Attachment 08 -- UFC Ammunition and Explosives Storage Magazines (1 May 2015).pdf

UFC 4-420-01

1 May 2015

UNIFIED FACILITIES CRITERIA (UFC)

AMMUNITION AND EXPLOSIVES

STORAGE MAGAZINES

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

AMMUNITION AND EXPLOSIVES STORAGE MAGAZINES

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity)

AIR FORCE CIVIL ENGINEER CENTER

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Hard copies of UFC printed from electronic media should be checked against the current electronic version prior to use to ensure that they are current.

AUTHORIZED BY:

JAMES C. DALTON, P.E. JOSEPH E. GOTT, P.E.

Chief, Engineering and Construction Chief Engineer U.S. Army Corps of Engineers Naval Facilities Engineering Command

JOE SCIABICA, SES MICHAEL McANDREW Director Air Force Civil Engineer Center

Director, Facilities Investment and Management Office of the Assistant Secretary of Defense (Energy, Installations, and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 http://dod.wbdg.org/

NEW DOCUMENT SUMMARY SHEET

Document: UFC 4-420-01, Ammunition and Explosives Storage Magazines Superseding: None

Description: This document serves as a reference tool to assist in the planning, siting, and design of Ammunition and Explosives (AE) storage magazines. It is intended to assist in the selection of an AE storage magazine providing available options and information related to the use of standard designs that have prior approval by the Department of Defense Explosives Safety Board (DDESB). This UFC also defines and discusses various issues and requirements that need to be incorporated in the design of these unique facilities.

Reasons for Document: UFC 4-420-01 was created for the following reasons:

• To describe various design issues and requirements that need to be considered in the design of AE storage magazines, including lightning protection, grounding, electrical hazard classification, temperature and humidity controls, ventilation, physical security, etc.,

• To provide a concise description of the various classifications of AE storage magazines and related siting requirements, and

• To provide a description of the requirements for Service/DDESB site approval for all new AE storage magazines.

Impact: UFC 4-420-01 describes unique considerations particular to this facility type that must be correctly incorporated into a design to avoid potentially costly omissions or over-designs. As a supplement to this UFC, the Whole Building Design Guide (WBDG) website provides clear concise descriptions of all available DDESB approved standard designs for AE storage magazines so that they can be easily compared in order to facilitate the selection of the most suitable design for a given site and function:

http://www.wbdg.org/design/ammo_magazines.php

Unification Issues Waterproofing and Drainage: The Navy currently has a prohibition against the use of any types of steel ECM for new construction due to the difficulty of properly waterproofing these magazines.

Earth Electrode System (Grounding): The Navy has additional requirements for magazine grounding systems due to interpretation of NFPA 780 requirements.

Additional Electrical Requirements (Navy Only): The Navy has additional electrical requirements and details for the older “standard magazine designs” that will bring these designs up to current safety practices.

http://www.wbdg.org/design/ammo_magazines.php i

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE

1-2 BACKGROUND

1-3 APPLICABILITY

1-4 GENERAL BUILDING REQUIREMENTS

1-5 CONFLICTS

1-6 WAIVERS AND EXCEPTIONS

1-7 REFERENCES

1-8 GLOSSARY

CHAPTER 2 PLANNING CONSIDERATIONS

2-1 MAGAZINE TYPES

2-1.1 Earth-Covered Magazines (ECM)

2-1.2 Aboveground Magazines (AGM)

2-2 SITING CRITERIA

2-2.1 Magazines as Potential Explosion Sites (PES)

2-2.2 Magazines as Exposed Sites (ES)

2-2.3 Approved ECM NEW Limits

2-2.4 Barricades

2-3 DESIGN APPROVALS

2-3.1 Magazine Design Approval

2-3.2 Approved ECM Designs

2-3.3 Magazine Construction and Explosives Safety Site Approval

2-4 MAGAZINE SELECTION CONSIDERATIONS

2-4.2 Net Explosive Weight (NEW) Limits

2-4.3 Magazine Characteristics

2-4.4 Storage and Loading Plans

2-5 ELECTRICAL PLANNING

CHAPTER 3 DESIGN CONSIDERATIONS AND REQUIREMENTS

3-1 EARTH COVER

3-2 FLOOR DESIGN

3-3 FOUNDATIONS

ii

3-4 WATERPROOFING AND DRAINAGE

3-5 VENTILATION, TEMPERATURE AND HUMIDITY CONTROL

3-5.1 Ventilation Only

3-5.2 Temperature and Humidity Control

3-5.3 Structural Coordination

3-6 FIRE PROTECTION AND LIFE SAFETY

3-6.1 Ammunition and Explosives (AE) Storage Facilities

3-6.2 Sprinklers and Hydrants

3-6.3 Means of Egress

3-6.4 Fire Alarm System

3-6.5 Mass Notification

3-7 PHYSICAL SECURITY

3-7.1 Assistance with Physical Security Components and Requirements

3-8 ELECTRICAL DESIGN

3-8.1 Hazardous (Classified) Location

3-8.2 Power

3-8.3 Lighting

3-8.4 Earth Electrode System (Grounding)

3-8.5 Bonding

3-8.6 Lightning Protection

3-8.7 Bonding of Horizontal Sliding Doors

3-8.8 Snow Melting System

3-8.9 Additional Electrical Requirements (Navy Only)

3-9 ADDITIONAL ELECTRICAL CONSTRUCTION QUALITY CONTROL. . 25

3-10 SPECIAL INSPECTIONS

3-11 DDESB AND SERVICE-SPECIFIC EXPLOSIVES SAFETY. CONTACTS.

APPENDIX A REFERENCES

APPENDIX B 7-Bar AND 3-Bar ECM APPROVED FOR NEW CONSTRUCTION (IP Units)

APPENDIX C SPECIAL INSPECTIONS

APPENDIX D HIGH PERFORMANCE MAGAZINE CONCEPT

APPENDIX E GLOSSARY

iii

TABLES

Table C-1 Special Inspection Schedule/Verification………………………………… 36

FIGURES

Figure 2-1: ECM Components……………………………………………………… 11 Figure 2-2: Typical ECM Blast Resisting Elements……………………………. 11 Figure 3-1: ECM Earth Cover………………………………………………………….. 17 iv

This Page Intentionally Left Blank

CHAPTER 1 INTRODUCTION

1-1 PURPOSE AND SCOPE.

This UFC serves as a reference tool to assist in the planning and design of Ammunition and Explosives (AE) storage magazines for the Department of Defense (DoD), by providing definitions and information related to the design, selection, and siting of these unique facilities. This UFC is intended to assist in the selection of a magazine design by providing available options and information related to the use of designs that have been used in the past and have been approved by the Department of Defense Explosives Safety Board (DDESB). The individual DoD Services can also provide additional guidance on the selection of magazine designs.

A web site designed to be a companion resource to this UFC is located on the Whole Buildings Design Guide and can be accessed at:

http://www.wbdg.org/design/ammo_magazines.php . This web site provides the following additional information and resources:

• Available electronic copies of referenced military regulations, manuals and standards.

• Available design drawings, approval letters, and specifications for 7-Bar and 3-Bar Earth-Covered Magazines (ECM) that have been approved for new construction.

• Available drawings and related information for the designs of 7-Bar and 3- Bar ECM that are no longer approved for new construction but still in use.

• Available drawings and related information for the designs of ECM and Aboveground magazines (AGM) and containers that have been approved for restricted use.

• A listing of the existing magazine designs that are classified as undefined

• Available drawings for barricade design utilizing various construction materials.

• Links to additional related resources and publications.

This UFC, when used with the companion web site, provides planners and designers of AE storage facilities access to up to date information and resources needed in the selection and design of new storage magazines and in the evaluation of existing facilities.

1-2 BACKGROUND.

The DDESB has established minimum AE safety standards for personnel and property that have the potential of being exposed to the effects of an accidental explosion.

These standards govern the design, construction, and use of all AE storage facilities within the DoD.

Magazines are used to store AE materials. Magazines are classified as Aboveground Magazines (AGM) or Earth Covered Magazines (ECM). ECMs are further divided (7- Bar, 3-Bar, or Undefined). An ECM is not designed to resist the damaging effects of its own exploding contents; it is accepted that the exploding magazine will be heavily damaged or even destroyed if an internal explosion occurs. The intended function of an ECM is to mitigate a sympathetic detonation of either AE or an adjacent ECM. The structure is designed to resist an external detonation, thereby interrupting the propagation chain.

DoD explosives safety standards are contained in DoD 6055.09-M, DoD Ammunition and Explosives Safety Standards. DDESB Technical Paper 15 (TP 15) provides a ready resource for DDESB-approved protective construction as well as the explosives safety criteria associated with them. Service-specific explosives safety standards that implement the DoD standards are contained in the following documents:

• DoD Contractors: DoD 4145.26-M, DoD Contractors’ Safety Manual for Ammunition and Explosives.

• Air Force: AFMAN 91-201, Explosives Safety Standards and Air Force Munitions Facilities Guide.

• Army: AR 385-10, U.S. Army Safety Program and DA PAM 385-64, Ammunition and Explosives Safety Standards.

• Navy: NAVSEA OP 5 Volume 1, Ammunition and Explosives Safety Ashore.

1-3 APPLICABILITY.

This UFC applies to all Service elements and DoD contractors involved in the planning, design, and construction of DoD AE storage facilities worldwide. Specialized magazines (Earth Covered and Aboveground), containers and modular systems with reduced net explosive weights (NEWs) and/or reduced quantity-distances (QD) are not covered by this document; however, DDESB TP 15 provides a listing of approved systems along with requirements, restrictions, and conditions for use in Table AP1-4.

1-4 GENERAL BUILDING REQUIREMENTS.

UFC 1-200-01, General Building Requirements, provides applicability of model building codes and government-unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, sustainability, and safety.

Use this UFC and the UFCs and government criteria referenced therein.

1-5 CONFLICTS.

This UFC and the companion web site supplement the information contained in the DoD and Service-specific explosives safety standards, and in the DDESB’s publications and memorandums. In the event of conflict or disagreement, the DoD and Service-specific explosives safety standards and the DDESB documents govern. All apparent conflicts must be brought to the attention of the authorizing design agency for additional guidance as necessary.

1-6 WAIVERS AND EXCEPTIONS.

For Waiver and Exception policy and guidelines refer to the DoD and Service- specific explosives safety standards.

1-7 REFERENCES.

Appendix A contains a list of references used in this UFC. The publication date of the code or standard is not included in this document. In general, the latest available issuance of the reference is used.

1-8 GLOSSARY.

Appendix E contains acronyms, abbreviations, and terms.

CHAPTER 2 PLANNING CONSIDERATIONS

2-1 MAGAZINE TYPES.

AE storage magazines are classified as either Earth Covered Magazines (ECM) or Aboveground Magazines (AGM). Magazines are considered uninhabited structures and are used for storage only. The use of an approved standard design for new magazine construction is mandatory within the DoD except where a preapproved design is not suitable due to special circumstances and the design meets all applicable requirements of DoD 6055.09-M, DOD Ammunition and Explosives Safety Standards.

A High Performance Magazine (HPM) concept has also been developed. This document does not specify design requirements for the HPM; however, Appendix D provides background information and references for the HPM concept.

2-1.1 Earth-Covered Magazines (ECM).

DoD 6055.09-M defines three basic ECM designations: "7-Bar," "3-Bar," and “Undefined,” based primarily on the relative strength of the magazine headwall and doors and the relative strength of the roof for non-arch or “flat roof” magazines. This designation is based on the structural strength and ability of the magazine to withstand blast loadings resulting from an accidental explosion of an adjacent magazine as a Potential Explosion Site (PES). Siting criteria, based on ECM designation, ensure a consistent level of protection across the AE storage area. Designations for previously designed ECM’s are contained in DDESB publication TP-15, Approved Protective Construction.

2-1.1.1 7-Bar ECM. A 7-Bar ECM provides the highest resistance to blast loading. Magazines designated as 7-Bar were referred to as “Standard” magazines prior to 1997.

2-1.1.2 3-Bar ECM. A 3-Bar ECM provides a lower level of resistance to blast loading than a 7-Bar ECM, but more than an Undefined ECM. In 1997, this designation was established as an intermediate designation between “Standard” and “Non-standard.”

2-1.1.3 Undefined ECM. An Undefined ECM has not been shown by analysis or testing to be capable of providing a level of resistance equivalent to either a 7-Bar or 3-Bar ECM. Magazines designated as Undefined were referred to as “Non-standard” magazines prior to 1997.

2-1.2 Aboveground Magazines (AGM).

All above grade magazines that are not earth covered, or an ECM with less than the minimum 2 feet (0.61 m) of cover, are considered AGM. This also includes storage pads for AE stored in the open.

2-2 SITING CRITERIA.

To ensure the prevention of unacceptable damage or injuries in the event of an accidental explosion, siting criteria have been established to define minimum required separation distances between a PES and surrounding Exposed Sites (ESs). The minimum separation distances, commonly referred to as explosives safety Quantity- Distances (QDs), are based upon several factors including, but not limited to:

• The level of protection mandated by the applicable explosives safety standard.

• The ES type and classification.

• The net explosive weight (NEW).

• The hazard classification of the AE at a PES.

• The physical orientation between the PES and the ES.

• The presence of effective barricading.

Minimum explosives safety QDs are defined in the applicable DoD and Service-specific explosives safety standards for various applications. These QDs are based on maximum levels of risk considered acceptable for various types of ES. Separation distances are not absolute safe distances, but are relative protective or safe distances.

Whenever practicable, use of greater distances than those shown in the explosives safety standards should be considered.

Generally, explosives safety site plans are required for construction projects involving new PESs, new facilities (explosive or non-explosive) within the QD arcs of existing PESs, as well as for the upgrading or renovation of existing facilities (explosive or non-explosive) that might impact the explosives safety criteria applied to these facilities (e.g., removal of a protective feature that previously allowed the facility to be sited at a lesser distance or a change of mission that requires the facility to now be at a greater distance). These site plans are reviewed at various authority levels to ensure explosives safety criteria are being met by the proposed work. DoD requires most explosives safety site plans to be forwarded to the DDESB for review and approval (see the section in Chapter 2, entitled “Design Approvals”). See DoD and Service explosives safety criteria for more detail on when a site plan is required and what level of site plan review and approval must be accomplished prior to commencing projects.

2-2.1 Magazines as Potential Explosion Sites (PES).

Magazines pose a hazard to surrounding ESs due to the potential for accidental explosions, which may result in blast overpressures, primary fragmentation, secondary debris, and thermal effects. DoD 6055.09-M defines minimum explosives safety QDs between a magazine as a PES and surrounding ESs including other magazines, operating buildings, inhabited buildings, and public traffic routes to ensure uniform minimum explosives safety standards for DoD facilities. In general, the required separation distances are greater from an AGM than an ECM based on the same quantity of NEW.

2-2.2 Magazines as Exposed Sites (ES).

Minimum explosives safety QDs have been established between a PES and a magazine as an ES to provide appropriate protection. Tables specifying minimum QD requirements can be found in the DoD and Service explosives safety documents. In general, required separation distances are greater for an AGM than for an ECM. For ECM, required separation distances are generally greater for a 3-Bar ECM than a 7-Bar ECM and greater still for an Undefined ECM.

Note: ECMs are not designed for, nor do they provide containment of, effects from an internal explosion.

The minimum explosives safety QDs between magazines is commonly referred to as the inter-magazine distance (IMD). The required IMD is dependent on several factors including but not limited to:

• The physical orientation of the magazines.

• The structural classification of each magazine as an ES.

• The NEW and type of AE within each magazine as a PES.

• The presence of an effective barricade.

2-2.3 Approved ECM NEW Limits.

With respect to an ECM’s structural strength designation, approved ECM NEW limits are based on their ability to withstand blast loads generated from an adjacent PES and NOT on their capacity for storage. Certain 7-Bar ECM have approved NEW limits that are less than the 500,000 lbs (226,800 kg) typically assigned to a 7-Bar ECM based on the limitations of their design as an ES and not on capacity as a PES.

Many military installations have ECMs that have not been evaluated against 7-Bar and 3-Bar strength requirements, and by default must be treated as Undefined. If, using the available structural drawings, an ECM (as an ES) cannot be shown by structural analysis to meet the 7-Bar or 3-Bar loads from an adjacent PES ECM containing 500,000 lbs (226,800 kg) NEW, then it may be possible to demonstrate that the ES ECM could meet 7-Bar or 3-Bar loading requirements if the surrounding PES NEWs were reduced. In other words, the ES ECM design could be site approved as a 7-Bar or 3-Bar ECM for a quantity less than 500,000 lbs (226,800 kg) in an adjacent PES ECM.

An advantage in doing this is that placing this information in automated explosives site planning software, such as Explosives Safety Siting (ESS) or Assessment Systems for Hazard Surveys (ASHS), allows the installation to determine more efficient separation distances for future storage construction. Selection of an appropriate magazine type to meet a specific siting requirement should be done in consultation with an experienced explosives safety site planning professional to ensure efficient use of existing real-estate and facilities while meeting mission requirements.

2-2.4 Barricades.

Barricades are used to decrease the required minimum separation distances between magazines and between magazines and other PESs. Specific requirements on the design and siting of front barricades as well as the reduction in the minimum separation distance resulting from a properly sited and constructed barricade are provided in the DoD and Service-specific explosives safety standards. Army Definitive Drawing 149- 30-01 illustrates several conceptual barricade designs utilizing various construction materials. ECM front barricades should be located as close as possible to the front of the ES (protected) ECM. The side of the barricade facing the protected ECM front should be a vertical, or near vertical earth retaining structure with the opposite side meeting ECM side slope requirements of the section in Chapter 3, entitled, “Earth Cover”. The front barricade must also meet the barricaded IMD geometry requirements of DoD 6055.09-M. When properly sited and constructed, barricades offer protection against high-velocity, low angle fragments.

2-3 DESIGN APPROVALS.

Site and construction plans for AE storage facilities must be approved by the sponsoring Service safety organization and the DDESB to ensure that the minimum DoD and Service-specific explosives safety standards have been addressed. See DoD and Service explosives safety criteria for more detail on when a site plan is required and what level of site plan review and approval must be accomplished prior to commencing projects.

2-3.1 Magazine Design Approval.

The design for all new ECMs must be reviewed and approved by the sponsoring Service’s explosives safety organization and subsequently by the DDESB to ensure compliance with minimum explosives safety design and construction criteria, including earth cover depth and slope, grounding, electrical equipment and installation, and lightning protection. DDESB approval does not address conventional load requirements. In addition, the approval of all 7-Bar and 3-Bar ECMs, and all flat-roofed Undefined ECMs, requires the submission of test results and/or detailed structural calculations in accordance with UFC 3-340-02, Structures to Resist the Effects of Accidental Explosions, to validate compliance with the blast design requirements of DoD 6055.09-M. New designs or designs that involve modifications to blast resisting elements of a magazine’s design must meet the requirements specified in DDESB-PD Policy Memorandum “Minimum Requirements to Validate Explosives Safety Protective Construction” available on the WBDG website. It is important to note that new ECM designs require a substantial review process; consequently, adequate time and resources must be allocated to allow for appropriate Service and DoD review prior to approval for construction.

The lightning protection system design for all new AGM designs must be reviewed and approved by the DDESB. New AGM designs involving protective construction to either reduce the NEW for which the facility is to be sited, or to reduce the required QD, must be reviewed and approved by the DDESB; this approval requires the submission of test results and/or detailed structural calculations to validate the proposed protective construction characteristics.

2-3.1.1 Use of Foreign Materials at OCONUS Locations.

Approved standard designs must be checked for adequacy when adapted for construction with foreign materials at OCONUS locations. Specifically, steel strengths, bar diameters, plate thicknesses, structural steel member dimensions, and concrete compressive strengths may vary for OCONUS locations. In addition to ensuring such modifications do not impact the conventional load capacity of a magazine design, the dynamic response of blast resisting elements of the design needs to be checked by a qualified structural engineer to ensure UFC 3-340-02 response criteria are met.

Modifications that alter the blast response of the magazine are to be treated as new ECM designs as detailed in the preceding paragraph.

2-3.1.2 Coordination with Service Organizations. The Service explosives safety office may require other explosives-safety related design information (e.g., ordnance ground system design) for review and approval. The Service design authority may require other non-explosives safety related design information (e.g., ability to withstand soil loads) for review and approval.

Prior to the start of a design, it is essential to closely coordinate the requirements with the sponsoring Service’s explosives safety organization to avoid excessive problems and delays in completing the design and obtaining the necessary approvals. The Service explosives safety organization will coordinate as necessary with the DDESB.

2-3.2 Approved ECM Designs.

2-3.2.1 7-Bar and 3-Bar ECM Designs Approved for New Construction. To facilitate the design and approval process for AE storage magazines, several approved designs have been developed for 7-Bar and 3-Bar ECMs. DDESB TP-15, Table AP1-1, includes a listing and basic description of 7-Bar and 3-Bar ECMs approved for new construction.

The most current construction drawings, approval letters, and additional information and notes related to the approved designs can be accessed at the Whole Building Design Guide website: http://www.wbdg.org/design/ammo_magazines.php .

Table AP1-1 of DDESB TP-15 identifies additional limitations, restrictions, and conditions associated with the use of approved designs.

2-3.2.2 Site Adaptation of Approved Designs. Once a standard ECM or AGM design has been approved by the DDESB and listed in TP 15, the design does not have to be reapproved for subsequent uses unless changes affecting the explosives safety aspects of the design have been made. Approved designs can be site-adapted or tailored to the requirements of a specific site. Allowed, site specific adaptation primarily involves minor modifications to the foundation, subgrade preparation, and the drainage systems to suit local soil and site characteristics along with design of supporting facilities (utilities, physical security and pavement). Any changes to the approved designs, other than minimal site adaptation, that may affect the explosives safety aspects of a magazine design must be approved by the sponsoring Service’s explosives safety organization and subsequently by the DDESB prior to construction.

(Note: Even if using an approved design, a site plan is still necessary to validate that required QD is met to surrounding ESs and from surrounding PESs. With regard to the ECM design, the site plan need only identify the approved drawing numbers if using a previously approved design that has not been changed other than for minimal site adaptation.) When adapting approved designs, reference the drawings numbers of the Standard on the project plans.

The DOR must ensure that modifications made during the site adaption process do not impact the blast-resisting elements of the approved design. This typically includes the required soil cover geometry, magazine headwall, blast door(s) and frame, pilasters and header beams that support the doors against blast loads, and the roof elements of magazines with flat (non-arch type) roofs. For blast doors that include a bottom support, foundation/slab modifications must ensure that the door support conditions of the standard design are not altered. See Figures 2-1 and 2-2 for a graphic showing the typical blast-resisting elements of an ECM.

Figure 2-1: ECM Components

Figure 2-2: Typical ECM Blast Resisting Elements

2-3.2.3 7-Bar and 3-Bar ECM Designs No Longer Approved for New Construction. The Whole Building Design Guide web site and DDESB TP-15, Table AP1-2 contain lists of ECM designs that have been previously approved for 7-Bar or 3- Bar siting but are no longer approved for new construction. In most cases, these designs have not been updated to satisfy criteria changes. The intent of this list is to assist activities in sitings involving existing magazines. NEW limitations and/or restrictions associated with their DDESB approval must be observed. These designs can be used as the basis for new ECM designs, but they must be updated to comply with current explosives safety requirements, current construction methods and criteria, and are reviewed and approved by the DDESB. Any updated design drawings must clearly identify all changes and revisions made to the original design prior to approval.

Available electronic drawings, approval letters, and additional information and notes related to current approved designs can be accessed at the following web site:

http://www.wbdg.org/design/ammo_magazines.php .

2-3.2.4 Undefined ECM Designs. DDESB TP-15, Table AP1-3 contains a listing of ECM designs that are classified as undefined. These designs have not been shown by analysis or testing to have the structural capacity of either a 7-Bar or 3-Bar

ECM.

An undefined ECM can be structurally analyzed in accordance with UFC 3-340-02, Structures to Resist the Effects of Accidental Explosions, to determine its structural capabilities and potentially justify an upgrade to its classification. HNC-EDC-S-13-10, Guide for Evaluating Blast Resistance of Existing Undefined Arch-Type Earth Covered Magazines, illustrates procedures that can be used for a preliminary determination of the adequacy of the headwall and doors of an existing arch-type ECM to provide an acceptable level of protection from a given quantity of explosives at a known distance.

A complete analysis is required to ensure the design complies with current explosives safety requirements as well as current construction methods and criteria, prior to reclassifying the ECM design. The sponsoring Service’s explosives safety organization and the DDESB must review and approve the upgraded classification.

Table AP1-3 of DDESB TP-15 includes a listing of Undefined ECM designs. This table and the accompanying notes identify additional limitations, restrictions, or conditions associated with the use of these designs.

2-3.3 Magazine Construction and Explosives Safety Site Approval.

Prior to construction, an explosives safety site plan for all new AE storage magazines must be reviewed and approved by the sponsoring Service explosives safety organization and the DDESB to ensure that the magazine has been sited in accordance with the minimum explosives safety QD appropriate to the magazine type and classification. An exception to this allows approval by a Service explosives safety organization for security and limited amounts of ammunition without DDESB approval;

refer to DoD 6055.09-M for exceptions.

2-4 MAGAZINE SELECTION CONSIDERATIONS.

Selection of the most suitable magazine design to use at a given site will depend on a number of factors including, but not limited to:

• The specific configuration (pallet or container size, and stacking requirements).

• Physical security

• The hazard classification and quantity of AE that is anticipated to be stored in the magazine.

• The cost of construction and maintenance.

• Siting limitations or restrictions.

• Ordnance storage and delivery operations.

• Flexibility for future revisions to operations or mission

• AE non-compatibility.

Some of these factors are discussed below. Facility planners / designers should involve both end user and installation explosives safety personnel in the earliest stages of the planning and design process to ensure the selection will both meet the users end requirements and be in compliance with explosives safety requirements.

The use of an approved standard design for new magazine construction is mandatory within the DoD except where a preapproved design is not suitable due to special circumstances. Design of a new magazine requires Service explosives safety organization concurrence that an approved standard design is not available to meet the requirements of a specific project.

2-4.2 Net Explosive Weight (NEW) Limits.

Each of the approved magazine standard designs is rated for a maximum quantity of HD 1.1 AE that can be stored, expressed as maximum NEW. A magazine is sited using explosives safety QD relationships corresponding to the maximum amount of NEW that will be stored within the magazine. The quantity of AE stored must never exceed the maximum rated value.

2-4.3 Magazine Characteristics.

2-4.3.1 Shapes and Sizes. ECM types that have been used in the past are shown in DDESB TP-15 and on the WBDG website. The physical dimensions and configurations of 7-Bar and 3-Bar ECM designs approved for new construction are provided in Table AP1-1 of TP-15.

Some approved ECM designs allow variable lengths to provide greater flexibility in sizing a magazine to its specific intended use.

2-4.3.2 Door Openings. The approved 7-Bar and 3-Bar magazine designs have various door opening sizes. The door opening size must be selected based on current and anticipated future usage requirements and in consideration of the usage requirements for material handling equipment (MHE).

2-4.3.3 Door Types. Magazine doors are vertical swinging or sliding type, single or double leaf. Doors are either manually or electrically operated. Electrically operated doors must have an option for manual operation.

Note: Doors are designed for specific bearing conditions under external blast loading and site adaption may not include altering the design bearing surface of the doors (top, side, and bottom).

2-4.3.4 Storage Options. AE is usually stored within a magazine utilizing forklifts. An overhead bridge crane storage option has been developed in the RC Box, Type “M” magazine.

2-4.4 Storage and Loading Plans.

AE packaging information and suggested storage loading plans have been developed for many of the approved magazine designs. These plans are to assist in the effective use of magazines and may be used to estimate the potential storage capacity of various types of ordnance within a given magazine.

The U.S. Army Materiel Command (AMC) provides Storage and out loading drawings for various AE within certain ECMs. These drawings, indexed in AMC 19-48-75-5, may be obtained at the Defense Ammunition Center web site: https://mhp.redstone.army.mil.

Contact the help desk MHP (Munitions History Program) for access permission.

Email: usarmy.redstone.usamc.mbx.immc-mhp-helpdesk@mail.mil

Telephone: DSN 897-2143, COM (256) 313-2143

Additional standard layout plans for palletized ammunition, missiles, and torpedoes within ECMs are provided in NAVSEA Instruction 8024.2, Magazine Stowage Layout Standards.

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2-5 ELECTRICAL PLANNING.

Perform an electrical hazards survey to determine the structure’s hazardous location classification per NFPA 70 Article 500. This classification is based on the possibility of an explosive atmosphere existing within the magazine rather than the material stored inside the magazine. Ordnance storage magazines that store only “DoD-titled ammunition and explosives” (AE) in its original packaging will typically only need to meet industrial standards for electrical service. If an explosive atmosphere can exist because of the presence of raw explosive material exposed to air, the magazine might qualify as a Class 1, Division 2 location.

Perform a survey of the surrounding area to determine the grounding and lightning protection requirements for the facility. This survey might confirm that unique installation requirements apply to minimize the total resistance to ground. Ground connection locations must be established while ensuring that future maintenance can be accomplished. Verify that the exterior distribution requirements in DoD 6055.09-M, Volume 2, Enclosure 3, can be achieved.

CHAPTER 3 DESIGN CONSIDERATIONS AND REQUIREMENTS.

3-1 EARTH COVER.

The minimum earth cover over the top of an earth covered magazine must be 2 feet (0.61m). The maximum slope must be maintained at 2 horizontal to 1 vertical. The earth cover above, to the sides, and to the rear of an ECM is the critical element of its design. The material for the earth cover must be free from deleterious organic matter (large tree roots and similar materials), trash, debris, and stones heavier than 10 pounds (4.54 kg) or larger than 6 inches (150 mm) in any dimension. The presence of large stones (cobbles) will be limited to the lower, central portions of the earth cover, and such stones will not be used as surface cover over the magazine soil cover where they may contribute to hazardous debris (refer to Figure 3-1). Clay soils must not be used due to excessive cohesion and the potential to contribute to hazardous debris.

Compact the material and prepare as necessary to maintain structural integrity and provide erosion control. In locations where it is impossible to use a suitable material to maintain side slope or where rainfall is insufficient to maintain a grass cover, use other suitable materials and stabilization methods to ensure the structural integrity of the cover.

Figure 3-1: ECM Earth Cover

3-2 FLOOR DESIGN.

The design floor live load must be the maximum anticipated loading of stored material within the magazine during its useful life. Considerations must also be given to wheel loading from weight handling equipment (especially large or side loading vehicles).

Floor live loading as shown on the Standard Approved Magazine Drawings is based upon the anticipated maximum loading for that particular magazine type. Where soil conditions are poor, the design floor live loading may be reduced if it can be demonstrated that a reduced floor loading will be acceptable at a given location based on the actual anticipated usage. In such case, the maximum design floor live loading must be prominently posted at the entrance and within the magazine structure. Under all cases, the minimum floor live loading for any magazine type must be 500 PSF (2441 kg/sm).

3-3 FOUNDATIONS.

Foundations must be provided with a safe working static load capacity equivalent to or greater than the safe working static load capacity of the foundation shown on the Standard Approved Magazine Drawings. Foundations for earth retention walls must be designed using conventional design methods. Foundations that support elements of the magazine that are required to resist dynamic incident pressures from an external explosion from a PES must have an ultimate dynamic load capacity equivalent or greater to the ultimate dynamic load capacity of the foundations shown on the Standard Approved Magazine Drawings. Elements of the magazine that are required to resist the loading from a PES typically include structural walls and columns supporting roof elements. Unless a more detailed analysis is warranted, it is required that foundations redesigned for poor soil conditions must have a safe working static load capacity equal to or greater than the safe working load capacity of the foundations of the Standard Approved Magazine Drawings.

3-4 WATERPROOFING AND DRAINAGE.

The soil cover of ECMs can lead to moisture issues within the structure, deterioration of structural components, and degradation of stored AE. Ensure that the magazine is watertight and offers adequate protection to the stored AE from water intrusion. An elastomeric membrane is appropriate for concrete magazines and a bituminous waterproofing is more suitable for steel magazines. Protect the waterproofing membrane from backfilling and compaction operations during construction.

Note: The Navy currently has a prohibition against the use of any types of steel ECM for new construction due to difficulty of properly waterproofing these magazines.

Provide a drainage system around the ECM to adequately channel the water away from the structure.

3-5 VENTILATION, TEMPERATURE AND HUMIDITY CONTROL.

Typically, ECMs contain some form of ventilation. This is usually accomplished by louvered openings in the headwall and ventilator stacks that exit through the rear wall and penetrate through the earth cover. Due to the broad range of possible storage products and weather conditions, the criteria for a specific project should be provided by the using activity. Coordinate with the user to confirm specific project requirements.

3-5.1 Ventilation Only.

Where the using activity identifies natural or mechanical ventilation only as sufficient space environmental control, verify the following and confirm potential consequences are acceptable to the user.

• If occasional interior magazine surface condensation is not acceptable to the user, prepare an analysis to determine the potential for that condensation. The large thermal mass of concrete and earth berm changes temperature more slowly than ambient air. Under certain circumstances, the ambient air can quickly become warmer and moister (a suddenly warm spring day) than it was a short time earlier. If the interior surface temperature remains cool (below the air dew point) for an extended period of time due to thermal mass, the result could be interior surface condensation.

• If condensation is likely and unacceptable to the user, determine a method to keep surfaces above dew point (i.e. heat space, insulate walls) or lower ventilation air dew point by mechanical cooling with reheat or desiccant system.

• All potential options must also be judged based on the considerations listed in “Temperature and Humidity Control.”

3-5.2 Temperature and Humidity Control.

In some cases, due to specific criteria or determination that ventilation alone is inadequate, the AE product being stored may require more than just ventilation control.

Specific criteria for special storage requirements should be provided by the using activity. For this application, some form of heating and cooling will be required. For cooling, heating, and humidity control systems, the following must be considered:

• Determine location of mechanical equipment. Will mechanical equipment require its own space outside of the magazine?

• Determine acceptable paths of connection from mechanical equipment to interior of magazine. Are penetrations compliant with structural integrity?

• Coordinate lightning protection with mechanical equipment and establish bonding requirements to ensure continuity of duct and piping.

• Mechanical humidity control using mechanical cooling requires some form of reheat. Reheat must be in accordance with ASHRAE Standard 90.1, Energy Standard for Buildings Except Low-Rise Residential Buildings.

• Mechanical humidity control using a desiccant drying system requires some form of desiccant regeneration (either integral to a package unit or by desiccant replacement). Base final determination on a Life Cycle Cost Analysis.

• Determine the hazardous location classification of the atmosphere within the magazine and select equipment and materials compatible with that classification (e.g. Class1, Division 2).

• Coordinate with the user on the criticality of maintaining the space environmental conditions and determine if sensors and status points should be provided and connected to the base Energy Monitoring and Control System for remote monitoring or to another central monitoring site.

3-5.3 Structural Coordination.

Any mechanical work must maintain the structural integrity of the magazine design.

• If required, consider implementation of blast valves (explosion dampers) and/or blast attenuation chambers.

• Coordinate location of any mechanical penetration with structural requirements, including possible designed blow out walls or roofs.

• Consult with the Service explosive safety organization.

3-6 FIRE PROTECTION AND LIFE SAFETY.

3-6.1 Ammunition and Explosives (AE) Storage Facilities.

AE storage facilities may be ECMs or AGMs as defined by DoD 6055.09-M. An AE storage facility can be used for AE storage only. An AE storage facility may not be used for handling; processing; testing; servicing; and inspection of ammunition, explosives, propellants, and oxidizers.

3-6.2 Sprinklers and Hydrants.

Automatic sprinklers and hydrant protection are not required for AE storage facilities.

3-6.3 Means of Egress.

Compliance with NFPA 101 means of egress requirements is not required for AE storage facilities.

3-6.4 Fire Alarm System.

A fire alarm system is not required for AE storage facilities.

3-6.5 Mass Notification.

Mass notification is not required for AE storage facilities.

3-7 PHYSICAL SECURITY.

Design AE facilities in accordance with DoDM 5100.76 and DoD 6055.09-M. Additional Service-specific guidance implementing DoDM 5100.76 are contained in OPNAV Instruction 5530.13C Department of the Navy Physical Security Instruction for Conventional Arms, Ammunition and Explosives (AA&E), 26 September 2003, Army Regulation 190-11, Physical Security of Arms, Ammunition and Explosives, 15 November 2006 (For Official Use Only), MCO 5530.14A Marine Corps Physical Security Program Manual, and AFI 31-101 Department of the Air Force Integrated Defense

Approved magazine standard designs identify minimum physical security features, including high security hasps on doors, steel bars at openings and conduit for electronic security systems. The goal is to provide a forced entry delay time that exceeds the response force response time. Coordinate the security requirements for a specific magazine with the Service and installation security personnel. The below information is provided to assist the end user in determining requirements for magazine door locking devices;

• MIL-DTL-43607J, Padlock, Key Operated, High Security, Shrouded Shackle states: “The padlock shall withstand a concentrated forced entry attack using battery powered tools for an accumulated work time of at least one minute.” To improve forced entry resistance of structures with High Security Padlocks and Hasps, an Anti-Intrusion Barrier (AIB) can be added to protect the locking system and increase the forced entry delay times against hand and battery powered tools.

• The Internal Locking Device (ILD) is a government developed and patented High

Security Locking System that mitigates the “exposure to attack” that external locking systems are prone to. This system has been tested to withstand 10 minutes of forced entry resistance against hand and battery powered tools. The ILD is an approved alternative to the current high security padlock and hasp requirement. The ILD is best suited to high security applications and in locations where extreme climate makes opening and securing externally mounted padlocks impractical.

3-7.1 Assistance with Physical Security Components and Requirements.

For help with information on security hardware selection, requirements, specifications, national stock numbers, purchasing, and troubleshooting of equipment failures, call the

Department of Defense Lock Program Technical Support Hotline (800) 290-7607, (805) 982-1212, DSN 551-1212, or send e-mail to:

W_NAVFAC_DoD_Lock_Program_Support@navy.mil

Additional information can be found at http://www.navfac.navy.mil/go/locks

3-8 ELECTRICAL DESIGN.

Provide site electrical utilities, interior distribution systems, and communications and security according to UFC 3-501-01, Electrical Engineering, and the latest installation design requirements.

• Site Electrical Utilities include equipment, overhead power distribution, underground electrical systems, grounding, metering, and exterior site lighting.

• Interior distribution systems include distribution and service entrance equipment, surge protective devices (SPDs), wiring devices, raceways, conductors, interior lighting systems, lightning protection systems, and hazardous locations.

• Communications and security includes telecommunications systems and electronic security systems (ESS).

In addition to the criteria identified above, comply with DoD 6055.09-M and the following Magazine-specific requirements.

3-8.1 Hazardous (Classified) Location.

The Designer of Record is responsible for determining the design based upon the classification established in Chapter 2 in the paragraph entitled, “Electrical Planning”.

Explosion-proof fixtures and equipment are not required unless the magazine is classified as a hazardous location.

3-8.2 Power.

Electric lines serving the magazine must be installed underground from a point not less than 50 feet (15 meters) from the facility.

The service entrance equipment can be installed inside of the magazine or on the exterior magazine headwall. Coordinate the location of the equipment with the user. All interior conduits must be galvanized steel rigid metal conduit. Locate duplex receptacles and electrical control equipment 48 inches (1,220 millimeters) above the floor.

3-8.3 Lighting.

Provide two separate exterior lighting systems :

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• Photocell-controlled for security lighting (0.2 foot-candles (fc), 2 lux).

• Switched lighting for loading activities (5 fc, 50 lux).

Provide interior lighting system:

• Switched lighting per bay or area for warehousing activities (30 fc, 300 lux). Incorporate manual on, vacancy off lighting controls.

Note: For Army projects, coordinate with the user and Activity to determine if there is a requirement for interior and exterior lighting, including lighting required to support electronic security systems. Otherwise, do not include in the project.

3-8.4 Earth Electrode…