This document is no longer a CPR. This document implements the requirements of Corporate Procedure ESH100.2.EXP.1, Manage Explosives Safety.

IMPORTANT NOTICE: A printed copy of this document may not be the document currently in effect. The official version is the online version located on the Sandia Restricted Network (SRN).

CHAPTER II – OPERATIONAL SAFETY - PART 3

Subject Matter Expert: Danton Humphries; CA Counterpart: Herman Armijo Contributors: Timothy Wallace and Ronald O’Hara
MN471011, Issue H
Revision Date: July 29, 2009; Replaces Document Dated: November 9, 2007
Review Date: July 17, 2006
Administrative Changes: March 4, 2010, April 9, 2010, and January 23, 2012

• 2-14.0 Materials Handling
• 2-14.1 General
• 2-14.1S General
• 2-14.2 Manual Handling of Bare Consolidated Explosives
• 2-14.3 Carts or Hand Trucks
• 2-14.4 Mechanical Handling Equipment
• 2-15.0 Materials Receipt
• 2-15.1 Motor Vehicles
• 2-15.2 Railcars
• 2-15.3 Damaged Shipments
• 2-15.3S Damaged Shipments
• 2-16.0 Transportation
• 2-16.1 Equipment and Operations
• 2-16.1.1 General
• 2-16.1.2 Motor Vehicles
• 2-16.1.3 Railcars
• 2-16.1.4 Materials Handling Equipment
• 2-16.2 General Operation Guidelines
• 2-16.2S General Operation Guidelines
• 2-16.2.1S Explosives Transportation Containers
• 2-16.2.2S Packaging Guidelines
• 2-16.3 Emergency Conditions
• 2-17.0 Explosives Storage
• 2-17.0S SNL Storage Requirements
• 2-17.1 Storage Magazine Facilities
• 2-17.1S Storage Magazine Facilities
• 2-17.2 Storage Magazine Operations
• 2-17.3 Storage Review Program
• 2-17.3S Storage Review Program
  • 2-17.3.1 Common Requirements
  • 2-17.3.2 Storage Review by Analogy
• 2-17.4 Storage Compatibility
• 2-17.5 Containers (Onsite)
• 2-17.5S Containers (Onsite)
• 2-17.6 Storage in Buildings Other Than Storage Magazines
• 2-17.6.1 Packing and Shipping Buildings
• 2-17.6.2 Service Magazines
• 2-17.6.2S Service Magazines
• 2-17.6.3 Warehouses
• 2-17.6.4 Prepositioned Storage of Security Response Munitions
• 2-18.0 Decontamination and Cleaning
• 2-18.2 Cleaning Contaminated Equipment
• 2-18.3 Cleaning Screw Threads
• 2-18.4 Final Decontamination and Disposal of Equipment
• 2-18.5 Inspection
• 2-18.6 Identification and Control of Decontaminated Items
• 2-18.7 Decontamination of Real Estate
• 2-18.8 Decontamination and Cleaning References
• 2-19.0 Waste Collection
• 2-19.1 General
• 2-19.2 Solid Wastes
• 2-19.3 Vacuum Collection of Explosives Dusts
• 2-19.4 Explosives Slurries
• 2-19.5 Metal Scrap
• 2-19.6 Explosives Recovery and Reuse
• 2-20.0 Waste Disposal
• 2-20.0S General Requirements
• 2-20.1 Preparation for Open Burning
• 2-20.2 Destruction by Burning or Flashing
• 2-20.2S Destruction by Burning or Flashing
• 2-20.3 Ignition System Malfunctions
• 2-20.4 Postburn Operations
• 2-20.5 Disposal Area
• 2-20.6 Destruction by Detonation
• 2-20.7 Use of Solvents
• 2-21.0 Laboratory Operations
• 2-21.1 General
• 2-21.2 Safety Shields
• 2-21.2S Safety Shields
• 2-21.3 Heating Operations
• 2-21.4 Laboratory Setups
• 2-21.5 Low Concentration of Explosives in Solution
• 2-21.6 Explosives Sample Control
• 2-21.7 De Minimis or Residual Quantities
• 2-22.0 Emergency Control
• 2-22.1 Placarding and Fire Symbols
• 2-22.1S Placarding and Fire Symbols
• 2-22.2 Explosives Emergency Control Plans
• Attachments
• 2-1 – Gunpowder, Bulk Propellant, and Ammunition
• 2-2 – Rocket Motors and Missile Systems
• 2-3 – Bulk Materials, Powders, Pellets, Bulk Moldables, Shaped Charges, Linear Materials, and Thermites
• 2-4 – Articles, Subassemblies, and Assemblies
• 2-5 – Hazard Mitigation Techniques

2-14.0 MATERIALS HANDLING

2-14.1 General

1. The distance that explosive materials can fall, if accidentally dropped during handling, shall be maintained at a minimum.
2. Hard surfaces and edges of equipment that could be struck by accidentally dropped, consolidated explosives should be padded with cushioning mats or coverings whenever possible and needed. (Protective padding includes both sheet material on work surfaces and on equipment and approved floor coverings.)
3. Explosives handling shall be permitted only in areas free of obstructions and where the walkway surfaces provide positive footing with no slipping or tripping hazards (e.g., explosives shall not be handled on snowy or icy walkways).
4. Incompatible explosives and materials shall not be handled together.
5. Detonators, actuators, EEDs, and other items normally shipped as Hazard Class/Division 1.4 explosives, should be kept in non-propagating trays or containers unless handled individually.
6. Dry explosive materials that generate dust shall be transported in closed containers.
7. Containers of explosives or explosive assemblies shall be labeled to identify contents during handling, storage, and transportation.
8. Explosives items that cannot be identified and labeled shall be stored as Hazard Class/Division Storage Compatibility Group 1.1L. A material analysis shall be performed to identify the material before it is returned to inventory or disposed of in accordance with regulatory requirements.
9. Components or devices that contain explosives should not be labeled or marked "inert" or "dummy." Nonconforming items shall be labeled/tagged indicating that they contain explosives. New components or devices containing explosives shall not be labeled or marked "inert" or "dummy."

2-14.1S General

1. Display empty/inert munitions, articles, and substances must be 100 percent visually inspected to ensure they are free of explosives. Items that cannot be visually verified will be inspected by any appropriate means necessary to ensure the items are free of all explosive material.

1. Maintain signed documentation identifying the inspector and all items inspected by nomenclature, unique serial number, quantity, and unit of measure.
   
2. The responsible line managers shall ensure that qualified personnel inspect and certify the material to be free of chemical/explosive contamination.

2-14.2 Manual Handling of Bare Consolidated Explosives

1. Manual handling shall be minimized as follows:

1.	One person may lift or carry up to 55.12 lb (25 kg) of explosive only if it can be securely gripped.
2.	Two people may lift or carry up to 110.2 lb (50 kg) of explosive only if manual lifting and handling tooling is provided.
3.	Explosive items weighing over 110.2 lb (50 kg) or that cannot be securely gripped should not be manually handled.

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

2-14.3 Carts or Hand Trucks

1. Explosives that cannot be handled manually handled shall be moved only on suitable carts or hand trucks. Carts used to handle bare explosives shall be provided with a padded surface to support the explosives. These carts shall be equipped with either a lip, sides of sufficient height, or tiedown straps to prevent the explosives from sliding or rolling off the cart. The cart-explosive load combination shall have a center of gravity low enough to prevent tipping if the cart suddenly stops.
2. Explosives handling carts or hand trucks should be equipped with brakes. Carts containing explosives shall be positively secured (e.g., setting wheel brakes or chocking) when the cart is stationary.

2-14.4 Mechanical Handling Equipment

1. All mechanical handling equipment (i.e., cranes, hoists, slings, etc.) used to lift and move explosives or assemblies containing explosives shall be initially proof-tested, periodically inspected, and maintained in first-class working condition. DOE-STD-1090-07 may be used as a guide for testing, inspection, and maintenance.
2. Equipment for vacuum lifting of consolidated explosives must comply with the following requirements.

1.	The lifting equipment shall be designed so that the explosives cannot be dislodged from the vacuum head by jerks or other irregular motions in the hoisting apparatus or bumping of other equipment.
2.	Equipment shall be designed to monitor the available vacuum and to control loss of vacuum if the power or vacuum source fails.
3.	Any handling where a loss of vacuum would allow the explosive to drop an excessive distance shall incorporate some safety device (i.e., collar, net, strap) to prevent dropping. "Excessive distance" shall be defined as a distance greater than the minimum drop height giving drop-skid initiation for the explosive being handled. "Initiation" in the drop-skid test refers to any indication of sample decomposition. An alternative method of protection can be a cushioning surface under and over all items that may be struck by the falling explosives.

2-15.0 MATERIALS RECEIPT

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

2-15.1 Motor Vehicles

1. A competent person using an approved checklist at a designated inspection station shall carefully inspect incoming motor vehicles loaded with explosives.

1.	When an inspection reveals that an incoming tractor is in unsatisfactory condition, the tractor should be disconnected from the trailer at the inspection station and moved to a position where it will not endanger any other explosives.
2.	When inspection reveals that a trailer or its load is in an unsatisfactory condition, the trailer shall be moved to a location that, for the particular material involved, is at least inhabited-building distance for the particular material involved from inert and administration
3.	Vehicles that cannot be immediately dispatched to points where they are to be unloaded may be moved to a holding yard that shall be sited in accordance with Section 6-3.2.3.
4.	Incoming or outgoing explosives loaded trailers that cannot be exchanged directly between the carrier and DOE facilities may be moved to an interchange yard. Quantity-distance provisions do not apply if the trailers are moved expeditiously.

2. Vehicles shall not be backed up to a dock on which explosives are resting and could be damaged.
3. The receiving facility’s doors should be closed while the motor vehicle is in motion or the engine is running. This requirement does not apply to vehicles equipped with spark arrestors or when no exposed explosives are present.
4. Once the vehicle is in position, the engine shall be shut off, the brakes set, and the wheels chocked.
5. After unloading, the vehicle shall be inspected for loose explosives materials. Any spilled material shall be cleaned up after the inspection. Spills involving liquid explosives or explosives in solution shall be reported immediately to the building supervisor. Appropriate cleanup procedures shall be used.

2-15.2 Railcars

1. Railcars containing explosives and ammunition entering a DOE facility must be inspected. This inspection comprises the examination of the outside and underside of each car for damage such as defective brakes, couplings, wheel flanges, etc.; for unauthorized and suspicious articles; and to confirm the individual car numbers and seal numbers against bills of lading.

1.	Cars of ammunition or explosives showing a defect that could affect the facility or contents of the car should be removed to the suspect car spur for additional inspection (see Section 6-3.2.3a).
2.	Cars that satisfactorily pass inspection may be considered reasonably safe, but care must be exercised in breaking car seals and opening car doors because of possible damage or shifted cargo, leaking containers, etc. Interior inspection should be conducted at the unloading point.

2-15.3 Damaged Shipments

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

2-15.3S Damaged Shipments

1. Refer to Section 2-20 of this chapter and ESH100.4.RPT.1, Report ES&H Concerns and Suggestions for Improvement, for damaged shipments or spilled material.
2. If explosives are repackaged into a different container type, the Hazard Class/Division and storage compatibility group may change. Contact Explosive Safety Engineering for approval.

2-16.0 TRANSPORTATION

2-16.1 Equipment and Operations

2-16.1.1 General

1. Qualified explosive handlers shall load and unload explosives (see Section 5-3.0).
2. Explosives shipped on common carriers shall be packaged and shipped in accordance with DOT regulations.
3. Explosives containing items transported by special agents in DOE approved secure transporters are governed by DOE O 452.2C and DOE O 460.1B.
4. Section 161.K of The Atomic Energy Act of 1954 as amended and Title 18 USC, Chapter 40, Section 845 govern security and emergency vehicles carrying explosives in support of approved contingency plans.
5. When transferring explosives within facilities, open body vehicles (other than flat bed types) shall have sides and tailgates or rear doors that are strong and securely fastened to safely retain the explosives.
6. The cargo on partly or completely loaded vehicles (including flat bed types) shall be blocked, braced, chocked, tied down, or otherwise secured to prevent shifting during transit.
7. Precautions shall be taken to prevent the exhausts of motor vehicles from igniting explosive material. When a motor vehicle approaches within 25 ft (7.62 m) of the doors of a structure through which a shipment is to be moved, the doors shall be kept closed until the motor has been turned off, unless the vehicle is equipped with an exhaust spark arrestor or there are no explosives exposed. Explosives packaged in DOT or onsite containers are not considered exposed.
8. No explosives shall be loaded or unloaded from a motor vehicle while the motor is running unless the motor is required to provide power to vehicle accessories used in loading and unloading operations and is equipped with an exhaust spark arrestor.
9. Onsite movements of explosives shall be in accordance with this Manual and local onsite packaging and transportation procedures. Where there is a conflict, this Manual shall take precedence.
10. During loading and unloading, explosive-laden vehicles shall have their emergency brakes set and wheels chocked to prevent inadvertent vehicle movement.

2-16.1.2 Motor Vehicles

1. Offsite shipments

1.	DOT regulations govern commercial motor vehicle shipments on public highways. Motor vehicle shipments from a DOE installation that meet the DOT definition of "in commerce" comply in full with the applicable portions of DOT regulations, and with state and municipal regulations, except as provided for in these regulations. A qualified inspector shall inspect and approve for compliance with an approved checklist any motor vehicle that may be loaded with explosives (Hazard Class/Division 1.1, 1.2, and 1.3) and is designated for movement over public highways. After loading, the cargo shall be inspected and approved.
2.	Before motor vehicles loaded with explosive materials leave a DOE facility, drivers shall be informed of the nature of their cargo and appropriate measures to take if the vehicle or load becomes involved in a fire.
3.	Drivers of explosive laden vehicles shall meet the pertinent requirements of 49 CFR Parts 390-397.

2. Onsite shipments

2-16.1.3 Railcars

1. A railcar must not be loaded with any Hazard Class/Division 1.1 and 1.2 explosives unless it has been thoroughly inspected by a carrier employee qualified to certify that the railcar conforms to DOT regulations. After the carrier has furnished a certified car, the shipper or an authorized employee of the shipper must inspect the interior before starting to load any such car and after loading to certify that the vehicle is in proper condition. A certificate will be completed and signed where applicable. Shipments of Hazard Class/Division 1.3 explosives may be loaded in a closed car or container car in good condition (i.e., sparks cannot enter the car and the roof does not have unprotected decayed wood that constitutes a fire hazard). Wooden-floored cars must be equipped with spark shields. Such cars do not require a car certificate, but must display a placard in accordance with DOT regulations.
2. The railcar certificate, printed on strong tag board measuring 7 by 7 in (17.78 by 17.78 cm) or 6 by 8 in (15.24 by 20.32 cm), must be executed in triplicate. The carrier must file the original in a separate file at the forwarding station, and the other two must be attached to the car, one to each outer side on a fixed placard board or as otherwise provided.

2-16.1.4 Materials Handling Equipment

1. Gasoline-powered materials-handling equipment (e.g., forklifts, etc.) may be used only in areas where all explosives are properly packaged and only if equipped in the following manner:

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

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

1.	Battery-powered equipment and its use in hazardous locations shall comply with OSHA standards. All equipment shall be appropriately labeled for ready identification.
2.	Types E, EE, ES, and EX-rated, battery-powered equipment are satisfactory for handling all classes of properly packaged ammunition and explosives. Types EE and ES battery-powered equipment may be used to handle packaged explosives or explosive components in corridors or ramps connecting hazardous operations, provided the ramps and corridors are not Class I or II, Division 1, hazardous locations (NEC). Type EE equipment is authorized for use in Class II, Division 2, Group G hazardous locations, and Type ES equipment may be authorized with facility management’s approval (see NFPA 505.
3.	Only Type EX equipment is approved for use in specifically named Class I, Division 1, Group D or Class II, Division 1, Group G hazardous locations. At this time, EX equipment does not carry a dual rating and shall only be used in hazardous areas for which it is specifically rated.

2-16.2 General Operation Guidelines

1. Explosives-containing items transported by special agents in SSTs are governed by DOE O 452.2C, and DOE O 460.1 B.
2. Drivers shall be given special training that emphasizes caution, road courtesy, and defensive driving.
3. The operator of an explosives-transport vehicle shall have proper training in the general safety precautions for explosives handling.
4. Congested areas should be avoided.
5. Road vehicles shall stop at all railroad crossings.
6. No personnel shall ride in the cargo area. Loose items (e.g., handling gear) in the cargo compartments are prohibited.
7. No smoking is allowed in or within 25 ft (7.62 m) of any vehicle containing explosives. Matches, lighters, or other fire-, flame-, or spark-producing devices shall not be in the vehicle or carried by personnel in the vehicle.
8. The vehicle shall be subjected to regular maintenance checks.
9. Before shipment by commercial carrier, explosives materials shall be classified by testing or analogy in accordance with DOT regulations.
10. Other than when opened for inspection, containers of explosives shall not be opened or repaired on any transportation vehicle.
11. Except for emergency situations, fueling or maintenance of vehicles containing explosives is forbidden.
12. Each facility shall establish traffic rules governing the operation of explosives-transport vehicles and the operation of other onsite vehicles in the vicinity of explosives-transport vehicles.
13. Industrial trucks shall not be used in locations where high concentrations of dusts or sublimation of explosives may result in contaminated surfaces (e.g., screening buildings, pouring bays, melt-pour units, drilling bays, consolidating bays, and explosive washout facilities).

2-16.2S General Operation Guidelines

1. Hazardous materials must not be moved by Storage/On-Site Hazmat Transportation without the proper information. When requesting that explosives be moved, comply with the following:

1.	Ensure all explosive materials have a Material Safety Data Sheet (MSDS) available (if one exists) in Sandia’s Chemical Inventory System (CIS) for review to ensure safe handling and transportation before scheduling the material for pickup and movement.
2.	Provide information to the Corporate Storage Transport Team clerk who fills out the Customer Service Request (CSR). Information needed includes the following: a. the point of contact at the pickup and delivery locations, which must be valid EIS locations b. trackable unit (TU) number c. number of containers d. type of containers, e.g., cardboard box, wood box. e. approximate gross weight of the heaviest container-- if the container is equal to or over 60 lbs. and whether or not there is a forklift on site to help load it f. requested movement date g. if the material is explosive radioactive, the survey number, tag date, and isotope h. whether or not the location is a classified work station.
3.	Mark all containers to identify the hazardous material listed on transportation documents or Move Orders using the EIS TU label. Refer to Chapter XI of this manual and SCM100.3.19, Move Non-Waste Hazardous Material Onsite and Offsite. a. Obtain hazardous material information from the following sources: transportation documents, packing slips, shipping memos, Reports of Shipment (REPSHIP), receipt container markings and labels, MSDSs, the requester, the shipper, the supplier, technical publications, onsite DOE/DoD agencies, technical personnel, and SNL Safety Engineers b. Comply with SCM100.3.19, Move Non-Waste Hazardous Material Onsite and Offsite, which identifies the requirements for transporting explosives and other hazardous items within the confines of SNL and Kirtland Air Force Base. Obtain specific information on packaging requirements from the Shipping and Receiving Services Department.

2. At SNL/NM, the Explosives Storage/On-Site Hazmat Team is responsible for transportation of all explosives. Security personnel may transport ammunition for training and operational requirements. The Health and Safety Department at SNL/CA is responsible for transporting explosives within the site and to and from adjacent test sites and for preparing shipments to be made from SNL in accordance with applicable regulations. At SNL/CA, the Explosives Section of the Health and Safety Department transports waste. At KTF, the Navy transports offsite to onsite. Onsite transportation is done by the participants in the experiment. At TTR, the support contractor transports the wastes.

2-16.2.1S Explosives Transportation Containers

1. DOT-approved containers are not required but are recommended for onsite transportation of explosives. Some examples of approved explosives containers for onsite transportation are as follows:

   1.	SNL-modified red ammunition can.
   2.	Aluminum mound suitcase.
   3.	Unpackaged bomb units or similar units/assemblies on H-gear (e.g. B-61, B-83).
   4.	Any DOT package approved for explosives (Examples: 4C wooden box, 4D plywood box or 4G fiberboard box).
   5.	Seamless steel pipe if packaged per DOT-E13133 exemption

2-16.2.2S Packaging Guidelines

1. Pack explosives or explosive devices carried in containers with non-static producing cushioning material to completely fill the void and prevent movement.

   Caution: Do not use polystyrene cushioning material. Polystyrene can produce an electrostatic discharge.

2. Some examples of approved inner packing materials for onsite transportation are as follows:

1.	Velostat bag.
2.	Static-negative material (complete wrap), followed by aluminum foil wrap.
3.	Approved static-negative material (complete wrap)

3. Explosives and explosive devices that have been prepared for testing may be moved from the buildup facility to the test site in accordance with an approved technical work document (TWD). This movement, because of test requirements, may not include packaging in any type of container.
4. Movement of explosives or explosive devices between laboratories in the same facility must comply with the facility ES&H SOP requirements.

2-16.3 Emergency Conditions

1. Explosives should not be transported in hazardous conditions (e.g., storms, icy roads, or poor visibility), unless an emergency plan is in effect to provide instruction and guidelines while an explosives-transport vehicle is in transit. The plan should address the following issues:

1.	Parking the vehicle.
2.	Safeguarding the vehicle from other traffic.
3.	Notifying appropriate authorities of the emergency situation
4.	Leaving the vehicle unattended

2. A plan shall be prepared to address mechanical breakdowns. The plan shall address the following issues:

1.	Removing the vehicle from the road as far as practical
2.	Posting emergency reflectors, signals, etc. (carrying flares on the vehicle is not permitted).
3.	Reporting the problem.
4.	Maintaining surveillance of the vehicle
5.	If necessary, removing the vehicle load to facilitate repair of the vehicle

3. If an explosives-transport vehicle is involved in an accident, the following steps should be taken:

1.	Inspect the load for evidence of fire.
2.	If there is a fire, but the explosives material is not presently or imminently involved, attempt to prevent the fire from spreading to the load. The fire may be fought using the vehicle's fire extinguishers. Ensure the security of explosives items removed from the vehicle.
3.	If a fire presently or imminently involves the explosives load, evacuate all personnel to a pre-established safe distance. Block or divert traffic from the vicinity of the accident. Evacuate potentially affected area residents.
4.	Unless the explosive cargo is imminently involved in fire, the operator is to stay with the vehicle until the cargo is properly dispositioned.
5.	Notify the fire department or fire brigade of the accident immediately and inform them of the general type and approximate quantity of explosives involved.
6.	Inform proper authorities of the accident

2-17.0 EXPLOSIVES STORAGE

2-17.0S SNL STORAGE REQUIREMENTS

1. All organizations that store or have their explosives stored shall comply with the following:

1.	Obtain the approval signature of the using organization's explosives material owner or designate before withdrawing explosives from facilities controlled by the Explosives Storage & Transportation Team and the Health and Safety Department.
2.	Maintain Material Safety Data Sheets (MSDSs) for all explosives, explosive devices, and hazardous materials in storage. Do not accept explosives for storage without adequate hazardous material information.
3.	Maintain the following information for all explosives: name; manufacturing date; and chemical composition, including stabilizers, enhancers and inhibitors. If any of this information is not available, those explosives must be tested for stability by a suitable laboratory or disposed of as waste. This information shall be maintained in the Explosive Inventory System (EIS) database for all explosive material.
4.	The Sandia EIS is the only inventory system to be used at SNL. It shall be used from cradle to grave to store, track, and control all explosive materials and items containing explosives that are owned by or under the control of Sandia personnel.
5.	The Trackable Unit (TU) number generated by the EIS shall be used for the unique identification of any explosive material for storage, tracking, and control.

2-17.1 Storage Magazine Facilities

1. Permanent explosives facilities shall comply fully with TM 5-1300 and DOE/TIC-11268. Portable magazines should be ventilated and resistant to water, fire, and, theft. They can be made of any material that meets these guidelines. (Portable facilities that comply with 27 CFR Part 555.203 and 27 CFR Parts 555.207 through 555.211 meet this criteria.) Portable magazines shall be sited per DoD 6055.9-STD as above ground magazines.
2. Placards shall be posted on or near each magazine door, specifying explosive and personnel limits and general safety precautions that should be observed during work in the magazine.
3. Vegetation around storage magazines should be controlled to minimize potential damage to the magazine (see Section 6-5.1).
4. At least two fire extinguishers, minimum rating 2A:10BC and winterized where necessary, should be provided and maintained for immediate use by personnel working around a magazine. These extinguishers may be located in the area or available on an explosives transportation vehicle. The purpose of these extinguishers is to fight small external fires or magazine fires that do not involve explosives.
5. Suitably rated telephone or other emergency communication equipment should be provided in magazine storage areas. All communication equipment located outdoors should be protected from the weather.
6. Temperature Control

1.	In general, storage magazines should not be heated unless heating is necessary to prevent damage caused by sudden temperature changes or when dimensional changes of components are undesirable.
2.	Magazines requiring heat should be heated with steam, hot water, or electrically heated hot water. Some magazines with tight temperature controls may require both heating and air conditioning. Electrical systems with forced air through ducts may be allowed if the systems are located exterior to any explosive hazard.
3.	Heating coils shall be arranged so that explosives material cannot come in contact with the coils. They shall be equipped with covers designed to prevent the storage of materials on top of the coils.
4.	Maximum and minimum temperature monitors should be provided in all heated magazines.

2-17.1S Storage Magazine Facilities

1. When storing explosives in magazine facilities, comply with the following:

1.	Use only locations that comply with the DoD 6055.9-STD, DoD Ammunition and Explosive Safety Standards, and are approved by Explosive Safety Engineering.
2.	Never exceed the maximum quantity of explosives approved for the storage facility.
3.	Earth Cover Requirement. The earth fill or earth cover between the earth-covered magazine (ECM) may be either solid or sloped. A minimum of 2 feet (0.61 m) of earth cover shall be maintained over the top of each ECM. If the specified thickness and slope of earth on the ECM is not maintained, the ECM shall be sited as an aboveground magazine. Earth cover shall be reasonably cohesive and free from harmful (toxic) matter, trash, debris, and stones heavier than 10 pounds or larger than 6 inches in diameter.

2-17.2 Storage Magazine Operations

1. Explosives items shall be properly packaged and stored in either DOT-approved manufacturers' container/packages or in specified onsite containers (see Section 2-17.5 of this chapter).
2. Explosives may be stored on magazine shelves. The bottom of the container should not be more than 6.56 ft (2 m) off the floor, except as permitted by Section 2-17.2c of this chapter.
3. Explosives and explosives containers in storage shall be positioned safely and securely. If explosives containers must be stacked, they shall be placed in stable arrays.
4. Load limits shall be established for shelving in magazines containing explosives. If overloading is possible, the loading conditions shall be posted.
5. Materials shall not be left suspended by booms, cranes, or hoists in any explosives storage facility.
6. Stored explosives should be segregated by lot designation. Stacks of explosives should be arranged so that air freely circulates to all parts of the stack. To prevent moisture accumulation, pallets or appropriate dunnage should be used to ensure that containers are not stacked directly on the magazine floor.
7. Aisles shall be wide enough to accommodate inspection, inventory, sampling, and materials handling operations on the stored explosives containers.
8. Crews shall not be permitted to work in a position that requires passing the work aisle or the position of a second crew to reach the exit. Unobstructed aisles shall be maintained to permit rapid exit of personnel.
9. Each crew working in a magazine must have its own exit route that does not interfere with exit routes for other crews.
10. Magazines shall be locked at all times except when permissible operations are in progress or opened for ventilation. Personnel shall be present while the magazine is open for ventilation. All exit doors shall be unlocked and open when personnel are working in the magazine.
11. Each magazine shall be inventoried at least annually to determine the total weight of explosives present (to assure this weight conforms to allowable quantity-distance constraints) and to remove and destroy materials that are not properly identified or labeled.
12. The liquid level in storage containers for wet explosives shall be checked and replenished as necessary at least once a year. A log of the checks shall be maintained.
13. Empty containers, tools, conveyors, lift trucks, skids, etc. should not be stored in a magazine containing explosives.
14. Combustible materials such as excess dunnage, packing material, and boxes shall not be stored in a magazine containing explosives.
15. Flammable liquids shall not be stored or used in explosives magazines unless the liquid is an explosive, is needed as an explosives-wetting agent, or is an integral part of an explosives device.
16. Operations in and around magazines shall be prohibited when an electrical storm is in progress and minimized when it is evident that such a storm is approaching.
17. Explosives-handling operations shall not be performed when magazine entranceways are icy or do not provide adequate footing for any other reason.
18. Unless excepted, no operation in which hazardous materials are involved shall be permitted in any magazine. The following exceptions are recognized:

1.	Those operations incident to storage or removal from storage.
2.	Inspection and surveillance sampling of compatibility Group D materials and Group C materials consisting of bulk propellants IHE, provided that each storage container sampled is in good condition (i.e., the container is not leaking, no evidence exists of explosives contamination at the closure or of seal failure, and the closure is mechanically sound and free of excessive corrosion, etc.). Only one container of explosives shall be opened at one time in a magazine.
3.	Adding liquid to adjust the liquid composition level in which a Group D explosive is stored. (Water and alcohol mixtures may be used) If only water is added to the explosive, the water should be distilled or deionized. (Bacteria present in untreated water may produce gas during storage.)

2-17.3 Storage Review Program

1. Each facility shall establish a program to review the explosive materials stored at that facility. Explosives may degrade during prolonged storage, increasing the hazards of handling or use. The following procedure is provided as an example:

1.	A storage review date should be assigned to each bulk explosive placed in storage. The storage review date should be shown on or adjacent to the identification tag or sticker attached to every container or package of explosive in storage or should be listed in the inventory records.
2.	Storage review intervals should be based, whenever possible, on stability data. A safe storage interval should be considered as that time period, at maximum anticipated storage temperature, during which an explosive material can be conservatively expected to show an acceptable level of decomposition.
3.	Facility management should designate or create a storage review committee to establish and approve storage review intervals for all explosives stored at the DOE facility. Also, the committee should prescribe for each explosive appropriate tests to evaluate the safety of handling and processing the material after it has exceeded its storage review interval. These tests may be referred to as "stability tests," although sensitivity, or other types of testing, may be included in the material evaluation program. In some cases, the review committee may simply require periodic stability testing rather than establishing a storage review interval (i.e., nitrocellulose, single- and double-base propellants, etc.).
4.	To store a new explosive, to increase (or decrease) the review interval for a previously approved material, or to use different stability test data for an explosive, the following procedure should be used: a. A responsible person should communicate the request to the storage-review committee. b. If the request concerns storage of a new explosive, the individual should recommend a storage review interval and stability-evaluation testing. c. Supporting data should be supplied with the recommended review interval and proposed stability tests for the explosive d. The storage review committee should review the request and supporting data and then prescribe a storage review interval and stability tests as appropriate. e. A new explosive should be assigned an interim storage review and stability test interval before Phase II scaleup (see Chapter VIII). f. The following general guidelines are offered to assist the storage-review committee in establishing review intervals when there is insufficient stability information to predict storage life. 1. If no information is available on a new material relative to storage stability, a review interval of 90 days or less should be assigned. 2. A new formulation should be assigned a storage review interval not exceeding that of its least stable component. 3. If the compound or formulation is new to DOE, but DoD agencies have extensive experience with it, the DoD information should be used conservatively. 4. For a formulation or ingredient with a manufacturer-assigned shelf life, a review interval that exceeds the recommended shelf life should not be assigned unless additional DOE tests indicate such storage is warranted.
5.	A storage review interval of up to 20 years should be permissible for an explosive if a conservative evaluation of stability data indicates that such an interval is justified.

2-17.3S Storage Review Program

1. The SNL Explosives Storage Review program is owned by the Sandia Explosives Safety Committee and supported by Sandia SMEs. EIS shall be used to track storage review dates for all Sandia-owned explosive material. EIS Owners are responsible for maintaining current storage review information for all material within the EIS, including notifications.
2. Materials are addressed in high (1) to low (5) risk hierarchy order. Materials covered by storage review requirements are the following:

   1.	Gunpowder, bulk propellant, and ammunition – Refer to Attachment 2-1.
   2.	Rocket motors and missile systems – Refer to Attachment 2-2.
   3.	Bulk materials, powders, pellets, bulk moldables, shaped charges, linear materials, and thermites – Refer to Attachment 2-3.
   4.	Articles, subassemblies, and assemblies not addressed above (commercial, DOE, DoD and other government devices and assemblies) – Refer to Attachment 2-4.

3. The following materials are not approved for use at SNL without written permission of Safety Engineering. Even when permission is granted for research purposes or support of the nuclear weapon stockpile, these materials shall be closely monitored.

   1.	Improved Military Rifle (IMR) powder older than 20 years is not approved. This is a DoD policy. DoD has determined that stability is difficult to establish and does not allow IMR older than 20 years in DoD inventories. After 20 years, the stability data for IMR, including devices containing IMR material, becomes increasingly erratic and difficult to analyze for stability.
   2.	Rocket motors and propellant compositions containing ferrocene and/or catocene are not approved. There are no exceptions. Compositions containing these materials have been known to cause incidents involving the loss of life. Constituents added enhance sensitivity. These constituents migrate to the exterior of the grain, where the grain becomes extremely impact and motion sensitive.

4. Owners shall conduct a storage review for the material being considered. Each storage review is unique to the material, the amount of sample available for analysis, and the duration of ownership. Owners shall acquire a sufficient amount of material to support the storage review in addition to operational needs.

2-17.3.1 Common Requirements

1. Each process contains notes that provide specific requirements. Many storage requirements are common to all materials and tables. Common requirements include:

1.	The quantity required to support a storage review depends on the test program and is an Owner-determined number. Some units and devices contain small amounts of explosives. Special consideration will be given to small surveillance programs that monitor these types of units and devices.
2.	Storage review data from parent samples, DoD surveillance programs, DOE surveillance programs, manufacturer, and/or the SNL Explosive Component Surveillance Program (ECSP) may be used in place of a storage review program on the sample where applicable. Data must be within the storage review period for the material being considered. For any material considered unstable with regard to either stability or sensitivity, the data must be from the same batch or lot of material.
3.	For a material with a manufacturer-assigned shelf life, a review interval that exceeds the recommended shelf life should not be assigned unless additional DOE tests indicate such storage is warranted.
4.	If there is no storage review of the material or there is no applicable storage review data from parent or applicable storage review programs, then the following is required: a. The material shall be assigned an "L" compatibility group as the stability of the material is undetermined and the review interval should be every 90 days. b. The material shall be handled and used as a primary. c. The material shall be stored in containers demonstrated to be non-propagating or in a configuration demonstrated to be non-propagating.
5	If there is no information available on a new or unknown material relative to storage stability, a review interval of 90 days or less will be assigned. After two consecutive and matching results, the interval may be extended to one year. When a sufficient history of good results has been established, a storage review interval normal for the material category will be assigned. Until stability is established, the requirements for storage and handling as listed in paragraph 17.3.1a(4) above apply.
6.	Exclusions from stability testing for samples less than 2 grams and the historical sample require the approval of Safety Engineering.
7.	The labeling of a sample as a small quantity, high cost, or historical sample shall be approved by Safety Engineering. In general, the review for the historical sample will follow the tests and intervals for that type of material. However, duration of ownership and amount of sample may require a modification of the storage review. Emphasis is on retaining the sample for historical purposes. With prior history established, the review period may be up to 20 years.
8.	Commercial items, which include ammunition and bulk gunpowder, shall not be retained for longer than 10 years.
9.	A storage review interval of up to 20 years should be permissible for an explosive if a conservative evaluation of stability data indicates that such an interval is justified.

2-17.3.2 Storage Review by Analogy

1. A storage review for any type of explosive material, article, subassembly or assembly can be conducted by analogy. The analogy can be made to data from a parent sample, a like sample for the same material, the SNL Explosive Surveillance Program, or other DOE or DoD surveillance programs.
2. When performing a storage review by analogy, the Owner must provide the supporting data from the surveillance, storage review, or parent program. Using analogy, the test required for the material does not have to be run on the material being considered; rather, the data from the analogy source is used. Table 1 gives some general sources for analogies.

2-17.4 Storage Compatibility

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

1.	Group A - Initiating explosives. Bulk initiating explosives that have the necessary sensitivity to friction, heat, or shock to make them suitable for use as initiating elements in an explosives train. Examples are lead azide, lead styphnate, mercury fulminate, and tetracene.
2.	Group B - Detonators and similar initiating devices not containing two or more independent safety features. Items containing initiating explosives that are designed to initiate or continue the functioning of an explosives train. Examples are detonators (all types, excluding EBWs and slappers), blasting caps, small arms primers, and fuzes.
3.	Group C - Bulk propellants, propellant charges, and devices containing propellant with or without their own means of initiation. Items that will deflagrate, explode, or detonate upon initiation. Examples are single-, double-, triple-base, and composite propellants, rocket motors (solid propellant), and ammunition with inert projectiles.
4.	Group D - High explosives (HE) and devices containing explosives without their own means of initiation and without a propelling charge, or articles containing a primary explosives substance and containing two or more effective protective features. This group shall include explosives and ammunition that can be expected to explode or detonate when any given item or component thereof is initiated.
5.	Group E - Explosives devices without their own means of initiation and with propelling charge (other than one containing a flammable or hypergolic liquid). Examples are artillery ammunition and rockets.
6.	Group F - Explosives devices with their own means of initiation and with or without propelling charge.
7.	Group G - Pyrotechnic materials and devices containing pyrotechnic materials. Examples are devices that when functioning, result in an incendiary, illumination, lachrymatory, smoke, or sound effect.
8.	Group H - Ammunition containing both explosives and WP or other pyrophoric material. Ammunition in this group contain fillers which are spontaneously flammable when exposed to the atmosphere. Examples are WP, plasticized white phosphorus (PWP), or other ammunition containing pyrophoric material.
9.	Group J - Ammunition containing both explosives and flammable liquids or gels. Ammunition in this group contain flammable liquids or gels other than those that are spontaneously flammable when exposed to water or the atmosphere. Examples are liquid or gel filled incendiary ammunition, fuel-air explosive (FAE) devices, flammable liquid-fueled missiles, and torpedoes.
10.	Group K - Ammunition containing both explosives and toxic chemical agents. Ammunition in this group contain chemicals specifically designed for incapacitating effects more severe than lachrymation. Examples are artillery or mortar ammunition (fuzed or unfuzed), grenades, and rockets or bombs filled with a lethal or incapacitating chemical agent.
11.	Group L - Explosives or ammunition not included in other compatibility groups which present a special risk requiring isolation of each type. This group shall include explosives or ammunition having characteristics that do not permit storage with other similar or dissimilar materials. Examples are damaged explosives, suspect explosives, and explosives, explosive devices or containers that have undergone severe testing unless documented determination is made that these items do not present a special risk; fuel/air explosive devices, and water-activated devices. Also included are experimental explosives, explosives of temporary interest, newly synthesized compounds, new mixtures and salvaged explosives until they have been established to be compatible with the original materials. Types presenting similar hazards may be stored together.
12.	Group N - Hazard Division 1.6 ammunition containing only extremely insensitive detonating substances (EIDS).
13.	Group S - Explosives, explosive devices, or ammunition presenting no significant hazard. Explosives or ammunition so designed or packed that when in storage any hazardous explosive effects from accidental functioning are limited to the extent that they do not significantly hinder fire fighting. Examples include: explosive switches or valves and small arms ammunition.

4. Mixing of Storage Compatibility Groups may be permitted as indicated in Table II-5.  When using the “Z” mixing authorized by Table II-5, items must be stored in approved containers and the net quantity of explosives for that location shall not exceed 1,000 lb (453.6 kg). SCG B and SCG F articles shall be segregated in storage from those of other compatibility groups by means that will prevent propagation of those articles.
5. Newly synthesized compounds and mixtures shall be stored in Group L storage facilities. After more complete evaluation, the EDC shall assign those compounds or mixtures of continuing interest (refer to Section 8-1.1 to the appropriate compatibility group, and stored according to the following considerations:

   1.	The material's sensitivity to initiating stimuli (i.e., friction, impact, spark, shock, and thermal) is similar to that of other explosives in the group.
   2.	The material's reactions and the effects of these reactions, in the event of application of initiating stimuli, are similar to other members of the group.
   3.	The material is chemically compatible with other materials in the group. Sensitivity and compatibility testing is described in Chapter VIII.

6. As an alternate to Table II-4 and Table II-5, samples of explosives up to 4.4 lbs (2 kg) total, may be stored in the same cubicle if the cubicle walls are designed to prevent propagation. The material shall be stored in separate cubicles in one of the following categories:

   1.	High explosives.
   2.	Propellants.
   3.	Detonators, actuators, and similar devices.
   4.	Primary and static-sensitive explosives.

   
   

2-17.5 Containers (Onsite)

1. Explosives containers shall be designed and constructed so they will not leak and will protect their contents from excessive movement, external stimuli, contamination, or spillage during handling, transportation (including transportation to disposal sites), and storage. Container closures shall prevent spilling or leakage of contents if the container is overturned. Screw-type container closures should not be used.
2. Explosives containers should be constructed of, or lined with, nonabsorbent materials that are compatible with the explosive contents. Use of glass containers is discouraged, except for small samples and shall be used only when the explosive reacts with other materials or when a high degree of purity is required.
3. Metal containers for materials that are potential dust producers shall be constructed without seams or rivet heads. Seams or rivet heads can provide locations for dust accumulation.
4. Containers for cast or pressed explosives pieces that are larger than 1 ft (0.3m) at their greatest dimension or weigh more than 11 lb (5 kg) loaded should be provided with handles or some other type of handhold. If the loaded container weighs more than 110 lbs (50 kg), provisions should be made to allow handling by mechanical-handling equipment.
5. Containers shall be labeled with the applicable UN hazard classification code and clearly marked to identify the contents.
6. Whenever possible, explosive pellets and items containing small quantities of explosives (e.g., detonators) shall be packaged in containers constructed so the functioning of one item will not propagate to the remaining items in the container. When a nonpropagating array is not possible, the pellets or detonators shall be stored inside a closed container and shall be labeled to indicate the total weight of the explosive contents.
7. Container closures shall be the type that will not apply excessive pinching or rubbing forces to explosives during closing and opening. The closures and surfaces of container openings shall be kept clean of explosives contamination to minimize any hazard during closing and opening.
8. Explosives and ammunition in damaged containers shall not be stored in a magazine with other explosives and ammunition. Damaged containers shall be repaired, or the contents transferred to new or undamaged containers, or the container plus contents moved to a Group L storage magazine.
9. Open containers and containers with covers not securely fastened shall not be stored in magazines. Containers that have been opened shall be properly closed before being returned to storage.

2-17.5S Containers (Onsite)

1. All containers with explosives must have marking and labeling information displayed prominently and legibly with storage labels generated by the EIS.
2. Single (loose) containers require individual EIS TU labels. Unitized packages (e.g. banded pallet) do not require labels on individual containers.
3. Empty containers shall be verified as “empty” and labeled “empty”. All other labels shall be removed.
4. SNL-modified red ammunition (ammo) cans may be used to store up to 2.3 grams of explosives in order to be hazard classified as 1.4S; if storing greater than 2.3 grams of explosives, the original HC/D and compatibility group applies. A 10 gram limit is recommended to fully contain fragment and blast overpressure.
5. Red explosive storage cabinets may be used to store up to 500 grams of explosives with a maximum of 25 grams per shelf to fully contain fragment and blast overpressure. Compatibility Group A materials shall not be stored on the same shelf with other materials. Placard cabinets in accordance with Section 2-22.1S of this chapter.

2-17.6 Storage in Buildings Other Than Storage Magazines

2-17.6.1 Packing and Shipping Buildings

1. In buildings specifically designated for packing and shipping, explosives may be stored subject to the following rules:

1.	Incoming shipments shall be distributed as soon as practical after receipt and shall not be allowed to accumulate.
2.	Items for outgoing shipments should not be accumulated before receipt of orders covering each specific shipment.
3.	Separate rooms shall be provided for the temporary storage of explosives awaiting shipment and for their preparation for shipment (i.e., assembling, crating, marking, etc.). The rooms shall be divided by walls or separated to prevent an explosion in the preparation area from propagating to the temporary storage area.
4.	The combined total amount of explosives permitted in shipping/receiving buildings, platforms, and transportation vehicles shall be based on quantity-distance constraints. When an adequate barricade (sufficient to prevent sympathetic detonation) is in place between transportation vehicles and the adjoining building or platform, quantities on each side of the barricade may be considered individually to determine quantity-distance requirements.
5.	If required by operational necessity, explosives and pyrotechnics that are part of the work in process within the building may be stored during non-operational hours in operating buildings provided: a. Explosives limits are not exceeded. b. Containers of bulk explosives or pyrotechnics are properly secured and covered. d. Processing equipment, such as hoppers and pipelines, is empty.

2-17.6.2 Service Magazines

1. The guidelines for storage magazines presented in Sections 2-17.1 through 17.5 of this chapter shall also apply to service magazines, except as modified below:

1.	An explosives item should be stored for no longer than necessary in a service magazine (with a maximum of 180 days).
2.	Service magazine inventory should be reviewed every three months. Any material that has been in the service magazine for a period approaching 180 days and is not expected to be used immediately should be disposed of or removed to an appropriate storage magazine.
3.	When practical, explosives stored in service magazines shall be in containers. Unpackaged explosives-containing devices and unsealed bulk explosives containers may be present in a service magazine. However, these items and unsealed containers shall be stored in a manner that renders them stable and unlikely to be dropped or spilled.
4.	Minimum/maximum temperature monitors are not normally required for service magazines.

2-17.6.2S Service Magazines

1. "Service magazines or service lockers" are approved by Explosive Safety Engineering and shall not contain explosive items for longer than 180 days. Once the 180-day limit has been reached, the explosive item must be transferred to a long-term storage facility. An exception to the 180-day storage criteria shall be approved by Explosive Safety Engineering when circumstances dictate.

2-17.6.3 Warehouses

1. Hazard Class 1.4 materials (refer to Section 6-3.1) packaged as Hazard Class/Division 1.4, Storage Compatibility Group S, may be stored in warehouses if they are placed in segregated and specifically designated areas.
2. Articles in Hazard Class/Division 1.4 and Storage Compatibility Group S are considered inert for storage purposes and are not subject to quantity-distance requirements as long as they are stored with inert items or other Hazard Class/Division 1.4S items only. This applies only if Hazard Class/Division 1.4 and Storage Compatibility Group S articles remain in their original packaging container or are proven to be self-contained. When stored with items in a Storage Compatibility Group other than S, normal quantity-distance requirements must be observed.

2-17.6.4 Pre-positioned Storage of Security Response Munitions

1. When required for defense against hostile forces, and in support of response and contingency plans, limited quantities of authorized response force munitions may be pre-positioned at locations other than bulk-storage magazine areas.
2. Compliance with Quantity-Distance and compatibility criteria is not required during a heightened security condition.
3. Munitions will be kept in their original shipping containers unless operational necessity dictates otherwise.
4. Personnel charged with the responsibility of overseeing storage of munitions at guard stations and contingency deployment sites shall be trained in explosives storage and transportation, as required in Chapter V of this manual.
5. When Hazard Class/Division 1.2 is stored inside or at less than inhabited-building distance from inhabited buildings, fragment barriers will be provided. Minimally acceptable fragment barriers are: 0.25 in. (6.35 mm) of mild steel plate, one layer of sand bags, 12 in. (.3 m) of loose sand or dirt, or other equivalent protection.

2-18.0 DECONTAMINATION AND CLEANING

2-18.1 General

1. Operating procedures shall specifically cover decontamination. These procedures should cover methods, inspection, marking, control, dismantling, maintenance, final disposition, etc.
2. Hot water or steam may be used to clean or remove explosives contamination from equipment. If necessary, solvents that have been tested for and are compatible with explosives can be used. Operating procedures must specify controls for their use. When cleaning or removing explosives material from equipment, work surfaces, and floors, only clean cloth rags, paper wipes, and approved non-metallic brushes or scrapers should be used in conjunction with hot water, steam, and solvents.
3. Disposal of waste generated during decontamination shall be coordinated with site environmental/waste management personnel.

2-18.2 Cleaning Contaminated Equipment

1. Items to be cleaned should be positioned so that water and residue will drain directly into an approved collection system. See Sections 2-19.0 and 2-20.0 of this chapter for guidance concerning waste collection and waste disposal.
2. Personal protective equipment as required shall be used by personnel decontaminating facilities and equipment. Emergency shower and eyewash shall be provided where needed.
3. Exhaust ventilation may be required to remove toxic explosives fumes or vapors and/or steam from the decontamination area.

2-18.3 Cleaning Screw Threads

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

2-18.4 Final Decontamination and Disposal of Equipment

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

1.	Items undergoing final decontamination by thermal techniques shall be subjected to sustained heating at a temperature at least 140º F (60º C) higher than required for decomposition of the most thermally stable explosive substance present. The item shall be kept at that temperature for a sufficient period of time to ensure that all parts have reached the temperature and all explosives material is decomposed. Thermal decomposition is usually accomplished by placing the items to be decontaminated in a high-temperature sustained fire (see TB 700-4). This operation shall be conducted remotely or with operator protection.
2.	Final decontamination also may be accomplished by immersing the item in a chemical cleaning agent. The period of immersion shall be sufficient to ensure that all explosive material is chemically decomposed. The chemical cleaning agent shall be one that the Department of Army TM9-1300-214 has approved for use. Chemical cleaning agents for decontamination or destruction of explosives should not be used for more than about 1 oz (or about 28 g) of explosives. Reference TM9-1300-214 for decontaminating chemicals for explosives and for color tests for identification of energetic materials.
3.	Before subjecting the item to final decontamination by thermal or chemical techniques, as much explosive as possible shall have been removed by approved means (hot water, steam, and approved solvents in conjunction with cloth or paper wipes and non-metallic brushes or scrapers).

2-18.5 Inspection

1. After decontamination procedures are complete and before transfer to a nonexplosive area, the item shall be inspected. The degree of decontamination shall be determined/documented and the item shall be labeled to indicate its decontaminated state. Representatives of at least two departments, such as operations or safety, should accomplish the inspection.

2-18.6 Identification and Control of Decontaminated Items

1. Decontaminated items shall be marked to indicate the degree of decontamination and stored separately from noncontaminated items until final disposition is made.
2. Degrees of decontamination shall be designated and all items shall be tagged and/or marked with this designation.
3. Guidelines for establishing a system for designating degrees of decontamination are provided below:

1.	X - A single X indicates that the facilities or equipment have been partially decontaminated. Additional decontamination processes are required before facilities or equipment are moved or any maintenance, repair, etc. is performed. The X rating would apply to facilities, rooms, bays, or equipment that have been subjected to routine decontamination performed by an operator at the close of the workday.
2.	XXX - Three Xs indicate the equipment or facilities have been examined and decontaminated by approved procedures; no contamination can be detected by appropriate instrumentation, test solutions, or by visual inspection on easily accessible surfaces or in concealed housings, etc. and are considered safe for the intended use. Items decontaminated to this degree cannot be furnished to qualified, DOE, DoD, or industry users or be in direct contact with an open flame (cutting, welding, high temperature heating devices), or operations which generate extreme heat, such as drilling and machining unless the following two conditions are met: a. It is determined that decontamination to the XXXXX level will destroy the item’s usefulness. b. Decontamination to a degree less than XXXXX in combination with administrative and technical safeguards will eliminate risk of injury. As a minimum, an approved SOP setting forth the specific operational limitations, precautions, and monitoring necessary to assure safety will be available and decontamination will be performed under the direction of the inspectors who will certify decontamination.
3.	XXXXX - Five Xs indicate the equipment or facilities are completely decontaminated, hazard-free, and may be released for general use or to the general public.
4.	O - A (Zero) indicates the item, although located in a contaminated area, was never directly exposed to contamination.

4. Reference TB 700-4 for decontamination methods and marking.

2-18.7 Decontamination of Real Estate

For decontamination of real estate reference DoD 6055.9-STD.

2-18.8 Decontamination and Cleaning References

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

   1.	DoD 6055.9-STD.
   2.	TB 700-4.
   3.	TM 9-1300-214

2-19.0 WASTE COLLECTION

2-19.1 General

1. Provision shall be made to remove explosives waste from areas where explosive waste is generated. Removal of explosives waste may be accomplished by collecting dust/fines or chips in a wet or dry vacuum system or a slurry of water or nonflammable solvent, or by collecting solid waste in receptacles (See also Chapter II, Sections 2-9.0, 2-10.0, and 2-11.0).
2. Explosives waste shall be collected and maintained separately from conventional waste.
3. Mixing of incompatible explosives shall be avoided. Receptacles shall be clearly labeled to indicate the type of waste permissible.

2-19.2 Solid Wastes

1. Areas where solid explosives wastes are not removed by vacuum or liquid systems shall be equipped with a seamless or lined receptacle to collect explosives wastes. The receptacle should never be more than half full.
2. Explosives waste shall be removed from the collection point on a regularly and frequently enough to keep aggregate levels within explosive weight limits.
3. Rubbish not contaminated by explosives or containing noncombustible materials shall not be placed in an explosives waste receptacle.
4. Explosives-contaminated rubbish shall be placed in separate waste containers and segregated as combustibles and noncombustibles.
5. Before being transported, explosives waste shall be packaged to prevent spills, leaks, or exposure to initiation stimuli. Incompatible materials shall not be packaged together. All packages of explosives waste shall be labeled clearly to indicate the nature and approximate quantity of contents.

2-19.3 Vacuum Collection of Explosives Dusts

1. Explosives dusts should be collected by a vacuum system, preferably the wet type. Dust in a wet vacuum should be maintained in wet form using a wetting agent that is kept close to the point of origin and kept wet in the collection system until removed for disposal. Water-soluble explosives such as Explosive D should be collected in a dry vacuum system.
2. Storage compatibility Group A explosives may be collected by a wet vacuum system, provided they are maintained in a wet form using a wetting agent that is kept close to the point of intake. Use of a vacuum system to collect these more sensitive materials should be confined to operations involving small quantities of explosives.
3. Dry-type dust collection chambers, except portable units, should be located in the open, outside operating buildings, or may be inside if adequate shielding is provided. The quantity of explosives collected shall not exceed the capacity of the shielding to protect operating personnel. The degree of barricading and the appropriate intraline distance shall determine this limit.
4. If dry dust collection outside a building is not practical, a separate room or shielded area within the building shall be designated for this purpose. This room or shielded area shall not contain other operations, or be used as a communicating corridor or passageway between other operating locations within the building when explosives are being collected.
5. Stationary and portable wet-type collectors may be placed in the explosives operating bays or cubicles if the quantity of explosives in the collectors does not exceed 4.4 lbs (2 kg). If placed in separate cubicles, the explosive weight limits may be increased by an amount determined by the extent of the cubicle walls' capabilities to serve as operational shields.
6. Collection systems and chambers shall be designed to prevent explosives from being pinched between metal parts. See Sections 2-9.0 and 2-10.0 of this chapter for additional design information.
7. Two collection chambers shall be installed ahead of the pump or exhauster in series to prevent explosives dust from entering the vacuum producer in dry vacuum collection systems. In addition, non-sparking fans and dust-tight motors shall be used.
8. Dry-type portable vacuum collectors shall not be located in bays or cubicles where explosives are present or in enclosed ramps, but may be positioned outside the building or in a separate cubicle. The building or cubicle walls shall provide adequate shielding for at least 4.4 lbs (2 kg) of explosives. Shielding and quantity-distance constraints shall define the explosives limits.
9. Explosives dust shall be removed from the collection chamber periodically to eliminate unnecessary and hazardous explosives concentrations. The entire system should be cleaned periodically, dismantling the parts if necessary. A cleaning schedule shall be established for the collection chamber and the entire system using the operating hours as a basis.
10. The entire explosives-dust collecting system shall be electrically bonded and grounded with resistance-to-ground not exceeding 10 ohms. The grounds shall be tested periodically.

2-19.4 Explosives Slurries

1. Machine tools shall be fitted with wet boxes to catch and direct water and explosives fines to an explosives waste gutter system.
2. Wastewater that might contain explosives materials shall be kept from contaminating potable water or conventional wastewater systems.
3. Settling tanks shall be inspected regularly to monitor the waste accumulation. Records of waste removal shall be kept.
4. When pumping settled explosives from a slurry-settling tank, the operation shall be arranged to preclude exposure of the explosive material to pinching.
5. Explosives materials in settling basins shall be kept wet until removed. The materials shall be maintained wet until spread out for disposal. Explosives materials containing powdered metals shall be kept sufficiently wet to prevent a dangerous temperature rise resulting from a reaction of the metal with water. The possibility of hydrogen generation in this situation must be anticipated. If an explosive or flammable gas can be generated, then proper ventilation shall be supplied to prevent an explosive or flammable mixture from accumulating.

2-19.5 Metal Scrap

1. Metal scrap shall be inspected to detect explosives-contaminated items and a qualified reviewer shall certify that the scrap is free of explosives before disposition.
2. When scrap is found to be contaminated with explosives, it shall be decontaminated in accordance with final decontamination procedures (see Section 2-18.4 of this chapter).

2-19.6 Explosives Recovery and Reuse

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

2-20.0 WASTE DISPOSAL

2-20.0S GENERAL REQUIREMENTS

1. The requirements  for explosive waste management and requesting disposal are located in ESH100.2.ENV.22, Manage Hazardous Waste at SNL.
2. If an emergency requires damaged or waste explosives to be burned, detonated, or otherwise reacted for the purpose of disposal, or if any unreacted explosives are released into the environment, immediately call either the emergency number, the non-emergency hotline, or the ES&H Hotline (SNL/CA) number as appropriate. Document the following information:

1.	Time and date of the event.
2.	Weather conditions at the time of the event.
3.	Exact location of the event and a brief description of the area.
4.	Description of the event.
5.	Description of all materials involved, including quantities.
6.	Name and title of the person responsible for determining the event was necessary.

2-20.1 Preparation for Open Burning

1. Preparations to burn or place explosives waste on a pad or in a pit shall not begin until 24 hours after the previous burn at the same burning point. The only exceptions are if the burn area has been thoroughly soaked with water and inspected by qualified person(s) or the temperature of the burning tray/surface has been measured and inspected by qualified person(s) or the temperature of the burning tray/surface has been measured and inspected by qualified person(s) to assure personnel safety during subsequent burning operations. In any case, the burning point shall be inspected for residual embers or hot spots before loading with explosives.
2. Before beginning preparations, firing controls shall be disconnected from power sources and circuits shunted and grounded.
3. Some explosives give off toxic vapors or fumes when destroyed by burning. Proper respiratory protective equipment shall be worn when such hazards are likely.
4. Incompatible explosives materials shall not be in the same pit or on the same pad at the same time.
5. Personnel engaged in burning explosives should be provided with non-static producing cotton clothing.
6. Containers of explosives materials shall not be opened less than 10 ft (3 m) from each other.
7. Empty explosives waste containers that are to be reused shall be situated an adequate distance from the burning point to prevent charring or damage during the destruction operation.
8. Based on past experience or analysis, a layer of excelsior or similar material may need to be placed on the bottom of the pit or pad where the explosives waste will be placed.
9. Powdered, granular, or slurry form explosives should be placed in a layer not more than 3.15 in (8 cm) thick. Water-wet initiating explosives (storage compatibility Group A) shall not be allowed to dry completely.
10. Wood, heating oil, LPG, or natural gas is authorized to ensure complete combustion of the explosives waste material.
11. The ignition train should be set up to burn upwind, except that the ignition train for burning IHE may be set to burn downward.
12. The firing circuit shall require a key for completion. Only one copy of the firing key shall exist, and it shall be in the lead operator's possession.
13. Radio transmitters and cellular phones in the control shelter and vehicles at the burning site shall be turned off during setup and firing of low energy electrical squibs to provide protection against radio frequency currents.
14. Precautions shall be taken to ensure that extraneous electrical currents from any source will not unintentionally activate the firing system.
15. The burn shall be primed after all other preparation work is complete and with a minimum number of personnel present.
16. Ignition shall be accomplished remotely.

2-20.2 Destruction by Burning or Flashing

1. Open burning operations will comply with the requirements of applicable Federal, State, and local air pollution, hazardous waste, and other environmental regulations and permits.

2. Explosives waste may be destroyed by remote burning if it can be done with little chance of detonation. Explosives-contaminated waste may be burned remotely in a wire cage.
3. An open furnace or burning area for explosives should be used to destroy wet-machining cuttings and classified parts. The same furnace or burning area may also be used for flashing casings after washout of an explosive charge.
4. Explosives should not be burned in closed containers or casings, or in large pieces likely to detonate. Special attention should be given to the placement and orientation of large items and those in closed containers or casings. Approved incinerators may be used to destroy small devices such as detonators, actuators, etc.
5. Concurrent burning operations shall not be conducted within 150 ft (45 m) of each other.
6. When several pads are burned, the downwind pad shall be ignited first, followed by the others in succession.

2-20.2S Destruction by Burning or Flashing

1. At SNL/NM, open burning must comply with the permitting requirements stated in ESH100.2.ENV.12, Obtain and Comply with Air Permits.
2. Except in emergencies as described in Section 2-20.0S (b) above, the following is prohibited: open burning or detonation of any explosive or explosive waste for the purpose of disposal or to change the physical or chemical character or composition of the explosive so as to neutralize, recover energy or material, or to render it non-hazardous or less hazardous, safer to transport, store, or dispose of, or to make it amenable for storage or recovery, or to reduce the volume.

2-20.3 Ignition System Malfunctions

1. If the ignition system fails to fire, check the circuit's continuity. If no open circuits are detected, refire.
2. If the squibs fire but fail to ignite the ignition train, remotely survey the area, and wait at least 30 minutes. When it appears safe to emerge from the control shelter, disconnect, shunt, and ground the firing circuit, and inspect the squibs, firing system, or ignition train.

2-20.4 Postburn Operations

1. No entry should be allowed into the disposal area until eight hours have elapsed unless it can be determined visually that all explosives have been destroyed.
2. Squib firing lines shall be disconnected, shunted, and grounded before personnel can enter the burn area.
3. Unburned or partially burned explosives materials remaining in the pit or pad may be moved or repositioned for further burning. The material shall not be raked or otherwise insulted. The burning operation shall be repeated to destroy any remaining explosives waste.
4. At least 24 hours shall elapse before ashes are collected, unless the burn area has been thoroughly soaked with water and inspected by qualified person(s) or the temperature of the burning tray/surface has been measured and inspected by qualified person(s) to assure personnel safety.

2-20.5 Disposal Area

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

1.	For destruction by open burning or flashing, the minimum separation distance from unprotected personnel and from facilities not associated with the operation shall be Hazardous Fragment Distance in DoD 6055.9-STD, unless carried out in pits or with other aids for limiting the range of fragments and debris if an accidental detonation occurs. Sites should be located taking into account the direction of the prevailing winds to prevent sparks from being blown toward explosives locations.
2.	The size of the danger zone for destruction by open detonation shall be determined by the formula D(ft) = 328 W⅓ [D(m) = 131 Q⅓]
3.	The minimum separation distance shall be: a. Non-fragmenting explosive materials – 1250 ft (381 m) b. Fragmenting explosive material - 2500 ft (762 m) 3. Bombs/projectiles with 5-in (12.7 cm) caliber or greater – 4000 ft (1220 m) 4. If known, the maximum fragment (debris) throw distances with an applicable safety factor may be used to replace the 2500 ft (762 m) and 4000 ft (1220 m) minimum separation distances but not below 1250 ft (381 m).
4.	Self-contained destruction facilities fully analyzed for the intended NEW are exempt from the above requirements.

2. The maximum quantity of explosives that may be destroyed at one time shall be determined by starting with a small quantity, gradually increasing until an optimum amount, consistent with safe and efficient operation, is reached.
3. Explosives waste and ordinary rubbish shall not be destroyed in the same destruction area at the same time.
4. During destruction operations, the area within 200 ft (60 m) of the destruction point shall be kept clear of dry grass, leaves, and other extraneous combustible material. This clearance may be reduced to fire brand distance if aids to limit the range of fragments and debris are provided for the destruction points used within the disposal area.
5. Explosives waste awaiting destruction shall be stored at least intraline distance from the explosives being destroyed.
6. Trucks transporting explosives to the burning disposal area shall meet the requirements of Chapter II, Section 2-16.0. Upon arrival at the burning grounds, explosives containers will be distributed to trays or other disposal locations. Vehicles shall be moved to a safe location as soon as explosives items have been removed. Explosives containers shall not be opened until vehicles have been withdrawn.
7. Provisions for emergency fire fighting shall be readily available at the waste disposal area.
8. The burning grounds shall be serviced with telephones or two-way radio communication.

2-20.6 Destruction by Detonation

1. Cased explosives should be removed from cases and burned or the cased item destroyed by detonation. Detonators, primary explosives, and other explosives that might detonate if burned should also be destroyed by detonation.
2. A high-energy detonator (e.g., an EBW) should initiate the detonation.

2-20.7 Use of Solvents

1. Solvent immersion may be used to prepare small quantities of explosives and explosive detonators for destruction.
2. The items to be destroyed shall be soaked in a suitable, compatible solvent until all the explosives material is dissolved. Saturated solvent solutions shall not be reused.
3. Solvent-explosives mixtures shall be destroyed by burning.

2-21.0 LABORATORY OPERATIONS

2-21.1 General

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

2-21.2 Safety Shields

1. If a laboratory operation involves an explosion hazard, personnel should be protected by safety shields or the operation should be performed remotely. Table II-6 lists shields that have been tested and found acceptable for the indicated quantities of explosive.

Note: Shields listed in Table II-6 were not tested for metal-fragment penetration (unless specifically indicated) and thus may not offer effective protection when the explosive is closely confined in a heavy-walled metal container. ("Heavy-walled" is defined here as wall thickness to diameter ratio greater than 0.01.)

Table II-6. Safety Shields for Explosives Laboratory Operations*

Shield	Minimum Distance From Explosive (cm)	Explosives Limit
Leather gloves, jackets or coats, and plastic face shields	--	50 mg
3-mm tempered glass	8	50 mg
7-mm Lucite/equivalent material	15	2.5 g
20-mm Lucite/equivalent material	15	10 g
15-mm laminated resistant glass	20	20 g
25.4-mm Lexan/Lexguard	30	50 g
2 units each of 25.4-mm plate glass laminated with 12.4-mm polycarbonate with a 9.5-mm air gap between units (glass sides facing the explosive)	30	50 g (steel confined)
* Recent blast testing has shown that laminated tempered glass is superior to monolithic tempered glass, and polycarbonate is superior to acrylic plastics, such as Lucite. Laminated tempered glass is recommended instead of monolithic tempered glass and polycarbonate is recommended in lieu of acrylic. The shields are recommended to be of equal or greater thickness than those listed in the table. Proof testing is highly recommended. When designing and/or replacing a safety shield with a polycarbonate, it should be UV stabilized, treated for abrasion resistance, and have met Mil Spec P-46144C. When designing and/or replacing a safety shield with laminated glass, it should be coated with a 0.1 mm fragment-resistant film on the viewer's side to minimize spalling. The shield, shield frame, and anchoring system shall be designed to resist maximum credible overpressure and fragments.

2. If an experiment poses a metal-fragment hazard (as opposed to a glass-fragment hazard), and the experiment cannot be conducted remotely, the proposed shield should be tested and approved under conditions simulating an explosion in the experimental setup but with at least 125 percent of the anticipated explosive content.
3. The shield shall be anchored to the hood frame or bench top when it is being used for protection against more than 0.16 oz (5 grams) of TNT equivalent.
4. Other shields may be used after successfully passing a test of 125 percent of the rated explosive charge and being approved.
5. For confined areas, a blast vent having less strength than the shield should be provided.
6. When explosives operations require personnel to reach around a shield to manipulate equipment, exposure shall be minimized.

2-21.2S Safety Shields

1. Use safety shields when they are required by a technical work document (TWD). Organization management must maintain documentation showing that the shielding will provide adequate protection in case of a maximum credible event.

2-21.3 Heating Operations

1. During synthesis, formulation, or experimental work, heat may be applied to initiate or maintain reaction, to increase solubility, etc., if the principles below are followed:
• Heat shall be applied indirectly using steam, a water bath, oil bath, or an approved laboratory electrical heating device such as a mantle.
• Utmost caution shall be exercised to ensure that reactive material does not come in direct contact with the heating elements.
• If an experiment must be conducted behind a shield, any heating device shall be mounted so that temperature can be controlled from the operator side of the shield. The heating device should be mounted so it can be separated quickly from the reaction vessel without operator exposure. Consideration should be given during design of the experiment to providing emergency cooling for the reaction vessel or its contents.
• Heating of explosives with devices without proper controls shall be monitored at all times. If the operator must leave for any reason, the heating device should be turned off. Heating systems that will be operated unattended shall have dual controls, an override shutoff, or some other protection against failure of the primary heating control. Systems capable of totally containing the effects of an explosion may be exempted from this requirement.
2. Periodic checks should be made to ensure that an experiment is proceeding satisfactorily and that the apparatus is not boiling dry, malfunctioning, etc. In the case of remotely controlled operations, provisions shall be made for observation, using mirrors, television monitors, etc.

2-21.4 Laboratory Setups

1. Good workmanship and laboratory practice shall be exercised in making and operating laboratory setups. In particular, the following guidelines apply:

1.	Equipment and apparatus shall be clean, in good condition, and in good working order.
2.	All glassware and apparatus shall be inspected for cracks, defects, etc., before use. Defective or damaged equipment shall be removed from service.
3.	Setups shall be geometrically and structurally stable
4.	Work areas should be as neat and uncluttered as possible.

2-21.5 Low Concentration of Explosives in Solution

1. After explosives are in dilute solution (less than 25 percent explosives by weight), the primary hazard shall be considered as that associated with the solvent and not with the explosive. Where supported by technical data and approved by the Explosives Development Committee (EDC), a solvent/explosives solution greater than 25 percent may also be similarly classified.
2. If the explosive recrystallizes or precipitates out of solution, safety guidelines for pure explosives shall apply.

2-21.6 Explosives Sample Control

1. Samples shall be delivered to the laboratory only at specific designated locations.
2. Each sample shall be properly identified and labeled.
3. Upon completion of the required tests or analyses, the sample should be removed from the laboratory.
4. A safety information sheet should accompany all samples of new experimental explosive material submitted to a laboratory for analysis.

2-21.7 De Minimis or Residual Quantities

Based on a total mass size less than the critical diameter, primary explosives .01543 gr (1 mg) or less and secondary explosives .1543 gr (10 mg) or less are considered non-detonable by abnormal stimuli or environment (see Chapter II-1.1a). Locations with explosives in these quantities are therefore exempt from the following requirements:

1. Electrical equipment requirements.
2. Posting of fire symbol signs and placards.
3. Quantity/distance requirements.
4. Posting of explosive limits.
5. Personnel limits.

2-22.0 EMERGENCY CONTROL

2-22.1 Placarding and Fire Symbols

1. Placards and fire symbols (as specified in DoD 6055.9-STD or the NFPA 704) shall be displayed consistently on buildings and work areas throughout an entire facility to warn of potential hazards from explosives and to provide information for emergency situations.

2-22.1S Placarding and Fire Symbols

1. Use a single method of marking all rooms, bays, lockers, and buildings where explosives are stored. Signs must reflect explosive items currently in the room, bay, lockers, or building. Remove all signs relating to explosives that are not applicable.

1.	Fire symbols are not required to be posted on the exterior of buildings in SNL/NM Tech Area I; however, rooms, bays, and lockers must comply with fire symbols.

2. The four fire divisions are represented by four distinctive shapes. For the purpose of identifying these symbols, the symbols differ in shape and require a metal backing in case the fire burns off the fire division number. The hazard decreases with ascending fire division numbers from 1 to 4 and are related to HC/D:

1.	Octagon Mass Explosion HC/D 1.1 and 1.5
2.	Cross Non-Mass Explosion, Fragment Producing HC/D 1.2 and 1.6
3.	Inverted Triangle Mass Fire, Minor Blast or Fragment HC/D 1.3
4.	Diamond Moderate Fire, No Blast or Fragment HC/D 1.4



Colors (per Federal Standard 595A or GSA Catalog)
Background: Orange #12246
Letters: Black #17038
NSN - National Stock Number

 

Table II-7. Fire Symbol Hazards and Actions [S]

Fire Symbol	Materials	Hazard	Action/Remarks
1	1.1 Explosives and class IV liquid propellants and 1.5 munitions	Mass Detonation	Do not fight fire unless rescue attempt is planned. If there is suitable separation to symbol 1 materials and fire chief approves, fire-fighting forces may attempt to extinguish the fire. If personal safety is in doubt, take cover.
2	1.2 Ammunition and explosives and 1.6 extremely insensitive detonating substances (EIDS)	Explosion with Fragments	Give alarm; attempt to extinguish fire if in early stage. Firefighting forces should fight fire. If not possible, prevent spread of fire. Detonation of items could occur. Provide protection from fragments.
3	1.3 Ammunition and explosives	Mass Fire	May be fought if explosives not directly involved. If WP munitions are involved, smoke is liberated. WP munitions may explode. Immerse Phosphorus in water or spray with water continuously. For fires involving HC and incendiaries use dry sand or dry powder in early stage. For fires involving pyrotechnics and magnesium incendiaries. Protect adjacent facilities and equipment. Do not use carbon dioxide, Halon extinguishers or water on or near munitions. Allow magnesium to cool unless upon flammable material. In this case, use a 2-inch layer of dry sand or powder on the floor and rake the burning material onto this layer and re-smother.
4	1.4 Ammunition and explosives	Moderate Fire	Fight these fires. Expect minor explosions and hot fragments

3. Full-sized (24 inch) fire division symbols are used for the following:

1.	Standard igloos. Attach the fire division symbol to the igloo at least five feet from ground level and center it on either the left or right wall so it is visible to anyone approaching or attach it to a freestanding post next to the igloo.
2.	Multiple cubicles. Place the fire division symbol on both ends and the back side of the cubicles. Center it so it is visible to anyone approaching.

4. Half-sized (12 inch) fire division symbols are used on inside doors and lockers containing explosives. Where possible, center them about 1 inch below the laboratory/interior facility sign.
5. Chemical hazard symbols warn fire fighters of possible hazards and protective measures to take. They may be used by themselves or with the fire division symbol. Place the appropriate sign on the front of the building at least 5 feet from ground level and centered on either the left or right wall so it is visible on approach.



6. If these requirements cannot be met, contact Explosive Safety Engineering.

2-22.2 Explosives Emergency Control Plans

1. Each installation shall have a facility-specific written plan for the control of emergencies involving explosives (The plan may need to be broken down for each operating area). An explosives emergency control plan may be part of the facility’s overall emergency control plan. All facility personnel shall be trained in the plan’s content applicable to their area. The plan shall be available to all personnel for ready reference.

2. Emergency situations that should be covered include the following:

1.	Fires and explosions.
2.	Floods.
3.	Extreme weather conditions.
4.	Conditions resulting in environmental disturbances
5.	Civil disturbance.
6.	Threats and bomb scares.
7.	Enemy attack.
8.	Other emergencies that require rapid mobilization of personnel and equipment to minimize death and injury to personnel or to prevent the spread of damage and destruction.

3. The plan should address:

1.	Reporting an emergency.
2.	Criteria for activating the emergency plan.
3.	Authority and responsibility for administering and execution of the plan.
4.	Mobilization of personnel to respond to an emergency or disaster
5.	Roles of operating personnel in responding to an emergency.
6.	Procedures for responding to an emergency or disaster.
7.	Accounting for evacuation of personnel.
8.	Plant and document security.

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