MIL-STD-1660B.pdf

AMSC N/A FSC 8140

DISTRIBUTION STATEMENT A. Approved for public release. Distribution is unlimited.

INCH-POUND

MIL-STD-1660B

20 April 2021

SUPERSEDING

MIL-STD-1660A

7 August 2008

DEPARTMENT OF DEFENSE

DESIGN CRITERIA STANDARD

AMMUNITION AND ORDNANCE UNIT LOADS

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FOREWORD

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

2. This standard establishes minimum design and evaluation procedures to be applied throughout the

Department of Defense to unit loads of ammunition. It provides guidelines covering unit loads for ammunition designed to establish reliability, safety, and compatibility with handling equipment most commonly found in the distribution system.

3. When ammunition items, packaged or unpackaged, are moved from one place to another, they are usually combined into a larger assemblage which can be easily and safely handled by mechanized equipment; e.g., a forklift truck. This assemblage is called a unit load.

4. The ammunition logistics system of the Department of Defense is based on distribution in unit loads unless the item, as packaged, is too large or too heavy to be so assembled. A unit load may be stored for prolonged periods before it is needed. It may be shipped by truck, rail, ship, or aircraft. Depending upon the particular operations of the consuming combatant unit, the unit load must withstand the rigors of over the beach handling, local transport and handling over rough terrain, or delivery by external or internal carriage by helicopter under the threat of enemy action, or by transfer-at-sea, or by combinations of these methods, at any time and under poor weather conditions. In addition to possible adverse effects on the reliability of the ammunition, failures of unit loads can lead to death or injury from falling heavy objects or from disastrous explosion. Because of these factors, a detailed design must be prepared, tested, and documented showing how the ammunition is to be assembled into a unit load, which will be safe and efficient to handle, ship, store, and deliver to the combatant unit.

5. This is a mandatory standard for use by DoD ammunition design activities and, when applicable, is to be invoked in specifications, purchase descriptions, and contracts when such design service is to be procured. It applies to ammunition terms as prepared for shipment and not necessarily to metal parts, bulk, explosives, and other components.

6. Comments, suggestions, or questions on this document should be addressed to Commanding Officer, Naval Surface Warfare Center, Indian Head Division, Detachment Picatinny, Code G12, Picatinny Arsenal, NJ

07806 or emailed to CommandStandards@navy.mil with the subject line “Document Comment”. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.dla.mil.

mailto:CommandStandards@navy.mil https://assist.dla.mil/ iii

CONTENTS

PARAGRAPH PAGE

1. SCOPE

1.1 Scope

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 Order of precedence

3. DEFINITIONS

3.1 General

3.1.1 Batten

3.1.2 Cap

3.1.3 Design activity

3.1.4 Edge protector

3.1.5 Handling equipment

3.1.6 Overhang

3.1.7 Pallet

3.1.8 Pallet adapter

3.1.9 Pallet, special purpose

3.1.10 Palletized unit load

3.1.11 Protection levels:

3.1.11.1 Level A – tactical (Army), fleet-issue unit load (FIUL) (Navy), amphibious unit load (Navy)

3.1.11.2 Level B – intermediate (Army), domestic (Navy)

3.1.11.3 Level C – minimum (Army)

3.1.12 Skid base

3.1.13 Strapping

3.1.14 Underhang

3.1.15 Unit load

3.1.15.1 Amphibious unit load

3.1.15.2 FIUL (Navy)

4. GENERAL REQUIREMENTS

4.1 General

4.2 Transportability requirement

4.2.1 Airlift compatibility

4.2.2 Railcar compatibility

4.2.3 Truck trailer compatibility

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PARAGRAPH PAGE

4.2.4 Ship compatibility

4.2.5 Container compatibility

4.3 Handling equipment compatibility

4.3.1 Forklift/pallet truck capability

4.3.2 Sling capability

4.4 Unit load configuration

4.4.1 Unit loads on pallets

4.4.1.1 Shape

4.4.1.2 Item placement and orientation

4.4.1.3 Protrusions

4.4.1.4 Item retention

4.4.1.5 Quantity of straps

4.4.1.6 Strapping placement

4.4.1.7 Vertical battens

4.4.1.8 Drainage

4.4.2 Unit loads not on pallets

4.4.2.1 Strapless unitization

4.4.2.2 Quantity of straps

4.4.2.3 Strapping placement

4.5 Size and weight

4.5.1 Length and width

4.5.1.1 Overhang

4.5.1.2 Underhang

4.5.2 Transportability limitations

4.5.3 Gross weight

4.5.4 High density ammunition

4.5.5 Special rule for amphibious assault ammunition

4.6 Stability

4.7 Stacking capability

4.8 Materials

4.8.1 Strapping

4.8.2 Strapping seals

4.8.3 Pallets

4.8.4 Fasteners

4.8.4.1 Nails

4.8.4.2 Screws

4.8.5 Staples

4.8.6 Edge protectors

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PARAGRAPH PAGE

4.8.7 Wood members

4.8.8 Plywood

4.9 Markings

4.10 FIULs (Navy), tactical (Army)

4.10.1 Sling compatibility

4.11 Protection levels

4.11.1 Level A – tactical (Army), FIUL (Navy), Amphibious Unit Load (Navy)

4.11.2 Level B – intermediate (Army), domestic (Navy)

4.11.3 Level C – minimum (Army)

5. DETAILED REQUIREMENTS

5.1 General

5.2 Satisfactory performance criteria

5.3 Test temperature

5.4 Test procedures

5.4.1 Stacking test

5.4.1.1 Stacking test rationale

5.4.2 Repetitive shock test

5.4.2.1 Repetitive shock test (superimposed load)

5.4.2.2 Repetitive shock test rationale

5.4.3 Drop test

5.4.3.1 Edgewise-drop (rotational) test

5.4.3.2 Cornerwise-drop (rotational) test

5.4.3.3 18-inch flat bottom drop test

5.4.3.4 Drop tests rationale

5.4.3.5 Drop surface recommendation

5.4.4 Impact test

5.4.4.1 Impact test (stacked)

5.4.4.2 Impact test rationale

5.4.5 Tipover test

5.4.6 Forklifting test

5.4.7 Pallet truck test

5.4.8 Sling compatibility test

5.4.9 Disassembly test

5.5 Testing

5.5.1 Unitized loads of ammunition within a limited (level C [Army]) transportation and storage cycle testing

5.5.2 Alternate material testing

5.5.2.1 High temperature testing

5.5.2.2 Low temperature testing

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PARAGRAPH PAGE

5.5.2.3 Rain testing

5.5.2.4 Solar radiation testing

6. NOTES

6.1 Intended use

6.1.1 Non-ammunition use

6.2 Acquisition requirements

6.3 Subject term (key word) listing

6.4 International standardization agreement implementation

6.5 Changes from previous issue

A.1 SCOPE

A.1.1 Scope

A.2 DEFINITIONS

A.2.1 Shock

A.2.2 Vibration

A.3 APPARATUS

A.3.1 Platform

A.3.2 Restraining devices

A.4 SPECIMENS

A.4.1 Contents

A.4.1.1 Specimen condition

A.4.1.2 Dummy load

A.5 CONDITIONING

A.5.1 Test specimen

A.6 PROCEDURE

A.6.1 Positioning

A.6.2 Restraining devices

A.6.3 Frequency

A.6.4 Additional positioning

A.6.5 Inspection

B.1 SCOPE

B.1.1 Scope

B.2 DEFINITIONS

B.2.1 Level of packing

B.2.1.1 Level A

B.2.1.2 Level B

B.3 APPARATUS

B.3.1 Edgewise-drop test

B.4 SPECIMEN

B.4.1 Contents

B.5 CONDITIONING OF SPECIMEN

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PARAGRAPH PAGE

B.5.1 Test specimen

B.6 PROCEDURE

B.6.1 Positioning

B.6.2 Procedure

B.6.3 Temperature

B.7 NOTES

C.1 SCOPE

C.1.1 Scope

C.2 DEFINITIONS

C.2.1 Level of packing

C.2.1.1 Level A

C.2.1.2 Level B

C.3 APPARATUS

C.3.1 Cornerwise-drop test

C.4 SPECIMEN

C.4.1 Contents

C.5 CONDITIONING OF SPECIMEN

C.5.1 Test specimen

C.6 PROCEDURE

C.6.1 Positioning

C.6.2 Height and number of impacts

C.6.3 Temperature

C.7 NOTES

D.1 SCOPE

D.1.1 Scope

D.2 APPLICABLE DOCUMENTS

D.2.1 General

D.2.2 Non-government publications

D.3 DEFINITIONS

D.3.1 Inline impact tester

D.4 APPARATUS

D.4.1 Inclined track

D.5 SPECIMEN

D.5.1 Contents

D.6 CONDITIONING OF SPECIMEN

D.6.1 Test specimen

D.7 PROCEDURE

D.7.1 Positioning

D.7.2 Number and velocity of impacts

D.7.3 Recording viii

PARAGRAPH PAGE

D.8 NOTES

D.8.1 Incline impact test

E.1 SCOPE

E.1.1 Scope

E.2 APPARATUS

E.2.1 Pendulum-impact tester

E.3 SPECIMEN

E.3.1 Contents

E.4 CONDITIONING OF SPECIMEN

E.4.1 Test specimen

E.5 PROCEDURE

E.5.1 Positioning

E.5.2 Number and height of drops

E.5.3 Recording

E.6 NOTES

F.1 SCOPE

F.1.1 Scope

F.2 APPARATUS

F.2.1 Tipover test

F.3 SPECIMEN

F.3.1 Contents

F.4 CONDITIONING OF SPECIMEN

F.4.1 Test specimen

F.5 PROCEDURE

F.5.1 Number and direction of tipover

F.5.2 Recording

F.6 NOTES

G.1 SCOPE

G.1.1 Scope

G.2 APPARATUS

G.2.1 Forklift handling

G.2.2 Hoisting with slings

G.2.3 Hoisting with grabs

G.2.4 Pushing

G.2.5 Towing

G.2.6 Conveying

G.3 SPECIMENS

G.3.1 Contents

G.4 CONDITIONING

G.4.1 Test specimen

G.5 PROCEDURE

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PARAGRAPH PAGE

G.5.1 Sequence of tests

G.5.2 Lifting and transporting by forklift truck

G.5.3 Undersling handling

G.5.3.1 Sling handling with attachments

G.5.3.1.1 Hoisting attachment strength test

G.5.3.1.2 Two-place attachment

G.5.3.1.3 One-place attachment

G.5.4 Hoisting with grabs

G.5.5 Pushing

G.5.6 Towing

G.5.7 Conveying

G.5.8 Inspection after handling

G.6 NOTES

G.6.1 Test procedure

H.1 SCOPE

H.1.1 Scope

H.2 REQUIREMENTS

H.2.1 General

H.2.2 Alternate tests

H.3 SPECIMEN

H.3.1 Test specimen

H.4 CONDITIONING OF SPECIMEN

H.4.1 Conditions

H.5 PROCEDURES

H.5.1 Stacking test

H.5.1.1 Purpose

H.5.1.2 Procedure

H.5.1.3 Rejection criteria

H.5.2 Vibration test

H.5.2.1 Purpose

H.5.2.2 Procedure

H.5.2.3 Rejection criteria

H.5.3 Drop test (edgewise-drop)

H.5.3.1 Purpose

H.5.3.2 Procedure

H.5.3.3 Rejection criteria

H.5.4 Mechanical handling test

H.5.4.1 Purpose

H.5.4.2 Procedure

H.5.4.3 Rejection criteria x

PARAGRAPH PAGE

H.5.5 Disassembly and final inspection test

H.5.5.1 Purpose

H.5.5.2 Procedure

H.5.5.3 Final rejection or acceptance criteria xi

LIST OF FIGURES

FIGURE PAGE

FIGURE 1 Vertical batten length FIGURE 2. Optional rough handling course for forklift trucks FIGURE B-1. Edgewise-drop (rotational) FIGURE C-1. Cornerwise-drop (rotational) FIGURE D-1. Incline impact test FIGURE E-1. Pendulum-impact test FIGURE G-1. Slings placed around specimen with load superimposed FIGURE G-2. Hoisting with sling attachment provisions FIGURE G-3. Hoisting with grabs

LIST OF TABLES

TABLE PAGE

TABLE I. Maximum safe working capacities of steel strapping TABLE II. Recommended unit load dimensions for transport and storage TABLE B-I. Height of rotational drops for unit loads of various sizes and weights TABLE C-I. Height of cornerwise drops (rotational) for unit loads of various sizes and weights TABLE H-I. Height of edgewise drops for unit load specimens of various sizes and weights

1. SCOPE

1.1 Scope. This standard establishes minimum design criteria and associated tests for ammunition and ordnance unit loads.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 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, or 5 of this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks 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.

INTERNATIONAL STANDARDIZATION AGREEMENTS

STANAG-2828 - Military Pallets, Packages and Containers

INTERNATIONAL STANDARDIZATION DOCUMENTS

AAP-23 - NATO Glossary of Packaging Terms and Definitions (English and French)

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-15011 - Pallets, Material Handling, Wood, Post Construction, 4-Way Entry

MIL-DTL-23312 - Pallets, Material Handling, Metal (for Ordnance Items); Mark 3 Mod 0, Mark 12

Mod 0 and Mark 12 Mod 1

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-648 - Specialized Shipping Containers

MIL-STD-810 - Environmental Engineering Considerations and Laboratory Tests

MIL-STD-1320 - Standard Practice for Designing Unit Loads, Truckloads, Railcar Loads, and

Intermodal Loads for Ammunition and Explosives

MIL-STD-1791 - Designing for Internal Aerial Delivery in Fixed Wing Aircraft

MIL-STD-2073-1 - Standard Practice for Military Packaging

(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, drawings, and publications 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.

AERONAUTICAL SYSTEMS CENTER

AFSC Design Handbook DH 1-11 - Air Transportability

(Copies of this document are available online at https://engineering.wpafb.af.mil/engstds/engstds.asp.)

NAVAL SEA SYSTEMS COMMAND (NAVSEA) DRAWINGS

564200 - Mk 3 Mod 0 Pallet

2086479 - Mk 12 Mod 0 Pallet

2614969 - Sling, Pallet Mk 85 Mod 0

2614970 - Sling, Pallet Mk 86 Mod 0

2614971 - Sling, Pallet Mk 87 Mod 0

2642587 - Sling, Pallet Mk 93 Mod 0 8000 Pound Capacity

2642914 - Sling, Weapons Handling Mk 99 Mod 0

2643919 - Sling, Pallet Mk100 Mod Assembly

2643482 - Sling, Hoisting Mk105 Mod 0

2644390 - Sling, Leg 4000 Pound Capacity

2645180 - Sling, Pallet, Mk 123 Mod 0 6000 Pound Capacity

2645217 - Mk 12 Mod 1 Pallet

5167555 - Sling, Container Lifting Mk 109 Mod 1

7516578 - Sling, Pallet Mk 85 Mod 1

7516579 - Sling, Pallet Mk 86 Mod 1

7516580 - Sling, Pallet Mk 87 Mod 1

7516581 - Sling, Pallet Mk100 Mod 2

(Copies of these documents are available from the applicable repositories listed in S0005-AE-PRO-010/EDM, which can be obtained online via Technical Data Management Information System (TDMIS) at https://mercury.tdmis.navy.mil/. Copies of these documents may also be obtained from the Naval Ships Engineering

Drawing Repository (NSEDR) online at https://199.208.213.105/webjedmics/index.jsp. To request an NSEDR account for drawing access, send an email to NNSY_JEDMICS_NSEDR_HELP_DESK@navy.mil.)

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NAVAL SEA SYSTEMS COMMAND (NAVSEA) PUBLICATIONS

NAVSEA OP 3221 (Army TM 55-607) - Loading & Stowage of Military Ammunition &

Explosives Aboard Break Bulk Merchant Ships

NAVSEA SW023-AJ-WHS-010 - Handling and Stowage of Amphibious Assault

Ammunition Aboard Amphibious Ships

MSC TW023-AB-WHS-010 - Handling and Stowage of Ammunition Aboard MSC

Class Ships

(Copies of these documents are available online via Technical Data Management Information System (TDMIS) at https://mercury.tdmis.navy.mil/. Refer questions, inquiries, or problems to: DSN 296-0669, Commercial

(805) 228-0669. These documents are available for ordering (hard copy) via the Naval Logistics Library (NLL) at https://nll.navsup.navy.mil. For questions regarding the NLL, contact the NLL Customer Service at nllhelpdesk@navy.mil (866) 817-3130, or (215) 697-2626/DSN 442-2626.)

U.S. ARMY DEFENSE AMMUNITION CENTER

AC200000331 - Sling, Adjustable, Double Basket

AC200000332 - Sling, Multiple Leg Projectile Pallet

AC200000398 - Sling, Multiple Leg Top-Lift Ammunition Pallet

ACV00561 - Unit Load Marking for Shipment and Storage, Ammunition and

Explosives

ACV00617 - Pneumatic Sealless Combination Tool for 3/4" Steel Strapping

(Clipless Seals)

AMC 19-48-4116-20PA1002 - Basic Procedures – Unitization Procedures for Boxed Ammunition and Components on 4-Way Entry Pallets

DA PAM 746-1 - Pallets and Storage Aids for Army Use

(Copies of these documents are available online at https://www.dau.edu/cop/ammo/.)

CODE OF FEDERAL REGULATIONS (CFR)

46 CFR 146.29-180 - Regulations Governing the Transportation of Military Explosives and

Hazardous Munitions on Board Vessels

49 CFR 170-178 - Hazardous Material Regulations of the Department of Transportation

(Copies of these documents are available online at www.ecfr.gov.)

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 these documents are those cited in the solicitation or contract.

AMERICAN LUMBER STANDARD COMMITTEE, INCORPORATED

Voluntary Product Standard PS 20 - American Softwood Lumber Standard

(Copies of this document are available online at www.alsc.org/home_docupdate_mod.htm.)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI S1.1 - Acoustical Terminology

(Copies of this document are available online at http://webstore.ansi.org/.)

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ASTM INTERNATIONAL

ASTM D3953 - Standard Specification for Strapping, Flat Steel and Seals

ASTM D6199 - Standard Practice for Quality of Wood Members of Containers and Pallets

ASTM F1667 - Standard Specification for Driven Fasteners: Nails, Spikes, and Staples

(Copies of these documents are available online at www.astm.org.)

AMERICAN ASSOCIATION OF RAILROADS/BUREAU OF EXPLOSIVES

Circular No. 43-E, Pamphlet

No. 45, BOE Pamphlet No. 6C

- Intermodal Loading Guide for Products in Closed Trailers and

Containers

(Copies of this document are available online at https://www.aar.org/publications/.)

INTERNATIONAL PLANT PROTECTION CONVENTION (IPPC)

ISPM No. 15 - Guidelines for Regulating Wood Packaging Material in International Trade

(Copies of this standards are available online at https://www.ippc.int/en/.)

SAE INTERNATIONAL

SAE AS5389 - Pallet Lift Truck and Container Fork Pocket Interface

(Copies of this document are available online at www.sae.org.)

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.

3. DEFINITIONS

3.1 General. The terms used throughout this standard are consistent with the following definitions. Packaging terms not defined below are in accordance with AAP-23. Definitions of shock and vibration terms are in accordance with ANSI S1.1.

3.1.1 Batten. A wooden member used to fill space, protect against damage, or to provide retention of unit load contents or to provide additional surfaces for strapping or bearing.

3.1.2 Cap. A cover with sides extending perpendicularly from the perimeter used as a protection against damage, or to help create a stable load. It may be used over the load, inverted under a load, or used under and over intermediate courses.

3.1.3 Design activity. The DoD activity responsible for designing ammunition and ordnance unit loads, or if the design service is procured for approving the design as being compatible with service needs. Examples of design activities as defined herein are:

a. Army: U.S. Army Defense Ammunition Center, McAlester, OK.

b. Navy: NSWC Indian Head Division, Detachment Picatinny, Naval Packaging, Handling, Storage, and

Transportation Center, Picatinny Arsenal, NJ.

c. Air Force: Armament Development and Test Center; Ogden Air Logistics Center.

3.1.4 Edge protector. A light piece of material placed under the strapping at the edge of the load to prevent the strap from crushing the load or to prevent sharp edges of the load from damaging the strap.

3.1.5 Handling equipment. Any equipment or special handling device used for moving packages, packs, unit loads, containers, items, or components.

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3.1.6 Overhang. The distance that the vertical edges of the components of a unit load extend beyond the edges of the pallet.

3.1.7 Pallet. A low portable platform of wood, metal, or other material to facilitate handling, stowage, and transportation of materials as a unit by mechanical equipment. It is used as the base of a unit load to support and combine groups of commodities (or to confine single items) for handling and shipping as a single entity.

3.1.8 Pallet adapter. A wood or metal framework designed to secure irregular shaped articles to a pallet.

3.1.9 Pallet, special purpose. A pallet that is specifically designed for use with a particular ammunition or ordnance item, or for use in a specific handling or transportation environment.

3.1.10 Palletized unit load. A unit load that uses a pallet as a base.

3.1.11 Protection levels:

3.1.11.1 Level A – tactical (Army), fleet-issue unit load (FIUL) (Navy), amphibious unit load (Navy). The degree of packaging and unit load integrity required for protection of ammunition and ordnance against the most severe conditions known or anticipated to be encountered during shipment, handling, and storage.

3.1.11.2 Level B – intermediate (Army), domestic (Navy). The degree of packaging and unit load integrity required for protection of ammunition and ordnance under anticipated favorable conditions during worldwide shipment, handling, and storage.

3.1.11.3 Level C – minimum (Army). The degree of packaging and unit load integrity required for protection of ammunition and ordnance under known favorable conditions.

3.1.12 Skid base. A type of pallet used as the base for unit loads of items that are packed in long wooden boxes

27 inches in length or greater.

3.1.13 Strapping. A length of flat steel or other material, placed in tension around a unit load to compact and secure the individual items into a single entity. Also referred to as banding.

3.1.14 Underhang. The distance the edges of the pallet extend beyond the vertical edges of the items, containers, or unit load.

3.1.15 Unit load. An assemblage of items (in or out of containers) designed to facilitate handling these items as a single entity.

3.1.15.1 Amphibious unit load. A unit load that is specifically designed to be loaded as assault cargo in ships, such as LPHs, LHAs, and LPDs, for rapid unloading in specific amphibious operations.

3.1.15.2 FIUL (Navy). A unit load that is specifically designed to permit transfer-at-sea operations and which is compatible with shipboard handling and stowage procedures.

4. GENERAL REQUIREMENTS

4.1 General. This section presents general requirements for unit loads of materials that can be verified by visual observation, simple measurement, or a certificate of compliance with material requirements. Inspection procedures are concerned only with those materials that are used to make up the unit load (i.e., pallets, adapters, battens, strapping, and dunnage materials). Inspection procedures for the ammunition or ordnance items and their packaging are contained in documents relevant to the procurement or maintenance of the specific item.

4.2 Transportability requirement. The unit load, insofar as possible, shall be designed to move without restriction, special routing, or special escort throughout the ammunition distribution system used by the Department of Defense in accordance with 49 CFR 170-178.

4.2.1 Airlift compatibility. Unit loads shall be in accordance with the general design and performance requirements of MIL-STD-1791 as amplified by AFSC Design Handbook DH 1-11. Air transportability criteria for nuclear weapons shall be in accordance with individual service regulations.

4.2.2 Railcar compatibility. The unit load shall, insofar as possible, be capable of being efficiently and safely loaded in standard commercial boxcars in accordance with MIL-STD-1320.

4.2.3 Truck trailer compatibility. Wherever practical, the unit load shall be capable of being efficiently and safely loaded into standard closed van trailers capable of meeting shipping requirements for explosives. In addition, consideration shall be given to providing appropriate strength members compatible with the fixed cross member spacing in the trailers or containers authorized for trailer on flat car or container on flat car service shown in Circular

No. 43-E, Pamphlet No. 45, BOE Pamphlet No. 6C.

4.2.4 Ship compatibility. Wherever the distribution system is sufficiently known to identify the type of ships to be employed, the unit load shall be capable of being safely and efficiently loaded and stowed aboard those ships.

Typical ship loading situations are described by NAVSEA OP 3221 (Army TM 55-607), SW023-AJ-WHS-010

(formerly OP4550), and MSC TW023-AB-WHS-010 (formerly OP3206).

4.2.5 Container compatibility. Wherever practical, the unit load shall be capable of being safely and efficiently loaded into MILVANS and commercial ISO containers in accordance with Circular No. 43-E, Pamphlet No. 45, BOE Pamphlet No. 6C.

4.3 Handling equipment compatibility. The unit load shall be compatible with the handling equipment used throughout the expected logistic flow patterns.

4.3.1 Forklift/pallet truck capability. Unit load designs shall be capable of being handled safely by forklift trucks of rated capacity appropriate to the gross weight and geometry of the palletized unit load. Minimum size of each forklift opening shall be in accordance with the limiting dimensions specified in STANAG-2828, minimum of

3.875 inches in height and 8.625 inches in width. Palletized unit loads shall also be in accordance with

SAE AS5389. Full four-way entry capability shall be provided unless a deviation is justified by life cycle cost and technical analysis. If pallet trucks are to be used in the logistic flow pattern, the pallet design shall be compatible with their use. Container unit loads shall be in accordance with the forklift/pallet truck capability guidance of

MIL-STD-648.

4.3.2 Sling capability. Unit loads shall be capable of being safely handled by the authorized slings which are commonly used in ammunition and ordnance handling operations. Fleet-issue unit loads shall also be capable of being safely handled by the authorized slings which are commonly used for underway replenishment operations.

See 4.10.1 for a list of authorized slings.

4.4 Unit load configuration.

4.4.1 Unit loads on pallets.

4.4.1.1 Shape. Insofar as practical, the complete unit load shall be configured in a shape in which all six sides are rectangles.

4.4.1.2 Item placement and orientation. Items shall be oriented on the pallet in accordance with pertinent instructions (e.g., THIS SIDE UP) or in the least fragile position. In the absence of such requirements, items making up the unit load shall be placed or oriented in such a way that space is utilized most efficiently, the unit load meets all stability requirements, the overhang requirements are met, and overall unit load dimensions are optimized.

NOTE: Ammunition loaded with white phosphorous shall be loaded so that the long axis of the round is vertical unless otherwise specifically authorized.

4.4.1.3 Protrusions. Protrusions from the individual items making up the unit load shall be oriented to minimize damage. Battens or other protective devices shall be used wherever protrusions are likely to cause damage or be damaged.

4.4.1.4 Item retention. All items shall be positively retained within the unit load in all directions by strapping, battens, plywood sheets, pallet adapter frames, adjacent items, or the positive interlock features of adjacent items.

Friction created by the tensioning of straps shall not be used as a means of retention.

4.4.1.5 Quantity of straps. Palletized unit loads shall have a minimum of four straps with two straps running the length of the unit load and two straps running the width of the unit load. Additional straps shall be used as necessary to stay within the strapping working load limits (see table I) and to ensure positive retention of all items.

TABLE I. Maximum safe working capacities of steel strapping.

Nominal width and thickness (inches) Safe working load of strap (pounds)

(ASTM D3953, type I, heavy duty)

¾ x 0.031 725

¾ x 0.035 725

1¼ x 0.031 1,190

1¼ x 0.035 1,190

4.4.1.6 Strapping placement. The following shall be considered when locating straps:

a. Strapping shall be located in such a way that it is not susceptible to snagging by adjacent unit loads, handling equipment, or transportation equipment.

b. Strapping shall only bear against edges that are straight and level to ensure even stress distribution across the width of the strap.

c. Strapping shall only bear against structurally rigid locations of the items (or adapter frames). When necessary, use load spreading objects such as edge protectors or battens to prevent the straps from crushing the item.

d. Avoid locating a strap directly over the space or seam between two adjacent items. When this cannot be avoided, place a batten or edge protector under the strap to prevent the strap from wedging itself between the items.

e. Unsupported strapping (i.e., strapping not directly in contact with the load structure or battens) shall be kept to minimum.

f. Strapping shall be located such that it does not obstruct palletized container features such as lift or tiedown rings, humidity indicators, breather valves, and observation windows.

4.4.1.7 Vertical battens. Vertical battens placed under the strapping on the sides of the unit load shall be cut to length such that the strapping bears down on the top of the load at approximately a 45-degree angle (see figure 1).

FIGURE 1 Vertical batten length.

4.4.1.8 Drainage. To the maximum extent practical, free drainage shall be provided in the normal storage position.

4.4.2 Unit loads not on pallets. Large weapon containers having skids or built-in fork pockets can be unitized without a pallet.

4.4.2.1 Strapless unitization. Containers may be equipped with mechanical interlock features which enable unitization without the use of strapping. Such features typically provide vertical restraint to the upper container(s) while the container’s stacking interface features provide lateral and longitudinal restraint. In situations when these interlock features are missing, damaged, or otherwise deemed unfit for use, an alternate procedure to unitize containers with strapping shall be provided.

4.4.2.2 Quantity of straps. In most cases, two straps holding an upper container to a lower container is sufficient to hold the items in place throughout their intended logistics cycle. However, the strapping safe working load capacities in table I shall not be exceeded. The working load per strap is calculated based on the weight of the upper container(s) only. The bottom container’s weight is not included. Thus, a unit load of two containers weighing 2,000 pounds each would require two 1¼ x-0.031 to 0.035-inch straps.

4.4.2.3 Strapping placement. The following shall be considered when locating straps:

a. Strapping shall not pass under those elements of the lower container in contact with ground unless positive steps are taken to recess the strapping to prevent frictional wear.

b. Usually, at least two straps are required. The straps shall be located as far apart as possible from one another.

c. Strapping shall be located such that it is not susceptible to snagging by adjacent unit loads, handling equipment, or transportation equipment.

d. Strapping shall be located such that it does not obstruct container features such as lift or tiedown rings, humidity indicators, breather valves, and observation windows.

e. Strapping shall only pass over edges that are straight and level to ensure even stress distribution across the width of the strap.

f. Strapping shall only bear against structurally rigid locations of the container.

g. Strapping shall bear down on the upper containers of a unit load with a significant vertical component

(i.e., at least a 45-degree angle from horizontal). When necessary, this can be ensured by placing a 2 x 4 or 2 x 6 batten under the strapping or by routing the straps over the top of the upper container. Do not use battens in the fork pockets of the bottom container.

h. Unsupported strapping (i.e., strapping not directly in contact with the load structure or battens) shall be kept to a minimum.

i. The locating of straps over sharp edges, which could damage the strap, should be avoided. When this cannot be avoided, edge protectors shall be placed under the strap.

4.5 Size and weight. Unless the ammunition or ordnance item and its shipping container are larger than the limits given herein, dimensions, size, and weight shall be determined in accordance with the following:

4.5.1 Length and width. Length and width shall, insofar as practical and consistent with other dimensional rules contained herein, be close to the plan view sizes of table II.

TABLE II. Recommended unit load dimensions for transport and storage.

Equipment or facility Size

Igloo magazine or equal

Minimum doorway dimensions:

48″ wide x 90" high

One horizontal dimension should be less than

47" with forklift entry perpendicular to that dimension.

Conventional vans (typical) Interior size:

570" or 630" long x 98" wide x 110" high

(Doorway height = 110″)

One horizontal dimension of the unit load should be 46" – 48½" to permit two wide loading to avoid lateral bracing. Three wide loading requires a horizontal dimension of 30¾" – 32".

Height should be 54½" for two high loading or

36" for three high loading.

MILVAN or 20' x 8' ISO containers Interior size:

232" long x 92" wide x 87" high (Doorway height = 84")

One horizontal dimension of the unit load should be 25" – 45½" to permit two wide loading.

Three-wide loading requires a horizontal dimension of 25" – 30½"

Unit load height should not exceed 41" for two-high loading or 27" for three-high loads.

20' x 8' – 6" ISO containers Interior size:

232" long x 92" wide x 93" high (Doorway height = 90")

Horizontal dimensions should be same as for

20'x 8' ISO containers.

Unit load height should not exceed 44" for two-high loading or 291⁄4" for three-high loads.

Side opening 20' x 8' – 6" ISO containers

Interior size:

232" long x 89" wide x 88" high (Doorway height = 84")

Horizontal dimensions should be 25" – 44" to permit two wide loading. Three wide loading requires a horizontal dimension of 25" – 291⁄4".

Unit load height should not exceed 40½" for two-high loading or 26½" for three-high loads.

Railcars (typical) Interior size:

606" or 720" long x 101" – 114" wide x 120" high

One horizontal dimension should be less than

64": with forklift entry perpendicular to that dimension to permit entry through the railcar door.

Height should not exceed 58" for two-high loading or 39" for three-high loading.

Ships (No standard size) Unit load design shall permit easy handling by approved slings and overhead crane. Ship dimensional constraints may be obtained from the specific ship or ship class manuals. For naval aircraft carriers, dimensional constraints may be found in MIL-STD-648.

T-Class ship dimensional constraints may be found in MSC TW023-AB-WHS-010. L-Class ship dimensional constraints may be found in

NAVSEA SW023-AJ-WHS-010.

Military airlift (with 463L system) 463L

Handling system pallet:

84" x 104" (full size)

84" x 50" (half size)

Optimum unit load size is 42" x 52". For more information, see AFSC DH 1-11 for other sizes usable.

*Logair pallet (HCU-10/C) is not compatible with the C-130, C-141, and C-5 aircraft.

4.5.1.1 Overhang. Unit loads shall be made up so as to ensure stability, to provide for efficient strapping application, and not to cause excessive bending force on those containers or items which may be structurally weak.

When standard pallets are used (see 4.8.3), the recommended overhang should not exceed 2 inches per edge.

Overhang greater than 2 inches can be allowed depending upon peculiarities of the commodity being unitized and identifiable factors that influence total cost effectiveness throughout the ammunition logistics system.

4.5.1.2 Underhang. Underhang shall not be permitted. When standard pallets are used, spacers, battens, or cap assemblies shall fill out the unit load so that the overall nominal view dimensions are at least flush with the pallet dimensions. The strength and dimensions of the materials shall permit shipment by all means of transport (e.g., cap assemblies shall be of such size that it will withstand all loads imposed on it by adjacent unit loads under impact conditions). When non-standard pallets or skid bases are used, the overall plan view size shall be tailored not to exceed the load dimensions. Skid bases shall be in accordance with U.S. Army Defense Ammunition Center

Drawing AMC 19-48-4116-20PA1002.

4.5.2 Transportability limitations. Unit loads shall be designed to be economically compatible with the methods by which they will be transported or stored. Guidance concerning the preferred length, width, and height characteristics for the more common conditions is given in table II.

4.5.3 Gross weight. Gross weight of an ammunition unit load shall not exceed 4,000 pounds unless specifically authorized by each using activity.

4.5.4 High density ammunition. Where optimization in all three dimensions produces a gross weight greater than 4,000 pounds, the number of complete layers of unit packs shall be reduced until the gross weight is less than

4,000 pounds.

4.5.5 Special rule for amphibious assault ammunition. Certain ammunition items are intended to be used in amphibious operations. This ammunition, at least during the assault phases, must be capable of being efficiently handled in specialized ships with fixed size elevators and horizontal or vertical conveyors. Maximum dimensions for these unit loads are:

a. Maximum length and width: 45 by 54 inches

b. Maximum height: 44 inches

c. Maximum weight: 3,000 pounds

4.6 Stability. Item placement shall be such that the assembled unit load is stable on a motionless level surface without depending on strapping. This criterion shall also apply following the rough handling tests of 5.4.2 to 5.4.9 if the assembly is not distorted by more than 2 inches.

4.7 Stacking capability. Unless otherwise specified by the design activity (see 6.2), unit loads shall be designed to ensure safe, stable, long-term stacking to an overall height of 16 feet.

4.8 Materials. Standard parts and materials shall be used unless they are technically or economically impractical. The material used shall not adversely affect the unitized items because of incompatibility of hydroscopic or chemical properties.

4.8.1 Strapping. All strapping shall be in accordance with ASTM D3953, type 1, heavy duty, finish B (grade 2)

Brite or slit edges shall have finish A overlay. Typical strapping size used for unit loads is ¾ inch or 11⁄4-inch wide by 0.035 or 0.031-inch thick. Current approved clipless tools for U.S. Army Ammunition loads are specified in U.S.

Army Defense Ammunition Center Drawing ACV00617.

4.8.2 Strapping seals. All seals for metallic strapping shall be in accordance with ASTM D3953, class H, finish B (grade 2), double notch type, style I, II, III, or IV. If all surfaces are painted, an allowable alternative seal finish Signode or Delta painted seal may be used. Gritted backing shall not be used. Designs shall be based on the use of a single seal, double notched. Use of crimped seals shall be authorized with non-lubricated strapping, provided two seals are used, each double crimped.

4.8.3 Pallets. Whenever practicable and consistent with satisfying the other design and performance criteria of this standard, unit loads shall be designed to use any of the pallets listed below. Unit loads designed to use standard steel pallets do not require the pushing and towing test (see 5.4.6) to be performed during qualification of the unit load. Special purpose pallets shall be used only when they are cost-effective on a life cycle basis.

a. Army pallets DA PAM 746-1.

b. Steel pallet Mk 3 Mod 0 (40 x 48 inches), Drawing 564200, MIL-P-23312.

c. Steel pallet Mk 12 Mod 0 or Mod 1 (35 x 45½ inches), Drawing 2086479 or 2645217, respectively, MIL-P-23312 Style 1A.

d. Standard hardwood pallets per MIL-DTL-15011, Class 1, Style 1 (40 x 48), Style 1A (35 x 45½ inches), or

Style 1B (42 x 53 inches).

4.8.4 Fasteners.

4.8.4.1 Nails. Nails shall be in accordance with ASTM F1667 common steel nails (NLCMS) or common steel nails mechanically driven (NLCMMS) of the style and size appropriate to the width and thickness of wood members being joined.

4.8.4.2 Screws. Screws shall not be used in unit loads.

4.8.5 Staples. Staples shall be in accordance with ASTM F1667, STFCS-189, or STFCS-207 (15⁄16- or 1-inch crown width by ¾-inch leg length) for ¾-inch strapping, type IV, style 3 and 117⁄32-inch crown width by ¾-inch leg length for 1¼-inch strapping. For FIULs, only use staples if necessary. Staples are a known source of foreign object damage/debris for jet aircraft engines.

4.8.6 Edge protectors. Edge protectors of a size appropriate for the strapping shall be used when specified

(see 6.2).

4.8.7 Wood members. Lumber shall be used as appropriate for all structural members in accordance with the quality requirements of ASTM D6199. Non-structural members may be fabricated from lumber in accordance with either ASTM D6199 or Voluntary Product Standard PS 20, whichever is cost effective. Generally speaking, battens, spacers, and other boards that only bear compressive loads resulting from tensioned strapping or from objects placed on top of them are not considered structural members. Wood shall meet the guidelines of ISPM No. 15 and be marked in accordance with the document.

4.8.8 Plywood. Plywood shall be commercial grade C-D with exterior glue.

4.9 Markings. Important markings or inspection data on the items shall not be concealed by the unit load members. Provisions shall be made or space allocated for attaching hazard marking placards to unit loads. For guidance for markings on Army ammunition unit loads, see U.S. Army Defense Ammunition Center Drawing

ACV00561.

4.10 FIULs (Navy), tactical (Army). All materials used to make up FIULs shall be nonflammable, with the exception of lumber items that may be used to construct the load (e.g., spacers or battens). Metal parts shall be suitably protected from corrosion.

4.10.1 Sling compatibility. FIULs shall be capable of being safely handled by the authorized slings commonly used in dockside stevedoring operations and at sea connected replenishment (CONREP) and vertical replenishment

(VERTREP) operations as cited below. The following slings are currently authorized for use in Department of the

Army and Navy handling operations:

Sling Nomenclature Drawing number Area of use

Mk 85 Mod 0 Pallet sling 2614969 CONREP/VERTREP

Mk 85 Mod 1 Pallet sling 7516578 CONREP/VERTREP

Mk 86 Mod 0 Pallet sling 2614970 CONREP/VERTREP

Mk 86 Mod 1 Pallet sling 7516579 CONREP/VERTREP

Mk 87 Mod 0 Pallet sling 2614971 CONREP/VERTREP

Mk 87 Mod 1 Pallet sling 7516580 CONREP/VERTREP

Mk 93 Mod 0 Pallet sling 2642587 Dockside

Mk 99 Mod 0 Weapons handling sling 2642914 CONREP

Mk 100 Mod 1 Pallet sling 2643919 CONREP/VERTREP

Mk 100 Mod 2 Pallet sling 7516581 CONREP/VERTREP

Mk 105 Mod 0 Hoisting sling 2643482 VERTREP

Mk 105 Mod 0 Long leg assembly 2644390 VERTREP

Mk 109 Mod 1 Container lifting sling 5167555 CONREP

Mk 123 Mod 0 Pallet sling 2645180 CONREP/dockside

1398-01-348-4670 Sling, multiple leg top-lift ammunition pallet AC200000398 Field vehicles with cranes

3940-01-209-6008 Sling, adjustable, double basket AC200000331 Field vehicles with cranes

3940-01-241-7400 Sling, multiple leg projectile pallet AC200000332

Lifting 8-inch and

55-millimeter projectile pallet units

4.11 Protection levels. Unit load(s) shall provide the level of protection required for the expected environment.

Levels of protection that apply to preservation and packing of DoD material are described in MIL-STD-2073-1.

More specific definitions of protection levels A, B, and C for ammunition unit loads are defined as follows:

4.11.1 Level A – tactical (Army), FIUL (Navy), Amphibious Unit Load (Navy) (see 3.1.11.1). Unit loads designated Level A shall be designed to protect ammunition and ordnance against direct exposure to all extremes of climatic, terrain, operational and transportation environments without protection other than that provided by the unit load. 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 1 year.

f. Stacking and supporting superimposed loads during shipment and 20-year storage.

4.11.2 Level B – intermediate (Army), domestic (Navy) (see 3.1.11.2). Unit loads designated level B shall be designed to protect ammunition and ordnance against physical damage and deterioration during favorable conditions of shipment, handling, and storage. This level of protection is typically used for OCONUS training ammunition and unit loads not subject to Navy UNREP, shipboard handling, and stowage. The conditions to be considered include, but are not limited to:

a. Multiple rough handling during transportation and in-transit storage.

b. Shock, vibration, and static loading of shipment worldwide by truck, rail, aircraft, or ocean transport.

c. Favorable warehouse environment for a minimum of 18 months.

d. Environmental exposure during shipment and in-transit transfers, excluding deck loading and offshore cargo discharge.

e. Stacking and supporting superimposed loads during shipment and extended storage.

4.11.3 Level C – minimum (Army) (see 3.1.11.3). Unit loads designated level C shall be designed to protect ammunition and ordnance during favorable condition of limited shipment, handling, and storage. This level of protection is used for CONUS interplant shipments of training rounds (highway movement only). The conditions to be considered include, but are not limited to:

a. Use or consumption of the ammunition at the first destination.

b. Shock, vibration, and static loading during the limited transportation cycle.

c. Favorable warehouse environment for a maximum of 18 months.

d. Effects of expected environmental exposure during loading, unloading, and in-transit delays.

e. Stacking and supporting superimposed loads during shipment and temporary storage.

5. DETAILED REQUIREMENTS

5.1 General. This section contains requirements for unit loads which shall be verified by physical tests.

Sections 5.1 through 5.4 describe unit load testing requirements for protection level A and level B as defined in 4.11.

For a description of unit load testing requirements for protection level C, see 5.5.1.

5.2 Satisfactory performance criteria. The unit load shall remain intact and be capable of continued safe handling and tiering. The assembly structure (the pallet, structural, or protective members, strapping, etc.) shall not fail nor permit individual parts of the unit load assembly to become unattached or separated. If the ammunition item is not protected by separate packaging or individual containers, the unit load configuration shall protect each item from damage beyond usefulness (e.g., thin structural members, fins, or other protrusions shall not be broken or deformed). If ammunition or ordnance commodities are packaged in containers, the unit load shall protect the containers’ external protrusions (e.g., latches, handles, lift rings, access ports, etc.) from damage beyond usefulness.

Note that the above criteria shall apply only to the unit load as a whole unit. The ability of a container, from a structural standpoint, to withstand the hazards of transportation, handling, and storage (either as a single unit or as a unit load), as well as its ability to protect the commodity from the same, must be determined by a separate evaluation process.

5.3 Test temperature. Tests are normally conducted at an ambient temperature of 77±18 °F (25±10 °C). If the materials used in the fabrication of the unit load are sensitive to temperature or moisture, see 5.5 for additional applicable tests that may be required in the appropriate logistic environment or as specified for testing specialized shipping containers in MIL-STD-648.

5.4 Test procedures. The prototype unit load shall be subjected to each of the tests in 5.4.1 through 5.4.9 in the order given. After each test, the unit load shall be evaluated for satisfactory performance as specified in 5.2. After evaluation and prior to commencement of the next test, repairs or replacement of any type may be made to the prototype unit load – up to and including replacement of the entire unit load. No repairs or replacements shall be permitted during the test series defined by 5.4.1 through 5.4.9.

5.4.1 Stacking test. The unit load shall be loaded to simulate a stack of identical unit loads, stacked to a maximum of 16 feet high, for a period of 1 hour minimum. Navy unit loads constructed with a plastic or other nonmetallic material that may deteriorate when exposed to elevated temperature or very humid conditions, shall have the stacking test conducted at a temperature of 120±5 °F and 90 percent humidity for a period of 168 hours.

Army unit loads issued to ground troops constructed with a plastic or nonmetallic material that may deteriorate when exposed to elevated temperatures or very humid conditions shall have the stacking test conducted in accordance with

High temperature cycles, climatic category A1 – Hot Dry method 501.7 of MIL-STD-810 for a period of 72 hours.

5.4.1.1 Stacking test rationale. This test is conducted to examine the ability of the unit load (and packaging) to withstand the forces imposed on it from stacking at the potential maximum height of 16 feet within storage and to determine if the strapping remains sufficiently tensioned to prevent subsequent disintegration of the load.

5.4.2 Repetitive shock test. This test shall be conducted in accordance with Appendix A.

5.4.2.1 Repetitive shock test (superimposed load). Unit loads which may reasonably be expected to…