Attachment 07_MIL-STD-1904C.pdf

MIL-STD-1904C (AR)

11 September 2022

SUPERSEDING

MIL-STD-1904B (AR)

09 March 2016

TEST STANDARDS FOR LEVEL A AND LEVEL B

PACKAGING FOR CONVENTIONAL AMMUNITION

AMSC N/A FSC 8140

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

INCH-POUND

Source: https://assist.dla.mil -- Downloaded: 2023-03-01T07:02Z Check the source to verify that this is the current version before use.

FOREWORD

1. This standard is approved for use by all Departments and Agencies of the Department of Defense.

2. Comments, suggestions, or questions on this document should be addressed to: U.S. Army DEVCOM Armaments Center: FCDD-ACE-QSA, Picatinny Arsenal, New Jersey 07806-5000 or emailed to usarmy.picatinny.ccdc-ac.list.ardec-stdzn-branch@army.mil Since contact information can change, you may want to verify the currency of this information using the ASSIST Online database at https://assist.dla.mil.

3. The logistical and tactical requirements for ammunition packaging/packing systems are varied and complex. In order to design packaging systems to meet these requirements, material and environmental criteria must be defined to ensure the success of the design and ultimate satisfactory use in the field. This standard interprets the environment that packed ammunition may be subjected to within the ammunition logistic system from time of production to time of expenditure and recommends material and design requirements to withstand that environment. The interpretation of the environment is in terms of test simulations which may be readily understood and executed during the packaging development period.

4. This revision has resulted in numerous changes/additions to MIL-STD-1904 Revision B, the most significant being:

a. Inclusion of requirements for Level B Ammunition Packaging from MIL-STD- 1905A, which was inactivated in April 2014. Level B packaging is for favorable worldwide shipping and storage conditions, without Level A pressure retention requirements. Test temperatures for Level B packaging are the same for Level A non-tactical (+145 deg. F, +72 deg. F, and -30 deg. F.

b. Level C Ammunition Packaging requirements from MIL-STD-1905A are no longer used by the Department of Defense. The latest revision to AR 700-15 only recognized two levels of Military Packaging: Level A and Level B.

ii

Check the source to verify that this is the current version before use.

mailto:usarmy.picatinny.ccdc-ac.list.ardec-stdzn-branch@army.mil https://assist.dla.mil/

CONTENTS

PARAGRAPH PAGE

FORWARD .................................................................................................................... ii

1. SCOPE

1.1 Purpose

1.2 Scope

1.3 Application

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications and standards

2.2.2 Other Government documents, drawings and publications

2.3 Non-Government publications

2.4 Order of precedence

3. DEFINITIONS

3.1 Packaged item

3.2 Packaged item damage

3.2.1 Physical damage

3.2.2 Mechanical damage

3.3 Packaging

3.4 Pack or container

3.5 Pallet

3.6 Unitization

3.7 Marking

3.8 Level A Tactical

3.9 Level A Non-tactical

3.10 Level B

3.10.1 Level B Maximum

3.10.2 Level B Standard

3.11 Moisture Sensitive

3.12 Design Activity

4. GENERAL REQUIREMENTS

4.1 Level A ammunition transportation, handling and storage

4.1.1 Packaging

4.1.2 Unitization

4.1.3 Containers

iii

4.1.3.1 Weight

4.1.3.2 Humidity control

4.1.3.2.1 Pressure retention

4.1.3.2.2 Desiccant

4.1.3.2.3 Gasket

4.1.3.3 Container materials

4.1.3.3.1 Metal

4.1.3.3.2 Plastic

4.1.3.3.3 Nuclear, biological, chemical (NBC) survivability

4.1.3.4 Security Seal

4.1.3.5 Interlock

4.1.3.6 Re-usability

4.1.3.7 Pallets

4.1.3.8 Markings

4.1.3.8.1 Container/Identification Marking

4.1.3.8.2 Performance oriented packaging (POP) Markings

4.2 Level B ammunition transportation, handling and storage

4.2.1 Packaging

4.2.2 Unitization

4.2.3 Markings

4.2.4 Performance oriented packaging (POP) markings

4.3 General Test Description

4.3.1 Vibration and handling tests

4.3.1.1 Vibration

4.3.1.1.1 Secured cargo vibration

4.3.1.1.2 Loose cargo vibration

4.3.1.1.3 Rack vibration

4.3.1.2 Free fall drop

4.3.1.2.1 Three foot drop

4.3.1.2.2 Seven foot drop

4.3.1.2.3 Forty foot drop

4.3.1.3 Edgewise-cornerwise-rollover

4.3.1.4 Hoisting

4.3.1.4.1 Sudden lift

4.3.1.5 Tiedown

4.3.1.6 Forklift

4.3.1.7 Stacking

4.3.2 End impact

4.3.3 Humidity control

4.3.3.1 Pressure retention

4.3.3.2 Desiccant (Humidity)

4.3.4 Container material

4.3.4.1 Solar radiation

4.3.4.2 Temperature shock

iv

4.3.4.3 High temperature

4.3.4.4 Chemical resistance

4.3.4.5 Container burning characteristics

4.3.4.6 Water vapor transmissibility

4.3.4.7 Electrical conductivity

4.3.4.8 Compatibility

4.3.4.9 Corrosion resistance (salt spray)

4.3.4.10 Accelerated heat aging – environmental stress cracking (AHA-ESC)

5. DETAILED REQUIREMENTS

5.1 Container testing - Level A ammunition packaging

5.1.1 Purpose

5.1.2 Background

5.1.3 Temperature range

5.1.4 Test conditions

5.1.5 Sequential testing for Level A tactical containers

5.1.5.1 Exterior containers under 150 pounds

5.1.5.1.1 Pressure retention test

5.1.5.1.2 Stacking test

5.1.5.1.3 Secured vibration test

5.1.5.1.4 Three foot drop test

5.1.5.1.5 Loose cargo test

5.1.5.1.6 Seven foot drop test

5.1.5.1.7 Rack vibration test

5.1.5.1.8 Forty foot drop test

5.1.5.1.9 Desiccant (humidity) test

5.1.5.2 Exterior containers over 150 pounds

5.1.5.2.1 Pressure retention test

5.1.5.2.2 Stacking test

5.1.5.2.3 Hoisting test

5.1.5.2.3.1 Sudden lift test

5.1.5.2.4 Secured vibration test

5.1.5.2.5 Loose cargo test

5.1.5.2.6 Edgewise-cornerwise-rollover test

5.1.5.2.7 End impact test

5.1.5.2.8 Tiedown test

5.1.5.2.9 Forty foot drop

5.1.5.2.10 Forklift

5.1.5.2.11 Desiccant (humidity) test

v

5.1.6 Container material test

5.1.6.1 Solar radiation

5.1.6.2 Temperature shock

5.1.6.3 High temperature

5.1.6.4 Chemical resistance

5.1.6.5 Container burning characteristics

5.1.6.6 Water vapor transmissibility

5.1.6.7 Electrical conductivity

5.1.6.8 Compatibility test

5.1.6.8.1 Reactivity (non-volatile packaging materials)

5.1.6.8.2 Reactivity (volatile packaging materials)

5.1.6.8.3 Vacuum stability (non-volatile packaging materials)

5.1.6.8.4 Vacuum stability (volatile packaging materials)

5.1.6.9 Corrosion resistance (salt spray)

5.1.6.10 Acceptance heat aging - environmental stress cracking (AHA-ESC)

5.1.7 Performance oriented packaging (POP) Test

5.1.8 Level A non-tactical

5.1.8.1 Packs 150 pounds and under

5.1.8.2 Packs over 150 pounds

5.2 Container testing - Level B ammunition packaging

5.2.1 Purpose

5.2.2 Background

5.2.3 Temperature range

5.2.4 Test conditions

5.2.5 Sequential testing for Level B ammo containers (150 pounds or less)

5.2.5.1 Level B maximum

5.2.5.2 Level B standard

5.2.6 Sequential testing for Level B ammo containers (more than 150 pounds)

5.2.6.1 Level B maximum

5.2.6.2 Level B standard

5.3 Acceptance Criteria for Level A and Level B Packaging

5.3.1 Ammunition - general

5.3.2 Ammunition/container/pallet - abnormal environment

5.3.3 Ammunition - normal environment

5.3.4 Container - normal environment

5.3.5 Pallet - normal environment

5.3.6 Pressure retention

5.3.6.1 Acceptance

5.3.6.2 Loaded containers under 150 pounds

5.3.6.3 Loaded containers over 150 pounds

5.3.7 Stacking

5.3.7.1 Loaded containers under 150 pounds

5.3.7.2 Loaded containers over 150 pounds

vi

5.3.8 Container material tests

5.3.8.1 Water vapor transmissibility

5.3.8.2 Container burning characteristics

5.3.8.3 Electrical conductivity

5.3.8.4 Container integrity

5.3.8.5 Reactivity (non-volatile packaging materials)

5.3.8.6 Reactivity (volatile packaging materials)

5.3.8.7 Vacuum stability (non-volatile packaging materials)

5.3.8.8 Vacuum stability (volatile packaging materials)

5.3.8.9 Corrosion resistance (salt spray)

5.3.9 Desiccant (humidity)

5.3.10 Container - performance degradation

5.3.11 Accelerated heat aging - environmental stress cracking (AHA-ESC)

6. NOTES

6.1 Tailoring

6.1.1 Test conditions

6.1.2 Moisture sensitivity

6.2 Additional testing

6.2.1 Unitization

6.2.2 Hazard classification

6.2.3 Testing of packaged ammunition ready for release

6.2.4 Aircraft delivery

6.3 Test planning and report

6.4 Performance Oriented Packaging (POP) tests

6.5 Subject term (keyword) listing

FIGURES PAGE

1 Level A transportation vibration/handling test (for exterior packs

150 pounds or less) 2 Level A transportation vibration/handling test (for exterior packs

150 pounds or more) 3 Level A non-tactical transportation vibration/handling test 4 Package orientation 5 Edgewise drop (rotational) 6 Cornerwise drop (rotational) vii

TABLE PAGE

I Level B packs weighing 150 pounds or less II Level B packs weighing more than 150 pounds III Random vibration schedule, wheeled vehicle

IV Random vibration schedule, 2 wheeled trailer V Narrowband random on random vibration, tracked vehicle VI Narrowband random on random vibration for the M109A3

Self-Propelled Howitzer (propelling charges) VII Narrowband random on random vibration for the M109A3

Self-Propelled Howitzer (155mm Ammunition transported on the sponson) ...56

APPENDIX PAGE

A Test Procedures B Test Equipment C Rack Vibration D Typical Test Plans E Accelerated Heat Aging - Environmental Stress Cracking Test

(AHA-ESC)

viii

1. SCOPE

1.1 Purpose. The intent of this document is to supply packaging designers with guidelines on the material, performance, and testing requirements which will lead to a container (packaging system) that can provide adequate protection to the munitions packaged and be successfully fielded for Army use. These guidelines can be tailored or modified to suit particular requirements for a unique piece of ammunition as determined by the responsible design activity. However, prior to changing or altering the requirements it is mandatory that complete justification be made for these changes. The design activity will coordinate with the integrated product team, user, and/or responsible authority in identifying or changing requirements. At the satisfactory conclusion of the environmental tests listed in this standard it can be assumed that the fielded container will perform satisfactorily.

1.2 Scope. This standard establishes container material, performance, and environmental tests for use in development of packaging and packing for conventional ammunition (excluding nuclear, biological, and chemical). For purposes of this document, conventional ammunition includes a broad category of Class 1 hazardous material such as small arms, projectiles, propelling charges, fuzes, cartridges (i.e., tank, mortar), primers, detonators, rockets, grenades, mines, simulators, flares, etc. This document applies to packaged ammunition meeting Level A (maximum military protection) packaging classification and Level B (intermediate protection under generally favorable environmental conditions of worldwide shipment). It will also cover those packs and items (i.e., propellant) which require fielded Level A protection for long term storage but are not normally fielded as tactical ammunition.

The Level A and Level B packaging requirements, in general, exceed the requirements of the

Code of Federal Regulations, Title 49 (49CFR). Conformance to 49CFR will ensure compliance with the Department of Transportation safety and legal requirements for CONUS and international movement whereas this standard should ensure the operability and safety of the Department of Defense munitions when subjected to world-wide distribution, storage, handling, transportation, and tactical deployment.

1.3 Application. This standard applies broadly to all those munitions and munitions related materials which must be packaged to a Level A or Level B protection. The tests include only those conditions that are recurrent in military operations and sufficiently fixed in procedure to permit standardization. Thus, for any special conditions of military operations not covered by this standard, it is the responsibility of the packaging designer to devise and apply the appropriate tests to cover the non-standard conditions.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, and 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, and 5 of this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications and standards. The following specifications and standards form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

MILITARY

MIL-D-3464 Desiccants, Activated Bagged, Packaging Use and Static

Dehumidification MIL-DTL-27166 Valve, Pressure Equalizing, Gaseous Products MIL-DTL-45449 Pallet, Units, Wood, for Shipment of Projectile Metal Parts, and

Projectile Ammunition MIL-DTL-53072 Chemical Agent Resistant Coating (CARC) System Application

Procedures and Quality Control Inspection

STANDARDS

MILITARY

MIL-STD-129 Marking for Shipment and Storage MIL-STD-648 Design Criteria for Specialized Shipping Containers MIL-STD-650 Explosive Sampling, Inspection & Testing MIL-STD-810 Environmental Test Methods and Engineering Guidelines MIL-STD-882 System Safety Program Requirements MIL-STD-1472 Human Engineering Design Criteria for Military Systems, Equipment and Facilities MIL-STD-1660 Design Criteria for Ammunition Unit Loads MIL-STD-1791 Designing for Internal Aerial Delivery in Fixed Wing Aircraft MIL-STD-2073-1 Standard Practice for Military Packaging MIL-STD-2105 Hazard Assessment Tests for Non-Nuclear Munitions

(Copies of these documents are available online at https://quicksearch.dla.mil.)

https://quicksearch.dla.mil/

2.2.2 Other Government documents, drawings and publications. The following other Government documents and publications form a part of this document to the extent specified herein. Unless otherwise specified, issues are those cited in the solicitation.

CODE OF FEDERAL REGULATIONS

49CFR Code of Federal Regulations Title 49 - Transportation of

Hazardous Materials

(The CFR titles available online at https://www.ecfr.gov/.)

JOINT TECHNICAL BULLETINS

TB 700-2 Department of Defense Explosives Hazard Classification Procedures

(The Joint Technical Bulletin is available online at https://www.ddesb.pentagon.mil/)

ARMY REGULATIONS

AR 40-10 Health Hazard Assessment Program in Support of the Army Materiel Acquisition Decision Process

AR 70-38 Research, Development, Test and Evaluation of Materiel for Extreme Climatic Conditions

AR 70-47 Engineering for Transportability AR 70-75 Survivability of Army Personnel and Materiel AR 700-15 Packaging of Materiel AR 740-1 Storage and Supply Activity Operations AR 700-143 Packaging of Hazardous Material

(Copies of these Army Regulation are available online at https://www.apd.army.mil/ and are available from the US Army Publications Distribution Center, 1655 Woodson Rd., St Louis, MO 63114-6181)

ITOP 01-2-601 Laboratory Vibration Schedules TOP 08-2-111A Test Operation Procedure for CBR Contamination Survivability, Small Items

(Copies of these documents may be obtained online at http://www.atec.army.mil/publications/topsindex.aspx.)

MS 20003 Indicator, Humidity, Card, Three Spot, Impregnated Areas

(Cobaltous Chloride)

(Copies of this document may be obtained online at https://quicksearch.dla.mil .)

Check the source to verify that this is the current version before use.

https://www.ecfr.gov/.)

http://www.ddesb.pentagon.mil/) https://www.apd.army.mil/ http://www.atec.army.mil/publications/topsindex.aspx.)

https://quicksearch.dla.mil/

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL

ASTM A109/A109M Steel, Strip, Carbon (0.25 Maximum Percent), Cold-Rolled ASTM B117 Operating Salt Spray (Fog) Apparatus ASTM D257 DC Resistance or Conductance of Insulating Materials ASTM D880 Impact Test for Shipping Containers and Systems ASTM D4279 Water Vapor Transmission of Shipping Containers - Constant and

Cycle Methods ASTM D6199 Quality of Wood Members for Containers and Pallets ASTM E162 Surface Flammability of Materials Using a Radiant Heat Energy

Source (Flame Spread Index) ASTM E662 Specific Optical Density of Smoke Generated by Solid Materials

(Smoke Density) ASTM E800 Measurement of Gases Present or Generated During Fires

(Copies of these documents are available from https://www.astm.org/products-services/standards-and-publications.html9.)

SAE INTERNATIONAL

SAE AS26860 Indicator, Humidity, Plug, Color Change

(Copies are available online at https://www.sae.org .)

AMERICAN NATIONAL STANDARDS INSTITUTE

ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration Laboratories

(Copies of these documents are available at www.iso.org or www.ansi.org or from the American National Standards Institute, 25West 43rd Street, 4th Floor, New York, NY 10036.)

NATIONAL CONFERENCE OF STANDARDS LABORATORIES

NCSL Z540.3 Requirement for Calibration of Measuring and Test Equipment

(Copies of these documents can be obtained online at https://www.ncsli.org or by contacting National Conference of Standards Laboratories, 2995 Wilderness Place, Suite 107, Boulder, CO 80310-5404.)

Check the source to verify that this is the current version before use.

https://www.astm.org/products-services/standards-and-publications.html https://www.astm.org/products-services/standards-and-publications.html https://www.sae.org/ http://www.iso.org/ http://www.ansi.org/

INTERNATIONAL MARITIME ORGANIZATION (IMO)

IMDG-CODE International Maritime Dangerous Goods Code (IMDG)

(Copies of IMDG-CODE may be obtained at https://www.imo.org/Publications/IMDGCode/Pages/Default.aspx. Application for hard copies should be addressed to International Maritime Organization, 4 Albert Embankment, London SE1 7SR, England.)

UNITED NATIONS (UN)

Recommendations on the Transport of Dangerous Goods

(Copies of UN publication may be obtained at https://www.unece.org. Application for hard copies should be addressed to United Nations Bookshop, GA-1B-103, New York, NY, 10017.)

INTERNATIONAL AIR TRANSPORT ASSOCIATION (IATA)

Dangerous Goods Regulation

(Copies of IATA publication may be obtained at https://www.iata.org/Pages/default.aspx.

Application for hard copies should be addressed to International Transport Association, 2000 Peel Street, Montreal, Quebec, Canada H3A 2R4.)

INTERNATIONAL CIVIL AVIATION ORGANIZATION (ICAO)

Technical Instructions for the Safe Transportation of Dangerous Goods by Air

(Copies of ICAO publication may be obtained online at https://www.icao.int/safety/dangerousgoods/pages/technical-instructions.aspx. Application for copies should be addressed to International Regulations Publishing and Distributing Organization, P.O. Box 60105, Chicago, IL 60660.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

Check the source to verify that this is the current version before use.

https://www.imo.org/Publications/IMDGCode/Pages/Default.aspx.

https://www.unece.org./ https://www.iata.org/Pages/default.aspx.

https://www.icao.int/safety/dangerousgoods/pages/technical-instructions.aspx.

3. DEFINITIONS

3.1 Packaged item. Ammunition unit of issue that will be protected from physical and mechanical damage through packaging and packing.

3.2 Packaged item damage.

3.2.1 Physical damage. Damage from internal or external forces which results in breakage, denting, marring, distortion, displacement, or abrasion of the packaged item.

3.2.2 Mechanical damage. Damage resulting from any direct or indirect force which may impair the mechanical or operating function of the packaged item.

3.3 Packaging. The application or use of adequate protective measures to prevent deterioration including, as applicable, the use of appropriate cleaning procedures, preservatives, protective wrapping, cushioning, interior containers, and complete identification marking, up to, but not including, the exterior shipping container.

3.4 Pack or container. The device used to encapsulate ammunition, unit or intermediate packages, containing the ammunition unit of issue. It can be fabricated from wood, plastic, or metal and, in general, is the last handling/lifting vehicle prior to unitization or, if large enough, containing its own pallet or skids.

3.5 Pallet. A platform or base for the purpose of aiding in the handling of unitized loads by forklift trucks, slings, etc.

3.6 Unitization. Assembly of packs of one of more packaged item(s) of supply into a single load in such a manner that the load can be handled as a unit through the distribution system.

Unitization (unitized loads/unit loads) encompasses consolidation in a container, placement on a pallet or load base, or securely binding together.

3.7 Marking. Application by stamping, printing, or painting of numbers, item name, national stock number, symbols, colors, etc., on containers, tags, labels, or items for identification during shipment, handling, or storage.

3.7.1 Ammunition and Explosives Palletization/Packaging Label (AEPPL) Marking. A 2D Bar

Code marking used on the exterior shipping container for all ammunition and explosive items. The AEPPL is to meet the requirements per Drawing 12999545.

3.8 Level A Tactical. The degree of packaging or packing required for protection of material against the most severe conditions known or anticipated to be encountered during shipment, handling, and storage. Packaging and packing designated Level A is designed to protect material against direct exposure to all extremes of climatic, terrain, operational and transportation environments without protection other than that provided by the pack. The conditions to be considered include, but are not limited to:

(a) Multiple rough handling during transportation and in transit storage from point of origin to ultimate user.

(b) Shock, vibration, and static loading during shipment.

(c) Deck ship loading and offshore or over-the-beach discharge to ultimate user, including transfer at sea.

(d) Environmental exposure during transit where port and warehouse facilities are limited or nonexistent.

(e) Outdoor storage in all climatic conditions for a minimum of 2 years.

(f) Static loads imposed by stacking.

(g) Special package and pack features for field combat operations (handling and utility).

(h) Special features as required by combat development agencies.

3.9 Level A Non-Tactical. For the purposes of this document, it includes those packaged items which require protection from moisture because of the detrimental effects which moisture causes even for limited periods. Due to this required protection, the item needs a sealed container but at a reduced testing level because of its non-tactical usage. This pack should meet environmental testing requirements that a packaged item would encounter during normal worldwide shipment from origin to user generally utilizing commercial vehicles for transportation and more controlled handling environment.

3.10 Level B. This packaging provides intermediate protection to packaged items under generally favorable environmental conditions of worldwide shipment, handling, and storage as defined in AR 700-15. For this standard, two Level B packs:

3.10.1 Level B maximum. This pack (e.g. training ammunition), unless otherwise specified, has the same environmental testing requirements (with the exception of test temperature) that a war reserve Level A packaged item would encounter during tactical field transportation and handling.

3.10.2 Level B standard. This pack (e.g. foreign military sales), meets environmental testing requirements that a packaged item would encounter during normal shipping generally utilizing commercial vehicles for transportation and a controlled handling environment.

3.11 Moisture Sensitive. For the purposes of this document, moisture sensitive items are those which may be reasonably expected to undergo a physical, mechanical, or chemical change when exposed to liquid water, water vapor, or other liquid or gaseous fluids.

3.12 Design Activity. For the purposes of this document, the design activity is the responsible packaging division and respective integrated product team.

4. GENERAL REQUIREMENTS

4.1 Level A ammunition transportation, handling and storage.

4.1.1 Packaging. Service ammunition must be packaged and protected as required in AR 700- 15 and AR 700-143. All packaging specified herein shall be designed so that it will function with no degradation after 20 years protected controlled storage and 2 years unprotected uncontrolled storage in all climatic conditions as prescribed in AR 70-38. The packaging must also protect the packaged items in accordance with AR 740-1 and AR 70-47 from natural and induced environments which occur during storage, transportation, and handling that the item cannot provide itself. Other requirements include but are not limited to as follows:

(a) The packaging (including dunnage) will minimize battlefield litter and signature.

(b) The packaging will not contribute to safety, health, or environmental hazards in accordance with AR 40-10 and MIL-STD-882.

(c) The packaging must provide for maximum density to reduce weight and cube and provide the most ammunition in the smallest and lightest package, at the least cost possible, consistent with weapon system or usage and protection to the packaged ammunition item.

(d) The ammunition packaging shall cause no restrictions which would preclude transportation by any type military or commercial aircraft, ship, rail, or wheeled vehicles unless specifically forbidden by regulations (e.g., 49CFR, IMDG Code, IATA, ICAO).

(e) The ammunition packaging must permit fast easy access to a clean round under all conditions, including the wearing of mission oriented protective posture gear or cold weather gear.

(f) The packaging must not contribute to the vulnerability of ammunition fires.

(g) The packaging will account for Insensitive Munitions (IM) requirements of MIL-STD- 2105 to the extent practicable.

4.1.2 Unitization.

(a) The packaged ammunition must be capable of being unitized on pallets that can be handled by existing and anticipated future materials handling equipment, provide for ease of access and be unpacked without the use of any special tools or equipment. Packaged large missiles/rockets may not be applicable to unitization but must not require any special tools and/or equipment for unpacking.

(b) The packaged ammunition shall be unitized at the LAP facility in a configuration capable of being transported throughout the logistics system without reconfiguration. Generally, one dimension of the unitized load (either length or width) will not exceed 44 inches and the height, including the pallet, will not exceed 54 inches. Optimum unit load gross weight should be less than 2500 pounds. Small arms ammunition pallets can weigh up to 4000 pounds. Loaded pallets must permit 4-way entry of forklifts, have top lift capability, use of US and NATO handling devices, and be tested in accordance with MIL-STD-1660.

(c) The unitized configuration must be designed to withstand stacking to a height of 16 feet as described in A.10. If the unitized load utilizes stacking supports between the top frame and the pallet base then the bottom container will only be required to support that load of containers which is above it to the top frame.

4.1.3 Containers.

4.1.3.1 Weight. The loaded ammunition container will be man-portable to the same extent as the bare ammunition where possible. If operational requirements preclude man-portability, then material handling features shall be provided as stated below:

(a) Any loaded container which weighs more than 75 pounds and less than 150 pounds shall be provided with lifting features (e.g., ropes, handles) for two-man carry.

(b) Any loaded container above 150 pounds should be considered to be non-portable and shall conform to the material handling requirements of MIL-STD-648.

4.1.3.2 Humidity control.

4.1.3.2.1 Pressure retention. All sealed ammunition containers shall be capable of withstanding a pressure differential of 3 psig with no apparent leakage when subjected to logistical and tactical transportation vibration and normal handling. Because of this capability, when coupled with the size of the container cover and the possibility of generating a partial vacuum, the force necessary to remove the cover may exceed those values for personnel as listed in MIL-STD-1472. In that case, a pressure relief valve must be installed on the container and meet the requirements of MIL- DTL-27166. The container must be capable of being resealed, after opening, and withstand the 3 psig pressure differential.

4.1.3.2.2 Desiccant. The use of desiccant and humidity indicating devices should be minimized for all ammunition containers. If the pressure retention requirement of 4.1.3.2.1 is met, then the use of desiccant is not generally required. If the munition item has some specialized requirement (as in the case of moisture sensitive components that require storage or field inspection), then desiccant use is required. If desiccant is necessary, easy replacement of desiccant and, depending upon container configuration, humidity monitoring is required. Desiccants shall meet the requirements of MIL-D-3464. The quantity of desiccant required to maintain a relative humidity (RH) of 40 or less shall be determined in accordance with paragraph 5.2.3.7 of MIL-STD-2073-1.

Internally placed humidity indicating devices shall conform to MS 20003 and externally mounted humidity indicator devices shall conform to SAE AS26860.

4.1.3.2.3 Gasket. Any gasket used to seal the container shall be pliable and be capable of functioning at temperatures from -65 degrees F to +160 degrees F.

4.1.3.3 Container materials. Material selection should be in conformance with the requirements of 49CFR, unless a Competent Authority Approval (CAA) is obtained. The container system can be fabricated from any material, metal, non-metal (plastic, wood, fiberglass, fiber, etc.), or any combination thereof which, in conjunction with the design, will achieve the greatest possible chance of success in meeting the requirements. Porous materials (e.g., wood or fiber) can be used if water vapor proof seal and NBC survivability is not required.

In considering any material, ultimate production cost, in addition to container performance, is a factor which should be considered. The container material must not contribute to the vulnerability of ammunition to fire and have good resistance to corrosion, petroleum, oil and lubricant products and be compatible with energetic materials.

4.1.3.3.1 Metal. The material for container hardware can be fabricated from aluminum or steel.

The basic container structure could be aluminum or steel but the use of high strength low alloy steel is the preferred material because of its cost, strength to weight ratio, versatility, etc.

4.1.3.3.2 Plastic. Any plastic material selected for the containers shall have the following properties:

(a) The material shall have properties favorable to low temperature (-65 degrees F) impact strength and high temperature (+160 degrees F) creep strength and not be degraded by solar radiation, temperature shock or accelerated heat aging - environmental stress cracking.

(b) The material shall be sufficiently conductive to eliminate the hazard associated with the discharge (spark) of static electricity when a hazardous item is packed in the container. In lieu of specific data, the use of anti-static agent shall make the material sufficiently conductive so that the material has a volume resistivity below 1010 ohms-cm, at +72 degrees F, and 15% relative humidity. The use of this value does not negate the intent which is to eliminate any potential hazard associated with the discharge of the spark. The government reserves the right to have any test conducted which would prove conclusively that a hazard does not exist or the container contractor can forward data which will show that the energy required to ignite the hazardous item is more than the energy which can be produced by the container.

(c) The container material shall have a flame spread index of 25 or less when tested in accordance with ASTM E162 and a smoke density of 200 or less when tested in accordance with ASTM E662. The container material shall be free of significant toxic by-products when tested in accordance with ASTM-E800.

(d) The container will exhibit a water vapor transmission rate of less than .001 grams/100

sq. in. /24 hours if specified by the design activity.

4.1.3.3.3 Nuclear, biological, chemical (NBC) survivability. Containers used to package mission - essential items that may encounter an NBC environment shall be designed of materials that meet the following criteria.

(a) Selection of materials used in the construction, fabrication, and painting of containers shall be chemical agent decontaminable to acceptable levels as specified in the U.S. Army Nuclear and Combating WMD Agency (USANCA) criteria and AR 70-75 when tested in accordance with TOP 08-2-111. NOTE: The USANCA criteria and any questions pertaining therein may be addressed to USANCA, 5915 16th Street, Building 238, Fort Belvoir, VA 22060.

(b) For materials that do not meet the USANCA criteria, a Chemical Agent Resistant Coating (CARC) may be applied in accordance with MIL-DTL-53072 as required.

(c) Container design shall be such that overall configuration will minimize contamination of NBC agents and facilitate effective decontamination to the maximum possible extent in view of the container’s specific cost and functional restrictions imposed.

4.1.3.4 Security seal. All containers shall be designed such that a security seal may be applied to the container to detect unauthorized entry.

4.1.3.5 Interlock. Any container which may exhibit instability in the palletized mode (i.e.

containers circular in cross section) shall incorporate interlocking features to connect each container in at least two axis.

4.1.3.6 Re-usability. The container shall be re-usable, may be repairable, and will be recoverable in peacetime but expendable under hostile conditions (except for large containers such as those used for missiles/rockets/bulk ammunition etc.).

4.1.3.7 Pallets. There are some munition items (such as 155mm projectiles) which are sealed and do not require a container for moisture protection. These items can be shipped on a wood pallet (MIL-DTL-45449) or a pallet fabricated from any other material provided that it can pass the environmental test for the load weight category. Under these circumstances the test plan has to be modified to eliminate the pressure retention test.

4.1.3.8 Markings.

4.1.3.8.1 Container/Identification Marking. All containers shall be designed such that they may be legibly and durably marked per the requirements of MIL-STD-129.

4.1.3.8.2 Performance oriented packaging (POP) Markings. POP markings shall be applied to the exterior pack only when the packaged items is identified as a hazardous material. When the container passes the POP tests as stated in 5.1.7 then POP markings shall be applied to the exterior container. The POP marking shall be as specified in Code of Federal Regulation Title 49.

4.2 Level B ammunition transportation, handling and storage.

4.2.1 Packaging. The packaging shall meet the requirements for Level B packs as defined in this document, AR 700-15 and the appropriate sections of Code of Federal Regulations, Title 49 (49CFR), and Performance Oriented Packaging in accordance with Code of Federal Regulations Title 49 and also meet or exceed the following minimum design and test requirements:

(a) All packaging materials that come in contact with energetic materials must be compatible with the energetic materials. Container material test requirements in accordance with this standard shall be met except that high and low temperatures shall be as specified herein for Level B pack.

(b) Each item shall be encapsulated in a unit package, to include wrapping and cushioning as necessary, in such a manner that it will afford the required protection against physical and environmental damage during shipment, handling, and storage. The unit package shall meet the design requirements of MIL-STD-2073-1. Sets, kits, assemblies or packaged items consisting of more than one part shall be individually unit packaged. Contents shall be suitably segregated and identified within the unit pack. Each set, kit or assembly shall include a list of contents.

(c) A multiple quantity of unit or intermediate packages, bearing the same stock number, shall be placed in a close-fitting container conforming to federal or military specifications. The exterior pack shall meet MIL-P-116 requirements for the method utilized and meet the design requirements of MIL-STD-2073-1. An exterior pack (container) containing packaged items, either a) not exceeding a gross weight of 150 pounds or b) exceeding 150 pounds, shall sustain the applicable environmental tests, specified for Level B Maximum or Level B Standard cited in Table I or II. (NOTE: Rough handling tests specified in MIL-P-116 or MIL-STD-2073-1 do not apply.) A unit or intermediate package that meet all common carrier rules, sustain the tests specified in this paragraph and provide safe delivery to the final destination need not be packed into an exterior container, then the unit or intermediate package becomes the exterior pack.

4.2.2 Unitization. Unitization shall be required when quantities per destination makes unitization costs effective. A quantity of items packed for shipment shall be placed on pallets conforming to the federal or military specifications in accordance with MIL-STD-2073-1. The load shall be secured to the pallet by any means that will ensure safe delivery to destination and not contribute to the deterioration of the exterior pack or its contents.

4.2.3 Markings. In addition to any special marking required by the contract or purchasing order, all unit packages, intermediate packages, and exterior shipping containers shall be legibly and durably marked in accordance with MIL-STD-129 and 49CFR, if a hazardous material. AEPPL is required and shall be applied in accordance with MIL-STD- 129.

4.2.4 Performance oriented packaging (POP) markings. POP markings shall be applied to the exterior pack only when the packaged item is identified as a hazardous material . When the container passes the POP tests as stated in 5.1.7 then POP markings shall be applied to the exterior container. POP marking shall be as specified in Code of Federal Regulations Title 49.

4.3. General Test Description

4.3.1 Vibration and handling tests. These tests consist of subjecting packaged ammunition to transportation, storage, and handling tests at specified temperatures to determine the adequacy of the pack to protect the ammunition and to ensure its operation and safety.

4.3.1.1 Vibration. The vibration tests are meant to simulate three types of field environments.

4.3.1.1.1 Secured cargo vibration. This test is a random vibration test used to simulate the environment encountered when packaged ammunition is transported in a “tied-down” condition carried in representative tactical wheeled and tracked vehicles from the port staging area to the using unit and in, when appropriate, the specific fighting tactical vehicle (FTV).

4.3.1.1.2 Loose cargo vibration. This test is used to determine survivability when packaged ammunition is transported over rough roads in an unrestrained condition.

4.3.1.1.3 Rack vibration. When ammunition in its packaging configuration is placed in racks in the FTV, this test is performed to simulate the random vibration that the packaged configuration will experience.

4.3.1.2 Free fall drops. The freefall drop tests are used during the development of ammunition packaging to determine the adequacy of the package and the protection provided to the ammunition following accidental drops.

4.3.1.2.1 Three foot drop. This test simulates accidental free fall drops of packaged ammunition during storage, maintenance, transportation and/or handling. The tests are conducted on the packages of de-palletized ammunition weighing 150 pounds or less.

4.3.1.2.2 Seven foot drop. This test simulates free fall drops of packaged ammunition from a truck or a hovering helicopter dropping packaged ammunition from a sling and is normally conducted on packages of de-palletized ammunition weighing 150 pounds or less. However, tests on unitized packaged ammunition shall be conducted if this mode of tactical shipment is anticipated.

4.3.1.2.3 Forty foot drop. This test simulates accidental free fall drops during ship loading/unloading operations, and is normally performed on de-palletized packaged ammunition.

NOTE: The destructive nature of this test and the quantities of ammunition items required to perform this test usually precludes conducting this test in the unitized configuration.

4.3.1.3 Edgewise-cornerwise-rollover. These tests simulate accidental drops of large (over 150 pounds) loaded containers during receipt, storage, maintenance, or issue operations.

4.3.1.4 Hoisting. This test simulates the mechanical handling of a loaded container through the use of appropriate slings utilizing the container lifting provisions.

4.3.1.4.1 Sudden lift. This test is primarily designed for 155MM projectile pallets in order to determine the ability of the pallet cover and restraining components to withstand a sudden force when the pallet drops while being hoisted.

4.3.1.5 Tiedown. This test simulates the restraining of a loaded container applied through the container tiedown provisions.

4.3.1.6 Forklift. This test simulates the ability of a loaded container to withstand handling by mechanical handling equipment (forklift truck).

4.3.1.7 Stacking. This test simulates the stacking of similar containers to a height of 16 feet in a storage environment.

4.3.2 End impact. The end impact test is intended to determine the ability of large (over 150 pounds) containers and unitized loads to resist impacts, such as severe railcar humping, and for determining the ability of the packaging to provide protection to the ammunition.

4.3.3 Humidity control.

4.3.3.1 Pressure retention. The pressure retention test is used to determine the ability of the container to prevent the entrance of moisture and NBC contaminants or loss of packaged item volatiles after normal logistical and tactical transportation/handling, during extreme storage conditions, and air delivery. It is to be decided by the design activity if a water vapor proof seal and NBC survivability is required.

4.3.3.2 Desiccant (Humidity). This test is conducted to determine the ability of a properly desiccated container to maintain the humidity within the container to an acceptable level.

4.3.4 Container material. The container material tests are conducted to determine the ability of the container to survive the various environments, both natural and induced, which can be expected to occur throughout worldwide deployment of ammunition containers. Obviously, all environments are not included but only those which are expected to have an impact on the containers. Those material tests which are non-destructive should be conducted first (before physical type tests) because (a) if the material is affected there is no point in continuing the tests and (b) the effect of the material tests on the container may surface after the same container is then subjected to the physical tests.

4.3.4.1 Solar radiation. This test is conducted to determine the effects of solar radiation

(ultraviolet) on containers that may be exposed to sunshine during operation or unsheltered storage on the earth’s surface or in the lower atmosphere.

4.3.4.2 Temperature shock. Temperature shock tests are conducted to determine if material can withstand sudden changes in the temperature of the surrounding atmosphere without experiencing physical damage or deterioration in performance.

4.3.4.3 High temperature. The high temperature tests are performed to determine if material can be stored and operated under hot climate conditions without experiencing physical damage or deterioration in performance.

4.3.4.4 Chemical resistance. These tests are conducted to determine if various fluids used in transportation, material handling, and tactical vehicles which through carelessness or accident can come in contact with the container and have a detrimental effect on the material.

4.3.4.5 Container burning characteristics. The container burning characteristics tests are applicable to containers and pallets (if used as exterior packs) when used to carry ammunition and are intended to determine the fire resistance characteristics against fire originating from sources outside the container. It is the intent of this requirement to indicate package performance during the test but not necessarily to require suitability of the ammunition or container for use after fire exposure.

4.3.4.6 Water vapor transmissibility. This test is used to determine the ability of the container to prevent moisture from entering through the container.

4.3.4.7 Electrical conductivity. This test is used to determine if, as a result of a material being a non-conductor, a static electric charge can be generated which could produce a potentially hazardous condition upon discharge.

4.3.4.8 Compatibility. These tests are conducted to determine the compatibility of any material that comes in contact with energetic materials.

4.3.4.9 Corrosion resistance (salt spray). This test is conducted to determine the capability of the container material and protective finish to resist corrosion.

4.3.4.10 Accelerated heat aging - Environmental stress cracking (AHA-ESC). This test determines the susceptibility of polyethylene plastic containers (see NOTE) or parts to fail prematurely by environmental stress cracking and heat aging at stresses far below normal design stresses and at times far shorter than expected.

NOTE: This test is designed primarily for polyethylene. Other plastic materials such as ABS, polystyrene, nylon, PBT and PET polyesters, polypropylene, PPO Noryl, polycarbonate, including alloys and glass-reinforced grades and any combination thereof, can stress crack due to “heat aging” and “coming in contact with various solvents and/or reagents”. These and other plastic materials should be tested using the solvent(s) and/or the reagent(s) the material is sensitive to in place of Igepal (CO-630, see 30 of Appendix C).

5 DETAILED REQUIREMENTS

5.1 Container testing - Level A ammunition packaging.

5.1.1 Purpose. The purpose of container testing is to determine the ability of the container to protect the ammunition against the adverse effects of normal and abnormal logistical and tactical transportation and handling conditions. Many of the following tests may be conducted singularly;

however, the vibration-handling tests shall be performed in the sequence shown in Figures 1, 2 and 3 because the information obtained at a particular point in the test sequence may reveal survivability at a point in the logistic chain and because some of the tests may be destructive and prevent further testing. It is intended that the tests will serve for engineering investigation, design evaluation, design margin determination, or quality control dependent upon the specific technical need. The test procedures cover a wide range of environments and constitute a general criteria for evaluation of the packaging to ensure end item reliability. The tests in this section should be performed only on packaged ammunition requiring a Level A packaging classification.

5.1.2 Background. The type of container (pack) used to protect ammunition is a function of the protection required by the ammunition. Because of the cost and weight consideration, the package should provide only that protection necessary to meet Level A requirements. If as a result of some unique operational requirements, a container is designed which has properties or performs a function that is different from that normally specified for Level A requirements, then the tests required to prove the unique operational requirements should supplement the tests listed below.

The packaging engineer should select all those tests which will adequately determine the ability of the container to protect the item based upon the design of the container (including unique operational requirements) and the logistical and tactical environment expected.

5.1.3 Temperature range. In general, all containers must protect the packaged item(s) and survive the transportation and handling environment at temperature range from +160 degrees F to -65 degrees F. Testing will be conducted in these temperature ranges, as specified, except when it is indicated that the packaged item(s) will be adversely affected by these temperature extremes. In those instances, the test temperature shall be adjusted when the packaged items are used for container testing.

5.1.4 Test conditions. All tests, unless otherwise specified, shall be performed at three temperatures (-65 degrees F, ambient (+72 degrees), and +160 degrees F). Three foot drop (see 5.1.5.1.4), loose cargo (see 5.1.5.1.5), seven foot drop (see 5.1.5.1.6), and rack vibration (see 5.1.5.1.7) tests may be performed at the operational temperature extremes for the item(s) being packaged. Ambient temperature tests should be conducted first in order to evaluate container performance under a “less severe” environment. Low and high temperature tests should be conducted after ambient temperature tests.