Part Ii

SUBCOURSE MM0169

EDITION A

EVALUATE CONVENTIONAL AMMUNITION STORAGE OPERATIONS (PART II)

US ARMY ORDNANCE MISSILE AND MUNITIONS CENTER AND SCHOOL

EVALUATE CONVENTIONAL AMMUNITION STORAGE OPERATIONS (PART II) Subcourse Number MM0169 EDITION A

Missile and Munitions United States Army Combined Arms Support Command Fort Lee, Virginia 23801-1809 6 Credit Hours Edition Date: October 1992

SUBCOURSE OVERVIEW

This subcourse is designed to provide you with the information required to plan storage operations in an ammunition supply point (ASP). Upon completion of this subcourse, you should be able to determine personnel and equipment requirements, direct ammunition logistical operations, and plan rewarehousing operations. There are no prerequisites for this subcourse. This subcourse reflects the doctrine that was current at the time the subcourse was prepared. In your own work situation, always refer to the latest publications. Unless otherwise stated, the masculine gender of singular pronouns is used to refer to both men and women. Terminal Learning Objective Action:

You will identify the procedures used for evaluating ammunition storage safety. You will also be able to plan rewarehousing operations, including personnel, equipment, and logistical management.

Condition:

This subcourse booklet contains all the information required for completion of this subcourse. This required information includes extracts from several military and nonmilitary publications. No additional equipment or documents are required.

Standard:

To demonstrate competency on this task, you must achieve a minimum of 70 percent correct on the subcourse examination.

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TABLE OF CONTENTS

Section

Page

Subcourse Overview............................................................................................................. .....................

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Lesson 1: Ammunition and Explosive Storage Safety....................................................... ..................... Overview.............................................................................................................................................. .. Introduction.................................................................................................................................... ........ Magazine Storage...................................................................................................... ........................... Outdoor Storage..................................................................................................................... ............... Storage Area Safety.................................................................................................. ............................ Inspections of Storage Areas and Facilities.............................................................................. .............

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Practice Exercise....................................................................................................................... ..........

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Answer Key and Feedback.............................................................................................. ...................

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Lesson 2: Warehousing and Rewarehousing Operations.................................................................. ..... Overview.............................................................................................................................................. .. Introduction.................................................................................................................................... ........ Warehousing......................................................................................................................................... . Rewarehousing.................................................................................................................................. ....

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Practice Exercise....................................................................................................................... ..........

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Answer Key and Feedback.............................................................................................. ...................

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Appendix: Publication Extracts............................................................................................. ........................ AR 190-11. Physical Security of Arms, Ammunition and Explosives. 31 March 1986............................................................................................................ ..................... SB 708-4. DOD Consolidated Ammunition Catalog, Volumes 1, 2, and 3. 1 October 1989..................................................................................................... ...........................

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LESSON 1 AMMUNITION AND EXPLOSIVE STORAGE SAFETY Critical Task: 03-4020.02-0001

OVERVIEW Lesson Description In this lesson you will review the basic standards for the safe storage of ammunition and explosives. The lesson covers modes of storage, storage structures, hazard placards, fire fighting, lightning protection systems, and general inspection criteria. Terminal Learning Objective Action:

Review the requirements that must be met to store various explosives and ammunition items safely and properly.

Condition:

This lesson contains all the information you will require. This information includes extracts from TM 9-1300-206 and AR 385-64. No additional equipment or personnel are required.

Standard:

You must be able to identify the requirements for the safe storage of ammunition and explosives.

References:

The material contained in this lesson was derived from AR 385-64 and TM 9-1300-206. INTRODUCTION

The primary purpose of ammunition and explosive storage is to maintain sufficient stockage levels for research and development, for military training, for contingencies, and for combat operations. There are several hazards involved in the storage of ammunition and explosives, since such items are designed to kill personnel or to destroy property and equipment when used. Various types of explosives and ammunition are sensitive to shock, heat, friction, and contact with other materials. Explosives must be handled carefully. They must be protected from contact with certain other materials, from the effects of weather, and from damage. This lesson describes the storage standards applicable to ammunition and explosives. The storage of ammunition in the zone of the interior (ZI) means storage in the 50 United States. Ammunition storage in the ZI is governed by different standards than ammunition storage in the theater of operations. This lesson covers ammunition storage in the ZI only. MAGAZINE STORAGE There are two categories of magazines, earth-covered and above-ground. Earth-covered magazines are preferred for the storage of all items of ammunition and explosives that require special protection for explosive or security reasons.

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Earth-Covered Magazines The three basic types of earth-covered magazinesstandard igloo, steel-arch, and Stradley-yurtare shown in Figure 1-1.

Figure 1-1. Standard igloo, Stradley-yurt, and steel-arch magazines.

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Standard Igloo. This is an older design. It is not practical for storing large missiles and rockets or palletized and containerized ammunition. The door is too small for a standard 40-by 48-inch pallet moved by a forklift. This type of magazine is obsolete and has been, or is being, replaced by the newer magazine types. Steel-Arch. This type of magazine has the same round inside walls as the igloo magazine. The inside looks like the inside of a Quonset hut. It has semicylindrical metal walls and ceiling, a concrete floor, and a door wide enough to handle pallets and missile containers. Stradley-Yurt. This type of magazine is built of reinforced concrete with a wide door or a double door to accommodate present-day ammunition packaging. Forklifts can easily go in and out with pallets and missile containers. Because of the straight side design of the Stradley-yurt, it can be used to store nearly 25 percent more ammunition than standard igloo or steel-arch magazines of similar size. Size. The size of earth-covered magazines varies, but some common specifications are as follows: • Standard igloo: 26 feet, 6 inches wide; 12 feet, 9 inches high; and 40, 60, or 80 feet long. • Steel-arch: 25 feet wide, 10 feet high, and 40 or 64 feet long. • Stradley-yurt: 20 feet wide, 14 feet high, and 40, 60, or 80 feet long. Remember, earth-covered magazines provide the best storage conditions for ammunition and explosives. Above-Ground Magazines There are three types of above-ground magazines – standard, high-explosive (HE) or blackpowder, and primer or fuze. They are described in the following paragraphs. Standard Magazines. A standard magazine is shown in Figure 1-2. These magazines are made with steel and concrete frames, and have hollow tile walls that are filled with sand. They have concrete floors that are sometimes covered with sparkproof topping. The largest standard magazines are about 51 feet wide by 218 feet long. They should be restricted to the storage of items in Classes (04) 1.2, (08) 1.2, (12) 1.2, 1.3, and 1.4 (excluding rockets and rocket motors). High-Explosive or Black-Powder Magazines. Magazines of this type are shown in Figure 1-3. These magazines are used to store bulk explosives such as trinitrotoluene (TNT) and black powder. They are about 27 feet wide by 45 feet long, and are spaced 800 feet apart. Should one blow up, nearby magazines would not be affected. Primer or Fuze Magazines. Magazines of this type are shown in Figure 1-4. These magazines have exactly the same construction and dimensions as high-explosive magazines. The difference is in the spacing; primer or fuze magazines are spaced 300 to 400 feet apart. Less spacing is required because primers and fuzes have a much lower explosive content than bulk explosives. Limitations. All of the above-ground magazine types are, and will continue to be, used to store only smallarms ammunition, firing devices, and other less-explosive or less-hazardous items. They are limited to the storage of such items regardless of the original design intent.

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Figure 1-2. Standard above-ground magazine.

Figure 1-3. High-explosive or black-powder magazines. MM0169

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Figure 1-4. Primer or fuze magazines. Operational Regulations for Magazine Storage Some operational regulations for magazine storage are as follows: • Vegetation around ammunition storage sites must be controlled; a 50-foot firebreak is required. • Dirt, grit, and foreign materials must be removed from containers and ammunition items before they are placed in storage. • Damaged containers may not be used to store munitions. • Containers in storage must be closed to prevent the examination, handling, or removal of ammunition and explosive items. • Containers may not be opened, repaired, packed, or repacked inside or within 100 meters of a magazine (except as specifically permitted by TM 9-1300-206). • Components or loose rounds should not be stored in the same magazine with properly packaged items. • Conveyors, pallet jacks, equipment, tools, empty boxes, and so forth must not be stored in a magazine with ammunition or explosives. • Smoking in a magazine is prohibited. • Doors and locks on magazines must be kept in good working condition. • Magazines must be kept locked at all times (except when personnel are working in them). • The doors of a magazine must be kept open when a crew is working inside. The number of crews must not exceed the number of doors. • Ammunition must be placed or stacked in a magazine according to the applicable drawings. • The lot number and other markings must be placed so that they can be read without moving boxes or climbing stacks. • Stacks must provide adequate ventilation; dunnage may be used under and between boxes for this purpose.

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• Always stack ammunition from the back to the front, large lots first. • When more than one lot is stored in a magazine, all items of a lot must be stored together, and a clear line of separation must be indicated between lots. OUTDOOR STORAGE Outdoor storage is neither desirable nor recommended. It is a field expedient method, and should be used in emergencies only. When it becomes absolutely necessary to store ammunition and explosives outdoors, as much of the ammunition as possible should be covered by waterproof and fire resistant tarpaulins rigged over sturdy frames. You should develop a priority list for covered storage based on the local security conditions and on the storage area contents. Certain items of ammunition and explosives are sensitive to exposure to water or direct sunlight. When your ASP has no indoor (magazine) storage available, items should be covered in the priority order that follows: • Fuzes, primers, and boosters. • Pyrotechnics. • Propelling charges. • Combustible cartridge case ammunition. • Demolition priming devices. • Illuminating and other rounds with black-powder expulsion charges. • Chemical ammunition. • Rocket ammunition. • Small-arms ammunition. • Grenades. • Mines. • Demolition items. • Fixed and semifixed ammunition (smallest caliber first). • Separate-loading projectiles. • Bombs. This list may be modified as required by local security conditions. Special Requirements for Outdoor Storage Site Requirements. Outdoor storage sites should be level, well-drained, and free from flammable material. At least three inches of dunnage must be used to keep the ammunition and explosives off the ground. Keep the stacks separated to allow air to circulate freely. An air space of at least 18 inches is needed between the top of the stack and the overhead cover.

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Fire-Prevention Measures. Perform frequent inspections to prevent the accumulation of trash and to detect and stabilize unstable stacks. When stacking munitions, ensure that dunnage awaiting immediate use is located at least 50 feet away from the stacks. Excess dunnage in the immediate work area may become a fire hazard. Fire-fighting equipment and fire symbols are discussed later in this lesson. Quantity-Distance Requirements. Munitions maintained in unbarricaded open storage must be treated as above-ground storage for quantity-distance (QD) purposes. No outdoor storage site may be located within 1,200 feet of an above-ground magazine. Open storage sites may be temporarily located between earth-covered magazines, provided the following conditions are met: • Adjacent earth-covered magazines are at least 400 feet apart. • The sites are barricaded, and are separated from the barricaded side of the nearest magazine by at least 185 feet. • The sites do not extend beyond the front or rear of magazines in the same row. Inert Items. All magazines or open barricaded sites in the magazine area may be used for the storage of ammunition-related inert items. These inert items include fuze wrenches, eyebolt lifting plugs, grommets for artillery projectiles, dummy ammunition, and so forth. Heavy Equipment. In some cases where a storage area is not available, motor vehicles, tanks, artillery pieces, and so forth may be stored in the open in an ammunition storage area. Such equipment must be parked at least 800 feet from magazines or open storage sites containing ammunition. Items Never Stored Outdoors. Bulk solid propellants, bagged propellants, pyrotechnics, bulk high explosives, and critical items must not be stored outdoors. Critical items include hand grenades of the fragmentation type, Claymore antipersonnel mines, and antitank weapons (such as the shoulder-fired light antitank weapon [LAW]). This type of ammunition could be stolen, and would be very dangerous in the wrong hands. Barricaded Outdoor Storage Properly-constructed barricades of the separated artificial type or the substantial natural type are an effective means of protecting structures or operations. General rules concerning barricades are as follows: • Barricades must not be used to reduce the separation distance required for fire-hazard materials (such as Class 1.3 propellants) and fragment-producing items (such as Class 1.2 ammunition). • Barricade protection is considered effective when a line drawn from the top of any sidewall of the explosives building to any other location within the site passes through the intervening barricade. • For railroads and highways to be considered barricaded, a line such as that described above must pass 12 feet above the center of the highway or railroad. • A barricade must be separated from both the building it is to screen and the building containing the hazard.

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• Barricades may be natural or artificial earth mounds. Such mounds may have naturally-sloping sides, or one side may be revetted with either wood or concrete, with an earth mound at least three feet wide at the top. • Existing double-revetted artificial barricades that are at least three feet wide at the top, with sloping sides, and with proper anchorage to give stability against overturning forces, are approved for reducing QD requirements for a maximum of 50,000 pounds net explosive weight (NEW) of high explosives. STORAGE AREA SAFETY QD and Compatibility Standards QD and compatibility standards must be applied at all times, regardless of the mode of storage. QD and compatibility tables are included in TM 9-1300-206, Chapter 5. The use of these tables is explained in subcourse MM 0168, Evaluating Conventional Ammunition Storage Operations (Part I). Fire Protection Within an ammunition and explosive storage area, whether permanent or temporary, fire protection measures and the posting of fire symbols is of critical importance. Fires in an ammunition and explosive area can cause catastrophic damage in an extremely short time. Fire Plan. A fire plan is one of the first things an explosive storage area needs. The fire plan covers the disposition of matches and other flame- or spark-producing devices. It specifies who can grant the authority to carry such devices, and how they must be carried. It specifies where smoking areas are located, when they may be used, and what type of fire extinguisher must be available at each location. The fire plan describes what everyone is to do in the event of a fire. It designates the key individuals, alternates, and organizations, and it defines their responsibilities, including who is responsible for the following tasks: • Reporting the fire. • Directing the orderly evacuation of personnel. • Notifying nearby personnel of the impending danger. • Initiating the means of extinguishing or controlling the fire. • Meeting the fire fighters and advising them as to the details of the fire. Fire-Prevention Measures. Fire prevention in an ammunition storage area is the responsibility of all personnel who work in or enter the storage area. The storage area must be kept in such a condition as to prevent fires from starting and to prevent fires from entering from other areas. The following paragraphs describe some specific fire prevention measures. Grass, weeds, undergrowth, and other flammables must be kept out of the ASP. By controlling the growth of vegetation, the possible spread of any fire is limited. Weed killer, mowing, animal grazing, plowing, and cutting are methods used to control vegetation. However, the proper supervision of personnel is required when any method is used. The burning of vegetation is not permitted within 50 feet of earth-covered magazines, nor within 200 feet of above-ground magazines or storage pads. All structure doors, windows, and ventilators must be closed during burning.

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Firebreaks that are at least 50 feet wide and are free of flammable material must be maintained around aboveground magazines and storage pads. Dunnage may not be stacked within 50 feet of magazines, and may never be stacked within the firebreaks. Diesel- and gasoline-powered vehicles operating within 25 feet of a structure or magazine must be equipped with properly-installed spark arresters. Heat-producing equipment may not be used without a permit from the quality assurance section, the safety officer, or the fire department. The permit must specify the location, time, duration, purpose, and safety precautions associated with the equipment. It must also specify any fire-fighting equipment required, and the names of personnel authorized to operate the equipment. Fire-Fighting Facilities. Fire-fighting facilities are of immediate importance to personnel within the ASP. Fighting fires in their beginning stages can prevent a major fire or a mass detonation of ammunition stocks. Keep in mind that personnel must not be exposed to the hazards of an imminent explosion. The fire-fighting equipment available varies depending on the permanency of the facility, the types of ammunition stored, and the availability of fire-fighting organizations. Temporary facilities may be equipped with the following items: • Water barrels. • Pails. • Sand boxes. • Shovels. • Water-type extinguishers. • Backpack pumps. • Other equipment (such as fire beaters). Permanent facilities may be provided with the following items: • 2.5-gallon water-type extinguishers. • Four-gallon backpack pumps. • Multi-purpose dry chemical extinguishers. • Pumpers or brush trucks. • Tank trucks. • A fire map. Both types of facilities should have an adequate supply of brooms, gunny sacks, hoses, grass beaters, and, where available, plows, graders, and bulldozers. Two hand extinguishers should be available for immediate use whenever ammunition or explosives are being handled. Fire Drills. Fire drills involving all available personnel should be held semiannually. Unannounced fire drills involving motorized emergency vehicles are prohibited. Fire Alarms. A fire alarm should be available to aid in passing the warning and speeding evacuation. The alarm should be both audible and visible, but must at least be audible.

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When evidence of a fire is noticed and the alarm has been given, at least one responsible messenger must be sent in the direction from which fire fighters are expected to arrive. This individual gives the responding units the location, nature, and extent of the fire. Fire fighters must not approach fires involving ammunition or explosives unless they have accurate information concerning the hazards and have determined that doing so is justified. Fire Hazard Markings As a guide to fire fighters, ammunition and explosives are divided into four fire divisions according to the hazards encountered when fighting fires involving the various types of munitions. The four fire divisions are identified on signs by the numerals 1, 2, 3, and 4. Each sign has a different shape to provide for easier identification in darkness and at long range. Their shapes and sizes are shown in Figure 1-5.

Figure 1-5. Fire hazard markings. Posting Fire Symbols. Fire symbols are normally posted on buildings or storage sites. They are posted in such a manner as to make them easily visible to approaching fire fighters at the maximum distance. Half-size signs may be used on doors or lockers inside buildings, on motor vehicles, and on railroad cars. In the interest of safety, installation commanders may designate blocks of earth-covered magazines as areas requiring only the symbol for the most hazardous materiel present. Removable signs may be used where the class of explosives present changes frequently. For long buildings, more than one sign per side may be needed.

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Railroad cars and motor vehicles containing ammunition or explosives destined for off-post transportation must have either fire symbols or Department of Transportation (DOT) placards. Once off post, such rail cars and motor vehicles must have DOT placards. Vehicles transporting small-arms ammunition only do not require DOT placarding, but while on an installation they should be regarded and marked as carrying fire division 4 materiel. Fire Divisions. Fire divisions 1, 2, 3, and 4 correspond with QD Hazard Classes 1.1, 1.2, 1.3, and 1.4. The lower the fire division number, the greater the hazard. Fire division 1 indicates the potential for mass detonation. Examples of stocks in this division are bulk high explosives (such as TNT and C-4), blasting caps, and 155mm HE projectiles. Fire division 2 indicates the potential for an explosion with a fragment hazard. Examples of munitions in this division are white phosphorous (WP) grenades, hand grenades, and rifle grenades; M16 antipersonnel mines; and M115A2 simulators. Fire division 3 indicates a mass-fire hazard. Examples of stocks in this division are aluminum zinc oxide hexacholoroethane (HC) grenades, smoke pots, rocket motors, and propellant grains. Fire division 4 indicates a moderate fire hazard. Examples of stocks in this division are commercial squibs, M2 cartridge igniters, and small-arms ammunition. Chemical Hazard Symbols Chemical hazard symbols are posted in addition to fire division symbols to identify any chemical agents stored in the marked locations. The chemical hazard symbols are shown in Figure 1-6. Their purpose is to alert fire fighters to the special hazards associated with chemical agents. Such added hazards require special preparation and precautions in case of fire. Table 1-1 shows the protective clothing set and the chemical hazard symbol required for each chemical agent.

Figure 1-6. Chemical hazard symbols.

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Table 1.

Chemical agents and fillers contained in ammunition and the chemical hazard symbols required in storage.

Wherever one of the symbols shown in Figure 1-6 is displayed, an additional symbol that pertains only to fire fighting must also be displayed. These additional symbols are shown in Figure 1-7.

Figure 1-7. Additional fire hazard markings. Symbol 1 in Figure 1-7 indicates the protective clothing that must be worn by fire fighters. The protective clothing needed is indicated by the color of the figure in the center and the color of the outer edge of the symbol. MM0169

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Symbol 2 in Figure 1-7 indicates that fire fighters must wear a gas mask or a self-contained breathing apparatus (SCBA) in areas so marked. This is usually because of the presence of incendiary or other highly-flammable chemical agents. The meaning of symbol 3 in Figure 1-7 is clear. The use of water on the chemicals marked with this symbol could spread the fire or cause an explosion. This usually involves chemicals such as oil-based incendiaries, metallic sodium, and triethyl aluminum (TEA) or HC. A classification list of chemical agents that you may be required to store and maintain is shown in Table 1-2. Be particularly aware of their compatibility groupings and color coding. Protective Clothing Sets Protective Clothing Set 1 (Red Figure and Rim). This is the toxicological agents protective (TAP) clothing set. It is used when fighting fires at sites marked with the G, VX, H, and L symbols. The items that must be worn are as follows: • A protective or SCBA mask. • An M3 TAP suit. • An M2 TAP hood • Undergarments. • Coveralls. • Protective footwear. • TAP gloves. Protective Clothing Set 2 (Yellow Figure and Rim). This clothing set is used when fighting fires involving riotcontrol gases, choking gases, or the FS/FM smoke symbol The items that must be worn are as follows: • A protective mask. • Coveralls. • Rubber gloves. Protective Clothing Set 3 (White Figure and Rim). This clothing set is used when fighting fires involving WP and TEA. Items that must be worn are as follows: • A protective mask. • Flame-resistant coveralls. • Flame-resistant gloves. If fire fighters are equipped with normal heat-resistant bunker suits and SCBA equipment, they do not need protective clothing sets 2 and 3. Lightning Protection Lightning protection systems should be installed on buildings and other structures used for processing, handling, or storing explosives, ammunition, explosive ingredients, and other hazardous materials. Approved lightning protection systems are as follows: • Integrally-mounted systems.

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Table 1-2. Classification list of chemical agents.

Lightning Protection Lightning protection systems should be installed on buildings and other structures used for processing, handling, or storing explosives, ammunition, explosive ingredients, and other hazardous materials. Approved lightning protection systems are as follows: • Integrally-mounted systems. • Separately-mounted shielding systems (mast type).

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• Separately-mounted shielding systems (overhead-wire type). • Integrally-mounted shielding systems (mast type). Exemptions. In locations where lightning storms occur with an average frequency of less than five per year, lightning protection systems may be omitted from certain structures specifically designated as exceptions. For existing igloo-type magazines without lightning protection, where damage from lightning would not handicap activities essential to the Department of Defense, protective systems need not be erected when specifically exempted by the major Army command (MACOM), providing that all metallic ventilators, doors, and reinforcing steel are electrically bonded together and grounded. All magazines constructed after the publication of TM 91300-206, Change 10, must be externally protected. Testing. Lightning protection systems must be visually inspected every seven months. They must be tested for continuity and grounding every 14 months. A record of the results of continuity and grounding tests must be maintained at the installation. This record must include the following data: • The building number, contents, and use. • The date of the inspection. • The part of the system tested. • The resistance (in ohms). • Remarks (mechanical condition, nature of soil, and so forth). • Corrective actions taken. INSPECTION OF STORAGE AREAS AND FACILITIES Inspecting Magazine Storage When inspecting a magazine that contains ammunition or explosives, you must check the inside and outside of the magazine. The following paragraphs describe some specific things to check during a magazine inspection. Fire Symbol and Chemical Hazard Symbols. As you approach the magazine, look for the appropriate fire symbol and chemical hazard symbols. If the magazine you are inspecting contains ammunition that is all of the same kind, the symbols may be located on the front doors, as shown in Figure 1-8. They may also be posted in front of the magazine area If all the magazines are storing the same hazard class, they may be posted at the entrance to the storage site. Vegetation and Erosion. Inspect the outside of the magazine for proper vegetation control. A 50-foot firebreak is required. Check the firebreak and the grounds surrounding the magazine to ensure that they are free from flammable material. Make sure there is no ground erosion around the storage magazine. Ventilators. Inspect the ventilators to ensure that they are open and that the fusible links that hold the dampers in the open position are not broken. Fusible links are positioned on the support chain of the ventilator closure as shown in Figure 1-9. They prevent fire from entering the magazine from the outside by melting and

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Figure 1-8. Underground magazine (front view).

Figure 1-9. Magazine ventilator unit with fusible link. releasing the closure when they are heated. Ventilators should also be equipped with screens to prevent animals and trash from entering the magazine. Check the screens covering the ventilators for holes and tears as shown in Figure 1-10. Doors. The doors to the magazine should be locked. They should be opened only by authorized personnel to permit entry by inspectors or to move ammunition in or out. Inspect the doors for heavy rust and broken parts as shown in Figure 1-11. Check the doors to make sure they open and close properly and that the seals are secure when the doors are closed. Walls, Floor, and Ceiling. Inspect the walls, the floor, and the ceiling of the magazine for holes, cracks, moisture, or other defects that require minor repairs. Inspect the storage magazine for general housecleaning. Trash, strapping, excess dunnage, or other debris must not be permitted to accumulate inside the storage magazine. Ensure that only hot, soapy water or authorized sweeping compounds are used to clean magazine floors. Cleaning compounds containing caustic alkalines must not be used. MM0169

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Figure 1-10. Damaged ventilator screens.

Figure 1-11. Damaged magazine door. 1-17

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Inspecting Outdoor Storage The outdoor storage of ammunition is not desirable and should be used only as a temporary measure. This is because keeping ammunition outdoors exposes it to natural elements (such as rain and snow) that can cause the rapid deterioration of the ammunition and its packaging. Ammunition stored outdoors is usually contained in either barricaded, uncovered areas or unbarricaded, covered areas. Barricaded storage sites have berms built around three or four sides of the site. Unbarricaded sites are usually covered by tarpaulins stretched over an A-frame structure. Both types are illustrated in Figure 1-12. An outdoor storage site should have an elevated, prepared pad. This pad may be constructed of crushed rock or of perforated steel planking. In a more stable situation, the pad could have a paved surface. Outdoor storage sites must have suitable fire-fighting equipment, and fire symbols should be posted at the site. Water barrels with at least two pails per barrel must be maintained. Inspect the barrels for leaks, and check to see that they are filled with water. An adequate supply of grass beaters and other similar equipment to fight fires must be maintained throughout the area. When inspecting outdoor storage areas, look for loose projectiles, broken pallets, and mixed lots. Check to see that all ammunition stored at the site is compatible.

Figure 1-12. Outdoor ammunition storage areas.

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Unbarricaded Storage. Covers for unbarricaded storage sites are usually built in A-frame fashion, with a fireproof and waterproof tarpaulin installed tightly over the top and sides. The tarpaulin should be supported in such a manner as to permit the free circulation of air. Check the tarpaulins to ensure that they are not in need of repair or replacement. This includes any frayed or broken ropes attached to the tarpaulin. Ammunition must be stacked on top of at least three inches of dunnage. There must be at least 18 inches of air space between the top of the stacks and the cover, as shown in Figure 1-13.

Figure 1-13. Dimensions required in an unbarricaded outdoor ammunition storage area. Barricaded Storage. Some of the details of barricade construction were described earlier in this lesson. Some additional inspection criteria are as follows: • Vegetation must be controlled. A firebreak at least 50 feet wide must be maintained around the storage site. It must be free from flammable material. • Excess dunnage may not be stored between magazines or between outdoor sites and magazines. It should be stored in a dunnage yard. During operations, dunnage for the stack or site being worked must be stored at least 50 feet from the stack or site. • A drainage ditch like the one shown in Figure 1-14 should be maintained around each pad. This is done to prevent water damage to pallets and ammunition. • Ammunition must be stored on no less than three inches of dunnage, as shown in Figure 1-15.

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Figure 1-14. Drainage ditch required for a barricaded outdoor ammunition storage site.

Figure 1-15. Dunnage required in a barricaded ammunition storage site. Inspecting Ammunition Stacks Refer to the applicable ammunition storage drawings for proper stacking of specific munitions. General rules that apply to all ammunition stacks are as follows: • All items in storage should be on dunnage. • At least two inches of dunnage is required for magazine storage. • There should be sufficient aisle space to accommodate MHE and emergency equipment. MM0169

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• There should be no more than one light pallet per lot number of ammunition. A light pallet is defined as a pallet from which one or more boxes are missing. An example of a light pallet is shown in Figure 1-16. • Stacks must be stable. • Ammunition lot numbers and markings must be placed so that they can be read without moving boxes or climbing on stacks. • Ammunition must be stacked by lot number with the nomenclature facing up and outward. • Ammunition is always stacked from the back to the front, with large lots stacked first.

Figure 1-16. A light pallet of ammunition. Verifying Required Documentation A DA Form 3020-R (Magazine Data Card) must be affixed to each stack of ammunition. The DA Form 3020-R must contain all the necessary information for each lot and stack of ammunition, including the national stock number (NSN), the Department of Defense identification code (DODIC), the lot number, and the quantity. An example of a completed DA Form 3020-R is shown in Figure 1-17. If there are any ammunition items present that have been suspended from issue, movement, or use, they must be properly identified with a DD Form 1575 (Suspended Tag-Materiel), or a DD Form 1575-1 (Suspended LabelMateriel). Completed examples of these forms are shown in Figure 1-18. Verifying Net Explosive Weight and Compatibility Check the explosive limit of the magazine. This limit establishes the maximum amount of explosives allowed in the magazine at any one time. Check the NEW of the stored munitions to ensure that the explosive limit of the magazine is not exceeded. Most standard magazines hold either 250,000 pounds NEW or 500,000 pounds NEW. If you are unsure about the NEW allowed for the magazine, check with the ammunition surveillance personnel for assistance.

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Figure 1-17. An example of a completed DA Form 3020-R (Magazine Data Card). Check the storage compatibility to ensure that the ammunition items in the storage magazine may be stored together. Use the compatibility mixing chart and notes given in TM 9-1300-206 to determine the storage compatibility of the items present. This chart and its notes are shown in Figure 1-19. Inspecting a Lightning Protection System Begin your inspection by examining the test records for the lightning protection system. The test records should indicate that the system was visually inspected every seven months and continuity-tested every 14 months. If the system has not been tested during the past 14 months, you must test the system to determine if it meets safety standards. Visually inspect the lightning protection system for proper installation or damage. The integrally-mounted system is the most common lightning protection system for a maintenance facility with masonry construction and a nonmetallic or non-reinforced concrete roof. As shown in Figure 1-20, this lightning protection system includes air terminals, ridge cables, down conductors, ground connections, and grounds. Air Terminals. Check the air terminals for serviceability. The air terminals should not be bent; they should be securely connected and electrically continuous with the ridge cable. They should be at least two feet high, but if the building has vents that may emit explosive dust, the air terminals must be at least five feet high. If combustible dusts and flammable gases or vapor are emitted under forced draft from opened stacks, the air terminals must extend at least 15 feet above the vent opening. When the air terminals are over two feet high, braces must be provided to prevent damage to the roof from whipping.

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Figure 1-18. Examples of a completed DD Form 1575 (Suspended Tag-Materiel) and a completed DD Form 1575-1 (Suspended Label-Materiel). Air terminals at the end of the building should not be set more than two feet from the end of the roof. Air terminals that are two feet high should not be spaced more than 25 feet apart on ridges, on parapets, or around the perimeter of flat roofs. Where it is necessary to exceed this spacing, make sure that the height of the air terminal is increased at least two inches for each foot of spacing over 25 feet. Ventilators. When metal ventilators are installed on a maintenance building, ensure that an air terminal is installed on each ventilator, as shown in Figure 1-21. If the air terminal is installed on one side of the metal ventilator, it should be bonded near the top and the bottom of the ventilator and securely connected to the ridge 1-23

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Figure 1-19. Ammunition and explosives storage compatibility mixing chart (with notes)(extracted from TM 91300-206). MM0169

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Figure 1-20. Integrally-mounted lightning protection system.

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Figure 1-21. Air terminal mountings for a lighting protection system.

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cable in three places, as shown in Figure 1-21. If a non-metallic ventilator is present, the air terminal may be mounted on the ventilator or on its side. There must be a direct connection between the air terminal and the ridge cable. Ridge Cables. Ridge cables, or roof connectors, may be connected directly to the roof. Bends or turns in ridge cables may not exceed an angle of 90 degrees. In all cases, connectors must follow a downward or horizontal course. The cables must be securely fastened every four feet along the ridge and down the building to the ground. Down Conductors. Down conductors must be electrically continuous from the air terminals or ridge cables to the ground connections. They should be placed over the extreme outer portions of the building, such as the corners. There must be no less than two down connectors, as widely separated as practicable, on any structure. The preferred locations are opposite corners. Rectangular structures more than 110 feet long with gable or hip roofs must have at least one additional down connector for each additional 50 feet or fraction thereof, as shown in Figure 1-22. Testing a Lightning Protection System If the lightning protection system has not been continuity-tested within the past 14 months, an electrical test must be made. This test measures the resistance of the system to the ground and the resistance of any grounding system or individual ground connection. Refer to Figure 1-23 as you read the procedure for testing an integrally mounted lightning protection system that follows: • Drive a test ground rod at least three feet deep and at least 50 feet from the system. • Attach one lead (either positive or negative) of a resistance meter to the test ground rod. • Attach the other lead to each of the air terminals, one at a time. • Read the resistance shown on the meter for each of the air terminals. If the continuity of the system is good, there should be almost no difference in the value at any of the testing points. If a marked increase in resistance is noted, it is an indication that a loose, corroded, or broken connection exists. If the resistance of all air terminals to the ground is high, then a test can be made at the down conductor. • Connect the test lead to the down conductor of the system. This will measure the resistance of the system ground only. If the resistance is again found to be high, then the system ground is the cause of the indicated high resistance value. If the resistance is low when the testing lead is connected to the down conductor, it is an indication of trouble between the original point of contact on the air terminal and the point of contact on the down conductor. Steps should be taken to reduce all resistances that are found to be over 10 ohms during the test procedure. Inspecting Equipment Grounding and Conductive Floors The equipment grounding system and conductive floors provide a path for static electricity to be carried to the ground as it is generated. Static electricity is only a hazard when it is allowed to accumulate. It could discharge as a spark near highly flammable material and become a source of ignition.

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Figure 1-22. Examples of the placement of down connectors for buildings of different sizes and shapes.

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Figure 1-23. Lighting protection system continuity-test connectors.

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Work surfaces and equipment in a maintenance building must be grounded even though they are in contact with conductive floors. Inspecting Fire-Fighting Equipment Fire barrels and pails must be available at each ammunition storage site. The fire barrels should be full of water that is treated to repel mosquitoes in warm weather and winterized with sodium chloride to prevent freezing in cold weather. Inspecting Roads, Fences, and Gates Check the roads and open areas around the ammunition storage area for trash; for dropped or discarded boxes, pallets, or other type containers; and especially for live ammunition. If the ammunition storage area you are inspecting is inside a fenced area, the fencing must be in a good state of repair. There must be no holes or gaps, and the top wires should not be broken or missing. Check the fence line for soil erosion and vegetation control. Gates must not have holes or gaps in them, and the top wires of a gate should not be broken or missing. If the storage area contains explosives, the proper fire symbol must be posted on the entrance gate. Completing the Inspection Make sure you have written down all deficiencies noted during your inspection. Have your personnel take on-thespot corrective action on those deficiencies involving personnel safety. You may be required to send your findings and recommendations for corrective action to the unit commander.

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LESSON 1 PRACTICE EXERCISE

The following items will test your grasp of the material covered in this lesson. There is only one correct answer for each item. When you have completed the exercise, check your answers with the answer key that follows. If you answered any item incorrectly, study again that part of the lesson which contains the portion involved. 1. Which of the following items has first priority for covered storage? A. B. C. D.

Projectile, 155mm HE, M101. Bomb, general-purpose, 2,000-pound, MK84. Charge, propelling, M6. Fuze, M10A1.

2. What is the minimum air space required between the top of an ammunition stack and the overhead cover for an unbarricaded outdoor storage site? A. B. C. D.

6 inches. 12 inches. 18 inches. 24 inches.

3. What is the minimum distance required between an open storage site containing Class (12) 1.2 munitions and an above-ground magazine? A. B. C. D.

800 feet. 1,200 feet. 1,800 feet. 2,400 feet.

4. What is the minimum width of the firebreak around an above-ground magazine? A. B. C. D.

25 feet. 50 feet. 75 feet. 100 feet.

5. How many fire divisions are used for ammunition and explosives? A. B. C. D.

Four. Three. Two. One.

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LESSON 1 ANSWER KEY AND FEEDBACK

Item

Correct Answer and Feedback

1.

D. Fuze, M10A1. Fuzes, primers, and boosters are sensitive to exposure to water or direct sunlight. (Page 1-6)

2.

C. 18 inches. An air space of at least 18 inches is needed between the top of the stack and the overhead cover. (Page 1-19)

3.

B. 1,200 feet. Sites not located between earth-covered magazines cannot be closer than 1,200 feet to any above-ground magazine. (Page 1-7)

4.

B. 50 feet. Firebreaks that are at least 50 feet wide and free of flammable materials must be maintained around above-ground magazines and storage pads. (Page 1-9)

5.

A. Four. As a guide to firefighters, ammunition and explosives are divided into four fire divisions according to the hazards encountered. (Page 1-10)

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LESSON 2 WAREHOUSING AND REWAREHOUSING OPERATIONS Critical Task: 03-4020.02-0001

OVERVIEW Lesson Description In this lesson you will review the basic principles of ammunition warehousing operations. Also given in this lesson is a description of how to determine rewarehousing requirements, plan rewarehousing operations, and evaluate the results. Terminal Learning Objective Action:

Review the requirements for warehousing and rewarehousing ammunition, and determine the effectiveness of rewarehousing operations.

Condition:

This lesson contains all the information you will require. This information includes extracts from TM 9-1300-206 and SB 708-4. No additional equipment or personnel are required.

Standard:

You must be able to describe ammunition warehousing and rewarehousing practices, plan rewarehousing operations, and compute space requirements.

References:

The material contained in this lesson was derived from the following publications: • TM 9-1300-206. •· FM 9-38. • SB 708-4. • DA Pamphlet 710-2-2. INTRODUCTION

As an ammunition officer, one of your biggest challenges is the efficient management of your available storage space. Due to the continuous turnaround of ammunition assets, the effective management of storage space represents a constant problem. Knowing and utilizing sound warehousing and rewarehousing principles will resolve most storage space problems, and will provide for the most effective use of the space available for ammunition storage. WAREHOUSING Warehousing is the art of using available space, personnel, and equipment to ensure the efficient receipt, storage, and issue of ammunition with minimum handling. Consolidation is the key to good warehousing. Location control and the conservation of storage space are ongoing processes.

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The paragraphs that follow describe some of the factors that affect warehousing planning decisions. Facilities The types of facilities available dictate what types and quantities of ammunition can be stored at a given site. Packaging Munitions packaging dictates what type of stacking is required for maximum space utilization. Packaging also dictates dunnage, MHE, and personnel requirements. Lot Segregation Lot number segregation must be maintained during storage. Segregating ammunition by lot number aids in identifying suspended and restricted lots, conducting inventories, and expediting issues. Suspensions Suspended ammunition items and components must not be issued. Ammunition lots in storage that are placed under suspension need not be moved to another area unless such action is specified in the suspension notice. Stacks of suspended ammunition must be clearly marked on all sides using DD Forms 1575 or DD Forms 1575-1. (See Figure 1-18 on page 1-23.) The DA Form 3020-R for each suspended lot must show the suspension date, the suspension number, and the authority. Safety The specific safety hazards involved must be taken into consideration. The compatibility standards and QD requirements given in TM 9-1300-206 must be applied carefully and consistently. Where the storage compatibility and QD standards given in TM 9-1300-206 cannot be met, installation commanders must request waivers. Security Physical security of pilferable items is also an important factor. The security risk categories identified in AR 19011 are contained in the Appendix at the back of this subcourse booklet. Protection Ammunition items must be protected from the elements. Accessibility The items must be readily accessible to transportation assets and MHE. REWAREHOUSING Rewarehousing involves moving munitions from one magazine or pad to another and rearranging ammunition pallets, boxes, or containers within the same storage site to achieve the goal of efficient munitions warehousing. Rewarehousing also includes completing the paperwork when the job is over.

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Because receipts and issues of ammunition seldom involve the same items at the same time, planning storage space can be very difficult. Generally, rewarehousing takes place when merging lots of the same type of items would make more space available at the magazine or storage site. Rewarehousing is an ongoing process that must be performed well in order to maintain an efficient storage area. Advance notice of an incoming shipment of ammunition could require a rewarehousing effort to make room for the incoming shipment. Developing a Rewarehousing Plan The stock control section reviews the advance shipment notice documents, determines storage compatibility, and identifies similar stocks for possible storage consolidations. It then computes NEWs, reviews QD requirements, and reviews site licensing to determine appropriate storage facilities. It prepares DA Forms 3260 (Igloo Planograph) and DA Forms 3261 (Planograph for Standard Magazine) showing the rewarehousing plan. An example of a completed DA Form 3260 is shown in Figure 2-1. These forms are then passed to the storage section for review. The storage section determines personnel and equipment requirements, and passes the plan to the operations office for approval. Once the rewarehousing plan is approved, the operations office sends the plan back to the stock control section for implementation. Implementing the Rewarehousing Plan The stock control section prepares the documentation necessary for moving ammunition. Stock control personnel complete DA Forms 3151-R (Ammunition Stores Slips) for all ammunition items to be moved. An example of a completed DA Form 3151-R is shown in Figure 2-2. The stock control section then passes all forms and master planographs to the storage section. The storage section ensures that all the equipment necessary to accomplish the mission is available. For example, if projectiles are to be moved, a forklift or a wrecker may be used, as shown in Figure 2-3. If a wrecker with slings is used, the slings must be load-tested and serviceable. In addition to lifting equipment, the storage section must ensure that fire-fighting and individual safety equipment are available. The storage crew must also ensure that all applicable storage drawings are available. Storage drawings are listed in AMC Drawing 19-48-75-5, Index of U.S. Army Unitization, Storage and Outloading Drawings for Ammunition and Components, dated April 1991. During rewarehousing operations, one of the primary goals is lot number consolidation. However, since normal management practices dictate the issue of smaller lots first, the smaller lots should always be placed near the front of the storage facility. Documenting a Rewarehousing Operation The DA Form 3020-R must be checked after each lot of ammunition is rewarehoused. (See Figure 1-17 on page 1-22.) There should be only one DA Form 3020-R per lot. This form is used to record any receipt or issue transactions. The rewarehousing receipts should be posted to the DA Forms 3020-R. Any of these forms that are completely filled in, or become excess due to rewarehousing, should be turned in to the stock control section. Accountability is critical during rewarehousing. After rewarehousing each lot of ammunition, the DA Form 3151-R should be checked. In the event that the DA Form 3151-R does not match what was moved, it should be corrected to reflect the actual quantities. At the same time, the planographs should be updated to reflect the

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Figure 2-1. An example of a completed DA Form 3260 (Igloo Planograph). MM0169

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Figure 2-2. An example of a completed DA Form 3151-R (Ammunition Stores Slip). 2-5

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Figure 2-3. Using a wrecker to move projectiles. new locations. Once all rewarehousing is completed, the DA Form 3151-R and the planographs are returned to the stock control section. When rewarehousing is performed at one location (that is, without changing storage sites), a DA Form 3151-R is not required. When all rewarehousing is accomplished, the stock control section posts all location transfers to the stock records.

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LESSON 2 PRACTICE EXERCISE

The following exercise will test your grasp of the material covered in this lesson. There is more than one correct solution for this exercise. When you have completed the exercise, check your solution with the answer key that follows. You have been tasked to develop a rewarehousing plan for section 2 of ASP 501 to provide space for a receipt of ammunition. The following information and resources are provided to assist you: • Magazines 12, 13, 14, and 15 are under renovation. • QD is adequate for all stocks. • Storage compatibility must be maintained. • Use the extract of SB 708-4 that is provided in the Appendix at the end of this subcourse booklet to determine the pallet dimensions for each ammunition item. • The layout of ASP 501 and planographs showing existing storage are illustrated on pages 2-11 through 2-22. The following table lists the munitions currently stored in your area. Table 2-1. Ammunition items currently stored in ASP 501.

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Table 2-1. Ammunition items currently stored in ASP 501 (continued).

The following table lists the ammunition items scheduled for receipt. Table 2-2. Ammunition items scheduled for receipt in ASP 501.

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Use the information from the tables on pages 2-7 and 2-8, Figure 1-19, the layout and planographs on pages 2-11 through 2-22, and the extract of SB 708-4 in the Appendix to complete the rewarehousing plan worksheet on page 2-10. Include in your solution all rewarehousing actions required for efficient storage and placement of ammunition receipts from the expected shipment. Be sure to rewarehouse for lot consolidation and to ensure the compatibility of items stored together. Prepare new planographs based on your rewarehousing plan using the blank planograph forms on pages 2-23 through 2-33. Include the stocks received in the shipment on your planographs

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Lesson 2 practice exercise – worksheet. MM0169

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Lesson 2 practice exercise – ASP 501 layout.

2-11

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Lesson 2 practice exercise – current planograph for magazine 1. MM0169

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Lesson 2 practice exercise – current planograph for magazine 2. 2-13

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Lesson 2 practice exercise – current planograph for magazine 3.

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Lesson 2 practice exercise – current planograph for magazine 4.

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Lesson 2 practice exercise – current planograph for magazine 5.

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Lesson 2 practice exercise – current planograph for magazine 6. 2-17

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Lesson 2 practice exercise – current planograph for magazine 7.

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Lesson 2 practice exercise – current planograph for magazine 8. 2-19

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Lesson 2 practice exercise – current planograph for magazine 9. MM0169

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Lesson 2 practice exercise – current planograph for magazine 10.

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Lesson 2 practice exercise – current planograph for magazine 11.

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Lesson 2 practice exercise – student s solution (magazine 1). 2-23

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Lesson 2 practice exercise – student s solution (magazine 2). MM0169

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Lesson 2 practice exercise – student s solution (magazine 3). 2-25

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Lesson 2 practice exercise – student s solution (magazine 4). MM0169

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Lesson 2 practice exercise – student s solution (magazine 5). 2-27

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Lesson 2 practice exercise – student s solution (magazine 6). MM0169

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Lesson 2 practice exercise – student s solution (magazine 7). 2-29

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Lesson 2 practice exercise – student s solution (magazine 8). MM0169

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Lesson 2 practice exercise – student s solution (magazine 9). 2-31

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Lesson 2 practice exercise – student s solution (magazine 10). MM0169

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Lesson 2 practice exercise – student s solution (magazine 11). 2-33

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LESSON 2 ANSWER KEY AND FEEDBACK

This solution is only one of the many possible correct solutions. Items Moved for Compatibility Move M131, LOP 5-9, from Magazine #11 to Magazine #1. Move N335, LOP 6-23, from Magazine #10 to Magazine #1. Move D675, IOP 50-12, from Magazine #10 to Magazine #2. Move D676, IOP 55-70, from Magazine #10 to Magazine #2. Move K145, MA 3-30, from Magazine #9 to Magazine #3. Move D680, PXC 5-60, from Magazine #6 to Magazine #3. Move A071, RA 6-19, from Magazine #7 to Magazine #4. Move A475, LC 9-18, from Magazine #7 to Magazine #4. Move A549, LC 1-9, from Magazine #7 to Magazine #4. Move H555, MA 6-55, from Magazine #9 to Magazine #5. Move D684, PXC 8-20, from Magazine #6 to Magazine #7. Move G890, NA 5-08, from Magazine #3 to Magazine #10. Move C449, IOP 7-48, from Magazine #2 to Magazine #11. This rewarehousing plan exceeds what is actually required for storage of the inbound shipment. It realigns the entire section for compatibility, and eases the receipt of the inbound shipment by allowing the ammunition to be offloaded and placed directly into the appropriate storage site. Additions from Shipment Place D540, PXC 5-9, in Magazine #2. Add A549, LC 1-9, to the existing lot in Magazine #4. Add D544, ZX 19-8, to the existing lot in Magazine #6. Add C445, LOP 6-31, to the existing lot in Magazine #8. Place C445, LOP 6-9, in Magazine #9. Add G890, NA 5-08, to the existing lot in Magazine #10. Add C449, IOP 7-48, to the existing lot in Magazine #11. Revised planographs are provided on pages 2-35 through 2-45 based on rewarehousing and storage of the shipped items. This rewarehousing plan is only a temporary fix to the storage problem. Once magazines 12, 13, 14, and 15 have been renovated, a long-term plan to relocate all Class (18) 1.1, Class (18) 1.2, and Class 1.1 items nearer the center of the ASP should be considered.

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Lesson 2 answer key – planograph for magazine 1. 2-35

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Lesson 2 answer key – planograph for magazine 2. MM0169

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Lesson 2 answer key – planograph for magazine 3. 2-37

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Lesson 2 answer key – planograph for magazine 4. MM0169

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Lesson 2 answer key – planograph for magazine 5. 2-39

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Lesson 2 answer key – planograph for magazine 6. MM0169

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Lesson 2 answer key – planograph for magazine 7. 2-41

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Lesson 2 answer key – planograph for magazine 8. MM0169

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Lesson 2 answer key – planograph for magazine 9. 2-43

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Lesson 2 answer key – planograph for magazine 10. MM0169

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Lesson 2 answer key – planograph for magazine 11. 2-45

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