SOPs) and (2) nonstandard procedures, which include experimental and special procedures.
Standard operating procedures are formalized documents prepared for performance of a task on a routine
basis. Existing and applicable Department of defense (DoD) ordnance publications (see section 3.0 for
references) will be reviewed for application of unexploded ordnance (UXO) work. Revisions to these
documents will invalidate the DoD procedures. If the documents are not appropriate for the situation,
then changes may be made, subject to the [DOE] review and approval process. Experimental and
special procedures are documents prepared for performance of a task on a limited basis. For the purpose
of this manual, special procedures are those written to correct a problem encountered in an explosive
operation.nnnn
2.0 GUIDELINES
The following general guidelines should be used in creating operating procedures.
2.1

Before Operation

a. Before starting any operation involving explosives a hazard risk analysis shall be undertaken to
identify any abnormal problems that will require special training, equipment, or procedures to
safeguard personnel conducting the operation.
b. A thorough review shall be conducted to determine whether the operation will require a safety
analysis report according to the current version of DOE O 5481.1B, Safety Analysis and Review
System, which will establish if the operation is safe to field. For UXO cleanups, a Safety Analysis
Report (SAR) is not required. In case of non-standard cleanups, such as mass burial or radiation
contamination, a Safety Assessment (SA) is required, along with SOPs/special procedures which
include the additional precautions to be taken.oooo
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c. General operating procedures shall be written and approved for each activity to ensure consistency
and safety of operations.
2.2

Supervisory Responsibility

Supervisory personnel shall be responsible for enforcement of the provisions of all procedures that are
used in their jurisdiction.
2.3

Preparation

a. Procedures shall be prepared by responsible personnel with knowledge of the operations involved.
b. All material in the procedure and operational steps called out shall be checked for compliance with
the guidance in this Manual and other DOE directives that may be applicable per DOE O 440.1.
c. The specific types of equipment and building or area in which the operation is to be conducted
should be designated in the procedure, when applicable.
d. If similar operations in the same area involve differences in equipment or process, supplemental
procedures or sections shall be written.
2.4

Approval

a. All new or revised operating procedures shall be reviewed and approved prior to use. Levels of
approval required should be based on the inherent risk in the operation and be established by each
operating contractor. Review and approval requirements shall include, as a minimum, line and
safety organizations.
b. Work control processes shall be in place prior to any operational activities.
2.5

Control

a. Distribution of procedures shall be controlled to ensure that each operating area has the most current
revision. Superseded or inactive procedures shall be removed from operating areas. No operation
shall be performed with a superseded, inactive, or unapproved procedure.
b. Files of active procedures should be maintained.

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Audits

a. An audit system should be established that will evaluate routinely the adequacy, availability, and
currency of procedures. Also, audits should include an evaluation of operator knowledge and
compliance with procedures.
b. Groups conducting the audits should include personnel from other than the operating department or
division using the procedure.
2.7

Reviews

a. All active procedures should be reviewed a minimum of once a year by the appropriate departments.
b. If the procedure is no longer completely applicable to the operation or if new safety considerations
(i.e., compatibility, toxicity, ignition sources, etc.) have been identified, the procedure shall be
revised.
c. If a procedure is not expected to be used during the coming year, it may be placed in an inactive
procedure file.
d. Before an inactive procedure can be reactivated, it shall be reviewed and approved. Minimum
approval shall be the same as that required for a new or revised procedure (see Section 2.4).
2.8

Content of SOPs

The following presentation is intended to specify procedures content, not format or organization. Each
operating contractor can develop its own system for preparing safety procedures.
2.8.1

General Operating Procedures

a. Introduction. The introduction to the procedure should include the following:
•
•
•

A statement of the scope of the procedure, defining what facilities and equipment are
covered;
The name of the department and/or individual responsible for the operation; and
If the procedure serves as the basis for an exemption or waiver from the requirements of this
Manual, a statement to this effect and a specific reference to the standard involved.

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b. Safety and Health. The safety section of the procedure should present the following information or
reference a safety manual that specifies the requirements:
•

•
•

General safety rules to be observed and techniques to be applied that will ensure safety of
operations, prevent injury or illness to personnel, and prevent damage to equipment. In
particular, this section of the SOP should describe the personnel control features of the
facility that protect personnel from exposure to hazardous operations, toxic materials, or
tests.
Personnel number and explosive weight limits.
Additional or specific emergency controls not addressed by the facility emergency plan.

c. Operations. The operations section should consist of general directions for operation of all major
items of explosives-handling equipment. Particular emphasis should be placed on safety interlocks
and controls, and the proper use of these systems.
If operation of a particular item of equipment or of an area requires that no other operation be performed
simultaneously in this same area, this requirement shall be clearly stated in the procedure.
2.8.2

Unit Operating Procedures

a. Introduction. The procedure introduction should include the following:
•
•
•
•

a statement of the nature of the operation and its objectives;
the name of the department responsible for the operation and the procedure;
a description of the range of work authorized by the procedure; and
if the procedure serves as the basis for an exemption or waiver from the standards of this
Manual, a statement to this effect and a specific reference the standard involved.

b. Materials and equipment. The materials and equipment section should present the following
information:
•
•
•

all significant tools, supplies, chemicals, and equipment necessary to perform the operation
should be listed in the SOP or in a separate required document;
specifications for approved chemicals, supplies, tooling, and equipment should be referenced
where applicable; and
an explanation of any specific hazard involved in the handling of chemicals or explosives for
the operation, or a reference to a document that describes the hazards should be included.

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c. Safety. The safety section should present the following information or reference a safety manual
that specifies the requirements:
•
•
•

safety rules that are specific to the operation;
protective equipment that must be used during the operation; and
emergency controls applicable to the operation that are not considered in the general
operating procedures.

d. Operations. The operations section should consist of sequential directions written or pictured in
clear, concise steps that describe how to perform a particular operation. If a particular operation
requires that no other operation be performed simultaneously in the same work area, this
requirement shall be clearly stated in the procedure.
2.9

Content of Special or Experimental Procedures

In addition to the applicable requirements listed in paragraph 2.8 of this chapter, the following shall also
be addressed:
a. Field operations that, due to their remoteness, will have to factor in procedures to ensure that both
fire and medical emergency services will be responsive within a reasonable time or be stage at the
event site.
b. Personnel involved with the operation shall be briefed or trained on any unique aspects of the
operation and emergency procedures.
When a special or experimental operation will be conducted a number of times, an SOP should be
written and approved.
3.0 Reference Documentspppp
The following documents set forth some of the non-DOE procedures to be used in UXO operations.
60-Series Publications, Commanding Officer, Naval Explosive Ordnance Disposal Technology
Division, 2008 Stump Neck Road, Indian Head, MD 20640-5070
OE CX Interim Guidance, US Army Corps of Engineers, Huntsville Center, P.O. Box 1600, Huntsville,
AL 35807-4301.

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CHAPTER VIII - FORMULATION SCALEUP
1.0 EXPLOSIVES DEVELOPMENT PROGRAM
1.1

Explosives Development Committee

A committee shall be established at each DOE facility engaged in explosives development to be the
approving authority for each phase of an explosives development program. This committee will be
referred to in this Manual as the Explosives Development Committee (EDC), but it may have a different
name at each DOE facility. Individuals chosen to serve on the EDC should have considerable
experience in explosives handling, processing, chemistry, sensitivity, and safety.
1.2

Phase-by-Phase Approvals

The EDC shall review and approve data generated in each phase of a development project that involves
a new explosive or new explosive formulation before the next phase begins.
1.3

Modified Formulations

Compositional modifications to previously evaluated explosive formulations shall be approved by the
EDC. However, the EDC may approve minor modifications to the explosives formulation for a given
phase of development without requiring all of the developmental steps and tests.
1.4

Sensitivity Data from Another Laboratory

If comparable sensitivity data for the subject material are available from another laboratory, the EDC
may waive some developmental phase tests.
2.0 DEVELOPMENT PROCEDURES
2.1

General

All DOE explosives handling facilities shall establish an administrative procedure that defines the basic
steps for developing and evaluating new explosives and explosive formulations. The procedure shall
require that each development effort proceed in phases from small to large quantities. The quantities of
materials that may be handled in each phase shall be limited. The EDC shall be responsible for
establishing criteria for acceptable explosive behavior in each test of each phase of the explosives
development procedure. The development procedure should consist of three phases plus a synthesis
phase and compatibility testing, when required. Guidelines for establishing this procedure are proposed
in the following paragraphs. Table VIII-1 summarizes these guidelines.

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Table VIII-1. Scaleup procedure guidelines for new explosives and formulations
Quantity of new
materiala

Recommended dataa

Data desired

Additional
recommendations

Synthesis
Specified by the
lab performing
the synthesis

Impact, Friction, spark, Before using the new
thermal stability
ingredient in a
formulation

----

Formulation
Compatibility
Testing:
2g

Thermal compatibility
of new ingredient with
other ingredients of
formulation

Before proceeding to
Phase I

Materials should be
processed remotely

Phase I
10g

Impact friction, thermal
stability

Before nonremote
processing and
handling in Phase I or
scaleup to Phase II

Materials should be
processed remotely
before passing
sensitivity and stability
tests

Phase II
500gb

Compatibility,c impact,
friction, spark, thermal
stability, thermal
characterization
before elevated
temperature pressing

d

e

Before Phase III
machining or handling
of billets 7 kg or
greater

Composition of
formulation shall be
fixed

Phase III
Specified by
EDC

a
b
c
d

e

Compatibility, highspeed machining,
drop, skid

Quantities and recommended data apply to both new formulations and explosive ingredients.
The EDC may allow more than 500 g in Phase II where larger quantities are needed for some tests.
Compatibility of explosives and formulations with materials contacting the explosives in test and production assemblies.
Before proceeding to Phase III if:
(1) The formulation to be scaled up to Phase III differs from that tested in Phase I, or
(2) The explosive or formulation prepared for Phase II development is produced by techniques different from those used
in Phase I.
Before proceeding to Phase II if the composition of a formulation is modified so that the composition is no longer within
the limits specified by the EDC.
Materials investigated in this phase should be produced by techniques similar to those that will be used to produce larger
batches in a subsequent phase.

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Synthesis Phase

Before mixing a new explosive with other materials, the sensitivity and stability of the explosive should
be determined and should comply with the criteria set by the EDC. Recommended tests include the
following:
a. drop-weight impact;
b. friction;
c. spark;
d. thermal stability - these tests should include two or more of the following:
•
•
•
•
2.3

differential thermal analysis or differential scanning calorimetry;
thermal gravimetric analysis;
gas evolution rate at elevated temperature (chemical reactivity test, vacuum stability, etc.);
and
time-to-explosion analysis.

Compatibility Testing

a. If a proposed formulation contains new ingredients (explosive or nonexplosive), the new ingredients
should be tested for compatibility with the other ingredients before preparing batches for Phase I
testing. Compatibility tests should include any of the stability tests listed under paragraph 2.2.d of
this chapter.
b. No more than 2 g of the new formulation should be prepared, handled, or stored before compatibility
testing.qqqq
c. Formulations for compatibility testing should be processed remotely, whenever possible.
2.4

Phase I - Preliminary Explosives Testing

a. The total quantity of material that may be processed, handled, or stored at any one time in Phase I
should not exceed 10 g. Whenever possible, this material should be processed remotely.
b. The new explosive or formulation should be subjected to sensitivity and stability tests. As a
minimum, drop-weight impact, friction, spark sensitivity, and thermal stability tests should be run.
Thermal stability testing need not be performed here if one or more of the compatibility tests listed
under paragraph 2.2.d of this chapter have already been conducted on the new formulation.
c. If the new explosive or formulation is acceptable in the above tests, it may be scaled up to Phase II.
The EDC may impose handling or processing restrictions or precautions on the material if its
performance in any of the above tests is questionable.

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d. After Phase I testing of a formulation is complete, the EDC should define, on the basis of the test
results, what variations in composition are permissible during Phase II development without
retesting.
2.5

Phase II - Experimental Characterization and Development

a. The total quantity of materials that may be processed or handled at any one time in Phase II should
not exceed 500 g. No limit exists on the quantity that may be stored, other than the storage facility
limits for Group L explosives.
b. Materials investigated in Phase II should be produced by techniques similar to those that will be used
to produce larger batches in a subsequent scaleup phase.
c. A thermal characterization test and evaluation should be run before pressing the new material at
elevated temperature.
d. The Phase I sensitivity and stability tests should be rerun in Phase II if the following conditions
apply:
•
•
•
•

2.6

The formulation to be scaled up to Phase III differs from that tested in Phase I. In this case,
testing should be completed before Phase III scaleup.
The explosive or formulation prepared for Phase II development is produced by techniques
different than those used in Phase I. Testing should be completed before Phase III scaleup.
During Phase II, the composition of a formulation is modified to an extent that the
composition is no longer within the limits specified by the EDC. (See paragraph 2.4.d of this
chapter.) Testing should be completed before proceeding with Phase II.
The compatibility of explosives and formulations with materials contacting the explosives in
test and production devices shall be evaluated before any such device is assembled. If
compatibility testing is required, one or more of the tests listed under paragraph 2.2.d of this
chapter should be recommended.

Phase III - Full-Scale Testing and Production

a. The maximum quantity of materials that may be processed or handled in Phase III should be defined
in the EDC’s grant of authorization to proceed with Phase III. No limit is imposed for the storage
facilities except the limits imposed by the quantity-distance tables.
b. All additional testing necessary to define storage compatibility grouping should be completed before
committing bulk quantities of the material to storage. (See Chapter II, Section 17.4).
c. During Phase III development, the composition of all formulations should be fixed.
d. Any new explosive material that is to be contact machined shall be subjected to a machining
overtest. Reaction threshold should be determined if possible.
e. If billets of 7 kg or greater are to be produced in Phase III, drop-skid testing should be performed
and EDC criteria for this test should be met.
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f. Paragraph 2.5.e of this chapter should also apply to Phase III development.

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CHAPTER IX - INSENSITIVE HIGH EXPLOSIVES
QUALIFICATION
1.0 INSENSITIVE HIGH EXPLOSIVES (IHE)
Some explosive substances, although mass detonating, are so insensitive that there is negligible
probability of accidental initiation or transition from burning to detonation. Any explosive that is a
candidate for classification as an IHE shall be subjected to the DOE qualification tests listed in Table
IX-1 or Recommendations on the Transport of Hazardous Goods-Tests and Criteria, Test Series 7. Test
procedures, where not specified, are contained in MHSMP-84-22, "IHE Material Qualification Tests,
Description and Criteria." Test data for each explosive requested for this classification will be submitted
by the DOE laboratory or contractor through the appropriate Operations Office to DOE Headquarters
Office of Worker Safety and Health (EH-5). The DOE Explosives Safety Committee will independently
analyze the data and recommend action on including the explosive in Table IX-2 as an approved IHE.rrrr
New candidate explosives formulations will not be classified by analogy as IHE until reviewed by the
DOE Explosives Safety Committee. The general guidelines for requesting and obtaining an IHE
approval by analogy are:
•
•

All requests, including rationale, must be submitted in writing to the DOE Explosives Safety
Committee for their analysis and recommended action.
Approved IHEs with complete test data must be used for baseline comparison purposes.

More Specific guidelines will depend on circumstances surrounding the specific analogy request.
In many instances a partial analogy can be drawn, necessitating only partial testing. This will depend on
the type and extent of change in the candidate IHE relative to the baseline IHE and the potential effects
of these changes on specific initiation mechanisms (shock, thermal, mechanical, impact, electrostatic,
etc.). A candidate IHE can be placed in one of the following categories to define the tests required for
approval:
•

CASE I (partial testing required). The candidate IHE formulation involves substitution of the
inert binder component of the approved baseline IHE with a new inert binder component.
Sufficient testing is required to verify that no chemical incompatibilities have been
introduced that would de-stabilize the base IHE. In this case, test data normally generated by
the requesting facility during their explosive development scaleup phasing process my be
submitted for approval consideration in lieu of the qualification tests of Table IX-1. During
this development phase, each facility EDC may dictate restrictions consistent with an IHE
internal to their facility only. Final approval as an IHE must be obtained through the DOE
Explosives Safety Committee. Tests 1, 2, 3, and 7 of Table IX-1 or equivalent are required
as a minimum.

•

CASE II (all IHE tests of Table IX-1 required; analogy inappropriate). The candidate IHE
involves the addition of an untested (IHE tests) energetic component to the approved baseline
IHE.

OR:
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The candidate IHE involves the same energetic and inert components as the approved
baseline IHE, the only change being a volume-% increase in the energetic component
content.
Any data over and above that required in Table IX-1 will be considered by the DOE Explosives Safety
Committee in its deliberations of the approval request.
Table IX-1. DOE qualification tests for IHE
1. Drop-weight impact testa

Comparable to or less sensitive than Explosive D
(ammonium picrate). Minimum of 20 drops per test series.

2. Friction testb

No reaction on Pantex friction machine (10 trials).

3. Spark test

a

4. Ignition and unconfined
burning test (small scale burn)

TB 700-2 test procedures, any shape, minimum thermal
path of 25 mm, no explosion.

5. Card gap testb

No reaction at Explosive D 50% gap thickness (or less)
using a Pantex modified NOL card gap test (6 trials). The
test diameter must be greater than the unconfined failure
(critical) diameter of the candidate IHE.

6. Detonation (cap) test

TB 700-2 test procedures-no detonation (5 trials).

7. Cookoff

No reaction of more than a pressure release using the
large-scale ODTX test conducted such that a reaction
must occur in not less than 4 hours (6 trials).

8. Spigot testb
9. Skid test

a
b

No reaction at minimum of 0.25 joules (10 trials)

b

No reaction for 120-ft drop in LANL test (3 trials).
No reaction up to 20-ft (or sample failure) drop at 14-15
degrees test angle using standard size billets (3 trials at
worst case condition).

10. Susan test

Less than or equal to 10% TNT output at a minimum of
333 m/sec (3 trials).

11. Bullet impact

No violent reaction with 5.56 mm and .50 cal. projectile
impact on material in schedule 40 steel pipe with closures
on each end (6 trials in axial orientation).

These tests are not applicable to compacted explosives.
These tests are not applicable for explosives powders.

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Table IX-2. Approved IHEs
TATB
TATB/KEL-F Formulations

2.0 IHE SUBASSEMBLIES
IHE Subassemblies are composed of IHE hemispheres or spheres with booster charges, with or without
detonators. Successful completion of the applicable DOE qualification tests listed in Table IX-3 is
required for classification as an IHE Subassembly. A test plan (defining specific test procedures) for
candidates for this classification shall be submitted by the DOE contractor through the appropriate
Operations Office to the DOE Explosives Safety Committee for review. On approval of the plan, tests
shall be run and the DOE Explosives Safety Committee shall independently analyze the data and
recommend approval or disapproval. DOE Headquarters will then issue a memorandum to appropriate
Operations Offices and DOE Contractors classifying those configurations meeting the required test
criteria as IHE Subassemblies. Approved IHE Subassemblies are listed in Table IX-4. Subassemblies
will not be classified as IHE Subassemblies by analogy until reviewed by the DOE Explosives Safety
Committee. When no other explosives are present in the same location, these subassemblies are
classified as Class 1.3 explosives (see Table IX-5) for storage and processing.ssss
Table IX-3. DOE qualification tests for IHE Subassemblies*
1. Spigot test

No burning or violent reaction of main charge of 120-ft drop
on booster in LANL test (3 trials).

2. Bonfire

No detonation or violent reaction of main charge when
engulfed in a fire (3 trials).

3. Slow cookoff

No detonation or violent reaction of main charge when
slowly heated to a reaction (3 trials).

4. Multiple bullet impact

No detonation or violent reaction of main charge with a 3round burst of 7.62 mm projectile impact on booster (3
trials).

5. Skid test

No burning or violent reaction of main charge up to a 20-ft
(or sample failure) drop at 14 to 15 degrees test angle
using subassembly configuration modified for impact on the
booster (3 trials at worst case condition).

*

Note:

Tests are not required for subassemblies when main charge and booster charge explosives have been qualified as IHE by tests in
Table IX-1.
The test plan shall specify applicable testing for cased and/or uncased configurations with or without detonators.

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Table IX-4. Approved IHE Subassembliestttt
B61*3/4/6/7/8/10/11

W80*

W81*

W84

W87

W89

*

B83*

Approval limited to boosters of the size tested or smaller. Any redesign that dimensionally increases the
booster size requires resubmission of an experimental plan and additional testing as another IHE
subassembly.

Table IX-5. IHE Hazard Classificationuuuu
IHE alone

1.3

IHE at magazine distance or greater from Class 1.1

1.3

IHE at magazine distance or greater from Class 1.2

1.3

IHE with 1.1 items

1.1

IHE with 1.2 items

see note 2

IHE with other 1.3 items

1.3

IHE with 1.4 items

1.3

IHE at less than magazine distance from Class 1.1

1.1

IHE at less than magazine distance from Class 1.2

see note 2

Note 1
Note 2

IHE may be stored with mock HE without regard to the quantity of mock high explosives.
1.2 or 1.3, whichever is most restrictive.

3.0 IHE WEAPONS
IHE weapons are those weapons listed in DOE DNA TP 20-7 that are exempt from storage and
transportation limits when stored or transported alone or in combination with each other. This
classification is valid only if the spacing between individual units is that provided by storage containers,
or if out of containers, by the spacing specified in TP 20-7. These weapons are classified as Class 1.3
explosives for storage, processing and transportation purposes.

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4.0 REFERENCE DOCUMENTS
The following documents set forth some of the non-DOE procedures to be used in the IHE and IHE
subassembly testing required by Tables IX-1 and IX-3:
TB 700-2, NAVSEA INST 8020.8A, TO 11A-1-47, DLAR 8220.1, "Department of Defense Explosives
Hazard Classification Procedures," Departments of the Army, the Navy, the Air Force, and the Defense
Logistics Agency, Washington, D.C.
MHSMP-84-22, "IHE Material Qualification Tests, Description and Criteria" (Rev 1, July 1985),
National Technical Information Service, U.S. Department of Commerce, 5285 Port Royal Road,
Springfield, VA 22161.
"Recommendations on the Transport of Hazardous Goods-Tests and Criteria," Second Edition,
ST/SG/AC.10/11Rev.1, LABELMASTER, Chicago, IL, 60646 USAvvvv

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Appendix A -

References

American Conference of Government Industrial Hygienists (ACHIH), ACHIH Ventilation Manual.
American National Standards Institute (ANSI), National Electrical Safety Code, ANSI C2.
American Society for Testing and Materials (ASTM), Standard Method for Rubber Property Durometer Hardness, ASTM D-2240-86.
Defense Logistics Agency, Industrial Engineering Study to Establish Safety Design Criteria for Use in
Engineering of Explosives Facilities and Operations, AD, 411445, Process Engineering Branch,
APMED Picatinny Arsenal, Dover, NJ; Defense Technical Information Center, Defense Logistics
Agency, Cameron Station, Alexandria, VA 22314.
Defense Logistics Agency, The Air Force Manual for Design and Analysis of Hardened Structures,
AFWL-TR-74-102, Air Force Weapons Laboratory, Air Force Systems Command, Kirtland Air Force
Base, NM 87117; ADB004152, Defense Technical Information Center, Defense Logistics Agency,
Cameron Station, Alexandria, VA 22314.
Departments of the Army, the Navy, and the Air Force; Structures to Resist the Effects of Accidental
Explosions; TM 5-1300, NAVFAC P-397, AFM 88-22; Chairman, Department of Defense Explosives
Safety Board, 2461 Eisenhower Avenue, Alexandria, VA 22331.
Departments of the Army, the Navy, the Air Force, and the Defense Logistics Agency, Department of
Defense Ammunition and Explosives Hazard Classification Procedures, TB 700-2.
Department of Commerce, IHE Material Qualification Tests, Description, and Criteria, Rev. 1, July
1985, National Technical Information Service, U.S. Department of Commerce, 5285 Port Royal Road,
Springfield, VA 22161.
Department of Defense (DoD) Department of Defense Ammunition and Explosives Safety Standards,
DoD 6055.9-STD, Assistant Secretary of Defense. (Force Management and Personnel), Chairman,
Department of Defense Explosives Safety Board, 2461 Eisenhower Avenue, Alexandria, VA 22331.
Department of Energy (DOE), DOE Hoisting and Rigging Handbook, DOE-HDBK-1090-95.
DOE, A Manual for the Prediction of Blast and Fragment Loading of Structures, DOE/TIC-11268, U.S.
Department of Energy, Albuquerque Operations, Amarillo Area Office, Facilities and Maintenance
Branch, P.O. Box 30030, Amarillo, TX 79120.
DOE, Nuclear Safety Criteria (for Warhead Storage), DOE-DNA TP-20-7, Classified.
Keenan, W.A. and J.E. Tancreto, Blast Environment from Fully and Partially Vented Explosions in
Cubicles, TR-828, Civil Engineering Laboratory, Naval Construction Battalion Center, Port Hueneme,
CA 93043.
National Electrical Manufacturers Association (NEMA), Enclosures for Electrical Equipment (1000
Volts Maximum), NEMA Publication No. 250-1979, 2101 L Street N.W., Washington, D.C. 20037.
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National Fire Protection Association (NFPA), Fire Protection for Laboratories Using Chemicals, NFPA
45.
NFPA, National Electrical Code, NFPA 70, ANSI C1.
NFPA, Life Safety Code, NFPA 101.
NFPA, Purged and Pressurized Enclosures for Electrical Equipment, NFPA 496.
NFPA, Powered Industrial Trucks, NFPA 505.
NFPA, Identification of the Fire Hazards of Materials, NFPA 704.
NFPA, Lightning Protection Code, NFPA 780.
Title 49 CFR, Parts 171-177, Transportation, Hazardous Materials Regulations, and Parts 300-399 (for
Driver Selection and Training).
U.S. Army Corps of Engineers, Suppressive Shields, Structural Design and Analysis Handbook,
HNDM-1110-1-2, U.S. Army Corps of Engineering, Huntsville Division, HNDED-CS, P.O. Box 1600,
Huntsville, AL 35807.

A-2

Appendix B -

Index
Clear pathway · 18
Clearance · 60
Clothing · 111, 112
Code · xii, 16, 18, 26, 31, A-1, A-2
Combustible material · 84
Compatibility · 5, 74, 86, 88, 90, 93, 94, 100, 119, 138, 139
Compatibility testing · 139
Concurrent burning operation · 101
Concurrent contact machining · 47
Conductive floor · 28
Conductive wristband · 28
Conductivity · 112
Construction · 51, 128, A-1
Construction operation · 51, 128, A-1
Contact operation · 69
Container · 74, 91, 92, 100
Contamination · 52, 57, 66
Control procedure · 23
Cooking and eating · 24
Cook-off · 144
Coolant · 49, 50
Coring · 50
Corrective action · 15
Criticality · xii, 15
Cubicle · 128, A-1

A
Acceptor · 124
Access control · 7, 11, 23, 24, 60, 65, 66, 67, 72, 125
Access ramps · 124
Accident potential · xii, 5, 9, 10, 11, 12, 17, 19, 40, 66, 69, 73,
86, 102, 109, 122, 123, 124, 125, 127, 143
Accident, vehicle · 12, 82
Accidental release · 31, 38, 114, 125
Accounting procedure · 16
Actuator · 61, 62, 72, 74, 89, 90, 101
Additive · 14
Adhesive · 14, 47
Adiabatic heating · 44
Administration areas · 8, 76, 121
Advisory requirement · 2, 3
Agitation · 40, 51, 54, 56
Aircraft · 60
Airlock · 20
Airspace · 60
Aisle · 84
Alarm · 17, 20, 33, 35, 42, 51, 54, 55, 126
Ammunition · 9, 12, 26, 64, 68, 76, 79, 80, 86, 87, 88, 89, 90,
92, 94, 97, 120, 127, 128, A-1
Analogy · 40, 81, 143, 144, 145
Approval procedure · 21
Approved IHE · 143, 145, 146
Arm · 4, 66
Arrestor · 33, 78, 80
Assembly · 1, 2, 8, 9, 31, 43, 44, 45, 47, 49, 51, 52, 65, 68
Audit · 133
Authority having jurisdiction · 1, 4

D
Damaged container · 92
Decontamination · 95, 97
Deflagration · 6
Detonation · 60, 103, 144
Detonator · 74, 87, 89, 103
Deviation · 18
Die · 44
Differential scanning calorimetry · xii, 6, 8, 35, 41
Differential thermal analysis · xii, 6, 8, 35, 41
Disassembly · 37, 51, 52
Disposal · xii, 57, 95, 102, 104
DNA TP 20-7 · 91, 125, 126, 146
Documentation · 22, 67
DoD 6055.9-STD · 33, 82, 86, 97, 107, 120, 121, 125, 127, 128,
A-1
DOE occupancy · 17
Door · 19
DOT regulation · 77, 79, 81
Drain · 39
Drilling · 49
Dry blending · 51
Dry run · 69
Drying · 40, 41, 42
Dust collection · 38

B
Barricade · 23
Battery-powered equipment · 80
Bay · 124, 125, 126, 129
Bearing · 56
Blast · 127, 128, A-1
Blast-resistant door · 19
Blending · 51
Bonding · 27, 89

C
Cart · 75
Cased explosive · 103
Checklist · 15
Chemical cleaning agent · 96
Chock block · 78
Class 1 · 12, 93, 110, 118, 145, 146
Class I · 31, 32, 34, 35, 36, 80, 118, 123, 124, 125, 126, 127, 129
Class II · 31, 32, 34, 35, 36, 80, 123, 124, 125, 126, 129
Class III · 123, 124, 126, 129
Class IV · 123, 124, 125, 126, 129
Classification test · 119
Cleaning · 21, 95, 97, 112

E
Electric line · 32
Electric transmission line · 32
Electrical resistance · 26
Electro-explosive device · xii, 6, 7, 8, 9, 11, 25, 28, 62, 66, 67,
74

B-1

Appendix B
Revision 8

DOE M 440.1-1
w/ Approved Changes through 5/19/98

Emergency · 16, 55, 81, 95, 107
Emergency plan · 55
Equipment speed and feed rate · 46
Evacuation · 25, 82
Exhaust ventilation · 38, 95
Existing facility · 2, 18
Exit · 16, 19, 20
Experimental explosive · 90
Exploding bridgewire · xii, 6, 7, 9, 87, 89, 103
Explosive
assembly · ii
operation · ii
Explosive dust · 98, 99
Explosives Development Committee · xii, 10, 41, 54, 58, 88,
137, 138, 139, 140, 141, 143
Explosives limit · 105
Explosives occupancy · 16
Explosives operating building · 17
Explosives Safety Committee · i, ii, 1, 3, 4, 72, 143, 144, 145, 1
Explosives waste · 98, 101, 102, 103
Explosives-carrying vehicle · 25
Exposed explosive · 78
Extrudable explosive · 52
Extrusion · 45

H
Handling · 74, 75, 80
Hard surface · 52, 73
Hazard and Operability Study · xii, 15
Hazard class (explosives) · 118, 119
Hazards · 14, 18, 59, 118, A-2
Heating · 40, 41, 42, 69, 83, 105, 106
Heating coil · 83
Heating control · 41
High explosive · xii, 49, 87, 89, 110, 146
High-hazard explosive · 17
Hoisting and rigging · 39, 75, A-1
Hot water · 94

I
IHE subassembly · 47, 123, 125, 126, 146, 147
IHE weapon · 8, 125, 126, 146
Impact · 119, 120, 138
Incompatible explosives · 100
Incompatible materials · 98
Industrial truck · 81
Initiating explosive · 87, 89
Initiation · 75, 87
Insensitive High Explosive · xii, 8, 9, 47, 85, 89, 110, 123, 125,
126, 143, 144, 145, 146, 147, A-1
Inspection · 13, 26, 53, 67, 72, 85, 96, 112
Inspection interval · 13
Instrument · 30, 36, 72, 73
Instrumentation · 34, 70
Interlock · 23, 45, 48
Intraline distance · 21

F
Facilities · 18, 33, 34, 82, 95, 97, 128, A-1
Facility · 3, 16, 22, 109
Facility management · 3, 16, 22, 109
Failure modes, effects, and criticality analysis · xii, 15
File · 16, 132
Final decontamination · 95, 96
Firing area · 59
Firing circuit · 67
Firing lead · 65
Firing mechanism · 68
Flame arrestor · See Arrestor
Flame-retardant coverall · 111
Flammable liquid · 84
Flashing · 101
Flexible cords/wiring · 34
Footwear · 28, 111
Formulation · 55, 137, 138, 139, 145
Fragment · 127, 128, A-1
Friction · 138, 144

L
Labeling · 37
Laboratory operation · 103, 104
Life Safety Code · 16, 17, 18, 19, 20, A-2
Lighter · 24
Liquid addition · 85
Low pressure · 58
Lower explosive limit · xii, 9, 10
Lower flammable limit · xii, 9, 10

G

M

Gasoline-powered · 80
General operating procedure · 132
Glove · 111
Grinding · 56
Ground fault circuit interrupter · 30, 111
Grounding · 27, 30, 33
Gun · 67, 68, 71

Machining · 45, 47, 49
Machining overtest · 49
Magazine · 82, 83, 84, 92, 93
Maintenance · 21, 22, 112, 113, 128, A-1
Manual handling · 74
Mass detonating · 118
Match · 24, 81
Material Safety Data Sheet · xii, 14, 114
Maximum Credible Event · 104
Melting · 51

B-2

Appendix B
Revision 8

DOE M 440.1-1
w/ Approved Changes through 5/19/98

Metal chip waste · 46
Metal container · 92
Metal scrap · 100
Milling · 10
ball or jar · 56
dry · 110, 123
roll · 56, 57
Misfire · 70, 71
Mixer · 56
Mixing · 56, 57, 86, 90, 98
Mock · 10
Modification · 37
Motor vehicle · 77

R
Radio transmitter · 101
Railcar · xii, 76, 77, 79, 120
Record · 21, 72, 99, 114
Reduced-hazard explosive · 17
Renovation · 33
Repair · 21
Resistance-to-ground · 50, 51
Respirator · 111
Review · 4, 85, 110, 132, 133
RF transmitter · 63, 64
Road · 23, 81, 147, A-1
Rocket · 89
Rubbish · 98

N
National Electrical Code · xii, 31, 32, 33, 34, 35, 36, 80, A-2
New equipment · 22
New explosive · 44, 54
Noise · 16

S
Safe secure railcar · xii, 77, 80
Safe secure trailer · xii, 77, 80
Safety analysis · 16
Safety equipment · 55
Safety shield · 105
Salvaged explosive · 100
Sawing · 50
Scaleup · 138
Screening · 50
Service personnel · 66
Shield · 104, 105, 128, A-2
Shipment · 77, 79
Shipping and receiving · 92
Shunt · 62
Siting · 128
Skin contact · 14, 111
Slapper detonator · 9
Slide escape · 20
Small arms · 90
Smoking · 24, 79
Solvent · 58, 94, 103, 104
Spark arrestor · See Arrestor
Spray mist coolant · 49
Squib · 89
Stability test · 44
Stacks of explosive · 84
Standard operating procedure · xii, 38, 67, 97, 131, 134, 135
Static ground · 27
Storage · 5, 8, 64, 74, 82, 83, 85, 86, 88, 89, 90, 91, 92, 93, 94,
98, 100, 104, 122, 126, A-1
Storage compatibility · 5, 89, 91, 98
Storage compatibility group · 5, 89
Storage review · 85
Structural collapse · 124, 125
Sump · 39
Surge arrestor · See Arrestor
Sweeping compound · 21
Synthesis · 54, 138, 139

O
Occupancy · 16
Open container · 92
Open flame · 104
Operating procedure · 94
Operation · ii, 3, 4, 5, 10, 13, 16, 25, 31, 42, 44, 46, 48, 49, 50,
52, 57, 58, 74, 79, 80, 83, 84, 102, 105, 128, 129, 131, 134,
135, 143, 145, A-1
Overpressure · 124, 125

P
Panic hardware · 20
Permanent wiring · 34, 36
Personnel limit · 17, 109
Pinch · 53
Pinch point · 53
Placard · 82, 107
Plastic bonded explosive · xii, 47, 89
Plastic explosive · 52
Plutonium · 125, 126, 129
Precaution · 37, 45, 50, 68, 78, 101
Press setup procedure · 44
Pressing · 43, 44
Pressure controller · 43, 45
Pressurized unit · 52
Process equipment · 25, 36
Proof-test · 69
Propellant · 90
Public traffic route · 23
Pyrotechnic · 87, 89

Q
Quantity-distance · 76, 109, 118, 122

B-3

Appendix B
Revision 8

DOE M 440.1-1
w/ Approved Changes through 5/19/98

T

V

TB 700-2 · 119, 144, 147, A-1
Team · 15
Temperature control · 43
Test assembly · 43, 65
Test firing · 60, 67
Test instrument · 72
Test procedure · 143
Thermal flux · 125
Thermal stability · 139
Threaded fastener · 53
Tiedown · 78
TNT equivalent · 67, 104, 127
Tool path control · 46
Toxicity · 14
Training · 114, A-2
Transmitter · 63, 64
Transportation · xii, 7, 21, A-2
Trap · 37

Vacuum drying · 42
Vehicle · 75, 76, 77, 78, 79, 120
Vented · 128, A-1
Ventilation · 38, A-1
Visual inspection · 26

W
Waiver · 3
Walkway · 16
Warehouse · 93
Wastewater · 99
Watertight equipment · 35
Wiring · 33, 34
Wristband · 28

B-4

Appendix C -

Approved Changes

a

Change 97-10, deletion of old FOREWORD, approved at 36th DOE ESC meeting.
Change 97-09, approved at 36th DOE ESC meeting.
c
Change 97-09, approved at 36th DOE ESC meeting.
d
Change 97-31, approved at 36th DOE ESC meeting.
e
Change 97-08, approved at 36th DOE ESC meeting.
f
Change 97-08, approved at 36th DOE ESC meeting.
g
Change 97-07, approved at 36th DOE ESC meeting.
h
Change 98-06, approved at 38th DOE ESC meeting.
i
Change 97-08, approved at 36th DOE ESC meeting.
j
Change 97-06, approved at 36th DOE ESC meeting.
k
Change 98-06, approved at 38th DOE ESC meeting.
l
Change 97-06, approved at 36th DOE ESC meeting.
m
Change 98-06, approved at 38th DOE ESC meeting.
n
Change 98-06, approved at 38th DOE ESC meeting.
o
Change 98-06, approved at 38th DOE ESC meeting.
p
Change 97-31, approved at 36th DOE ESC meeting.
q
Change 97-39, approved at 36th DOE ESC meeting.
r
Change 97-05, approved at 36th DOE ESC meeting.
s
Change 97-05, approved at 36th DOE ESC meeting.
t
Change 97-52, approved at 37th DOE ESC meeting.
u
Change 97-05, approved at 36th DOE ESC meeting.
v
Change 97-39, approved at 36th DOE ESC meeting.
w
Change 97-05, approved at 36th DOE ESC meeting.
x
Change 97-05, approved at 36th DOE ESC meeting.
y
Change 97-05, approved at 36th DOE ESC meeting.
z
Changes 95-06 and 97-05, approved at 34th and 36th DOE ESC meeting, respectively.
aa
Change 97-05, approved at 36th DOE ESC meeting.
bb
Change 98-01, approved at 38th DOE ESC meeting.
cc
Change 97-18, approved at 36th DOE ESC meeting.
dd
Change 96-10, approved at 35th DOE ESC meeting.
ee
Change 97-37, approved at 36th DOE ESC meeting.
ff
Change 96-11, approved at 35th DOE ESC meeting.
gg
Change 95-02, approved at 34th DOE ESC meeting.
hh
Change 95-02, approved at 34th DOE ESC meeting.
ii
Change 97-42, approved at 37th DOE ESC meeting.
jj
Change 97-17, approved at 36th DOE ESC meeting.
kk
Change 97-17, approved at 36th DOE ESC meeting.
ll
Change 97-17, approved at 36th DOE ESC meeting.
mm
Change 97-17, approved at 36th DOE ESC meeting.
nn
Change 97-17, approved at 36th DOE ESC meeting.
oo
Change 97-17, approved at 36th DOE ESC meeting.
pp
Change 97-17, approved at 36th DOE ESC meeting.
qq
Change 97-03, approved at 36th DOE ESC meeting.
rr
Change 97-51, approved at 37th DOE ESC meeting.
ss
Change 97-38 and 97-49, approved at 36th and 37th DOE ESC meeting, respectively.
b

C-1

Appendix C
Revision 8

DOE M 440.1-1
w/ Approved Changes through 5/19/98

tt

Change 97-35, approved at 36th DOE ESC meeting.
Change 97-48, approved at 37th DOE ESC meeting.
vv
Change 97-02, approved at 36th DOE ESC meeting.
ww
Change 97-19, approved at 36th DOE ESC meeting.
xx
Change 98-02, approved at 38th DOE ESC meeting.
yy
Change 97-50, approved at 37th DOE ESC meeting.
zz
Change 97-23, approved at 36th DOE ESC meeting.
aaa
Changes 97-23 and 97-40, both approved at 36th DOE ESC meeting.
bbb
Change 97-44, approved at 37th DOE ESC meeting.
ccc
Change 97-04, approved at 36th DOE ESC meeting.
ddd
Change 97-36, approved at 36th DOE ESC meeting.
eee
Change 97-11, approved at 36th DOE ESC meeting.
fff
Change 97-25, approved at 37th DOE ESC meeting.
ggg
Change 96-09, approved at 35th DOE ESC meeting.
hhh
Change 97-16, approved at 36th DOE ESC meeting.
iii
Change 96-06, approved at 35th DOE ESC meeting.
jjj
Change 97-01, approved at 36th DOE ESC meeting.
kkk
Change 97-01, approved at 36th DOE ESC meeting.
lll
Change 97-01, approved at 36th DOE ESC meeting.
mmm
Change 97-46, approved at 37th DOE ESC meeting.
nnn
Change 97-01, approved at 36th DOE ESC meeting.
ooo
Changes 95-03, 95-11, and 97-45, approved at the 35th, 33rd, and 37th DOE ESC meeting,
respectively.
ppp
Change 97-01, approved at 36th DOE ESC meeting.
qqq
Change 97-20, approved at 37th DOE ESC meeting.
rrr
Change 97-12, approved at 36th DOE ESC meeting.
sss
Change 97-13, approved at 36th DOE ESC meeting.
ttt
Change 97-14, approved at 36th DOE ESC meeting.
uuu
Change 97-14, approved at 36th DOE ESC meeting.
vvv
Change 97-29, deletion of section 20.8, approved at 36th DOE ESC meeting.
www
Change 97-34, approved at 36th DOE ESC meeting.
xxx
Change 96-04, approved at 34th DOE ESC meeting.
yyy
Change 96-03, approved at 35th DOE ESC meeting.
zzz
Change 95-29, approved at 34th DOE ESC meeting.
aaaa
Change 95-29, approved at 34th DOE ESC meeting.
bbbb
Change 97-27, approved at 36th DOE ESC meeting.
cccc
Changes 97-32, approved at 36th DOE ESC meeting.
dddd
Change 97-30, approved at 37th DOE ESC meeting.
eeee
Change 97-30, approved at 37th DOE ESC meeting.
ffff
Change 96-10, approved at 35th DOE ESC meeting.
gggg
Change 96-10, approved at 35th DOE ESC meeting.
hhhh
Change 97-24, approved at 36th DOE ESC meeting.
iiii
Change 97-22, approved at 36th DOE ESC meeting.
jjjj
Change 96-01, approved at 34th DOE ESC meeting.
kkkk
Changes 96-02 and 96-05, approved at 34th DOE ESC meeting.
uu

C-2

Appendix C
Revision 8

DOE M 440.1-1
w/ Approved Changes through 5/19/98

llll

Change 96-12, approved at 36th DOE ESC meeting.
Change 96-10, approved at 35th DOE ESC meeting.
nnnn
Change 97-29, approved at 37th DOE ESC meeting.
oooo
Change 97-29, approved at 37th DOE ESC meeting.
pppp
Change 97-29, approved at 37th DOE ESC meeting.
qqqq
Change 96-10, approved at 35th DOE ESC meeting.
rrrr
Changes 96-01 and 98-06, approved at 34th and 38th DOE ESC meetings, respectively.
ssss
Change 96-01, approved at 34th DOE ESC meeting.
tttt
Change 96-07, approved at 35th DOE ESC meeting.
uuuu
Change 97-15, approved at 36th DOE ESC meeting.
vvvv
Change 96-01, approved at 34th DOE ESC meeting.
mmmm

C-3
Source Exif Data: 
File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.4
Linearized                      : Yes
Create Date                     : 1999:03:19 16:29:33Z
Modify Date                     : 2002:04:30 14:31:45-04:00
Subject                         : DOE Explosives Safety Manual - Pantex Version DOE M 440.1-1, Revision 8
Keywords                        : explosive, safety, manual;, pantex, version;, DOE, M, 440.1-1;, DOE/EV/06194;, explosive, safety, committee;, handling, explosives;, explosive, safety;, safety, manual;
EHDL Originator                 : U. S. Department of Energy; Enviroment, Safety and Health; OFfice of Worker Safety and Health; Battelle Pantex Nuclear Explosive Safety Department
DC Date                         : 19980501
DC Type Category                : Safety
DC Type Doctype                 : Report
DC Type Doc Sub-Type            : dp
EHDL Site                       : Battelle Pantex
EHDL Docno                      : DOE M 441.1-1; DOE/EV/06194
Page Count                      : 173
Creation Date                   : 1999:03:19 16:29:33Z
Producer                        : Acrobat Distiller 3.0 for Windows
Mod Date                        : 2002:04:30 14:31:45-04:00
Author                          : N˘
Metadata Date                   : 2002:04:30 14:31:45-04:00
Title                           : DOE Explosives Safety Manual - Pantex Version DOE M 440.1-1, Revision 8
Description                     : DOE Explosives Safety Manual - Pantex Version DOE M 440.1-1, Revision 8
Creator                         : N˘
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