# Contractors' Safety for Ammunition and Explosives

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URL: https://www.frixlaw.com/law-library/documents/fr%3A05-5429

## Record

- **Collection:** Federal Register
- **Document type:** Proposed Rule
- **Published:** March 29, 2005
- **Citation:** 70 FR 16038

## Text

DEPARTMENT OF DEFENSE
Office of the Secretary
32 CFR Part 184
RIN 0790-AH76
[DoD 4145.26-M]
Contractors' Safety for Ammunition and Explosives

AGENCY:

Office of the Secretary of Defense.

ACTION:

Proposed rule for comment.

SUMMARY:

The Department of Defense (DoD) is codifying its revised explosives safety standards for ammunition and explosives (A&E) work performed under DoD contracts. This proposed rule is necessary to minimize the potential for mishaps that could interrupt DoD operations, delay project completion dates, adversely impact DoD production base or capability, damage or destroy DoD-owned material/equipment, cause injury to DoD personnel, or endanger the general public. The benefits of this proposed rule in terms of the protection of the public and ensuring contract performance are expected to balance its potential cost or administrative impacts. Only provisions related to conventional AE operations have been included in this proposed rule. No attempt was made to encompass general industrial safety, occupational health concerns, chemical warfare agents, radiation, or over-the-road transportation requirements, because these are either the responsibility of other regulatory agencies (for example DOT, DOL/OSHA, or NRC) or may be addressed elsewhere in the contract by the procuring activity. Budgetary effects of this proposed rule are minimal since existing DoD Federal Acquisition Regulation Supplement coverage already requires compliance with safety requirements in AE solicitations and contracts. Finally, because this proposed rule is needed to minimize the potential for AE mishaps that could adversely impact DoD and the public, timely publication in the
Federal Register
is important.

DATES:

Comments are to be received not later than May 31, 2005.

FOR FURTHER INFORMATION CONTACT:

Dr. Jerry M. Ward, Director, Engineer Technical Programs Division, DDESB, telephone (703) 325-2525, fax: (703) 325-6227; e-mail:
Jerry.Ward@DDESB.OSD.mil
.

SUPPLEMENTARY INFORMATION:

Pursuant to the authority vested in the Secretary of Defense in accordance with 10 U.S.C. 172, DoD Directive 6055.9 established the Department of Defense Explosives Safety Board as a joint activity of the Department of Defense subject to the direction, authority and control of the Secretary of Defense. The majority of the standards impacting upon the public were adopted prior to the enactment of the Administrative Procedure Act. This proposed rule is intended to ensure public awareness of the extent of the explosives safety standards as well as offer the public an opportunity to comment on the standards. The information addresses the HCSDS sometimes furnished with solicitations or contracts to provide an insight into potentially hazardous characteristics of the materials involved in the production of the item addressed in the solicitation. Contractors retain the ultimate responsibility for assuring the safety of their personnel and establishment. Information provided by the HCSDS is derived from other sources. Verification of such data as shipping and storage hazard division and storage compatibility group information must be done through the DoD Joint Hazard Classification System (JHCS) or Title 49, Code of Federal Regulations.

These classifications pertain to AE packaged for transportation or storage. Such hazard classification information may not be valid when applied to the hazards associated with manufacturing or loading processes. For such processes, the materials and processes must be analyzed on a case-by-case basis. Sources of information to support this analysis are available from service research and development organizations through contract channels and other sources.

Executive Order 12866

This proposed rule does not:

(1) Have an annual effect of the economy of $100 million or more or adversely affect in a material way the economy, a sector of the economy, productivity, competition, jobs, the environment, public health or safety, or state, local, or tribal governments.

(2) Create a serious inconsistency or otherwise interfere with an action taken or planned by another agency.

(3) Materially alter the budgetary impact of entitlement, grants, user fees, or loan programs or the rights and obligations of recipients thereof; or

(4) Raise novel legal or policy issues arising out of legal mandates, the President's priorities, or the principles set forth in this Executive Order.

Regulatory Flexibility Act of 1980 (5 U.S.C. 605(b))

Regulatory Flexibility Act. It has been certified that this proposed rule, if promulgated, shall be exempt from the requirements under 5 U.S.C. 601-612. This proposed rule does not have a significant economic impact on small entities as defined in the Act.

Unfunded Mandates Act of 1995 (Sec. 202, Pub. L. 104-4)

This proposed regulatory action does not contain a Federal mandate that will result in the expenditure by State, local, and tribal governments, in aggregate, or by the private sector of $100 million or more in any one year.

Paperwork Reduction Act of 1995 (44 U.S.C. Chapter 35)

Paperwork Reduction Act. The proposed rule imposes no obligatory information requirements beyond internal Department of Defense needs.

Federalism (Executive Order 13132)

This proposed regulatory action does not have federalism implications, as set forth in Executive Order 13132. It will not have substantial direct effects on the States, on the relationship between the national government and the States, or on the distribution of power and responsibilities among the various levels of government.

Section 202, Public Law 104-4, “Unfunded Mandates Reform Act”

It has been determined that this rule does not involve a Federal mandate that may result in the expenditure by State, local and tribal governments, in the aggregate, or by the private sector, of $100 million or more and that such rulemaking will not significantly or uniquely affect small governments.

List of Subjects in 32 CFR Part 184

Ammunition and explosives, DoD contractors.

Accordingly, 32 CFR part 184 is proposed to be added to read as follows:

PART 184—DOD CONTRACTORS' SAFETY MANUAL

Sec.
184.1
Introduction.
184.2
Mishap investigation and reporting.
184.3
General safety requirements.
184.4
Quantity-distance and siting.
184.5
Hazard classification, storage principles, and compatibility groups.
184.6
Electrical safety requirements for AE facilities.
184.7
Manufacturing and processing propellants.
184.8
Safety requirements for manufacturing and processing pyrotechnics.
184.9
Storage of ammunition and explosives.
184.10
Fire protection.
184.11

Risk identification and management.

184.12
AE building design and layout.
184.13
Safety requirements for specific AE and AE operations.
184.14
Test and testing requirements.
184.15
Collection and destruction requirements for AE.
184.16
Construction and siting criteria.
Appendix A to 32 CFR Part 184—Glossary

Authority:

10 U.S.C. 172.

§ 184.1
Introduction.

(a)
Purpose.
This part provides safety requirements, guidance and information to minimize potential mishaps which could interrupt Department of Defense (DoD) operations, delay production, damage DoD property, cause injury to DoD personnel, or endanger the public during contract work or services involving ammunition and explosives (AE). The part contains the minimum contractual safety requirements to support the objectives of DoD. These requirements are not a complete safety program and this part does not relieve a contractor from complying with Federal, State and local laws and regulations.

(b)
Applicability.
These safety requirements apply to contractors performing AE work or AE services on DoD contracts, subcontracts, purchase orders, or other procurement methods. The requirements also apply to non-DoD contractor operations to the extent necessary to protect DoD work or services.

(c)
Mandatory and advisory requirements.
The part uses the term “shall”, or an affirmative statement, to indicate mandatory requirements. The terms “should” and “may” are advisory. When advisory provisions are not met, adverse consequences might develop and become proximate causes of AE mishaps.

(d)
Compliance with mandatory requirements.
(1) The Department of Defense requires compliance with mandatory provisions of this part and applicable portions of DoD 6055.9-STD.
1

Siting criteria for AE are provided in quantity distance (Q-D) standards contained in Chapter 9 of DoD 6055.9-STD. In order to provide consistent and current information to all DoD AE contractors, Q-D requirements of DoD 6055.9-STD are incorporated by reference in paragraph C317.

1
Copies may be obtained via Internet at
http://www.dtic.mil/whs/directives
.

(2)
Waivers.
Procuring contracting officers (PCO) may grant contract-specific waivers to mandatory provisions of this part. Rationale for waiver of DoD pre-award safety surveys must be documented and provided to the cognizant ACO for transmittal to the cognizant DoD Component explosives safety office for their records. Military or commercial ammunition and explosives shall not be procured unless their use is authorized by the cognizant DoD Component explosives safety approval authority. Methods of addressing non-compliance with mandatory requirements and requests for waivers are different during the pre- and post-award phases of a contract.

(3) In the
pre-award phase
, the PCO will request a DoD pre-award safety survey to help determine contractor capability. During pre-award surveys, noncompliance with mandatory safety requirements normally results in a recommendation of “no award.” Any noncompliance should be resolved during the pre-award survey. Contractors may choose to correct the deficiencies immediately, may offer a letter of intent to correct the deficiencies (which will become binding upon award of contract), or may request that the PCO accept specifically identified existing conditions of facilities (contract-specific waiver).

(4) In the
post-award phase
, the contractor has 30 days from the date of notification by the administrative contracting officer (ACO) to correct the noncompliance and inform the ACO of the corrective actions taken. The contracting officer may direct a different time period for the correction of any noncompliance. If the contractor refuses or fails to correct any noncompliance within the time period specified by the ACO, the Government has the right to direct the contractor to cease performance on all or part of affected contracts. When the contractor cannot comply with the mandatory safety requirements of the contract, the contractor will develop and submit a request for a waiver through the ACO to the PCO for the final determination. The request will contain complete information concerning the requirements violated, actions planned to minimize the hazard, and a proposed date for correction of the deficiency.

(e)
Pre-award safety survey.
DoD safety personnel conduct pre-award surveys to evaluate each prospective contractor's ability to comply with contract safety requirements. The pre-award safety survey is also an opportunity for the contractor to request clarification of any safety requirement or other AE issue that may affect the contractor's ability to comply. During pre-award surveys, the contractor shall provide the following:

(1) Site plans conforming to paragraphs (h)(5)(i) through (h)(5)(iv) of this section for proposed facilities to be used in contract performance.

(2) Evidence of implementation of a safety program containing at least mandatory requirements described in § 184.3.

(3) General description of proposed contract facilities, including size, building layouts, construction details, and fire resistive capabilities.

(4) Fire prevention program and available firefighting resources including local agreements or other documentation demonstrating coordination.

(5) Copies of required licenses and permits or demonstration of the ability to obtain approvals necessary to support the proposed contract.

(6) A safety history including mishap experience, safety survey or audit reports by insurance carriers or Federal, State, and local authorities, and any variances, exemptions or waivers of safety or fire protection requirements issued by Federal, state or local authorities.

(7) Details of proposed operations and equipment to include process flow narrative/diagram, proposed facility or equipment changes, hazard analysis, and proposed procedures for all phases of AE operations.

(8)
Subcontractor information.
(i) Identification of all subcontractors proposed for the AE work.

(ii) Methods used to evaluate capability of subcontractor to comply with the requirements of this part.

(iii) Methods used to manage subcontractor compliance.

(f)
Preoperational safety survey.
The DoD reserves the right to conduct a preoperational survey after contract award of new items with limited contractor experience, after major new construction or major modifications, or after an AE mishap. When these situations occur, the contractor shall notify the ACO, sufficiently in advance, to provide the Department of Defense the opportunity to schedule and perform a preoperational survey.

(g)
Post-award contractor responsibilities.
The contractor shall:

(1) Comply with the requirements of this part and any other safety requirements contained within the contract.

(2) Develop and implement a demonstrable safety program, including operational procedures, intended to prevent AE-related mishaps.

(3) Designate qualified individuals to administer and implement this safety program.

(4) Prepare, and keep available for review, all hazard analyses used to justify alternative methods of hazards control that differ from those recommended in this part.

(5) Provide access to facilities and safety program documentation to Government safety representatives.

(6) Report and investigate AE mishaps in accordance with § 184.2.

(7) Provide identification and location of subcontractors to the ACO for notification or approval in accordance with terms of the contract.

(8) Establish and implement management controls to ensure AE subcontractors comply with paragraphs (g)(1) through (g)(7) of this section.

(h)
Site and construction plans.
(1) Contractors must prepare site and construction plans for support of the pre-award process, and for any change in layout or construction potentially affecting Q-D incident to the contract. Contractors shall also maintain a current site map depicting Q-D relationships for all AE locations within the facilities.

(2) When the place of performance of the contract is at a DoD-owned facility, site and construction plans shall be prepared and processed (content and staffing) in accordance with the requirements of DoD 6055.9-STD, as well as, appropriate military service regulations contained within the contract.

(3) For contractor-owned, contractor-operated (COCO) facilities, the contractor shall submit, through the ACO to the PCO, site and construction plans for all new construction or major modification of facilities for AE activities and for the facilities that may be exposed to AE hazards if improperly located. The contractor shall provide sufficient copies for the review process. The contractor shall not begin construction or modification of proposed facilities until receiving site and construction plan approval from the PCO through the ACO.

(4) Minor new construction, changes, and modifications of existing AE facilities involving Hazard Class/Division (HC/D) additions and deletions or that add or remove small portable operating buildings and magazines may not require formal site plan submission. Minor applies to all changes that involve only 1.4 HC/D materials. Minor also applies to changes of other HC/D materials that do not increase the existing maximum credible event (MCE) for an AE facility or do not extend any quantity distance arcs beyond existing fragment, inhabited building, and public traffic route distance arcs for other nearby potential explosion sites (PES). When the contractor thinks a modification/change is minor, he shall notify the ACO and request a determination. The ACO shall make the final determination as to whether a formal site plan submission is necessary.

(5) Site plans shall comply with the following:

(i) Plans shall include maps and drawings which are legible, accurate, and of a scale which permits easy determination of essential details. For general layout of buildings, this is normally a scale of 1 inch to 400 feet (or metric equivalent) or less. Site plans may require other-scaled drawings, which provide details of construction, structure relationships within the project area, barricades, or other unique details. Plans may also include pictures to illustrate details and videotapes of MCE testing data.

(ii) Maps and drawings shall identify distances between all PESs, all exposed sites (ESs) within the facility, the facility boundary, any additional property under contractor control, ESs on adjacent property when applicable, public railways and highways, power transmission lines and other utilities.

(iii) Plans shall identify and briefly describe all PESs and all ESs within any applicable fragmentation distance and/or inhabitable building distance of a PES. Site plans for major new construction or modification shall also identify and briefly describe all PESs whose inhabitable building distance are includes the proposed new or modified site.

(iv) Plans shall include the maximum net explosive weight(s) (NEW) and the HC/Ds of all PESs and, when applicable, shall include MCE information and maximum NEW for each room or bay. Plans shall also include engineering or test data when substituting construction or shielding for distance to protect from fragmentation or overpressure.

(v) Plans shall include a topographical map in sufficient detail to permit evaluation, when the contractor uses natural terrain for barricading to reduce fragment distance.

(6) Construction plans for proposed facilities shall contain the information required in paragraphs (h)(5)(i) through (h)(5)(v) of this section and construction details of dividing walls, venting surfaces, firewalls, roofs, operational shields, barricades, exits, ventilation systems and equipment, AE waste disposal systems, lightning protection systems, grounding systems, processing equipment auxiliary support structures, and, general materials of construction, as applicable.

§ 184.2
Mishap investigation and reporting.

(a)
General.
This section contains requirements for investigating and reporting mishaps involving AE.

(b)
Reporting criteria.
The contractor shall investigate and report to the ACO and cognizant Defense Contract Management Agency (DCMA) contract safety specialist all mishaps involving ammunition or explosives that result in one or more of the following:

(1) One or more fatalities.

(2) One or more lost-work day cases with days away from work as defined by 29 U.S.C. 651-678.

(3) Five or more non-fatal injuries (with or without lost workdays).

(4) Damage to government property exceeding $20,000.

(5) Delay in delivery schedule exceeding 24 hours. (This requirement does not constitute a waiver or amendment of any delivery schedule required by the contract.).

(6) Contractually required notifications of mishaps other than in paragraphs (b)(1) through (b)(5) of this section; or

(7) Any mishap that may degrade operational or production capability, or is likely to arouse media interest.

(c)
Mishap investigation requirements.
Paragraph (e) of this section contains the elements of information which a basic investigation shall produce. Based upon the seriousness of the mishap and impact on munitions or munitions systems involved, the ACO or PCO may require an additional, more comprehensive investigation. The PCO retains the right to participate in contractor investigations, or to perform an independent DoD investigation. In the event the PCO directs DoD participation, or an independent DoD investigation, the contractor shall preserve the mishap scene, taking only those actions necessary to protect life and health, preclude further damage, or prevent access by unauthorized persons in order to preserve investigative evidence. The contractor shall obtain the PCO's permission to disturb the evidence, with the exception of paragraph (b)(2) of this section. Nothing in the reporting requirements contained in this part relieve the contractor of making other notifications required by Federal, State, or local requirements.

(d)
Telephone report.
The contractor shall report any mishap described in paragraph (b) of this section by telephone to the ACO and cognizant DCMA contract safety specialist as soon as practicable, but not later than three hours after the mishap.

(e)
Written report.
(1) The contractor shall submit a written report to the ACO and cognizant DCMA contract safety specialist by the end of the second business day after mishap occurrence.

(i) Contractor's name and location.

(ii) Date, local time, and plant facility/location of the mishap.

(iii) Type of mishap (explosion, fire, loss, other).

(iv) Contract, subcontract, or purchase order.

(v) Item nomenclature, hazard classification, lot number.

(vi) Mishap narrative.

(vii) Number of injuries, fatalities, degree of injuries. (viii) Description of property damage and cost.

(ix) Quantity of energetic material involved (pounds, units, rounds).

(x) Probable cause(s).

(xi) Corrective action taken or planned.

(xii) Effect on production.

(xiii) Name, title or position, and phone number of person submitting the report.

(xiv) Remarks.

(2) The contractor shall provide to the ACO supplemental information to the initial report within 30 days of mishap occurrence.

(f)
Special technical mishap investigations and reports.
When warranted by the circumstances of a mishap, the PCO may require a special technical investigation conducted by DoD personnel. The PCO may also direct the contractor to conduct a special technical investigation. In either case, the investigation report shall provide details such as fragmentation maps, photographs, more detailed description of events of the mishap, effects on adjacent operations, structural and equipment damage, Q-D drawings, detailed description of occurrence and related events, findings and conclusions. If the contractor performs the special technical mishap investigation, the contractor shall forward the report through the ACO to the PCO within 60 days of the direction by the PCO to perform the investigation. Upon determination by the PCO that a DoD investigation is required, the PCO will immediately advise the contractor.

§ 184.3
General safety requirements.

(a)
General.
This section provides general safety requirements for all AE operations addressed in this part. When these practices exceed or differ from local or national codes or requirements, the more restrictive shall apply.

(b)
Personnel and material limits.
(1) Control of all locations or operations presenting real or potential hazards to personnel, property, or the environment is essential for safety and efficiency. Control measures include minimizing the number of personnel exposed, minimizing the duration of the exposure, and minimizing the amount of hazardous material consistent with safe and efficient operations.

(2) All buildings, cubicles, cells, rooms, and locations containing AE shall have AE and personnel limits prominently posted. Include supervisors, production workers, and transient personnel when determining personnel limits. Posted personnel limits are not required in storage magazines, magazine areas, or transfer points.

(3) All buildings, cubicles, cells, rooms or locations containing AE shall have prominently posted limits for the quantities of AE permitted. The posted limits shall not exceed the quantity stipulated in the site plan, and shall accurately reflect current process requirements. Post AE limits in storage magazines when the limit differs from that for other magazines in the block, or when circumstances prevent the limit from being readily apparent. It is not required to express AE limits in units of weight or in the number of items. Express limits in terms of trays, boxes, racks, or other units more easily observed and controlled.

(c)
Standard operating procedures (SOP).
(1) Clearly written procedures are essential to avoid operator errors and ensure process control. Therefore, before commencing manufacturing operations involving AE, qualified personnel shall develop, review, and approve written procedures.

(2)
Preparation.
The contractor shall prepare and implement written procedures which provide clear instructions for safely conducting AE activities. The use of controlled tests is an acceptable method for developing and validating SOPs. SOPs shall include the following:

(i) The specific hazards associated with the process.

(ii) Indicators for identifying abnormal process conditions.

(iii) Emergency procedures for abnormal process conditions or other conditions which could affect the safety of the process.

(iv) Personal protective clothing and equipment required by process personnel.

(v) Personnel and AE limits.

(vi) Specific tools permitted for use by the process operator.

(vii) The chronological sequence of job steps the operator is to follow in performing the work.

(viii) Procedures for disposing of any scrap and waste AE.

(3)
Dissemination.
Personnel involved with AE processes, and personnel who maintain AE equipment, shall have written operating procedures readily accessible.

(4)
Training.
Personnel shall receive appropriate training before performing work involving exposure to AE. The training shall include emphasis on the specific safety and health hazards, emergency operations including shutdown, and safe work practices applicable to the employee's job tasks. The contractor shall ascertain that each employee involved in an AE process has received and understood the training. The contractor shall prepare a record that contains the identity of the employee, the date of training, and the means used to verify that the employee understood the training.

(5)
Emergency procedures.
The contractor shall instruct employees on procedures to follow in the event of electrical storms, utility or mechanical failures, equipment failures, process abnormalities, and other emergencies occurring during the manufacturing, handling, or processing of AE.

(6)
Revalidation.
Qualified personnel shall review SOPs on a regular basis. The managing authority shall change and validate SOPs as often as necessary to reflect improved methods, equipment substitutions, facility modifications, or process revisions.

(d)
Storage in operating buildings.
(1) The contractor may store limited quantities of hazardous materials, other than AE materials, which are essential for current operations in an operating building.

(2) The contractor shall store AE materials that exceed minimum quantity necessary for sustained operations in a service magazine located no closer than the intraline distance (ILD) (based on the quantity in the magazine) from the operating building or area. If ILD distance is not available for a separate service magazine, the contractor may designate storage locations within the operating building. Designated storage locations shall preclude immediate propagation from the operational location to the storage location. The quantity of AE material in the internal storage location shall not exceed that needed for one half of a work shift. The contractor should consider personnel exposure, structural containment afforded, and the venting ability of the proposed storage location when determining where to locate a designated storage location. When storage containers completely contain all fragments, debris, and overpressure, AE material may be stored without regard to Q-D requirements.

(3) At the end of the workday, personnel should remove all AE material from processing equipment and store it in an appropriate magazine or designated storage location. If operationally required, personnel may store in-process AE materials in the

building during non-operating hours provided the physical characteristics and stability of the AE materials are not degraded, and the AE material would not compromise the safety of the process equipment or personnel when the process is restarted.

(4) The contractor may use a separate enclosed room or bay in an operating building specifically adapted for the interim storage of production items awaiting the results of testing before final pack-out. The room or bay must afford the equivalent of service magazine distance protection to other parts of the building, and ILD to other buildings. Such a room or bay is limited to its defined and designed function and items, but is not subject to the four-hour supply limitation for the building or the ultimate pack-out operation.

(e)
Housekeeping in hazardous areas.

(1) The contractor shall keep structures containing AE clean and orderly.

(2) Explosives and explosive dusts shall not accumulate on structural members, radiators, heating coils, steam, gas, air or water supply pipes, or electrical fixtures.

(3) Written procedures shall include instructions for the removal of spilled material.

(4) Floor cleaning methods shall not create an ignition hazard or alter the conductive ability of floors in AE areas, nor should they result in an environmental contamination potential.

(5) Cleaning methods for AE processing equipment shall not result in any foreign material or AE remaining in the equipment.

(f)
Precautions for maintenance and repairs to equipment and buildings.
(1) The contractor shall examine and test all new or repaired AE processing equipment prior to placing the equipment in service in order to ensure that it is safe to operate.

(2) Before proceeding with maintenance or repairs to AE processing equipment, contractor personnel shall decontaminate the equipment to the degree necessary to perform the work safely. The contractor shall protect maintenance personnel from the effects of a reaction resulting from AE material in or on other parts of the equipment. Contractor personnel shall tag AE processing equipment before proceeding with repairs. The tag shall identify the decontaminated parts of the equipment, and those parts that contain AE.

(3) The contractor shall have SOPs for maintenance personnel performing work on AE equipment or performing building maintenance, repair, or modification activities in AE areas. The SOPs shall include a provision for inspecting equipment after maintenance work to ensure no tools or foreign materials remain in AE equipment. The SOPs shall identify the specific tools required to perform work on equipment which may contain explosive residues or areas which could have an explosive atmosphere.

(4) Before performing any building repair, modification or maintenance activity, the contractor shall ensure the removal of all AE materials from areas that may pose a hazard. The contractor shall also ensure the decontamination of all places where AE material could accumulate, such as, equipment, crevices, vents, ducts, wall cavities, pipes and fittings.

(g)
Operational shields.
(1) The purpose of operational shields is to prevent propagation of AE material from one AE operation or location to another, protect facilities and equipment, and provide personnel protection. Shields used for these purposes require an evaluation to determine their suitability for their intended purpose. All AE operations and processes require a hazard assessment prior to work performance to determine the type of hazard involved, the level of risk associated with the AE material or item, and the corresponding level of protection required.

(2) The primary hazards that accompany explosions and deflagrations are blast overpressure, fragmentation (primary and secondary) and thermal effects. The hazard assessment shall consider these hazards and the quantity of AE materials, initiation sensitivity, heat output, rate of burning, potential ignition and initiation sources, protection capabilities of shields, various types of protective clothing, fire protection systems, and the acute and chronic health hazards of vapors and combustion products on exposed personnel.

(3) When the hazard assessment indicates an unacceptable probability of explosion or deflagration, conduct operations or processes remotely. When an analysis of the hazard assessment indicates the hazards associated with an explosion or deflagration are controllable by using operational shields, the contractor shall design, install, and use shields which effectively protect personnel from the hazards. Shields complying with MIL-STD-398 are acceptable protection.

(4) The contractor shall test operational shields under conditions that simulate the operational environment. AE materials or items used in the test shall correspond to those that may be involved in a maximum credible event (MCE), plus 25 percent. The contractor shall maintain records of the test that demonstrate the shields will function as planned. Analysis rather than testing of shields may be acceptable on a case-by-case basis.

(5) When the doors of AE processing equipment function as operational shields, interlocking devices are required to prevent the operator from opening the door while the equipment is in operation.

(h)
Protective clothing.
(1) All AE operations require a hazard assessment to determine the need for protective clothing and personal protective equipment. The assessment shall include an evaluation of all hazards and factors contained in paragraph (g)(2) of this section.

(2) The contractor shall provide a changing area for employees who must remove their street clothes to wear protective clothing, such as explosive plant clothing, anti-contamination clothing, impervious clothing, and so forth. To avoid exposing personnel not involved in AE operations to unnecessary risks, employees shall not wear or remove protective clothing from the premises. Employees shall not wear any static producing clothing in areas where static electricity is a hazard.

(3) Explosives plant clothing, generally referred to as powder uniforms, shall have nonmetallic fasteners and be easily removable.

(4) When sending explosives-contaminated clothing to an off-plant laundry facility, the contractor is responsible for informing the laundry of the hazards associated with the contaminants and any special laundering or disposal requirements.

(i)
Material handling equipment.
(1) The contractor shall not refuel gasoline, diesel or liquefied petroleum gas (LPG) powered equipment inside buildings containing AE. Refueling shall take place at least 100 feet from structures or sites containing AE. Doors and windows through which vapors may enter the building shall not be open during refueling. Position refueling vehicles at least 100 feet from structures or sites containing AE during refueling.

(2) Gasoline-, diesel- or LPG-powered equipment shall not be stored in buildings, loading docks, or piers containing AE. The contractor shall store gasoline-, diesel-, and LPG-powered equipment at the appropriate fire protection distance from buildings containing AE.

(3) Gasoline, diesel, and LPG powered equipment shall have spark arrestors. The contractor shall perform and document inspections of the exhaust and electrical systems of the equipment

as necessary to ensure that the systems are functioning within the manufacture's specifications. The contractor shall maintain documentation of the inspections for a period of one year.

(j)
Parking of privately owned vehicles.
(1) Control of parking of privately owned vehicles within an AE establishment minimizes fire and explosion hazards and prevents congestion in an emergency.

(2) Parking lots serving multiple PESs shall not be closer than the ILD from each PES. Parking lots serving a single PES shall not be closer than 100 feet to the associated facility to protect it from vehicle fires, and shall be at least public traffic route distance from unassociated PESs. Parking lots for administration areas shall be located at public traffic route distance from all PESs.

(3) Vehicles shall not obstruct access to buildings by emergency equipment or personnel.

(k)
Ignition sources in hazardous areas.
The contractor shall not permit any nonessential ignition sources in operating buildings.

(l)
Operational explosives containers.
(1) Containers shall be compatible with the material they contain.

(2) Containers used for intraplant transportation or storage of process explosives and energetic materials shall not leak. Because of their fragility and potential for fragmentation, glass containers are not acceptable.

(m)
Intraplant rail transportation.
(1) The contractor shall develop written procedures to ensure safe and efficient rail movement of AE. The SOPs shall include information covering the inspection of the engine, car mover, and cars, normal and emergency operating procedures for the engine and car mover, AE loading and unloading procedures, and emergency procedures including fire fighting.

(2) Railcars positioned for loading shall have their brakes engaged to prevent movement. Contractor personnel shall inspect each railcar before loading to ensure it is suitable to carry the specific AE cargo. Contractor personnel shall check the cargo to ensure it is stable and secure, and close the railcar doors before car movement. If using an engine to move railcars, the contractor shall ensure that personnel have connected the air brakes of the railcars in sequence to the engine. If moving a railcar with a car mover the contractor shall station an individual at the hand brake of the railcar.

(3) A single parked railcar shall have the hand brakes set and the wheels chocked. When more than one railcar is parked, personnel shall set hand brakes on enough railcars to ensure the cars will not move. Personnel shall set hand brakes on the downgrade end of a group of parked railcars. Do not rely on the automatic air brakes to hold parked railcars.

(4) Contractor personnel shall avoid rough handling of railcars. Personnel shall not disconnect railcars containing AE from each other or a locomotive while in motion. Personnel shall couple railcars gently in order to avoid damaging the AE cargo or shipping containers. Disconnected railcars shall not strike railcars containing AE.

(5) The contractor shall maintain all rolling stock used for intraplant transportation of AE in a safe and good working condition.

(6) Portable transmitters and railroad locomotives equipped with two-way radios shall not transmit when passing AE operating buildings where electro-explosive devices are in use. The contractor shall determine minimum safe distances based on radio frequency and power output of the transmitter.

(n)
Intraplant motor vehicle transportation of AE.
(1) The contractor shall develop written procedures for the safe transportation of AE in motor vehicles. The SOP shall include procedures for vehicle inspection, vehicle operation, loading and unloading AE materials, and emergency procedures, including fire fighting.

(2) The operator responsible for transporting AE material shall perform a daily inspection of the vehicle before transporting materials. The operator shall verify that the fire extinguisher is charged and in working order, there are no fuels or other fluid leaks, and that brakes, tires, steering, and other equipment are in good operating condition. Before transporting AE, the operator shall inspect the cargo compartment to ensure it does not contain any residual AE material or any object which could present a hazard to the cargo.

(3) When loading or unloading AE, the operator shall shutoff the vehicle's engine, unless the engine is required to provide power to equipment for loading or unloading. The operator shall engage the emergency brake and use wheel chocks when the vehicle could move during loading or unloading. The operator shall stabilize and ensure the load is secure to prevent damage to containers or their contents. The operator shall not transport AE material in the passenger compartment of the vehicle.

(4) The vehicle operator shall understand and follow established procedures involving a vehicle fire, breakdown, accident, damaged or leaking containers, and spilled material.

(5) Transportation containers shall not allow the contents to leak or spill in transit.

(6) Non-sparking material shall cover the cargo compartment when transporting AE in containers capable of exposing their contents if damaged.

(7) Motor vehicles transporting AE within the establishment boundaries but outside the AE area shall bear at least two placards. Placards based on the fire division symbols discussed in § 184.10, “Fire Protection,” are acceptable. Motor vehicles or equipment with internal combustion engines, used near explosives scrap, waste, or items contaminated with explosives shall have exhaust system spark arresters and carburetor flame arresters (authorized air cleaners).

(8) The contractor shall maintain vehicles and material handling equipment used to load and transport AE in a safe operating condition.

(9) Batteries and wiring shall be located to prevent contact with containers of AE material.

(o)
Inspection of AE mixing equipment.
(1) The contractor shall establish a preventative maintenance program which includes the inspection of all AE mixing equipment on a periodic basis. The SOP for the inspection shall include criteria for inspecting the blades to bowl clearances, alignment of the blades and bowl, and detection of any distortion of the blades or bowl. The inspection procedures shall also include instructions for checking critical drive system components for wear, damage or misalignment. The procedures shall include criteria for determining that associated equipment used to control the mixer is functioning as designed. The contractor shall maintain a record of all inspections. After performing maintenance of the equipment, the contractor shall run the equipment under load to ensure it is safe to operate.

(2) The SOPs for operating mixing equipment shall include instructions for inspecting specific equipment components before each use.

(p)
Facility requirements.
(1)
Buildings.
The design, construction techniques, process layout, and siting of AE buildings are important considerations in explosives safety and directly influence quantity distance (Q-D) requirements and the degree of exposure to personnel, equipment, and facilities. Construction features which limit the amount of explosives involved, attenuate the resulting blast overpressure or thermal radiation, and reduce the quantity and range of

hazardous fragments and debris will help to minimize the effects of an explosion. Incorporating Q-D criteria, when locating an exposed site (ES) in relation to a potential explosive site (PES), will reduce the amount of damage and injuries in the event of an incident.

(2)
Building exteriors.
The contractor should design and erect AE buildings with the ability to allow for the venting of an internal explosion without collapsing. The use of lightweight materials in exterior wall and roof sections designed to vent the effects of an explosion will help reduce the number of large fragments. Exceptions from using lightweight materials include earth-covered magazines, containment type structures, firewalls, substantial dividing walls, special roof loadings, and walls and roofs used for external overpressure protection. Non-combustible exterior wall and roof coverings of operating buildings help prevent the spread of fire from one area of a building to another and from building to building.

(3)
Interior walls, roofs, and ceilings.
(i) Non-combustible material is preferred for the interior surfaces of buildings. The contractor should treat or cover exposed combustion supporting building materials with fire retardant material.

(ii) Where hazardous locations exist, interior surfaces shall be smooth, free from cracks, crevices and openings which may create a hazardous condition. This is important to prevent the accumulation or migration of explosive dust and vapors which could result in an incident. The National Fire Protection Association (NFPA), Standard 70
2

provides criteria for determining if a location is hazardous.

2
Obtain NFPA publications from the National Fire Protection Association at
http://www.nfpa.org/catalog/home/index.asp
.

(iii) The contractor should use hard gloss, easily cleanable, paint on painted surfaces.

(iv) Periodically clean any surface where explosive dust could accumulate. Establish cleaning schedules on information obtained from the job hazard analysis.

(v) Do not use suspended ceilings in hazardous locations.

(4)
Floors and work surfaces.
(i) Locations where exposed explosives or hazardous concentrations of flammable vapor or gas are present require non-sparking floors and work surfaces.

(ii) § 184.12 provides requirements for conductive non-sparking floors and work surfaces.

(iii) Floors and work surfaces require periodic cleaning to prevent the accumulation of energetic materials. In addition, all conductive and non-sparking floors and work surfaces require preventative maintenance to ensure their functional integrity.

(5)
Substantial dividing walls.
The contractor shall design and construct substantial dividing walls to prevent simultaneous detonation of explosives on opposite sides of the wall. The design and construction shall meet the criteria contained in Army TM 5-1300, Navy NAVFAC P-397, or Air Force AFR 88-22 (different designations for the same publication).

(6)
Exits and doors.
(i) All AE buildings require adequate exits and doors. NFPA Standard No. 101, “Life Safety Code,” provides information concerning exits and doors.

(ii) NFPA Standard No. 80, “Standard for Fire Doors, Fire Windows,” provides information on the selection and installation of fire doors and windows.

(iii) No AE hazards shall occupy space between an operator and an exit.

(7)
Safety chutes.
Multi-storied locations where rapid egress is vital and not otherwise possible require safety chutes.

(8)
Passageways.
(i) Weather-protected passageways and ramps for travel between buildings or magazines should include features to help prevent fire from spreading from one building to another. Fireproof construction materials, fire stops, fire doors, and fire suppression systems aid in preventing the spread of fire.

(ii) The incorporation of weak sections, openings, or abrupt change in direction of passageways will aid in the prevention of funneling the explosion forces from one building to another.

(9)
Roads and walkways.
(i) Only roads servicing a single magazine or AE processing building, including its service facilities, may dead end at the magazine or building.

(ii) Hard surfaced roads and walkways at the entrances to or between adjacent operating buildings containing AE will help reduce the amount of foreign material tracked into the building by personnel.

(iii) Avoid a road system which requires personnel to pass through an AE area when traveling from one area to another.

(10)
Windows and skylights.
(i) Inhabited building distances do not protect against glass breakage and the hazards of flying glass. Buildings separated by inhabited building distance should not have windows or other glass surfaces exposed to PESs.

(ii) Minimize personnel hazards from glass breakage by means such as building orientation and/or keeping the number of exposed glass panels and panel size to a minimum. When window panels are necessary and risk assessment determines a glass hazard will be present, blast resistant windows must be used. The framing and/or sash of such panels must be of sufficient strength to retain the panel in the structure.

(11)
Hardware.
(i) AE operations and hazardous locations require an evaluation to determine the safest type of hardware and fasteners to use in order to reduce the risk of an accidental ignition. Consider using non-sparking hardware and fasteners if they will meet the design parameters of the intended application. Depending on the potential hazard, a locking device or some other installation technique shall retain the hardware and fasteners securely in place. This will prevent the hardware and fasteners from becoming loose, entering process equipment and creating a spark or pinch point.

(ii) The contractor should avoid installing hardware, pipes, ducts, and other items on blowout panels in order to prevent the materials from becoming secondary fragments. If it is necessary to install items on blowout panels, select items made of materials which will not yield heavy fragments in an explosion.

(12)
Ventilation systems.
(i) Well-designed ventilation systems reduce personnel exposures to airborne contaminants and prevent the accumulation of flammable or explosive concentrations of gases, vapors or dusts. A local ventilation system, which removes the gases, vapors, or dusts at the source, is more effective than a general ventilation system.

(ii) A ventilation system is required in areas of buildings generating potentially explosive dusts, gases or vapors. Testing, inspection, and maintenance of ventilation systems used for contaminant control require documentation.

(iii) Exhaust fans through which combustible dust or flammable vapor pass shall have nonferrous blades or a casing lined with nonferrous material. The electrical wiring and equipment of the system should comply with provisions of NFPA Standard No. 70, “National Electrical Code”. Bonding and grounding of the entire system is required.

(iv) A slight negative pressure is required in rooms where AE operations generate explosive dust.

(v) NFPA Standard No. 91, “Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists, and Noncombustible Particulate Solids,” provides standards for exhaust systems.

(13)
Steam for processing and heating.
(i) Steam used to heat buildings containing explosives shall not exceed 228 °F (108.9 °C) or have a pressure greater than 5 psi (34.48 kPa).

(ii) Process steam shall not exceed 249.5 °F (120.8 °C), or exceed 15 psi (103.43 kPa). Steam pressure greater than 15 psi (103.43 kPa) requires procuring contracting officer (PCO) approval.

(iii) The surface temperature of steam and hot water pipes in contact with combustible materials shall not exceed 160 °F (71 °C). Pipes with an ambient temperature greater than 160 °F (71 °C) shall not contact combustible materials. An insulating pipe covering capable of reducing the surface temperature of the covering to 160 °F (71 °C) or less is acceptable.

(iv) In AE handling or storage locations where resistance to ground is high, ground steam and hot water lines where they enter the building.

(v) When using a reducing valve, consider installing a relief valve on the low-pressure piping. The throttling action of reducing valves requires a positive means to prevent the production of superheated steam.

(14)
Tunnels.
Tunnels between buildings that contain AE shall incorporate features that resist the shock wave of an explosion. This is important in order to minimize the possibility of an explosion in one building from affecting the operations in the other building. For further information on tunnels go to DoD 6055.9-STD.
3

3
See footnote 1 to § 184.1(d)(1).

(q)
Quantity-distance (Q-D) requirements.
(1) Minimum Q-D requirements are contained in DoD 6055.9-STD, DoD Ammunition and Explosives Safety Standards.

(2) For AE work involving an MCE of 0.25 kg (0.55 lbs) or less of HD 1.1 materials, the use of the separation distances listed in Table 1 to § 184.3 are acceptable for meeting minimum Q-D requirements.

Table 1 to § 184.3.—Minimum Q-D Requirements for Small Quantities of Hazard Division 1.1 Material

Net explosive weight
Inhabited building and fragment distance
Public traffic route and fragment distance
Intraline and fragment distance

Less than 0.003 kg (0.0066 lb)
0
0
0.

0.003 kg-0.01 kg (0.0066 lb-0.022 lb)
5 m (16.5 ft)
3 m (9.9 ft)
2 m (6.6 ft).

0.01 kg-0.25 kg (0.022 lb-0.55 lb)
15 m (49.5 ft)
9 m (29.7 ft)
5 m (16.5 ft).

§ 184.4
Quantity-distance and siting.
Refer to DoD 6055.9, Chapter 9 for guidance.

§ 184.5
Hazard classification, storage principles, and compatibility groups.
Please refer to DoD 6055.9, Chapter 3 for guidance.

§ 184.6.
Electrical safety requirements for AE facilities.

(a)
General.
Initiation systems often use the controlled input of electrical energy to initiate explosive mixtures and compounds, which start an explosive train. The uncontrolled release of electrical energy in explosive atmospheres or near explosives and explosive-loaded articles can result in unintended initiation and serious mishaps. Electrical energy manifests itself in many forms (
e.g.
, standard electrical installations, lightning, electrostatic discharge, electrical testing) and with various intensities which require special precautions. This chapter contains minimum electrical safety requirements for existing, new, or modified explosives facilities and equipment.

(b)
Electrical installations.
(1) National Fire Protection Association (NFPA) Standard No. 70 and this section are minimum requirements for areas containing explosives. NFPA Standard No. 70 does not specifically address explosives, but it does establish standards for the design and installation of electrical equipment and wiring in atmospheres containing combustible dusts and flammable vapors and gasses which, in general, are comparably hazardous. NFPA Standard No. 70 (Article 500) defines “hazardous locations” according to the hazard presented by electrical equipment installed in environments where flammable gases or vapors, combustible dusts or flyings may exist. The presence of AE may or may not result in rating a particular location as a “hazardous location.” The following exceptions shall be used by DoD contractors when applying the NFPA Standard No. 70 definitions of Class I, Division 1, and Class II, Division 1 hazardous locations:

(i) Classify areas containing explosive dusts or explosive substances which may produce dust capable of suspension in the atmosphere as Class II, Division 1 hazardous locations.

(ii) Classify areas where explosive sublimation or condensation may occur as both Class I Division 1 and Class II Division 1 hazardous locations.

(iii) Exceptions are extraordinarily hazardous explosive substances, such as nitroglycerin (NG), which require special consideration, including physical isolation from electric motors, devices, lighting fixtures and the like.

(2)
Multiple classifications.
In some potential explosion sites (PES) (
e.g.
, powder blending with solvents), hazards resulting from both dusts and flammable vapors may exist. In these cases, it is necessary for that area to have a dual, or multiple, classification. Use only electrical equipment listed by Underwriters Laboratories (UL) or other recognized testing laboratory as suitable for use in all classes of hazardous locations.

(3)
Change of classification.
The specific processes performed in operating buildings and magazines dictate the requirements for electrical equipment installation. If functions performed in the facility change, responsible personnel shall inspect, approve, or reclassify the hazardous locations.

(4)
Alternate power source.
Facilities shall have an alternate power source for special processes and operations requiring a continuous supply of power, whenever the loss of power will result in a more hazardous condition.

(5)
Portable engine-driven generators.
The exposed, non-current-carrying, metallic frame and parts shall be electrically grounded. In addition, observe the following requirements when supplying power to magazines or explosives operating facilities.

(i) Place generating units at least 50 ft (15.2 m) from magazines or hazardous (classified) locations.

(ii) Keep the ground area between and around the generator and the NFPA Standard No. 70 hazardous (classified) location clear of debris and other combustible materials.

(iii) The exhaust from the generator shall not impinge on grass or any other combustible material.

(iv) Position the power cord connecting the generator to the load to

prevent trucks or personnel from running over or otherwise damaging the cord.

(v) Do not use cable-to-cable splices within a magazine, explosive operating facility, or other NFPA Standard No. 70 hazardous (classified) location. Use only three-wire, three-prong, approved service type plugs and connectors.

(vi) Refer to § 184.3(i)(1) for refueling procedures.

(6)
Electric supply systems.
Electrical and explosives hazards may mutually exist when PES are in close proximity to electric supply lines. To protect these hazards from each other, the following separation requirements shall apply:

(i) Separate overhead service lines from a PES of combustible construction or a PES in the open by the distance between the poles or towers supporting the lines, unless an effective means is provided to ensure that energized lines cannot contact the facility or its appurtenances if they are severed. Four acceptable alternatives are cable trays and messenger lines, a ground-fault circuit-interrupter which causes a disconnecting means to open all ungrounded conductors of the faulted circuit, weighted triangle line separators or similar weights which ensure broken lines fall straight down away from PES, and constructed physical barriers.

(ii) Separate electric distribution lines carrying less than 69 kV, the tower or poles supporting those lines, and unmanned electrical substations from PES by public traffic route distance (PTRD).

(iii) Separate electric transmission lines carrying 69 kV or more and the tower or poles supporting them from PES by:

(A) Inhabited building distance (IBD) if the line in question is part of a grid system serving a large area off the establishment.

(B) PTRD if loss of the line does not create serious social or economic hardships. (
Note:
Base PTRD and IBD on airblast overpressure only. Fragment distances shall not apply.)

(C) Distances in accordance with paragraph (b)(6)(1) of this section when the line(s) in question can be interrupted without loss of power (
i.e.
, other lines or networks exist for rerouting power).

(iv) Avoid locating permanent electric installations in NFPA Standard No. 70 Class I or Class II hazardous locations. When practical operating reasons prevent locating permanent electrical installations outside of hazardous locations, or require the use of portable electrical equipment (
e.g.
, lighting equipment) in hazardous locations, contractors shall only install or use electrical equipment approved for the National Electric Code (NEC) defined “hazardous location” and listed by Underwriters Laboratories (UL) or other nationally recognized testing agencies.

(c)
Primary electric supply.
The primary electric supply to an entire explosives area should be arranged to allow cutting off the supply by remote switches located at one or more central points away from the area.

(d)
Ventilation.
Equip exhaust fans, through which combustible dust or flammable vapor pass, with nonferrous blades, or line the casing with nonferrous material. Motors shall meet the proper NEC class for the hazard (NFPA Standard No. 70). Clean and service exhaust systems on a regular schedule. Bond and ground the entire system.

(e)
Lightning protection.
When lightning protection systems are installed, the installation, inspection, and maintenance shall comply with the NFPA Standard No. 780, at a minimum. Typically, six month visual tests and 24-month electrical tests of installed systems are acceptable.

(f)
Static electricity and grounding.
(1) Two unlike materials (at least one of which is non-conductive) produce static electricity due to contact and separation. Contact creates a redistribution of charge across the area of contact and establishes an attractive force. Separation of the materials overcomes these attractive forces and sets up an electrostatic field between the two surfaces. If no conducting path is available to allow the charges to equalize on the surfaces, the voltage difference between the surfaces can easily reach several thousand volts as they separate.

(2) The potential hazard of static electricity arises when an accumulated electrical charge subsequently discharges as a spark in the presence of hazardous atmospheres, flammable vapors, dusts, exposed sensitive explosives, or electro-explosive device (EED). Electrostatic discharge (ESD) does not present a substantial hazard during the handling of most bulk explosive substances if the explosives are in approved containers. It also does not present a hazard near explosives totally contained and unexposed within loaded articles. It is not possible to prevent the generation of static electricity entirely. Elimination of potential ESD hazards requires proper grounding to dissipate static charges before they accumulate to dangerous levels. The NFPA, UL and the U.S. Department of Commerce publish detailed discussions of the hazards of static electricity and ways of reducing it. Where static spark discharge may be hazardous, NFPA Standard No. 77, shall apply, except as otherwise specified.

(3)
Static ground system.
A static ground system consists of one or more electrodes in contact with the earth and a conductor (
i.e.
, metal wire) bonded to the electrode and routed throughout the protected facility. The static ground system may use building structural steel (unless structural steel is used as lightning protection down conductor), metallic water pipes, ground cones, buried copper plates, and rods driven into the earth as electrodes. The ground system shall not use gas, steam, or air lines, dry pipe sprinkler systems, or air terminals and down conductors of lightning protection systems as earth electrodes. A static ground system provides a conductive path to earth from conductive floors, conductive work surfaces, and AE equipment and allows any generated static charges to dissipate.

(4)
Testing equipment grounds.
Trained personnel shall test ground systems after installation, after repairs, and at locally determined intervals and shall keep all records. Remove all exposed explosive or hazardous materials from the room or area before testing. The resistance of the electrode to earth shall not exceed 25 ohms. The electrical resistance from any point on the conductor to the electrode shall not exceed 1 ohm. The ground system design shall provide for interconnecting all ground electrodes of structures equipped with a lightning protection system.

(5)
Grounding of equipment.
Contractor maintenance personnel shall bond all AE equipment (
e.g.
, mixers, grinding mills, screening and sifting devices, assembly and disassembly machines, conveyors, elevators, steel work tables, presses, hoppers) to the ground system wherever ESD presents an ignition hazard. The resistance of the AE equipment to the grounding system shall not exceed 1 ohm. Trained personnel shall test this resistance initially at installation and at least semiannually thereafter, and shall keep all records. Exclude the resistance of conductive belting when testing for resistance of belt-driven machinery to the ground system. Bonding straps shall bridge contact points where oil, paint, or rust could disrupt electrical continuity. Permanent equipment in contact with conductive floors or tabletops does not meet the bonding requirement to the ground system. Maintain compatibility of metallic bonding and grounding cables, straps, or clamps with the explosives involved in the process.

(6)
Belts.
Use conductive belting wherever ESD is an ignition hazard. The resistance of conductive conveyor belts shall not exceed one million ohms as measured between two electrodes placed on the belt and as measured between an electrode placed on the conductive conveyor belt and an electrode attached to the ground system. Do not use static combs to drain off static charges generated from belts or pulleys used in hazardous locations.

(g)
Conductive floors, tabletops, and footwear.
Contractors shall use conductive tabletops and, shall use conductive floors and conductive shoes for grounding personnel at operations involving exposed explosives with electrostatic sensitivity of 0.1 J or less (
e.g.
, primer, initiator, detonator, igniter, tracer, and incendiary mixtures). Bonding wires or straps shall connect the tabletops and floors to the static ground system. Materials sensitive to initiation by ESD sparks include lead styphnate, lead azide, mercury fulminate, tetrazene, diazodinitrophenol, potassium chlorate-lead styphanate mixtures, igniter compositions, grade B magnesium powder, and exposed layers of black powder dust. Dust from solid propellants can be ignited from spark energy, making conductive floors and shoes necessary where such dust is present. Air and dust mixtures of ammonium picrate, tetryl, tetrytol, and solid propellants are also sensitive to initiation by ESD. Testing indicates mixtures of air with vapors from many flammable liquids (
e.g.
, ethyl ether, ethyl alcohol, ethyl acetate, acetone, and gasoline) may ignite by ESD from the human body. Therefore, contractors shall equip areas where personnel might contact these kinds of explosives or with conductive floors and tabletops, except when hazard analysis indicates adequate housekeeping, dust collection, ventilation, or solvent recovery methods eliminate the ignition hazard.

(1) Unless hazard analyses indicate otherwise, conductive tabletops, floors, and shoes shall also protect operations involving the following:

(i) Unpackaged detonators and primers and electro-explosive devices.

(ii) Electrically initiated items, such as rockets, with exposed circuit and

(iii) Hazardous materials capable of initiation by ESD from the human body.

(2) When a hazard remains localized, the contractor may use conductive mats or runners instead of conductive floors throughout an entire building or room. These mats and runners shall meet all the specifications and test requirements that apply to conductive floors. When justified by hazard analysis, contractors may use conductive wrist straps in place of conductive floors and shoes for grounding personnel at small scale and isolated operations. When using wrist straps, operators shall test wrist straps before each use (whenever removed and re-worn) and record test results. The resistance of the wrist strap while the operator is wearing the strap shall fall within a range of 25,000 ohms (minimum) and 1,200,000 ohms (maximum) when measured from opposite hand to ground. Use test equipment capable of testing 1,200,000 ohms + 10%. (
Note:
Operators with dry skin may use special contact creams to decrease the resistance to the required value.)

(3)
Conductive floor and tabletop specifications.
Conductive floors and tabletops, made of, or covered with non-sparking materials such as lead, conductive rubber, or conductive compositions, shall meet the following requirements:

(i) Provide a continuous electrical path to the static ground system and the electrical resistance shall not to exceed the limits specified in paragraph (g)(5)(i) of this section.

(ii) Provide a reasonably smooth surface which is free from cracks. and

(iii) Maintain compatibility of conductive floor and tabletop materials with the energetic materials present.

(4)
Conductive footwear.
Operators shall wear conductive shoes in areas requiring conductive mats, floors, or runners. Personnel visiting such areas shall wear conductive shoes, ankle straps, or similar devices, one on each leg. Prominent markings should identify conductive shoes to help supervisors ensure personnel compliance. Personnel required to work on electrical equipment in areas where conductive floors are installed shall not wear conductive shoes and shall not begin work until operators remove all AE.

(5)
Testing conductive footwear, floors, and tabletops.
(i)
Test criteria.
The maximum resistance of a body, plus the resistance of the conductive shoes, plus the resistance of the floor to the ground system shall not exceed 1 million ohms total. That is, if 500,000 ohms is the maximum resistance allowed from the floor to the ground system, then 500,000 ohms is the maximum combined resistance allowed for the person's body plus the resistance of the conductive shoes (
i.e.
, 500,000 + 500,000 does not exceed 1 million). The contractor can set the maximum resistance limits for the floor to the ground system and for the combined resistance of a person's body plus the shoes, as long as the total resistance does not exceed 1 million ohms.

(ii) To protect against electrocution, the minimum resistance of the floor to the ground system and the minimum resistance of the tabletop to the ground system shall exceed 11,000 ohms in areas with 110 volts service and 22,000 ohms in areas with 220 volts service. A ground fault interrupt (GFI) circuit also meets this requirement.

(iii)
Tabletop test criteria.
The maximum resistance of conductive tabletops to the ground system shall not exceed 1 million ohms.

(iv)
Conductive footwear.
All personnel shall test conductive footwear daily before use to ensure that the combined resistance of the person's body and the conductive shoes do not exceed the limit specified in paragraph (g)(5)(i) of this section. Supervisors shall keep documentation of all test results, including calibration of test equipment. The test voltage of the shoe tester shall not exceed 500 volts. The short circuit current across the shoe tester electrodes (plates) should be limited between 0.5 ma and 2.0 ma. The design of the test instrument shall include built-in safeguards to prevent the test subject from experiencing electric shock. Personnel shall not test shoes in rooms or areas with exposed explosives or flammable gas mixtures. Personnel shall not wear static generating stockings such as silk, wool, and synthetics; and shall not use foot powders, which have a drying action which can increase resistance. Dirt and grit increase resistance of conductive shoes. Personnel should avoid wearing conductive shoes outdoors and shall keep shoes clean.

(v) Trained personnel shall test conductive floors and tabletops upon installation and at least annually thereafter using test equipment specifically designed for this purpose and shall keep records of all test results for at least five years. Testing shall proceed only when the room or area is free from exposed explosives and flammable gas mixtures. The test procedure shall measure the resistance of the floor between an electrode attached to the ground system and an electrode placed at any point on the floor or tabletop and also as measured between two electrodes placed 3 ft (1 m) apart at any points on the floor or tabletop. Each electrode shall weigh 5 lb (2.3 kg) and shall have a dry, flat, circular contact area diameter of 2.5 in (64 mm). The contact area shall have a surface of aluminum or tin foil which is 0.0005 in to 0.001 in (0.013 mm to 0.025 mm) thick and is backed by a layer of rubber 0.25 in (6.4 mm) thick. The surface hardness shall measure between 40 and 60 Shore A when measured by

a Shore Type A Durometer (see American Society for Testing and Materials (ASTM) D-2240-68, Institute of Electrical and Electronics Engineers (IEEE) Standard 14 and NFPA Standard No. 99. Make both electrode-to-electrode and electrode-to-ground system measurements at five or more locations in each room with at least two of the points in heavily trafficked areas. If the resistance measurement changes appreciably with time, record the resistance at the 5-second interval. To prevent biased measurements, locate the electrodes for both the electrode-to-electrode and electrode-to-ground measurements a minimum of 3 ft (1 m) away from an earth ground or other grounded items such as a door frame, ordnance handling equipment, or any grounded item resting on a conductive floor. (
Note:
The size of the floor or tabletop may make it impractical to conduct five surface resistance (electrode-to-electrode) or resistance-to-ground measurements and still remain 3 ft (1 m) away from all grounded items. In such cases, take enough measurements to ensure adequate testing of all parts of the conductive surface and document the justification for a reduced number of electrode-to-electrode or electrode-to-ground measurements in the grounding system test plan.) Only trained personnel shall operate and maintain test instruments.

(h)
Handling low-energy initiators.
Supplement typical precautions, such as shielding and safety glasses, with the following measures, as appropriate, when manufacturing, processing, using, or testing low-energy initiators initiated by 0.1 J of energy or less.

(1) Electrically bond and ground all metal parts of equipment.

(2) Ensure personnel wear clothing which prevents generation of static electricity. Test conductive shoes with a resistance meter before entering an area where low-energy initiators are being processed.

(3) When low-energy initiators are being handled, ground personnel directly by wrist straps. The acceptable resistance reading, taken once daily when the operator is wearing the strap, shall be between 250,000 and one million ohms when measured from opposite hand to ground. Special contact creams may be used to decrease the resistance to the required value.

(4) Periodically coat glass, acrylic, or polycarbonate materials required for transparent shielding with an anti-static material to prevent buildup of static electricity, when static sensitivity is indicated to be a hazard.

(5) The sounding of a static electricity alarm, installed with the setting best able to provide ample warning, signals a work stoppage until the problem has been located and corrective action taken.

(6) Check relative humidity and temperature before starting operations and throughout the workday where such conditions are used to mitigate or prevent safety problems (
i.e.
, hydroscopicity or static control).

(7) Do not paint metal surfaces subjected to rubbing or friction. If a lubricant is necessary, use a composition which allows the metal's surface resistance to remain at or below 25 ohms.

(8) Work on or with low-energy initiators only in areas equipped with conductive floors and table tops. Exceptions may be made when the initiators are in their original packaging, or are part of a finished metallic end item affording them complete protection from electromagnetic or electrostatic energy.

(9) Do not work in the vicinity of actual or potential electromagnetic or electrostatic fields (
e.g.
, radio transmission, electrical storms, transformer stations, high voltage transmission lines, improperly grounded electric circuitry, rotating equipment, belts, etc.). Establish adequate lightning protection and grounding and adequate resistances for fixed sources of energy for locations with low-energy initiator operations. Shield these areas to afford protection against local mobile radio transmission.

(10) Locate electrical equipment out of the range of an operator working with a low-energy initiator. With soldering irons, it may be advisable to ground and limit energy to levels below initiating thresholds.

(11) When not part of an end item or end item subassembly, transport initiators only when packed according to the latest packing specifications for low-energy initiators.

(i)
Electrical test equipment.
Use the lowest possible power source for all electrical and electronics test equipment. When possible, use batteries in lieu of 110 Vac power sources. During testing, do not use power sources capable of initiating the AE. When test specifications require using electrical energy at or above the initiating threshold level of explosive devices, use test chambers or provide shielding capable of containing all hazards and apply energy remotely. Provide safeguards against the possibility of human error.

(j)
Humidification and ionization.
(1) Humidification which maintains relative humidity above 60 percent effectively prevents static electricity accumulations and subsequent discharges. This technique involves pre-operational checks and regular monitoring of the humidity levels throughout the day. Do not use humidification with metallic powders unless hazard analysis indicates the powders are not susceptible to spontaneous ignition in air with 60 percent relative humidity.

(2) Ionization is electrical neutralization and serves as an effective method of removing static charges from certain processes and operations. Methods of application can be found in NFPA Standard 77.

(3) Contractors may use ionization or humidification to augment their ESD control program but, may not use them in lieu of conductive floors and footwear (where required).

§ 184.7
Manufacturing and processing propellants.

(a)
General.
(1) These requirements apply to propellant manufacturing and augment other requirements contained in this part.

(2) The safety precautions for fabrication of propellants, propellant loaded items, gun ammunition, and rocket motors follow the generally accepted principles used for many types of explosives and energetic materials. Solid propellants can be divided into general categories such as single, double, and triple base, castable composite, and modified double base composite. (
e.g.
, castable composite propellant modified with explosive plasticizer such as nitroglycerin). Liquid propellants include a wide range of liquid fuels, liquid oxidizers and fuel-oxidizer monopropellants.

(3) Although processing safety considerations for finished propellant AE and loaded rocket motors are similar, each propellant type has its own characteristics for processing of raw materials, intermediate compositions, and final processing. Hazards data for intermediate and finished propellant can help to define the requirements that ensure safety in processing. Hazards data includes initiation thresholds to such stimuli as impact, friction, heat, and electrostatic discharge for specific processes and handling situations. In evaluating and properly applying the guidelines of this chapter, consider the response of the materials in terms of energy input sensitivity and magnitude of energy release. Follow the general requirements for manufacturing and processing of pyrotechnics given in Chapter 8 for safety precautions for ignition system fabrication. (
Note:
An exception to this requirement is processing of a

propellant grain igniter the same as motor propellant until the grain is mated with the initiator assembly.)

(4) In addition to generally accepted safety precautions for handling of explosives and other energetic materials, the following paragraphs provide general guidance pertinent to the manufacturing of propellants, propellant loaded items, gun ammunition and rocket motors.

(b)
Properties of propellants.
Knowledge of the properties and types of propellants is critical to the establishment of proper hazard controls. Propellants present a wide range of hazard characteristics even within the various types due to variations in grain size of ingredients and energy content of additives, both solid and liquid. As described below, test data is essential for determining the chemical, physical, physiological and explosive properties and hazards of raw materials, intermediate compositions, processing aids, and liquid or solid propellant, both uncured and cured.

(1)
Single base propellants.
Single base propellants have the principal explosive ingredient of nitrocellulose. Remaining ingredients include stabilizers as well as other additives. The mixture is shaped into tubes, perforated tubes, flakes, etc. by extrusion and cutting.

(2)
Double base propellants.
Double base propellants contain nitrocellulose and nitroglycerine (or other liquid nitrate ester) as the two main ingredients. Remaining ingredients include stabilizers as well as other additives. This propellant can be extruded/cut or cast into its final shape.

(3)
Triple base propellants.
Triple base propellants contain three main components: nitrocellulose, nitroglycerine (or other liquid nitric acid ester), and nitroguanidine. This propellant can be extruded, cut or cast into its final shape.

(4)
Composite propellants.
Composite propellants consist of finely divided oxidizers dispersed in fuel matrix with the binder normally being made of plastic material. Nitrates and perchlorates are commonly used as oxidizers. Common binders include: hydroxyl terminated polybutadiene, carboxyl terminated polybutadiene, polybutadiene-acrylonitrile, polyurethane, polybutadieneacrylic acid, and polysulfides. This propellant is typically cast into its final shape.

(5)
Composite modified double base propellants.
Composite modified double base propellants contain a dispersed phase of finely ground oxidizer and usually powdered fuel additive. This propellant is typically cast into its final shape.

(6)
Liquid propellants.
Liquid propellants include a wide range of liquid fuels, liquid oxidizers and fuel-oxidizer monopropellants. (
Note:
Refer to the DOD 6055.9-STD, 9.6 for more information and requirements associated with specific liquid propellants.

(c)
In-process hazards.
(1) During scale up from research and development of new propellants to an existing manufacturing process, determine the chemical, physical, physiological, explosive properties, and hazards of raw materials, intermediate compositions, processing aids, and liquid or solid propellant, both uncured and cured.

(2) Unless available from other sources, conduct testing to determine thermal stability, chemical compatibility of ingredients, exothermic reactions, and sensitivity to ignition or detonation from friction, impact, and electrostatic discharge. Additionally, deflagration-to-detonation and card gap test data can be valuable. Applicable tests are described in TB 700-2, Explosives Hazard Classification Procedures.

(3) Minimum testing may satisfy the classification requirements for several in-process operations. For example:

(i) If reliable data exist that indicate that the propellant mixing operations are H/D 1.1, no testing would be needed to adopt this classification.

(ii) If testing shows that uncured propellant will detonate, the casting and curing operations are HD 1.1 hazards.

(iii) If detonation tests show that the cured propellant will detonate, all operations with cured or curing propellant are HD 1.1 hazards.

(4) Make safety information for all materials used in the formulation available as required. Train personnel on the hazards involved in propellant process situations.

(d)
Q-D requirements.
Operate new manufacturing and support facilities for processing of propellants and propellant loaded items to conform to the latest QD requirements for the HD of the propellant in its in-process condition.

(e)
Separation of operations and buildings.
(1) Perform propellant and rocket motor manufacturing and processing in special areas (
i.e.
, operating lines) whose boundaries are separated from all other areas outside the line in accordance with applicable QD criteria. Table 1 to § 184.7 provides remote control and personnel protection requirements for certain propellant processing operations.

(2) Generally treat sequential operations on rocket motors as one process operation in one building.

(3) When the hazard classification of a propellant has not been established, classify the propellant during site and construction planning as the most hazardous class/division that might possibly apply during manufacturing and processing.

(4) Locate safety shelters, lunchrooms, convenience buildings, and private vehicle parking for personnel working in an operating building in accordance with applicable QD criteria.

Table 1 to § 184.7.—Control and Personnel Protection Requirements for Certain Propellant Processing Operations

Operation
Remote control

Personnel protected
1

Blending and screening of ammonium perchlorate
Mandatory
Mandatory.

Blending, screening of nitramines and Mandatory perchlorates other than ammonium

Mandatory
2

Mandatory.
2

Grinding, and mechanized drying of perchlorates and nitramines
Mandatory
Mandatory.

Grinding, blending, screening, and mechanized drying of ammonium nitrates
Advisory
Advisory.

Rotating blade propellant mixing
Mandatory

Mandatory.
4

Power-driven cutting, machining, sawing, planing, drilling, or other unconfined operations in which rocket motors or propellant of Hazard Division 1.1 and 1.3 are involved.
2

Mandatory
3

Mandatory.
3

Mandrel break away removal from cured propellant

Mandatory
3

Mandatory.
3

Pressing, extruding, pelletizing or blending
Mandatory
Mandatory.

Casting Propellants

Mandatory
3

Mandatory.
3

1
Operating personnel shall be at K24 or in a control room that will limit overpressure to less than 2.3 psi.

2
Attended screening of wet material may take place if shown acceptable by hazard analysis.

3
Attended operation permitted if shown to be acceptable by hazard analysis.

4
The attended operation may take place when a hazard analysis shows the MCE to only be fire hazard.

(f)
Equipment and facilities.
(1) Except as provided for in other applicable documentation, follow the mandatory requirements of this part for the design, layout, and operation of facilities and equipment for propellant operations. Where there is no guidance, govern operations by the results of hazard tests and analyses (see § 184.12) performed and documented to address specific operations. As some propellants can be sensitive to initiation by static electricity, consider bonding and grounding of equipment, tooling, and rocket motor conductive components along with other means of static elimination and control. Use conductive work surfaces and floors or floor mats for assembly of igniters and igniter subassemblies.

(2) Use non-sparking and non-rusting materials, which are chemically compatible with the propellant material, for equipment, tooling, and machinery that will come in contact with propellant or propellant ingredients.

(3) Certain propellant operations involve significant energy input that enhances the possibility of ignition. Examples are rolling mills, machining and drilling operations. In these situations, conduct complete hazard analysis and evaluation prior to starting the operation.

(4) Special requirements of this part apply to heat-conditioning equipment.

(5) Exposed radiant surfaces in the form of S-shaped smooth pipe or fin-type radiators are easy to clean. Other types of radiators are acceptable, but are less desirable because of cleaning difficulties.

(6) When mechanical ventilating equipment is used in operations involving potential concentrations of solvent vapors, dusts, and nitroester vapors, do not locate the electric motor and motor controls directly in the potentially contaminated air stream. Provide the ventilation system with a suitable means of collecting condensate.

(7) Design air conditioning and cure oven air-circulating equipment of the closed system type to prevent contaminated air from contacting the air motor and controls. Monitor recirculated air to ensure concentration of vapors and dusts do not reach flammable (or explosive), or personnel threshold limits. Use dustproof and vaporproof electric motors and controls. Preferably use air mover blades that are nonmetallic.

(8) Rigidly fix and stabilize the equipment during mixing to preclude contact between fixed and movable parts. Design mix bowl lift mechanisms (
i.e.
, elevators) to assure adequate blade-to-blade and blade-to-bowl clearances during the complete operation cycle.

(9) Provide positive controls to physically block or stop bowl or mixer head movement in case of drive mechanism malfunction. Assure maintenance of blade-to-blade and blade-to-bowl clearance at all times.

(10) Use rigid and strong mix blades and shaft to ensure minimum flex from viscosity of the mix and speed of the shaft.

(11) Use electrical components of all mixers that meet the appropriate electrical classification or remotely locate them or shroud and purge them with inert gas. Design purged systems to provide automatic warning upon loss of gas pressure.

(12) Equip mixer blade shafts with seals or packing glands that prevent migration of liquids or solvent vapors into bearings. Avoid submerged bearings and packing glands. However, if used periodically test them for contamination and clean them.

(13) Establish a program to detect significant changes in blade/shaft position relative to mixer head. Check clearances between mix blades and mixer bowls at regular intervals based on operating time and experience to make sure the clearance is adequate. Maintain a record of such checks, mixer blade adjustments, and any damage to the mixer blades and bowls.

(14) Electrically bond and ground mix bowl, blades, and drive unit.

(15) Inspect blades and other moving parts of new mixers and replacement parts for old mixers. Inspect (
i.e.
, magnaflux or X-ray) for cracks, crevices, and other flaws.

(16) Interlock electric service to propellant mixers with fire protection system controls so that the mixer cannot start when the fire protection system is inoperative.

(17) Regularly check and maintain all process equipment that applies energy to in-process propellant for wear and misalignment. Keep a record of these checks and any maintenance performed for the process equipment.

(18) Control equipment performing sequential operations on propellants (
e.g.
, extrusion and cutting) to prevent interference.

(g)
In-process quantities and storage.
(1) Allow only the quantity of propellant and loaded subassemblies needed to ensure a safe and efficient workflow, when conducting operations in an operating building. Short-term storage of larger quantities in an operating building is permissible when it is not in use for other operations.

(2) Completed assemblies with or without installed ignition system may be stored in operating buildings provided there are no other operations in progress and quantity/distance complies with requirements.

(3) Production igniters may be stored in designated areas within an assembly or disassembly facility.

(4) Indoor storage is preferable for all types of explosives and is mandatory for bulk HE, solid propellants, and pyrotechnics. Give priority of existing indoor storage to AE requiring the most protection from the weather (based on the method of packing). Protect propellant and propellant materials from overheating by exposure to direct sunlight when in transit or on temporary hold.

(5) Consider the propulsive characteristics and the ignition probability of AE (
e.g.
, propellant loaded devices, rocket motors, assist take-off units and missiles) during all logistical phases in order to obtain as much safety as possible under the circumstances. Because of the great number of types and sizes of propellant loaded devices and conditions of assembly encountered, only general safety guidance is provided in this part. Thus, the contractor should make every effort to prevent ignition of any units being manufactured, assembled, disassembled, handled, stored, transported or deployed. Use approved flight restraining devices (tie-downs) to the maximum extent possible. When doubt exists as to whether a given AE or configuration (state of assembly) is propulsive or nonpropulsive, treat the AE as propulsive until pertinent technical information can be obtained.

(h)
Ingredients processing.
(1)
Weighing, measuring, and handling raw materials.
(i) Electrically ground scales for weighing raw materials, where needed, to properly protect the operation. This grounding is especially important where flammable or combustible materials are involved.

(ii) Provide separate weight or measurement rooms, cubicles, or areas (dependent upon the quantity and sensitivity of the materials handled) provided. Separate oxidizer and metallic powder weighing from each

other and from other materials by physical barriers rather than distance.

(iii) It is important that containers, equipment, hand tools, scale pans, etc., used for weighing processes do not mix with those weighing or measuring oxidizers and fuels, particularly where distance rather than physical barriers separates these areas. Use positive measures to ensure the complete separation of such equipment and tools.

(iv) Do not change the designated use of space and equipment without a thorough cleaning and inspection to make sure that all traces of the previous material have been removed, if any possibility exists that materials are incompatible.

(2)
Oxidizer Processing.
Solid propellant oxidizing agents are perchlorates, nitrates, nitroesters, and nitramines used in solid rocket motor propellants.

(i) Avoid contaminating an oxidizer agent with any metal or chemical (fuel) which may result in a more sensitive composition.

(ii) Use closed systems as much as possible for dust, humidity, and tramp material control.

(iii) Use fire-retardant materials to make flexible connections (socks) in pipes or duct systems that convey oxidizer materials and dust socks in collectors or hoppers. Only use connection materials that are chemically compatible with the oxidizers.

(iv) Make the pipes and duct systems electrically continuous. Avoid threaded joints and fittings in contact with oxidizer. Preferably use quick clamp neuter end pipe joints.

(v) Use static electricity control measures to dissipate static charges to an acceptable level if transporting oxidizer by fluidization.

(3)
Oxidizer drying.
(i) Establish the safe temperature for drying each material and do not exceed that temperature at any point in the drying apparatus or drying room.

(ii) Use thermostatic controls to prevent exceeding the maximum safe temperature in the drying process. Install and use redundant temperature controls.

(iii) Do not use electrical heating elements that may contact the oxidizer or oxidizer dust.

(iv) Hold dust to a minimum in the drying process. Use a dust collection system if dusting can create a potential hazard.

(v) Exercise care to prevent drying of incompatible materials simultaneously in the same drying process. Do not dry oxidizers in an oven, drying room, etc., used for processing flammable or other incompatible materials until after cleaning and inspection shows it is free of any residual contamination.

(4)
Screening oxidizers.
(i) Construct screening equipment so it cannot subject oxidizer material to pinching, friction, or impact as a result of metal-to-metal contact. Keep rooms in which screening units are operated thoroughly clean to eliminate hazardous accumulations of dust.

(ii) Electrically ground oxidizer screens and bond them to the receiving vessel.

(5)
Blending oxidizers.
(i) If blending of oxidizers generates gases, design and install a suitable means of gas pressure relief into the blender.

(ii) Electrically bond the blender throughout.

(iii) Construct blending equipment so it cannot subject oxidizer material to pinching, friction, or impact between metal-to-metal surfaces.

(iv) When blending ammonium perchlorate using powered mechanical equipment, protect operating personnel. Use remote controls for mechanical blending.

(v) When using powered mechanical methods for blending HD 1.1 substances (such as RDX or HMX), use remote controls and personnel protection (See Note 1 to Table 1 to § 184.7).

(6)
Grinding oxidizers.
(i) When using impact type mills, provide sufficient clearance between stationary and moving parts to prevent metal-to-metal contact. Check clearances as often as needed to ensure they are adequate. Air purge mill bearings to prevent contamination. Do not use impact type grinders for HD 1.1 substances.

(ii) Pass oxidizer feed materials through a screen mesh with openings no greater than the clearance between hammer and plate. Use the smallest screen mesh size for ammonium nitrate that allows free flow of the prills. Use magnetic separators if screening is not possible.

(iii) Use only compatible lubricants in grinding equipment.

(iv) Install and use heat sensing devices for the bearing housing of grinding and conditioning equipment.

(v) Determine the optimum cleaning cycle and method for grinding equipment and include them in SOP.

(vi) Provide grinding operations with wet dust collection systems, where appropriate.

(vii) Thoroughly ground and bond pneumatic grinding operations to provide for electrostatic charge dissipation.

(7)
Preparation of fuel compositions.
(i) Determine the sensitivity characteristics of fuel compositions prior to production mixing operations.

(ii) Establish compatibility of materials. Develop procedures that preclude the formation of highly sensitive compositions or hazardous conditions during processing, such as, dry AP and powdered metal mixtures.

(iii) Preferably bond equipment, piping, and vessels used in fuel preparation to form a continuous electrical path with each other and to building ground. When pouring metallic powder or flammable liquids from one container to another, bond the containers together prior to the transfer.

(iv) Minimize the formation and accumulation of dust in all preparation operations.

(v) Use fume hoods, dust socks, closed systems, and dust/fume vacuum exhaust hoses, as appropriate, to prevent vapors and dust getting into the operating areas.

(8)
Transfer operations.
(i) Transfer finely divided powdered ingredients by methods that control flow rate and minimize electrostatic charge generation.

(ii) Before transferring flammable solvents, electrically bond the transfer and receiving vessels to eliminate electrostatic potential differences.

(i)
Mixing
. (1) Secure hardware and associated equipment to prevent loose items falling into mixers.

(2) Pass liquids and powders to be added to the mix vessels through a screen or orifice with an opening(s) less than the smallest clearance in the mixer. You may directly add smaller amounts of material, provided a positive means exists to ensure the material does not contain any foreign material.

(3) Use other means such as x-rays to examine materials that you cannot screen or that are opaque or not easily inspected.

(4) When consistent with the process system and requirements, cover the mixer bowl after completing charging or mixing to prevent the accidental introduction of foreign objects into the mixer and to prevent sunlight impinging directly on the materials in the bowl.

(5) Use only non-sparking devices for hand scrapping the sides and blades of mixers. Set up controls to prevent accidental introduction of these and other devices into the mixer.

(6) Account for all loose tools and equipment before starting or continuing mixing operations.

(7) Do not allow loose objects such as jewelry, pens and coins in the mixer operating area where accidental introduction into the mixers might occur. Pocketless coveralls should be used.

(8) Provide direct and unobstructed routes for personnel egress from mixer buildings or bays.

(9) Do not attempt to fight propellant fires.

(10) Preferably equip propellant mixers, inside and outside of the mixing vessel, with a high-speed deluge system.

(j)
Casting and curing
. (1) Personnel may attend cast operations if you first conduct a thorough safety review of the operation is conducted.

(2) Multiple or single production line type casting is permitted. However, when the survivability of the production facility is critical or the risk to the program is significant, the PCO may require the contractor to provide protection that prevents propagation of an incident from the casting operation to adjacent bells or pits.

(3) Use only smooth cast piping surfaces in contact with propellant. Use tooling free of cracks, pits crevices, and weld slag for propellant casting and curing operations. Avoid threaded joints as much as possible, especially at unions requiring disassembly for process operation or cleaning.

(4) Do not design or use cast tooling and mandrels that permit metal-to-metal friction or impact sites.

(5) Design and use propellant flow valves that prevent propellant pinching or compression between two metal surfaces.

(6) Design and use pressurized casting vessels capable of withstanding at least twice the maximum allowable working pressure.

(7) Secure lids to pressurized casting vessels so that they will withstand the rated pressures of the vessels.

(8) Do not exceed the working line pressure of casting vessels. Install a relief valve downstream of the regulator on pressure lines.

(9) Equip each vessel with a blowout disk (burst diaphragm) designed to blow out at less than 120% of the vessel's maximum allowable working pressure. Allow for the release of the potential rapid rise of pressure in the vessel should the propellant ignite.

(10) When curing or casting propellant under pressure, provide emergency pressure relief.

(11) Pressurize and depressurize propellant cure operations remotely.

(12) Physically and electrically disconnect casting vessels from lifting devices during cast operations.

(k)
Extrusion processes
. (1) Design solventless extrusion presses and compression molding equipment to remove air from the propellant before compaction and extrusion begin. Assure that procedures provide for checking operation of the vacuum system and for cleaning it of propellant residue and condensed vapors such as those generated from nitroglycerin volatilization.

(2) Check ramheads for alignment with the press bore to preclude metal-to-metal contact. Include flashing removal in the process procedures.

(3) Provide interlocks to preclude press operation during loading or other attended operations.

(l)
Propellant loaded AE
. (1) When performing operations on cured propellant contained in pressure vessels or rocket motor cases and there may be a risk of ignition due to energy inputs (
e.g.
, electrical check of pyrotechnic devices). In such cases, secure the unit in a fixture capable of withstanding 2.5 times the rated thrust of the assembly.

(2) Use remote control to apply mechanical force to “breakaway” the mandrel or other tooling embedded in propellant. However, see Table 1 to § 184.7 for exceptions.

(3) Avoid moving loaded rocket motors with cores in place. If loaded motors containing cores must be moved, however, support the core and motor case by or suspended from a common source or in some manner locked or tied together to prevent independent movement of either.

(4) When determining the safest method to use, evaluate and consider the hazard characteristics of individual propellants you will cut, machine, or contour.

(5) Design propellant machining equipment:

(i) To prevent contact of cutting tools or blades with motor cases and other metal objects.

(ii) To minimize generation of heat.

(iii) To facilitate removal of dust and chips, and to afford personnel protection. If there is a possibility that a metal or other foreign object may be in the propellant, x-ray the motor or grain prior to machining.

(6) Frequently remove propellant dust, chips and shavings from the work area during machining and contouring.

(7) Preferably position rocket motors in final assembly process to permit ready access to all sides of the motor. Keep aisles and exit doors clear and unobstructed. Install quick release hardware on all exit doors.

(8) Keep the number of items in the final assembly building at the minimum consistent with a safe and efficient operation.

(9) Grounding of propellant loaded assemblies in storage is optional, based on a case-by-case review.

(10) If the process requires removing an igniter-shorting clip, keep the igniter shorted until immediately before insertion. Minimize the time that the igniter remains unshorted.

(11) Provide means for controlled dissipation of static electrical charges during igniter insertion.

(12) Conduct operations that involve electrical continuity checking/testing of ignition systems installed in rocket motors according to thoroughly reviewed and approved procedures. Conduct these checks by remote control with the motor mounted in a test stand designed to withstand 2.5 times the thrust of the motor.

(m)
Disassembly
. (1) As much as possible, avoid metal-to-metal movement and trapping of explosive substance in process equipment or tooling that require disassembly in a process operation.

(2) Use clean, external clamp fittings on pipe assemblies for propellant transfer.

(3) Before starting non-routine disassembly of equipment or tooling (such as that necessary for equipment repair or for securing the process), evaluate potential hazards of trapped material or process residuals.

Table 1-1 to § 184.7.—Control and Personnel Protection Requirements for Certain Propellant Processing Operations

Operation
Remote controls

Personnel protected
1

Blending and screening of ammonium perchlorate
Mandatory
Mandatory.

Blending, screening of nitramines and perchlorates other than ammonium

Mandatory
2

Mandatory.
2

Grinding, and mechanized drying of perchlorates and nitramines
Mandatory
Mandatory.

Grinding, blending, screening, and mechanized drying of ammonium nitrates
Advisory
Advisory.

Rotating blade propellant mixing
Mandatory

Mandatory.
4

Power-driven cutting, machining, sawing, planing, drilling, or other unconfined operations in which rocket motors or propellant of Hazard Division 1.1 and 1.3 are involved
2

Mandatory
3

Mandatory.
3

Mandrel break away removal from cured propellant

Mandatory
3

Mandatory.
3

Pressing, extruding, pelletizing or blending
Mandatory
Mandatory.

Casting propellants.

Mandatory
3

Mandatory.
3

1
Operating personnel shall be at K24 or in a control room that will limit overpressure to less than 2.3 psi.

2
Attended screening of wet material may take place if shown acceptable by hazard analysis.

3
Attended operation permitted if shown to be acceptable by hazard analysis.

4
The attended operation may take place when a hazard analysis shows the maximum credible event (MCE) to only be fire hazard. For guidance on ENERGETIC (PROPELLANT) LIQUIDS, please refer to DoD 6055.9, Section 9.5.

§ 184.8
Safety requirements for manufacturing and processing pyrotechnics.

(a)
General.
(1) Pyrotechnics, as well as propellants and explosives, are chemical mixtures which release large amounts of energy. The amount of energy released, the speed of reaction, and the form of the output energy are the characteristics that distinguish between pyrotechnics and other forms of high-energy (HE) mixtures, and between types of pyrotechnics. The safety precautions for manufacturing and processing pyrotechnics parallel those of many types of explosives and propellants. However, incident mitigation techniques must recognize the unique characteristics of the particular mixtures, and not rely on techniques appropriate to other types of explosive substances (
e.g.
, HE). Rates of reaction of pyrotechnic mixtures vary greatly, from mixtures with very low rates of reaction to rates equivalent to high explosives. Energy output also varies from very low to very great. Process variables, such as ingredient particle size, can affect reaction rate and output to the extent that a change in process variables can negate protective measures. Complicating safety in pyrotechnics operations is the variety of highly flammable solvents often used as processing aides.

(2) Pyrotechnics are mixtures of fuels and oxidizers, typically held together by binders. Pyrotechnics display many different characteristics, because they are formulated for different purposes. General categories of pyrotechnics are: initiators (igniters); illuminants; smokes. gas generators; sound generators; heat producers; and timing compositions. Each has its own characteristics and attendant processing requirements.

(b)
Properties of pyrotechnic materials and mixtures.
Knowledge of the various pyrotechnic properties is critical to the establishment of proper hazard controls.

(1)
Oxidizers.
Oxidizers are oxygen rich substances which decompose to liberate oxygen gas, or substances which act as oxidizers with active metal fuels. Typical inorganic oxidizers are nitrates, chlorates, perchlorates, oxides, chromates, and dichromates. Fluorine and chlorine, as in hexachloroethane and Teflon (brand of fluorine containing compound) are examples of organic compounds used as oxidizers. All oxidizers, if not well controlled, tend to increase the risk of undesired reactions, particularly in the presence of organic materials (including wood). Potassium chlorate compositions are particularly susceptible to accidental ignition. Impurities in process materials, or introduced by poor process control (
e.g.
, oils, lubricants) can readily increase the sensitivity of mixtures or result in ignition. Some oxidizers with trace impurities, or by themselves (
i.e.
, ammonium perchlorate (AP)), can detonate when subjected to severe stimuli such as an adjacent explosion or thermal energy. Safety requires absolute control of oxidizers to prevent contamination, uncontrolled moisture absorption (many are hydroscopic), fires or explosions from accidental mixing with fuels.

(2)
Fuels
. Fuels react with the oxidizers to produce heat and an oxidized product. It is the proper pairing of the fuel with an appropriate oxidizer that determines the reaction characteristics, and the use for the mixtures. Metals, such as magnesium or aluminum, create high heat or light output. Fuels include an almost unlimited variety of organic (sugars and red gum) and a more limited variety of inorganic materials (
e.g.
, sulfur boron, phosphorus, and sulfides). Although generally more stable than oxidizers, fuels also have unique characteristics that contribute to risk. These include the liberation of hydrogen from magnesium and aluminum powders which become wetted. Again, storage and handling of fuels requires tight process controls which respect the characteristics of the specific materials and prevent contamination which may result in a reaction.

(3)
Binders
. Homogeneity of the mixtures governs the effectiveness of pyrotechnic compositions. Some pyrotechnics (
e.g.
, black powder) are self-bound by the manufacturing process to maintain the charcoal, sulfur, and potassium nitrate in the correct, proportionate, intimate mixture needed. Other mixtures, because of differences in particle size or weight of ingredients, require the use of a binder to retain the homogeneous blend. Other binders include lacquers, epoxies, and a variety of polymers activated by heat or solvents. Some solvents are similar in composition to fuels, and the binder may also be a fuel or burn rate modifier. Some binders are flammable, others require the use of a highly flammable solvent, and thus the ignition characteristics of these materials are important risk factors.

(4)
Types of pyrotechnic compositions
. Pyrotechnic compositions are usually grouped by the function of the end item. There is no universal single grouping, but typical major groupings are: heat and delay compositions (
e.g.
, ignition, delay, heat, and propellant), color and light compositions, smoke (
e.g.
, obscuring and signal smokes, noise). The range of sensitivity to initiation and the rate/amount of output energy varies greatly both within and between groups.

(i)
Heat and delay compositions
. Pyrotechnic fuzes, electric matches, first fires, primers, igniters, delay compositions are all members of this group. The end products must function with very little stimulus, and thus the mixtures, as well as individual ingredients, are sensitive to initiation. First fire, igniter and primer mixtures are generally the most sensitive to initiation stimuli (
i.e.
, heat, friction, impact, static electricity). (Note: Primer mixes containing initiating explosives such as lead azide or lead styphnate are properly classed as explosives.) These

mixtures often use black powder or potassium chlorate/metal combinations or potassium chlorate/phosphorous mixtures. This group also contains mixtures with high heat outputs for such purposes as document destroyers and welding. These high heat producers are generally metallic fuels and metallic oxidizers, as in the iron oxide/aluminum powder formulations for Thermite. Black powder, when used to launch or expel items is a propellant and is included in this group.

(ii)
Color or light producing compositions
. There are a wide variety of mixes and compositions which produce light, color, or both. Illuminant candles, photoflash, decoy flares all are part of this very broad category. Many of the compositions, notably the photoflash and decoy flare compositions, are characterized by very rapid reactions, and extreme temperature outputs. Both have resulted in fatal accidents. Metallic fuels are characteristic of the high light (visible, IR) output mixtures. Output temperatures exceeding 2000 °F (1093 °C) characterize many of the items in this category. Accidental initiation of large mix batches of some compositions may have a significant pressurization effect in addition to the heat, with resultant structural damage.

(iii)
Smoke and noise producing compositions
. Obscurants, colored markers, weapons simulators and weapons effects simulators comprise this category. Smoke compositions are characteristically slow burning in finished form, but must burn at a temperature high enough to vaporize the dye compound (usually organic). Chlorates are often the oxidizer in colored smoke mixes. “Flash-bang compositions” used in weapons simulators and weapons effects simulators are actually explosives in most instances, and will detonate with adequate stimulus in unconfined bulk form. “Flash-bang” compositions, particularly in display or commercial fireworks, but also in military items, were the cause of many injury-producing accidents. Similarly, “whistle” compositions are very sensitive to ignition and can detonate.

(c)
Process requirements.
Pyrotechnic operations, because of the sensitive nature of the ingredients and compositions, the dangerous effects of contamination, including cross contamination of oxidizers and fuels, and the amount of open or exposed ingredients and mixtures, require stringent housekeeping and cleanliness. Materials control and cleanliness are mandatory not only to reduce the likelihood of accidental initiations, but also to minimize the effects of a mishap.

(1) Do not allow ingredient or composition dusts to accumulate, whether on the exterior work surfaces or the interior of process equipment and ventilation systems. (Note: Accident investigations frequently identify dust buildups as the source of initiation when items are dropped on, or scraped across them.) Dust accumulations also provide a propagation path, which can follow from initiation to a significant source of material, causing an accident.

(2) Similarly, where flammable solvents are part of the process, positive vapor control is mandatory to prevent initiation of a solvent vapor cloud, which may be injurious in itself, or may be the propagation path which ignites a mixture. Just as dusts in ventilation systems may provide a propagation path for an event, solvent vapors in ventilation systems, hallways, conduits, or pipes may also provide a propagation path.

(3) As many pyrotechnic ingredients, mixtures or the solvents used in their production are highly susceptible to initiation by static electricity, static control systems (
i.e.
, conductive floors/mats, shoes, wrist straps, grounding of equipment, etc.) are mandatory where hazard analysis indicates a need for static control.

(4) For all pyrotechnic operations, a documented hazard analysis and risk assessment is mandatory to validate the layout of operations, selection of materials and equipment, and process control parameters. See § 184.11.

(5)
Weighing raw materials.
Positive means of separation of fuels and oxidizers is mandatory. The scale of the operation will dictate whether separate rooms, cubicles, areas, or other means for separation are required. It is important that equipment (
e.g.
, containers, hand tools, scale pans, etc.) used for weighing fuels or oxidizers are not interchanged or shared among incompatible operations, unless thoroughly cleaned between fuel and oxidizer use, particularly where distance rather than physical barriers separates these areas. A hazard analysis shall determine appropriate personnel protective equipment for personnel weighing or handling exposed oxidizers or fuels.

(6)
Drying materials.
Drying materials may result in the generation of flammable vapors or dust which have the potential to create an explosive atmosphere. The dust settling out of the atmosphere may increase in sensitivity. Operational hazard analysis must address these possibilities and the possibility of initiation by over-temperature or extended heating. Use the minimum temperature necessary for drying component and pyrotechnic materials. Dust and residue control is very important in drying operations, as elevated temperatures frequently results in increased sensitivity of materials. The requirements for drying apparatus are described in § 184.8.

(7)
Mixing and blending.
Mixing, blending, and cleanup of pyrotechnic compositions from equipment apparatus require attention because of the high potential for mishaps during these operations. As compositions vary, no single type of mixer or blender can be the exclusively approved equipment for pyrotechnic mixing and blending operations.

(i) Select the mixing equipment and methods appropriate for each composition. Hazard analysis or test shall determine the type of mixer or blender and batch size. Devices using a tumbling action eliminate many of the problems associated with rotating blade mixers, plows and scrapers. Rotating blade type mixers create points where frictional heat may develop or where accidentally introduced foreign material can create hot spots through friction or crushing of the composition. Equip enclosed mixers and blenders with pressure relief, to preclude a transition from burning to detonation. Minimize personnel exposure when charging and emptying mixers and blenders. Unless hazard analysis indicates otherwise, charge, operate and empty mixers and blenders remotely. Use appropriate interlocks, clutch brakes, and similar devices to preclude personnel exposure during mixer or blender operation, and to preclude the movement of mixer or blender parts during periods when operators are present.

(ii) Mixing and blending operations often present a high risk of explosion. Facility construction and procedural controls, guided by hazard analysis or test, must reflect this risk. Prevention of propagation, protection of production capability and personnel require separation and isolation of these operations. At least one wall or equivalent panel area in each bay shall be frangible to provide pressure relief in case of an incident. Preclude personnel exposure to pressure relief areas.

(iii) Flammable solvents used in mixing operations present a potential fire or explosion vapor hazard. When flammable solvents are used, install ventilation equipment, interlocked to the mixers. Design interlocks to preclude mixer operation without ventilation. Ventilation systems must operate in the presence of solvent vapors. Vapor sensors provide warning

of flammable vapor levels approaching the lower explosive limit. Design ventilation systems to prevent propagation of an incident from one bay to others served

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Source: Frix Law Library, https://www.frixlaw.com/law-library/documents/fr%3A05-5429. Public record. Not legal advice.