Part Iv

SUBCOURSE MM0171

EDITION A

EVALUATE CONVENTIONAL AMMUNITION STORAGE OPERATIONS (PART IV)

US ARMY ORDNANCE MISSILE AND MUNITIONS CENTER AND SCHOOL

EVALUATE CONVENTIONAL AMMUNITION STORAGE OPERATIONS (PART IV) Subcourse Number MM0171 EDITION A

Missile and Munitions, United States Army Combined Arms Support Command Fort Lee, Virginia 23801-1809 8 Credit Hours Edition Date: March 1992

SUBCOURSE OVERVIEW

We designed this subcourse to teach you basic procedures involved with selecting and using the appropriate storage and outloading drawings, planning ammunition maintenance, and preparing a Storage Space Management Report. There are no prerequisites for this subcourse. This subcourse reflects the doctrine that was current at the time it was prepared. In your own work situation, always refer to the latest official publication. Unless otherwise stated, the masculine gender of singular pronouns is used to refer to both men and women. Terminal Learning Objective Action:

You will determine the procedures for selecting and using storage and outloading drawings; develop a maintenance plan that includes a process flow sheet, a maintenance line layout, and a standing operating procedure (SOP); and prepare a Storage Space Management Report.

Condition:

In this booklet, you will find all of the information required to complete this subcourse. This information includes extracts from AR 740-1 and DARCOM Drawing 19-48-41155PA1002.

Standard:

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

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TABLE OF CONTENTS

Section

Page

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

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Lesson 1: Select and Use Storage and Outloading Drawings............................. ..................... Overview...................................................................................................................... ............ Introduction........................................................................................................... ................... Select and Use Ammunition Storage Drawings............................................................ ............ Select and Use Ammunition Outloading Drawings............................................... ....................

1-1 1-1 1-1 1-2 1-14

Practice Exercise........................................................................................... ........................ Answer Key and Feedback............................................................................................. .......

1-18 1-20

Lesson 2: Plan for the Care, Preservation, and Maintenance of Ammunition..................................................................................................... ............................. Overview...................................................................................................................... ............ Introduction........................................................................................................... ................... Maintenance Levels.............................................................................................. ................... Maintenance Facilities............................................................................................................ .. Maintenance Plan............................................................................................ ........................

2-1 2-1 2-1 2-2 2-3 2-3

Practice Exercise........................................................................................... ........................ Answer Key and Feedback............................................................................................. .......

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Lesson 3: Prepare Storage Space Management Report........................................................ .... Overview...................................................................................................................... ............ Introduction........................................................................................................... ................... Reporting Requirements.................................................................................... ...................... Computing Storage Space...................................................................................... ................. Preparing DD Form 805............................................................................................ ...............

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Practice Exercise........................................................................................... ........................ Answer Key and Feedback............................................................................................. .......

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Appendix: Publication Extracts............................................................................................. ...... AR 740-1, Storage and Supply Activity Operations, 23 April 1971........................................... DARCOM Drawing 19-48-4115-5PA1002, Loading and Bracing (CL & LCL) in Box Cars of Boxed Ammunition and Components on Pallets, Unitized with Strapping, Revision 1, July 1981............................................................ .......................

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LESSON 1 SELECT AND USE STORAGE AND OUTLOADING DRAWINGS STP 9-91DII-MQS 03-4020.02-0001

OVERVIEW Lesson Description In this lesson you will learn to select, interpret, and use ammunition storage and outloading drawings. Terminal Learning Objective Action:

Determine the procedures for selecting, interpreting, and using the appropriate ammunition drawings for storage or transportation of ammunition.

Condition:

You will have this subcourse booklet and will work without supervision. There are no supplementary requirements for this lesson.

Standard.

Selection, interpretation, and use of ammunition storage and outloading drawings will be in accordance with this lesson and the extract of DARCOM Drawing 19-48-41155PA1002 found in the Appendix at the back of this subcourse.

References:

The material contained in this lesson was derived from AMC Drawings 19-48-75-5 and 19-48-4005-1-2-3-4-14-22A1000 and from DARCOM Drawing 19-48-4115-5PA1002.

INTRODUCTION As an ammunition officer assigned to an ammunition operations position, you may be required to inspect ammunition storage. You must be able to select and read storage drawings to determine if the ammunition is stored properly. You may also be required to produce a storage plan for incoming shipments. You may be required to inspect loads of ammunition leaving the ammunition storage area. In order to inspect blocking and bracing properly, you must be able to interpret ammunition outloading drawings. In addition to the publication extracts found in the Appendix at the back of this subcourse, a helpful source of information is AMC Drawing 19-48-75-5. This drawing aids all Army activities and contractors in the effective use of storage and outloading drawings to ensure safe, economical, and standardized procedures for storing and transporting ammunition commodities and related ground support equipment. It applies to guided missiles and rocket systems, conventional ammunition, nuclear ammunition, and miscellaneous ammunition-related items.

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SELECT AND USE AMMUNITION STORAGE DRAWINGS Select Storage Drawings Before selecting an ammunition storage drawing, you must determine what type of storage facility you are to inspect and what type of munitions are stored there. Additionally, you must determine how the individual items are packed and if the boxes or containers are loose or palletized. Having this information, you must then select the ammunition storage drawing that will assist you in inspecting the storage facility. There are several types of storage drawings. Each type of drawing provides storage configurations and requirements for either single-round items or multiple items packed in a single container, both palletized and unpalletized. For the purpose of this lesson, you are to inspect an arch-type igloo that contains boxed conventional ammunition (not palletized). To find the correct storage drawing, look at the Table of Contents (Page i) of AMC Drawing 19-48-75-5 (Figure 1-1). You see that Chapter 1 of the drawing covers conventional ammunition. Now turn to Chapter 1, and find the page that lists boxed ammunition and components (not palletized). The items that you are to inspect are listed under Index Number < 1 > (Figure 1-2, Page 1-4). Listed under Index Number < 1 >, Boxed Ammunition and Components, Not Unitized, you find storage drawing file number 19-48-4005-1-2-3-4-14-22A1000 listed. Now that you know which storage drawing you need, look at the storage drawing itself. The cover page of the drawing (Figure 1-3, Page 1-5) contains the following information: • Title. Gives the type of drawing (storage or outloading) and tells how the ammunition is packed. • Index. Lists the items covered in the drawing and the page number where information on each item is found in the drawing. • Revisions block. Lists all revisions to the drawing. • Drawing identification numbers: -Class: The number "19" is always assigned to ammunition. -Division: The number "48" is always assigned to ammunition. -Drawing: This number indicates the numerical sequence of a drawing within an ammunition group. -File: The numeric and alphabetic designators indicate the types of magazines and identify the package or type of ammunition and the specific drawing in a numerical sequence. • Cautionary note. States that the general notes must be read prior to storage operations. Any special notes within the drawing must also be read prior to storage operations.

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Figure 1-1. Partial extract of Table of Contents from AMC Drawing 19-48-75-5.

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Figure 1-2. Extract from AMC Drawing 19-48-75-5 showing index numbers.

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Figure 1-3. Extract of cover page from AMC Drawing 19-48-4005-1-2-3-4-14-22A1000.

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Table 1 shown in Figure 1-4 provides further information as follows about the numeric designators in the file number: • • • • • •

The number "1" indicates an igloo or arch-type magazine drawing. The number "2" indicates a standard above-ground magazine drawing. The number "3" indicates a box-type magazine drawing. The number "4" indicates a Corbetta magazine drawing. The number "14" indicates a Stradley magazine drawing. The number "22" indicates a steel-arch or an oval-arch magazine drawing.

The alphabetic designator in the file number identifies the type of package or the type of ammunition. See Table 2 in Figure 1-4. For example, the letter "A" identifies the commodity as being packed in boxes. As you can see by looking at storage drawing file number 19-48-4005-1-2-3-4-14-22A1000, the drawing may be used to inspect four different types of storage facilities containing ammunition that is packed in wooden or metal boxes. General notes (Figure 1-5, Page 1-8) are normally found on Page 2 of a storage drawing. These notes apply to areas throughout the drawing. General notes should be read first, as they give technical data necessary to store ammunition. Use Storage Drawings Now go to the magazine and check the position of the boxed ammunition within the magazine and determine the method that was used to stack it. There are four box positions (Box Positions 1, 2, 3, and 4) that may be used to stack unpalletized boxed ammunition. Box Position 1 is used to stack cleated boxes with the cleats positioned parallel to the side wall of the magazine. See Figure 1-6, Page 1-9. Special Note 1 states that floor dunnage may be of randomlength material. However, in magazines with sloping floors, dunnage joints are centered on wedges as shown in the Positioning of Wedges Detail. Most igloo-type magazines have sloping floors that drop 1 1/2 inches in height from the center of the floor to each side of the magazine. This drop facilitates the drainage of any moisture from the magazine. Floor dunnage should be 2 inches by 2 inches and placed 1 1/2 inches in from each end of the box. If the boxes are longer than 42 inches, a third piece of floor dunnage is required and positioned at the center of the box. When cleated boxes are stacked, longitudinal dunnage that is 1 inch by 2 inches is required on every fourth layer. This dunnage is placed on the cleats. However, if the thickness of the dunnage is greater than the thickness of the cleats, the dunnage may be placed directly on the box and next to the cleat. Box Position 2 is used to stack uncleated boxes. See Figure 1-7, Page 1-10. When the length of the box is less than 1 1/2 times the width of the box, the length of the box is positioned parallel to the side wall of the magazine. The size and placement of the floor dunnage is the same as for Box Position 1. Longitudinal dunnage that is 1 inch by 2 inches is required on all layers except at every fourth layer. Two layers of dunnage are required for each layer. The dunnage is positioned near each end of the box. The dunnage may be of random-length material; however, each piece must span a minimum of three boxes when the box dimension that is parallel to the dunnage is 20 inches or less, or span a minimum of two boxes when the dimension is more than 20 inches.

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Figure 1-4. Table 1 and Table 2 extracted from AMC Drawing 19-48-75-5, Page iii. An exception to longitudinal dunnage is listed in note "R" of the General Notes section of AMC Drawing 19-48-4005-1-2-3-4-14-22A1000. Refer to Figure 1-5, Page 1-8. It states that storage procedures within the drawing specify the use of wooden dunnage between all layers of wirebound boxes and/or wooden boxes without cleats when they are not stored on pallets. This dunnage is required to provide for air circulation through all stacks throughout the length of the magazine. Air circulation is necessary for long-term storage (that is, for more than 90 days, such as at depots). Posts, camps, and stations that normally rotate stocks on a 90-day authorization basis at ASPs may eliminate dunnage between layers, except at every fourth layer. Lateral dunnage that is 1 inch by 2 inches is placed every fourth layer and is positioned perpendicular to the side walls of the magazine. The dunnage may be of random-length material; however, each piece must span a minimum of three boxes when the box dimension that is parallel to the dunnage is 20 inches or less, or span a minimum of two boxes when the dimension is more than 20 inches. Box Position 3 is used to stack uncleated boxes when the length of the box is 1 1/2 times, or more than 1 1/2 times, the width of the box. Refer to Figure 1-7, Page 1-10. The width of the box is positioned parallel to the side wall of the magazine. The size and placement of floor dunnage is the same as for Box Positions 1 and 2.

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Figure 1-5. Extract of General Notes from AMC Drawing 19-48-4005-1-2-3-4-14-22A1000.

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Figure 1-6. Extract from AMC Drawing 19-48-4005-1-2-3-4-14-22A1000 showing Box Position 1.

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Figure 1-7.

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Extract from AMC Drawing 19-48-4005-1-2-3-4-14-22A1000 showing Box Positions 2 and 3.

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Longitudinal dunnage that is 1 inch by 2 inches is required on all layers. Two layers of dunnage are required for each layer. This dunnage is positioned near each end of the box. If the box length exceeds 42 inches, a third layer of dunnage must be positioned at the center of the box. Note "R" of the General Notes section of the drawing also applies to this box position. Lateral dunnage that is 1 inch by 2 inches is required only when the length of the boxes is less than 27 inches. If required, two layers of lateral dunnage are positioned on every fourth layer and placed near the edges of the boxes and perpendicular to the side walls of the magazine. If the box length is 27 inches or less and lateral dunnage is used, longitudinal dunnage is omitted every fourth layer as the stack will be stable. Box Position 4 (Figure 1-8, Page 1-12) is used to stack uncleated, wirebound boxes. The width of the box is placed parallel to the side wall of the magazine. Floor dunnage that is 2 inches by 4 inches is positioned parallel to the side wall of the magazine. A piece of floor dunnage is placed flush with each end of the box when the box length is 36 inches or less. A third piece of dunnage is required when the length of the box exceeds 36 inches. If required, the third piece of dunnage is placed at the center of the box. Floor dunnage may be of random-length material; however, each piece must span a minimum of three boxes when the box width is less than 24 inches, or span a minimum of two boxes when the box width is 24 inches or more. If the floors are sloped, wedges must be positioned as described for Box Position 1. Longitudinal dunnage that is 1 inch by 4 inches is required on all layers. Two outer pieces of longitudinal dunnage are required for each layer and are positioned parallel with the side walls of the magazine and flush with the ends of the boxes. If the box length exceeds 36 inches, a third piece of dunnage must be positioned at the center of the box. Again, note "R" of the General Notes section of the drawing also applies to this box position. Lateral dunnage that is 1 inch by 4 inches is required at every fourth layer. Lateral dunnage is placed near the edges of the boxes and perpendicular to the side walls of the magazine. Lateral dunnage may be of random-length material except that each piece must span a minimum of three boxes when the box length is less than 24 inches. Lateral dunnage must span a minimum of two boxes when the box length is 24 inches or more. Some magazines may contain ammunition in wooden boxes with wide cleats. Called unit stacks, these boxes are stored on short dunnage. See Figure 1-9, Page 1-13. A unit stack is defined as a group of boxes arranged in rows and layers and placed on short dunnage in order to handle the group in a single lift using a forklift truck. The number of boxes in a unit stack depends upon the width and height dimensions of the boxes. However, the total weight of the unit stack must not exceed the weight capacity of the forklift truck. The number of rows in a unit stack is determined by the length of the forklift tines and the width of the boxes. To facilitate safe handling, not more than one-third of the width of the box should extend beyond the ends of the forklift tines. Generally, the number of layers should not exceed a total of 54 inches in height. When a unit stack consists of narrow boxes, or it is otherwise deemed necessary, a length of 5/8-or 3/4-inch steel strapping may be used to circle the unit stack in order to provide stability in handling and in storage. An alternative method of providing stability to a unit stack is to position a length of strapping horizontally around the top layer of boxes. A typical unit stack should have 4 inches by 4 inches of short dunnage by the length required to provide full bearing across the width of all boxes in the bottom layer. If the boxes are less than 42 inches long, only two pieces of short dunnage are required. These two pieces are aligned with the cleats of the boxes. Boxes that are 42 inches or longer require a third piece of short dunnage. This third piece is placed at the center of the box. The top layer of boxes in each unit stack must be inverted.

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Figure 1-8. Extract from AMC Drawing 19-48-4005-1-2-3-4-14-22A1000 showing Box Position 4.

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Figure 1-9.

Extract from AMC Drawing 19-48-4005-1-2-3-4-14-22A1000 showing wooden boxes stacked on short dunnage.

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SELECT AND USE AMMUNITION OUTLOADING DRAWINGS Before selecting an ammunition outloading drawing, you must determine what type of transportation has been selected and what type of munitions will be transported. Additionally, you must determine how the individual items are packed and if the boxes or containers are loose or palletized. For this part of the lesson, you are to inspect a conventional boxcar that has been loaded with boxes of conventional ammunition on pallets and unitized with strapping. Follow the same procedures as for selecting a storage drawing. As this is conventional ammunition, AMC Drawing 19-48-75-5, Chapter 1, Page 1-2 lists boxed ammunition and components on wooden pallets by Index Number < 7 >. See Figure 1-10. Listed under Index Number < 7 >, you see outloading drawing 19-48-4115-5PA1002 listed for "boxcar." As with storage drawings, remember the numbers "19" and "48" are always assigned to ammunition. The drawing number "4115" indicates the numerical sequence of the drawing within an ammunition group. In the file number "5PA1002," the number "5" indicates a carloading drawing. The letters "PA" further identify the commodity as being palletized boxed ammunition. See Figure 1-11, Page 1-16. The number "1002" identifies the specific drawing in a numerical sequence. Use the extract from DARCOM Drawing 19-48-4115-5PA1002 in the Appendix throughout this part of the lesson. Turn to the appropriate page number of the outloading drawing as the following information is discussed. The title of the drawing (Page A-9 in this subcourse) gives the type of drawing (outloading) and how the ammunition is packed. The index lists the types of boxcars covered in the drawing and the page numbers for each type of boxcar. The revisions block gives the date of the drawing and the current revision date. Page 85 of the drawing (Page A-44 in this subcourse) contains an itemized index chart that breaks down every item covered in the drawing by load, type, and page number. Page 2 of the drawing (Page A-10 in this subcourse) contains general notes and material specifications information. These general notes are referred to throughout the drawing. Pay attention to general note "L." It states that the loads shown are typical and that the actual quantity that is to be shipped will not be depicted in any of the loading procedures. Page 3 of the drawing (Page A-11 in this subcourse) contains several typical palletized units that are used throughout the drawing. Page 4 of the drawing (Page A-12 in this subcourse) contains general notes for conventional-type boxcars to include a weight distribution chart. Page 5 of the drawing (Page A-13 in this subcourse) contains special notes and load planning guidance for conventional boxcars. Chart number 1 may be used in selecting a load pattern, such as 2-wide or 3-wide, for the width of the boxcar that is to be loaded. Chart number 2 may be used in determining the quantity of units that can be positioned within the length of a boxcar. Chart number 3 may be used in determining the number of tiers that can be loaded in a boxcar, based only on the height of the unit. Chart number 4 may be used as guidance in determining the quantity of units that can be loaded in a boxcar, based only on the weight of the unit. Pages 6 through 9 of the drawing (Pages A-14 through A-17 in this subcourse) provide illustrations and specific guidance for outloading a typical 2-wide load in a conventional boxcar that is 50 feet 6 inches long by 9 feet 2 inches wide. Special notes, bill of material charts, isometric views, and key numbers

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Figure 1-10. Extract from AMC Drawing 19-48-75-5 showing index numbers. 1-15

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Figure 1-11. Table 1 and Table 2 extracted from AMC Drawing 19-48-75-5, Page iii. on these pages all contribute to proper blocking and bracing techniques. Care must be used when reading the special notes and key numbers, because they give the necessary instructions on the positioning of the units (pallets) in the boxcar. They also refer you to other parts of the drawing for detailed instructions on the construction of blocking and bracing and how units are positioned. Pages 18 and 19 of the drawing (Pages A-18 and A-19 in this subcourse) show a typical less than carload (LCL) load using the upper-layer knee-brace method of partial-layer (tier) bracing to include long-knee braces and bill of materials. Special notes and key numbers are also included. Pages 26 and 27 of the drawing (Pages A-20 and A-21 in this subcourse) contain examples of Bulkhead Gates A, B, and C to include gate construction, dimensional charts, and end views. Pages 28 and 29 of the drawing (Pages A-22 and A-23 in this subcourse) show a typical LCL load using the first-layer kneebrace method of partial-layer (tier) bracing to include special notes, key numbers, key letters, and construction details.

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Pages 30 through 33 of the drawing (Pages A-24 through A-27 in this subcourse) show a typical LCL load using the K-brace method of partial-layer (tier) bracing. Type B, Type C, and Type D braces to include special notes, key numbers, isometric views, and construction details are shown. Pages 38 through 42 of the drawing (Pages A-29 through A-33 in this subcourse) contain information on the shipment of mixed items to include riser methods, and the requirements and limitations, height dimension tables, and construction details for each riser method. Pages 46 through 48 and 51 through 57 of the drawing (Pages A-34 through A-43 in this subcourse) contain examples of Center Gates A through F to include gate construction.

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LESSON 1 PRACTICE EXERCISE

The following exercise 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 answer any items incorrectly, study again that part of the lesson that contains the portion involved. 1. Which publication should you use to determine the storage or outloading drawing number? A. B. C. D.

AMC Drawing 19-48-75-5. SB 742-1. TM 9-1300-206. DOD Consolidated Ammunition Catalog.

Situation. You are to use AMC Drawing 19-48-4005-1-2-3-4-14-22A1000 to inspect a magazine where boxed conventional ammunition is stored. 2. Stacks of cleated boxes require longitudinal dunnage every fourth layer. Where should the dunnage be positioned if the thickness of the dunnage is greater than the thickness of the cleats? A. B. C. D.

On top of the cleats. Directly on the box and 2 inches from the cleats. Directly on the box and flush with the ends. Directly on the box and next to the cleats.

3. A typical unit stack generally should not exceed how many inches in height? A. B. C. D.

24 inches. 36 inches. 54 inches. 62 inches.

4. You are inspecting a stack of uncleated boxes in Box Position 3. At least how many inches must the box length be in order to omit lateral dunnage every fourth layer? A. B. C. D.

20 inches. 22 inches. 25 inches. 27 inches.

5. What size floor dunnage is required for Box Position 4? A. B. C. D. MM0171

1 inch by 2 inches. 2 inches by 2 inches. 2 inches by 4 inches. 4 inches by 4 inches. 1-18

Situation. Use the extract of DARCOM Drawing 19-48-4115-5PA1002 to answer questions 6, 7, and 8. 6. How many support cleats are required on the Type D K-brace? A. B. C. D.

One. Two. Three. Four.

7. How many units (pallets) weighing 1,800 pounds each may be loaded on a 120,000-pound capacity conventional boxcar? A. B. C. D.

55. 66. 77. 83.

8. You are constructing a Center Gate A. As a minimum, how many horizontal pieces are required for a typical 3-tier load? A. B. C. D.

Two. Four. Six Eight.

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LESSON 1 ANSWER KEY AND FEEDBACK

Item

Correct Answer and Feedback

1. 2. 3. 4. 5. 6. 7. 8.

A. D. C. D. C. B. B. C.

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AMC Drawing 19-48-75-5. (Pages 1-2 and 1-14) Directly on the box and next to the cleats. (Page 1-6) 54 inches. (Page 1-11) 27 inches. (Page 1-11) 2 inches by 4 inches. (Page 1-11) Two. (DARCOM Drawing 19-48-4115-5PA1002, Page 33) 66. (DARCOM Drawing 19-48-4115-5PA1002, Page 5) Six. (DARCOM Drawing 19-48-4115-5PA1002, Page 46)

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LESSON 2 PLAN FOR THE CARE, PRESERVATION, AND MAINTENANCE OF AMMUNITION STP 9-91DII-MQS 03-4020.02-0001

OVERVIEW Lesson Description In this lesson you will learn the basic requirements necessary to plan for the care, preservation, and maintenance of ammunition. Terminal Learning Objective Action:

Describe maintenance levels and maintenance facilities. Determine the procedures for developing a maintenance plan that includes a process flow sheet, a maintenance line layout, and a maintenance line SOP.

Condition:

You will have this subcourse booklet and will work without supervision. There are no supplementary requirements for this lesson.

Standard

Description of maintenance levels and maintenance facilities and the procedures for developing a maintenance plan will be in accordance with this lesson.

References:

The material contained in this lesson was derived from TM 43-0001-47, TM 9-1300-25120, TM 9-1300-251-34, and TM 9-1300-250. INTRODUCTION

The Ammunition Stockpile Reliability Program, as well as reports of ammunition problems received from the field, result in ammunition that must be suspended or restricted from use. Permanently suspended ammunition requires some action before it can be released. The repair requirement, as well as requirements for modification, conversion, or demilitarization, make it necessary to establish an ammunition maintenance program. Ammunition officers may be called upon to serve in a variety of positions where a knowledge of the ammunition maintenance process will be required. Care and preservation is the term commonly used to describe ammunition maintenance. Care stresses protection and is performed at the serviced unit (the using unit) and at the ammunition supply point (ASP). Preservation, while it includes protection, stresses maintenance. Preservation is also performed at the ASP. This lesson is for ammunition officers, who must be able to plan for the proper care and preservation of ammunition at the ASP. Care and preservation of ammunition is a must in order to ensure that stocks anywhere are serviceable for training and combat missions.

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MAINTENANCE LEVELS There are three levels of ammunition maintenance-general support (GS), direct support (DS), and organizational (the ASP). Simple care and preservation should be performed at the lowest level of maintenance, organizational. However, it may be performed at any level where there is ammunition. Care and preservation of materiel with major components require special skills, tools, equipment, and facilities not available at the organizational level. Major component care and preservation can be done only at DS and GS levels. General Support Maintenance GS maintenance is performed by conventional ammunition maintenance detachments in depots in the communications zone (COMMZ). These detachments may also be deployed forward to the Army service area to perform certain tasks. All GS ammunition renovation operations essentially consist of five basic procedures: unpack, disassemble, perform the required work, reassemble, and repack. GS maintenance consists of, but is not limited to: • • • • •

Removing extensive rust and corrosion. Painting and stenciling. Performing major repairs to, or fabrication of, boxes and containers. Repairing and renovating ammunition. Replacing unserviceable cartridge cases, primers, propellants, base detonating fuzes, or tracer units. • Replacing unserviceable boosters, fuzes, primers, and igniters on all conventional ammunition. Direct Support Maintenance DS maintenance is performed by conventional ammunition companies and includes surveillance and limited maintenance of stocks under their control. DS maintenance consists of inspections, tests, care and preservation, and service and repair (as authorized) on all types of conventional ammunition. As a minimum, DS maintenance consists of the following: • • • • •

Repairing, restenciling, or replacing packing materials. Declipping, reclipping, and changing the ratio linkage of small arms ammunition. Replacing readily removable parts and components. Removing exudation from artillery projectiles. Performing electrical circuit continuity testing on rocket ammunition.

Organizational Maintenance Organizational maintenance is performed by all activities that have conventional ammunition on hand, including using units. It is performed in order to prevent deterioration of ammunition due to rough handling and exposure. Organizational units may call upon DS units for technical advice, assistance, and support. Organizational maintenance consists of the following: • Cleaning. • Removing minor rust and corrosion. • Repairing and replacing boxes.

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• Repalletizing and repacking. • Repainting. • Marking containers. MAINTENANCE FACILITIES A maintenance building is a specially designed structure that provides maximum safety for operators while at the same time facilitates production. It is constructed with laced reinforced concrete dividing walls that are a minimum of 12 inches thick. These walls prevent the simultaneous detonation of explosives within the building. The walls are not designed to provide complete protection for personnel. Some buildings are constructed with twice this thickness so that completely different operations may be conducted on both sides of the building. Permanent structures used for labor intensive operations must be separated from adjacent potential explosion sites (PES) by not less than the unbarricaded intraline distance, based on the quantity of explosives in the adjacent PES (normally magazines). The walls and the roof covering should be of a noncombustible material. The interior surfaces should be of a fire-retardant material and be as free of cracks as possible. Seams should be taped over and, if painted, the paint should be a gloss to facilitate cleaning. The building is designed to vent an explosion. The building is designed so that materials enter one end of the building and flow to the other end. Conveyors and hoists are set up throughout the building. Larger items of machinery, electrical power, and compressed air are installed in the bays as needed for the operation. The work is divided so that different operations are performed in each of the bays. The building can be adapted for numerous jobs by installing or removing items of equipment and machinery. Safety in operations is a prime consideration in all maintenance facilities. Marking and color coding of equipment, water lines, high-pressure air lines, hazardous areas, and electrical lines all contribute to safety. As an example, color coding for identification of the different high-pressure lines, electrical lines, and hazardous areas could be as follows: • • • •

High-pressure water lines-red. High-pressure air lines-green. Electrical lines-blue. Marking of hazardous areas-black and yellow.

Normally, safety and hazard markings are established by the maintenance facility commander and published in local policies and SOPs. Different geographical areas may use systems that utilize different color coding and marking requirements. Therefore, local safety policies must be checked prior to marking safety areas and equipment. AMC Regulation 385-100 establishes policies and procedures required for ammunition maintenance facilities. However, Army Materiel Command (AMC) publications are applicable to AMC facilities only. Each facility performing maintenance will comply with local policies. In overseas commands, portions of AMC Regulation 385-100 may be extracted or modified in order to establish local policies. MAINTENANCE PLAN Ammunition maintenance is performed only after receipt of a properly validated work authorization. There are two main reasons a work authorization has been generated. Either an inspector at any level has found a substandard lot, or a using unit turns in what it considers unserviceable ammunition. 2-3

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The condition of ammunition is determined through inspections conducted by ammunition surveillance inspectors. These inspectors identify the degree of serviceability by using ammunition condition codes. DA Form 2415 (Ammunition Condition Report) is used to report unserviceable, repairable ammunition items in condition codes E, F, G, and N. This form is also used to report unserviceable, uneconomically repairable ammunition items in condition code H and permanently suspended ammunition in condition code J. An individual DA Form 2415 is prepared for each line item reported. However, more than one lot of identical items may be reported on the same form. DA Form 2415 is prepared in sufficient copies, as prescribed by local SOPs, and forwarded through command channels for disposition. The processed DA Form 2415 is normally returned through command channels with an endorsement and thus constitutes the authority for disposition of the reported item. See Figure 2-1. Once the disposition instructions are received, the operations section generates DA Form 2407 (Maintenance Request). See Figure 2-2, Page 2-6. The completed DA Form 2415 and the DA Form 2407 are then passed to the maintenance section. Before maintenance on any item may start, each operation to be performed must be completely planned in order to assure a smooth-running operation. Background information must be obtained so that the operation will be performed correctly. Most of the technical data necessary to plan each operation are found in depot maintenance work requirements (DMWRs). See Figure 2-3, Page 2-7. If other technical data are required, look in specific technical manuals or packaging drawings. See Figure 2-4, Page 2-8. DMWRs for renovation, repair, or demilitarization of ammunition are composed of a series of sheets in the form of a pamphlet. Each sheet is a study of the operation to be accomplished. The DMWR is approved by the commanding officer or by a qualified member of the commander's staff who has been delegated the responsibility to review and approve the DMWR. The sequence of operations in a DMWR may not be applicable to a DS or GS facility. DMWRs are prepared by the US Army Armament Materiel Readiness Command for a variety of installations operating on a comparatively large production basis. The manner in which the field unit does a job properly will be different from the manner in which an established depot does the same job. A DMWR received in the field serves as a guide to the ammunition officer in making up the SOP. A study should be conducted to determine specific operations required and at what point they should be accomplished. To determine total materials required, complete rounds or items to be worked on must be inspected. All of the tools and equipment used to do the job must be procured and distributed to the points where they will be used. Necessary replacement parts or components must be determined, then procured, and stored. Supplies such as paint, varnish, steel wool, cardboard, and sealing compound must be obtained in the proper quantities. Personnel experienced in the operation must be assigned to various sections of the job. Inexperienced personnel must receive training so that they will be able to help when needed. Consideration must be given to safety so that each operation is conducted with the minimum possibility of injury to either the operator or the equipment. Once the operations are under way, provisions must be made to remove bottlenecks and increase production, make operations more simple, and increase safety. This system of planning an operation by deciding ahead of timeWhat is the work to be done? How is the work to be done? Who is to do the work? Where is the work to be done? applies itself very well to maintenance.

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Figure 2-1. DA Form 2415 (Ammunition Condition Report) authorizing ammunition maintenance. 2-5

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Figure 2-2. DA Form 2407 (Maintenance Request) authorizing ammunition maintenance. MM0171

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Figure 2-3.

One page of a Depot Maintenance Work Requirement describing one maintenance operation.

Process Flow Sheet What must be done to the ammunition has been stated on the authorization and becomes the basis for the operation to be performed. These operations are planned for on a process flow sheet. The flow sheet is a locally prepared form that acts as a blueprint for the layout of the maintenance line. An example of a flow sheet is shown in Figure 2-5, Page 2-9. In planning the process flow sheet, the following questions should be considered: • Can any of the operations be eliminated? • Can any of the operations be combined? • Can any of the operations be performed better in a different order? • Can any of the operations be simplified? The process flow sheet lists each operation in the maintenance process. It also has space for listing all of the technical data: the tools and equipment, personnel, and material requirements for the particular maintenance operation. The DMWRs, technical manuals, and packaging drawings provide the tools and equipment requirements and the material requirements. TM 43-0001-47, TM 9-1300-251-20, and TM 9-1300-251-34 list ammunition peculiar equipment (APE) and components for certain items. Material requirements are supplies that are used up (for instance, lubricants and paint). Personnel requirements are largely a matter of experience and personal judgment and the ammunition to be worked on. 2-7

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Figure 2-4. An ammunition packaging drawing that might be used to plan a process flow sheet.

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Figure 2-5. Example of a process flow sheet used to plan maintenance. If the ammunition officer has any further questions on these matters, he or she may coordinate with personnel in the operations or surveillance sections. When filling out the process flow sheet, every effort should be made to eliminate or combine operations or to arrange them in a different manner in order to simplify the overall process as much as is practical and safe. To fill out the flow sheet, look at the example shown in Figure 2-5. The first column lists the number of the operation in the process. Each operation is described as an action in the next column. Then, each operation is noted as either primary or secondary. A primary operation is one that is essential for a smooth production flow. It is also called a main-line operation, because it is on the main line of the layout. A secondary operation is one that is necessary for the completion of production, but one that may not interrupt the smooth flow. A secondary operation may be routed from the main lines into branch lines to be returned at a point further along the main line. The most common reasons for these detours are facility limitations, safety, complicated or bulky operations, or operation exceptions that may result in delays. (For example, it is discovered on the receiving dock that only 1 package out of 50 needs refurbishment.) After the operations have been identified, the personnel, the tools and equipment, the materials, and the time required to do each step are determined from the reference documents and filled in on the flow

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sheet. Operations that are arranged in the proper sequence fall naturally into five major operations. All types of ammunition to be processed must go through the following five operations: • Unpack. • Disassemble. • Replace/Repair. • Reassemble. • Repack. Maintenance Line Layout The maintenance line layout of the entire operation is arranged on the basis of the process flow sheet. The layout may be straight-line or U-shaped. See Figure 2-6 and Figure 2-7, Page 2-12. Each layout can be used to perform the same maintenance operation. The road network available determines which layout will be used. The U-shaped layout is used when there is one road available for delivering and removing munitions. The straight-line layout is used when there are two roads available. The process flow sheet is used to arrange the order of the bays. Bays are work areas set aside for each operation. The bays must be identified by either letters or numbers. A test run is then made on a small sample of items to see if the layout is efficient and workable. If it is not, the layout must be adjusted, keeping in mind efficiency, simplicity, and safety. If the layout is useable, the layout is finished. A detailed layout of each bay showing fire protection, operational shields, and permanently installed equipment is posted within each individual bay. Operational shields are detailed to show the type of material used and the height and thickness of the shields. Permanently installed equipment is shown whether or not it is used on a specific operation. The locations of pallets, tables, APE, et cetera, must be shown where they will be used. A legend may be used to briefly explain the operations, inspections, and locations of pallets, tables, and APE within a bay. Standing Operating Procedure After the process flow sheet is completed, an SOP will be prepared. An SOP is a step-by-step guide to be used for each maintenance operation. Remember, an SOP must be prepared for each operation. Before writing an SOP, the following questions should be answered: • What is to be done? Refer to the DA Form 2407 or the DA Form 2415. • Where can it be done? Check with personnel in the surveillance section. • How shall it be done? Refer to the process flow sheet. • With what shall it be done? Refer to the process flow sheet. • What safety precautions are necessary? Refer to the technical manuals for the items being maintained and to TM 9-1300-206, Ammunition and Explosives Standards. SOPs must be clear, tell exactly what the operation is to do, be conclusive, leave nothing open to interpretation, and be easily understood by the operators. In overseas commands where indigenous personnel are used, SOPs should be written bilingually in English and in the language of the host nation. The SOP for each operation should tie into the operation before and the operation after and should detail all of the identification characteristics of the operation. See A through I in Figure 2-8,

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Figure 2-6. Example of a U-shaped line layout. Page 2-13. Each operation should also describe its activity, special requirements, and equipment. As a minimum, an SOP for an operation should contain the following: • Safety requirements. • Personnel. The minimum number required to do the job efficiently and safely. • Explosive limits. These limits are listed and expressed in the DMWR as rounds. They are based on the net explosive weight for the ammunition. The limits in the DMWR, however, are based on depot work flows and are usually too high for ASP operations. Consider safety, size of the operation, and past experience to decide the explosive limits for a particular operation.

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Figure 2-7. Example of a straight-line layout. • Equipment required for the operation. • Location and sequence of the operation in order to maintain a smooth flow. This is usually a diagram of the maintenance line layout. Finally, the SOP should have a cover sheet with information on it as shown in Figure 2-9, Page 2-14. When the SOP has been written, it becomes a part of the maintenance plan that is submitted to the commanding officer or a designated representative for review and approval. In addition to the SOP, the maintenance plan consists of the work authorization, the DMWR, the process flow sheet, and the line layout. Upon approval, a copy of the SOP is posted at the location of each operation, and maintenance may begin.

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Figure 2-8. Example of an SOP for one ammunition maintenance operation.

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Figure 2-9. Information necessary for the cover sheet of an SOP for a maintenance operation.

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LESSON 2 PRACTICE EXERCISE

The following exercise will test your grasp of the material covered in this lesson. There is only one correct answer for each item. When you complete the exercise, check your answers with the answer key that follows. If you answer any item incorrectly, study again that part of the lesson that contains the portion involved. 1. What is the first thing necessary for a smooth-running operation for the proper care and preservation of ammunition? A. B. C. D.

Equipment. Planning. Personnel. An SOP.

2. What kind of background information is needed to begin the planning process for a maintenance operation? A. B. C. D.

Supply catalogs. Field manuals. Technical data. Administrative data.

3. When is a straight-line layout used? A. B. C. D.

When one road is available. When two roads are available. When no roads are available. When a U-shaped road is available.

4. For what purpose is a process flow sheet used? A. B. C. D.

To request ammunition maintenance parts. To start the care and preservation maintenance operation. To give guidance to surveillance personnel. To plan the operations in an ammunition maintenance line.

5. What is one of the forms used for authorizing care and preservation of ammunition? A. B. C. D.

DA Form 2407. DA Form 2406. DA Form 2405. DA Form 2404.

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LESSON 2 ANSWER KEY AND FEEDBACK

Item

Correct Answer and Feedback

1. 2. 3. 4. 5.

B. C. B. D. A.

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Planning. (Page 2-4) Technical data. (Page 2-4) When two roads are available. (Page 2-10) To plan the operations in an ammunition maintenance line. (Page 2-7) DA Form 2407. (Page 2-4)

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LESSON 3 PREPARE STORAGE SPACE MANAGEMENT REPORT STP 9-91DII-MQS 03-4020.02-0001

OVERVIEW Lesson Description In this lesson you will learn how to prepare a DD Form 805 (Storage Space Management Report). Terminal Learning Objective Action:

Compute storage space and prepare a DD Form 805.

Condition:

You will have this subcourse booklet and will work without supervision. There are no supplementary requirements for this lesson.

Standard:

Computation of storage space and preparation of a DD Form 805 will be in accordance with this lesson and the extract of AR 740-1 found in the Appendix at the back of this subcourse.

Reference:

The material contained in this lesson was derived from AR 740-1. INTRODUCTION

The efficient use of assigned storage space at an installation is the responsibility of the installation commander. The Department of Defense (DOD) requires that installation commanders report, through channels, their utilization of assigned storage space on a DD Form 805. As an ammunition officer, you will become involved in preparing a Storage Space Management Report. This report provides a basis for management of storage space for purposes of allocation, utilization, and occupancy performance. It provides background information on which to base responses to inquiries from higher headquarters. The report is also used to determine the requirement for, and location of, new storage facilities. REPORTING REQUIREMENTS Installations required to report all available storage space fall into the following three categories: • All installations listed in Table 6-1 of AR 740-1 (see Appendix). • All installations with 50,000 gross square feet (GSF) or more of covered storage space (even though not listed in AR 740-1). • Any installations, with less that 50,000 GSF of covered storage space, that are important because of their mission assignment, location, or activity (at the discretion of the Department of the Army).

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Storage space used for the following purposes is excluded from reporting • • • •

Bulk petroleum, oils, and lubricants. Post exchange and commissary storage space. Bench and back-up stocks in shops. Transit sheds and open areas at terminals used for cargo throughput operations.

All Storage Space Management Reports are prepared either annually (A) or semiannually (L) as indicated in the "Report" column of Table 6-1, AR 740-1. Annual reports are prepared as of 30 June. Semiannual reports are prepared as of 30 June and 31 December. Those installations with keypunch capability will transfer elements of data and narrative from the DD Form 805 to data submission cards (general-purpose cards) in accordance with AR 740-1. See Figure 3-1 and Figure 3-2, Page 3-4. Hard-copy reports are submitted by installations without keypunch capability, newly activated installations that have not received an installation identity code, and installations that expand their covered storage space to 50,000 GSF or more and that have not received an installation identity code. DD Form 805 submission requirements differ as shown below: Activity CONUS installations reporting annually reporting semiannually AMC activities overseas installations

Report Due 14 working days after "as of" date 10 working days after "as of" date in accordance with AMC regulations 15 working days after "as of" date COMPUTING STORAGE SPACE

All entries on the DD Form 805 that pertain to storage space are made in square feet or cubic feet rounded out to the nearest thousand. (For example: 23,499 would be rounded to 23,000; 23,500 would be rounded to 24,000.) All entries on the DD Form 805 requiring an expression of areas in cubic space capacity are computed by multiplying the square feet by the unobstructed stacking height permitted by safety restrictions. All entries requiring an expression of areas in GSF are computed by using inside measurements between exterior walls. No deductions are made for fire walls or other structural losses including employee parking areas when covered space is used. Employee parking areas are reported as vacant. Use the overall measurements to compute open storage areas with no deductions for railroad tracks and permanent roads within the areas. For unimproved open areas, only the space actually occupied by stored material is reported. PREPARING DD FORM 805 One DD Form 805 is prepared per installation. When an installation has an annex or subinstallation that is geographically separated and has at least 50,000 GSF of covered storage space, a separate DD Form 805 must be filled out for that annex or subinstallation. The parent installation is identified in the MM0171

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Figure 3-1. Example of a data submission card. Extracted from AR 740-1. 3-3

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Figure 3-2. General instructions for completing data submission cards. Extracted from AR 740-1. Remarks block. Data pertinent to the subinstallation are not included in the report submitted by the parent installation. All reports must balance before they are turned in. A narrative analysis on a separate sheet must accompany each report. The instructions that follow explain how to prepare a DD Form 805. Installations reporting annually fill out Sections A and B. Those installations reporting semiannually complete Sections A through D. Refer to Figure 3-3 as necessary. How To Complete DD Form 805 (Storage Space Management Report) Block Number

Enter

Block 1, report date

Last digit of calendar year and "06" for June or "12" for December to represent the "as of" date.

Block 2, frequency

"A" for annually or "L" for semiannually.

Block 3, installation code

Four-character alpha identity code from Table 6-1, AR 740-1.

Block 4, DOD component

"A" for Army.

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Figure 3-3. DD Form 805 (Storage Space Management Report). 3-5

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Block 5, name of installation

Name of the installation.

Block 6, city name

Name of city as shown in Table 6-1, AR 740-1. On initial reports, enter the name of the nearest city or town and the state or country.

Block 7, state/country code

The state or country in which the installation is located.

Section A-Gross Storage Space (Square Feet) Line Number

Enter

1. Prior 30 June report

Under Columns (b) through (i), the amount of gross storage space (sq ft) as reported on Line 2 on the prior 30 June report. These lines must agree. If the prior data were incorrect, indicate under "Remarks" the correct information. Installations reporting for the first time enter "None-Initial Report." (No keypunched data submission card is required for Line 1.)

2. This report

Under Columns (b) through (i), all of the gross storage space (sq ft) at the installation or activity (regardless of its location or the purpose for which the space being used was designed or is designated) that is assigned or used for any operation concerning storage or the support of storage functions at the installation or activity. Explanations will be furnished under "Remarks" for any deviation from Line 2 of the prior June report. Installations reporting semiannually will include all deviations since the prior June, even though such deviations were shown on the prior 31 December report, as outlined under "Remarks" column below.

3. Unusable

Under Columns (b) through (h), the amount of gross storage space (sq ft) included in the following defined categories: a. Space so deteriorated that it fails to provide a sufficiently protective environment for the storage of material. b. Space that is unsafe for any storage purpose or operation. c. Space that because of its location is an unwarranted security risk or its occupancy would be in violation of local safety ordinance. No data entry is required on Line 3, Column (i).

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4. Standby

Under Columns (b) through (h), the amount of gross storage space (sq ft) in standby status that is contained in completely empty, covered structures or open, improved areas that are not required to support the installation's mission and that has been secured. This entry will not include vacant Y-sites (sites with earthen barricades on four sides). Igloos currently used as fallout shelters will be included and identified under "Remarks." Space in completely empty sections of covered structures that can be isolated and locked is authorized to be placed into standby. No data entry is required on Line 4, Column (i).

5. Outgranted to non-DOD users

Under Columns (b) through (i), the amount of gross storage space (sq ft) that is outleased, licensed, or permitted to private or nonDOD Government (Federal, state, county, local, or foreign) agencies for their operation. This includes all space that is allocated, assigned, or used for the storage of materiel other than that owned by the Department of the Army, Navy, Air Force, Marine Corps, or Defense Supply Agency. For purposes of this report, materiel or supplies belonging to all other defense agencies will be treated as non-DOD materiel. Include space outleased to private industry on a landlord-tenant basis for which rent is paid by the lessee. Also, include space classified as storage space at the time it was outleased, licensed, or permitted, even though it is not now being used for storage purposes. Show under "Remarks" the complete agency names, the company or companies concerned, and the amount of gross space (covered and open separately) used, assigned, or allocated to each. Exclude gross space licensed, permitted, or operated under a cross-servicing agreement to other military services, agencies of DOD, or to federalized National Guard units.

6. Outgranted to DOD users

Under Columns (b) through (i), the amount of gross storage space (sq ft) that is licensed or permitted to military services or agencies of DOD for their operation. Include space classified as storage space at the time it was licensed or permitted even though it is not now being used for storage purposes. Exclude space that is common/cross-serviced. Show under "Remarks" the agency name and the amount of gross space (covered and open separately) licensed or permitted to each.

7. Used for storage operation

Under Columns (b) through (i), the amount of gross storage space (sq ft) used for storage operations by subtracting the sum of Lines 3, 4, 5, and 6 from Line 2. (No keypunched data submission card is required for Line 7.)

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8. Aisles, structural loss, support space

Under Columns (b) through (i), the amount of gross storage space (sq ft) used in support of storage functions at the installation (for example, areas used for preservation and packaging, assembly, packing and crating, container manufacturing, receiving, shipping, inspection and identification, administrative storage offices, employee rest areas, tool rooms, time clock areas, battery charging stations, and other similar support functions). Also, include the amount of space used for aisles, including those aisles in bin and rack areas, plus the amount of space not usable for storage because of construction features or physical characteristics. Within covered storage areas, such items as toilets, posts, firewalls, elevator shafts, stair wells, ramps, steam pits, switch panels, loading wells, and door clearances will be considered structural loss. Within improved open storage areas, such additional items as firebreaks, streams, stream beds, railroad tracks, and clearances maintained for utility lines should be considered as structural loss.

Section B-Net Storage Space 9. Total square feet

Under Columns (b) through (i), the amount of net storage space (sq ft) at the installation. This includes the floor area upon which bins or racks are erected plus the floor area upon which bulk materiel can be stored. Determine this space by subtracting Line 8 from Line 7. (No keypunched data submission card is required for Line 9.)

10. Total cubic feet

Under Columns (b) through (i), the amount of total net cubic feet obtained by multiplying the amount on Line 9 by the unobstructed stacking height permitted by safety restrictions. To accumulate net cubic space for covered storage, multiply the unrestricted stacking height for each facility by that facility's net square feet, then total the amount for all facilities. Cubic space in improved open storage will be computed by multiplying net storage space (sq ft) by an average stacking height of 10 feet. Cubic space in unimproved open storage, for recording in Column (i), will be actual occupancy.

11. Attainable cubic feet

Under Columns (b) through (i), the amount of net cubic feet available for the storage of materiel. These entries will be the results of adding the amounts of cubic space in bin, rack, and bulk areas. Amounts will be computed as follows: a. Bin cubic capacity is the product of the bins' outside dimensions, length, width, and height (LxWxH). Cubic space available above the bins will not be included in the net available cubic space unless actually occupied by stored materiel or supplies.

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b. Rack cubic capacity is the product of the racks' outside dimensions, length, width, and height (LxWxH). Cubic space above the racks will be included to the extent that use of such space is permitted by safety limitations and the capacity of available materials handling equipment (MHE). c. Bulk cubic capacity will be the product of the net square feet used for bulk storage multiplied by the stacking height permitted by safety restrictions and floor load limitations attainable with available MHE and storage aids, as appropriate. Cubic space beyond the reach of available MHE lift height and floor load limitations will not be reported even though safety limitations or permissible stacking height have not been attained. The cubic capacities reported on this line are limited to those attainable under present storage arrangements and achieved with available equipment (for example, storage aids and MHE). d. Open improved cubic capacity will generally be computed by using an average stacking height of 10 feet. Where local conditions and actual commodity characteristics dictate a specific stacking height, the latter will apply. e. Open unimproved cubic capacity will be that actually occupied and reported on Line 13. 12. Occupied square feet

Under Columns (b) through (i), the amount of total square feet (Line 9) that is occupied by bins, racks, and materiel in covered and open bulk storage areas. Bin and rack space is considered occupied whether or not materiel is stored therein. Space that is vacant due to restrictions by quantity-distance factors, storage compatibility limitations, or criticality limitations will be considered occupied. Exclude space occupied by materiel reported on Lines 5 and 6. Include space occupied by materiel for such activities as depot property, organizational field maintenance, organizational (company, battalion) supply rooms, and common/cross-service stored materiel.

13. Occupied cubic feet

Under Columns (b) through (i), the cubic feet that represents the capacity of occupied bins and racks and occupied covered and open bulk storage space including bulk space above floor areas (Line 13a plus Line 13b). a. Bin and rack occupancy in cubic feet will be based on the cubic space usable for the storage of materiel (Line 11) (the product of the outside dimensions [LxWxH] of all available bins and racks). This will generally be a one-time total unless bins and racks are newly constructed or dismantled and removed.

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b. Bulk occupancy in covered storage areas will be an average based on a quarterly survey of randomly selected bulk locations from each storage facility. The areas selected for survey of bulk cubic space occupancy will be determined by the individual installation or activity. Areas to be surveyed should be based on a system of bulk-grid locations with a least 20 grids selected within each section of a storage facility. Measure the actual height of the materiel in the selected locations and determine an average stacking height for the entire storage facility. Compute corresponding cubic occupancy by multiplying the average stacking height by the square feet occupied for each facility surveyed. c. Occupancy of improved open storage space will be based on the square feet occupied times the average stacking height of 10 feet. d. Occupancy of unimproved open storage space will be actual occupancy. (No keypunched data submission card required for Line 13.) 13.a. Reporting component's materiel

Under Columns (b) through (i), that amount of cubic space occupied by Army-owned materiel.

13.b. Common/cross-serviced

Under Columns (b) through (i), the amount of cubic space that is common/cross-serviced. Exclude that space reported on Lines 5 and 6. (No keypunched data submission card is required for Line 13b.)

13.b.(1) DOD materiel

Under Columns (b) through (i), that portion of Line 13b that is occupied by DOD materiel. This includes space occupied by household goods and personal effects belonging to military service personnel. Exclude space reported on Line 6.

13.b.(2) Non-DOD materiel

Under Columns (b) through (i), that portion of Line 13b that is occupied by non-DOD materiel. Exclude space reported on Line 5.

14. Vacant square feet

Under Columns (b) through (h), the amount of vacant net storage space in square feet. Space occupied by empty pallets or dunnage in support of storage operations will be reported as vacant. Covered space used for employee parking will be considered vacant. Vacant space in front of stacks that can be used only to store like items will also be reported as vacant. Vacant open unimproved space will not be reported. This entry will be the difference in square feet between Lines 9 and 12. (No keypunched data submission card is required for Line 14.)

15. Vacant cubic feet

Under Columns (b) through (h), the amount of vacant net storage space in cubic feet. This entry will be the difference in cubic feet between Lines 11 and 13. (No keypunched data submission card is required for Line 15.)

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16. Unobligated square feet

Under Columns (b) through (h), the estimated portion of Line 14 in square feet that is not obligated to any future requirement. No data entry is required on Line 16, Column (i).

17. Unobligated cubic feet

Under Columns (b) through (h), the estimated portion of Line 15 in cubic feet that is not obligated to any future requirement. No data entry is required on Line 17, Column (i).

18. Recoupable cubic feet through rewarehousing

Under Columns (b) through (g), the amount of cubic space in occupied locations (from Line 13) that can be recouped through rewarehousing. No data entry is required on Line 18, Columns (h) and (i).

Section C-Storage Space Analysis (Net Cubic Feet) 19. Requirements

Under Columns (b) through (h), that amount of net cubic space needed to satisfy the obligated requirements for the next fiscal year. Requirements for materiel currently stored in open unimproved space (Column (i) will be shown under the appropriate column(s). No data entry is required on Line 19, Column (i).

20. Recoupable with additional resources

Under Columns (b) through (h), the sum of the following: a. The difference between Line 10 (total cubic feet) and Line 11 (attainable cubic feet). b. That sum obtainable through the reactivation of standby space and the retrieval of outgranted space. These gross quantities will be adjusted by the ratios existing between Line 10 (total cubic space) and Line 7 (gross storage space used for storage operations) to yield a statement of net cubic feet per gross square foot. No data entry is required on Line 20, Column (i).

21. Requires major repair/ modification

Under Columns (b) through (h), the net cubic feet in need of major repair/modification in order to raise it to an adequate status for storage purposes. (Adequate status/condition is as specified in DOD 4145.19-R.) The repairs/modifications to be reported are those estimated to cost $50,000, or more, for each structure or open storage area. No data entry is required on Line 21, Column (i).

22. Requires replacement

Under Columns (b) through (h), the net cubic feet of space, in need of replacement, for which there is a continuing requirement and the repair of which is not economically justifiable. No data entry is required on Line 22, Column (i).

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Section D-Five-Year Storage Space Requirement (Net Cubic Feet) for Years 2 Through 5 23. Attainable

Under columns for each fiscal year, those net cubic feet shown on Line 11, Columns (b) through (h), adjusted as needed to reflect ongoing programmed changes.

24. Requirements

Under columns for each fiscal year, the cubic space required to satisfy the projected requirements.

25. Excess (+ plus) /deficit (- minus)

Under columns for each fiscal year, the differences obtained by subtracting Line 24 from Line 23. (No keypunched data submission card is required for Line 25.)

26. Recoupable with additional resources

Under columns for each fiscal year, those quantities of both covered and open space computed for Line 20, with adjustments, as appropriate.

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LESSON 3 PRACTICE EXERCISE

The following exercise will test your grasp of the material covered in this lesson. There is only one correct answer for each item. When you complete the exercise, check your answers with the answer key and the completed copy of DD Form 805 that follow. If you answer any items incorrectly, study again that part of the lesson that contains the portion involved. Situation. Given the DD Form 805 from the previous report (Figure 3-4, Page 3-14) and the facts listed below, fill in each numbered space on the blank DD Form 805 (Figure 3-5, Page 3-15). • Your report originates at Fort Bliss. • You have 30,000 square feet of unimproved storage space. • You have no standby space. • You have no storage space outgranted to non-DOD users. • You have 56,000 square feet of covered shed storage space outgranted to the 7th Ordnance Company. • You have 26,000 square feet of storage space for packing and crating in an improved open space area. • Your unobstructed stacking height is 10 feet. • Your total amount of net square feet for all facilities is 424,000 square feet. • Your facility has four bins with outside dimensions of 24 feet (length), 18 feet (width), and 10 feet (height). • You have no vacant storage space.

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Figure 3-4. Previous copy of DD Form 805 that includes information needed to complete Practice Exercise.

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Figure 3-5. Copy of DD Form 805 to be used to complete Practice Exercise. 3-15

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LESSON 3 ANSWER KEY AND FEEDBACK

Figure 3-6, Page 3-18, shows the completed DD Form 805. Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Correct Answer and Feedback 1-06. The last digit of this calendar year is "1" and "06" represents the month of June (Page 34). A. Given the name of the installation, go to the report column of Table 6-1, AR 740-1 (Appendix) and find Fort Bliss. The letter "A" indicates an annual submission (Page A-7). Table 6-1, AR 740-1 lists "HCRL" as the installation identity code for Fort Bliss (Page A-7). A. "A" for Army (Page A-7). Fort Bliss. Given in instructions (Page 3-13). El Paso. Shown in Location column of Table 6-1, AR 740-1 (Page A-7). TX. Same as Item 6. 536,000. Taken from the previous report (Page 3-14, Figure 3-4). 10,000. Same as Item 8. 526,000. Same as Item 8. 536,000. Same as previous report unless there have been deviations (Page 3-6). 10,000. Same as Item 11. 526,000. Same as Item 11. 30,000. Given in instructions (Page 3-13). 56,000. Shed storage space outgranted to DOD user (7th Ordnance Company). Given in instructions (Page 3-13). 56,000. Same as Item 15. 450,000. Subtract total of Items 14 and 15 from the amount in Item 11 (Page 3-7). 26,000. Given in instructions (Page 3-13). 424,000. Subtract the amount in Item 18 from the amount in Item 17 (Page 3-8). 424,000. Same as Item 19. 4,240,000. Multiply the amount in Item 19 by the unobstructed stacking height (Page 3-8). 4,240,000. Same as Item 21. 17,280. The site has four bins that are 24x18x10 feet. Multiply 24x18x10x4 to find the total cubic feet contained in these bins (Pages 3-8 and 3-9). 17,280. Same as Item 23.

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25. 26. 27. 28. 29.

424,000. Total occupied square feet (Page 3-9). 424,000. Same as Item 25. 4,240,000. Multiply the average stacking height (10 feet) by the total square feet occupied for each facility (Pages 3-9 and 3-10). 4,240,000. Same as Item 27. 4,222,720. Subtract the amount in Item 23 from the amount in Item 27 (Page 3-10).

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Figure 3-6. Copy of DD Form 805 completed for the Practice Exercise.

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