BY ORDER OF THE SECRETARY OF THE AIR FORCE AIR FORCE MANUAL 91-201 21 MARCH ...

488 Pages·2017·16.8 MB·English

BY ORDER OF THE SECRETARY AIR FORCE MANUAL 91-201
OF THE AIR FORCE
21 MARCH 2017
AIR FORCE SPACE COMMAND
Supplement
13 SEPTEMBER 2017
Safety

EXPLOSIVES SAFETY STANDARDS
COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available on the e-Publishing website at
www.e-Publishing.af.mil for downloading or ordering.
RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AFSEC/SEW Certified by: AFSEC/CD
(Mr. James Rubeor)
Supersedes: AFMAN 91-201, Pages: 488
12 January 2011
OPR: AFSPC/SEW Certified by: AFSPC/SEW
(Mr. Martin Reynolds)
Supersedes: AFMAN91-201_AFSPCSUP, Pages: 488
28 May 2012

This Manual implements Air Force Policy Directive (AFPD) 91-2, Safety Programs, and DoD
6055.09-M, Volumes 1–8, DoD Ammunition and Explosives Safety Standards. It establishes a
central source for explosive safety criteria. It identifies hazards and states safety precautions and
rules when working with explosives. It applies to all Air Force, Air National Guard (ANG), Air
Force Reserve Command (AFRC), and contractor personnel and facilities involved in explosive
operations. The use of the name or mark of any specific manufacturer, commercial product,
commodity, or service in this publication does not imply endorsement by the Air Force. This
AFI may be supplemented at any level, but all supplements that directly implement this
publication must be routed to SAF/AAII Policy Branch for coordination prior to certification and
approval. Refer recommended changes and questions about this publication to the Office of
Primary Responsibility (OPR) using the AF Form 847, Recommendation for Change of
Publication; route AF Forms 847 from the field through the appropriate functional chain of
command. The authorities to waive wing/unit level requirements in this publication are
identified with a Tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See
AFI 33-360, Publications and Forms Management, Table 1.1 for a description of the authorities
2 AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017
associated with the Tier numbers. Send MAJCOM supplements to AFSEC/SEW, 9700 G
Avenue SE, Kirtland AFB NM 87117-5670. Ensure that all records created as a result of
processes prescribed in this publication are maintained in accordance with (IAW) Air Force
Manual (AFMAN) 33-363, Management of Records, and disposed of IAW the Air Force
Records Disposition Schedule (RDS) in the Air Force Records Information Management System
(AFRIMS).
(AFSPC) This supplement implements and extends the guidance of Air Force Manual
(AFMAN) 91-201, Explosives Safety Standards. This supplement describes AFSPC’s
procedures for use in conjunction with AFMAN 91-201. It applies to all Air Force Space
Command (AFSPC) and subordinate units. This supplement applies to those Air National Guard
and Air Force Reserve units participating in AFSPC classic association with the active Air Force.
Refer recommended changes and questions about this publication to the Office of Primary
Responsibility (OPR) using the AF Form 847, Recommendation for Change of Publication; route
AF Forms 847 from the field through the appropriate functional’s chain of command. Ensure
that all records created as a result of processes prescribed in this publication are maintained in
accordance with AFMAN 33-363, Management of Records, and disposed of in accordance with
Air Force Records Information Management System (AFRIMS) Records Disposition Schedule
(RDS). The authorities to waiver wing/unit level requirements in this publication are identified
with a Tier (“T-0, T-1, T-2, T-3”) number following the compliance statement. See AFI 33-360,
Publications and Forms Management, Table 1.1 for a description of the authorities associated
with the Tier numbers. Submit requests for waivers through the chain of command to the
appropriate Tier waiver approval authority, or alternately, to the Publication OPR for non-tiered
compliance items. This publication may be supplemented at any level, but all Supplements must
be routed for coordination prior to certification and approval. The use of the name or mark of
any specific manufacturer, commercial product, commodity, or service in this publication does
not imply endorsement by the Air Force. See Attachment 1 for a glossary of references and
supporting information.
SUMMARY OF CHANGES
This revision reflects changes in guidance and procedures dealing with Air Force explosives
safety standards. Major changes include incorporation of GM1; expansion of blast effects on
personnel; updates weather watch/warning procedures; expansion of protective design
construction requirements; and the deletion of Chapter 9, Protection of Electro-Explosive
Devices From Hazards of Electromagnetic Radiation to Ordnance (HERO) and its replacement
with a chapter on Munitions Potentially Presenting and Explosive Hazard. The HERO
information previously presented in Chapter 9 is available in AFI 91-208, Hazards of
Electromagnetic Radiation to Ordnance (HERO) Certification and Management. It also
includes guidance for overpressure barricade design; clarification of chocking requirements for
explosives-loaded vehicles (e.g., munitions materials handling equipment (MMHE) and
materials handling equipment (MHE)); updates to electromagnetic radiation (EMR) formulas for
pulsed systems; clarifies withdrawal procedures for ammunition and explosives (AE) not
involved in a fire; updates compatibility requirements for licensed location; adopts new
rounding rules used for quantity distance (QD) calculations; updates QD criterion for various
facility types and situations; and, corrects and updates notes used in QD tables. Furthermore, it
AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017 3
removes written Commander acceptance requirements for parking aircraft at less than
survivability; reduces coordination host/tenant requirements for explosives site plans (ESP)
(may also be referred to as a QD safety submission (QDSS)) without exceptions; removes
references and procedures for Risk Based Siting; includes additional chapters for Real Property,
Waste Military Munitions, Material Potentially Presenting an Explosive Hazard (MPPEH);
Unexploded Ordnance (UXO); includes review elements for both munitions response explosives
safety submissions (MRESS) and munitions response explosives site plan (MRESP) packages;
and incorporates use of a revised Automated Explosives Safety Siting Program for use in
developing ESPs. Additionally, this Manual introduces new phraseology for an MRESS,
formerly an explosives safety submission (ESS); a munitions response chemical safety
submission (MRCSS), formerly a chemical safety submission (CSS); and an MRESP, formerly
an explosives site plan (ESP) when referring to munitions response activities under the Military
Munitions Response Program (MMRP).
(AFSPC) Recent changes include the addition of paragraph 7.5.4.1. and paragraph 7.5.4.1.1.
providing guidance on general public safety. Paragraph 7.13.3 provides guidance on aircraft
grounding, and paragraph 12.97.4.3 provides guidance on spacecraft explosives siting.

Chapter 1— INTRODUCTION AND EXCEPTION PROGRAM 29
Section 1A— Explosives Safety General Instructions 29
1.1. Purpose.................................................................................................................... 29
1.1. (AFSPC) Explosives safety is survivability of ........................................................ 29
1.2. Scope. ...................................................................................................................... 29
Section 1B— Exception Program 32
1.3. General. ................................................................................................................... 32
1.4. Deviations. .............................................................................................................. 33
1.5. Event Waivers (Nonrecurring). ............................................................................... 34
1.6. Waivers. .................................................................................................................. 35
1.7. Exemptions. ............................................................................................................ 35
1.8. SECAF New Construction Exemption. .................................................................. 36
1.9. Exceptions for Non-DoD Explosives Activities on Air Force Installations. .......... 36
1.10. Waiver and Exemption Information Requirements. ............................................... 37
1.11. HAF-Level Waiver and Exemption Information Requirements. ............................ 37
1.12. Waiver and Exemption Decision Nomograph. ....................................................... 39
1.13. Periodic Reviews for Exceptions. ........................................................................... 40
4 AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017
Figure 1.1. Waiver and Exemption Decision Nomograph-Peacetime/Armistice Operations. .. 41
Figure 1.2. Waiver and Exemption Decision Nomograph-Wartime/Contingency Operations. 42
Table 1.1. Likelihood of a Mishap. .......................................................................................... 43
Table 1.2. Exposure. ................................................................................................................ 44
Table 1.3. Explosive Mishap Severity. .................................................................................... 45
Chapter 2— REACTION EFFECTS 48
Section 2A— Principal Effects of Hazard Division (HD) 1.1 Events 48
2.1. Blast. ....................................................................................................................... 48
2.2. Fragments................................................................................................................ 50
2.3. Thermal Hazards. .................................................................................................... 50
2.4. Groundshock and Cratering. ................................................................................... 50
2.5. Expected Consequences. ......................................................................................... 50
Section 2B— Principal Effects of HD 1.2 Events 53
2.6. Blast. ....................................................................................................................... 53
2.7. Fragments................................................................................................................ 54
2.8. Thermal Hazards. .................................................................................................... 54
2.9. Expected Consequences. ......................................................................................... 54
Section 2C— Principal Effects of HD 1.3 Events 55
2.10. Gas Pressures. ......................................................................................................... 55
2.11. Fragments................................................................................................................ 55
2.12. Thermal Hazards. .................................................................................................... 55
2.13. Expected Consequences. ......................................................................................... 56
Section 2D— Principal Effects of HD 1.4 Events 56
2.14. Blast. ....................................................................................................................... 56
2.15. Fragments................................................................................................................ 56
2.16. Thermal Hazards. .................................................................................................... 56
2.17. Expected Consequences. ......................................................................................... 56
Section 2E— Principal Effects of HD 1.5 and HD 1.6 Events 56
2.18. HD 1.5 Effects. ....................................................................................................... 56
AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017 5
2.19. HD 1.6 Effects. ....................................................................................................... 56
Table 2.1. Expected Peak Incident Pressures From HD 1.1 Events. ....................................... 57
Table 2.2. Probability of Window Breakage from Incident Pressure. ..................................... 57
Table 2.3. General Blast Effects on Personnel Eardrum Rupture. ........................................... 58
Table 2.4. General Blast Effects on Personnel – Lung Damage. ............................................. 59
Table 2.5. General Blast Effects on Personnel – Lethality Due To Lung Rupture. ................. 59
Chapter 3— HAZARD CLASSIFICATION 60
3.1. Purpose of Hazard Classification. ........................................................................... 60
Section 3A— DoD Hazard Classification System 60
3.2. Responsibility for Hazard Classification. ............................................................... 60
3.3. Hazard Classification Authorities ........................................................................... 60
3.4. Standards for Determining DoD Hazard Classification. ......................................... 60
3.5. Description of DoD Hazard Classification System................................................. 60
3.6. Net Explosive Weight (NEW) and NEW for Quantity-Distance (NEWQD). ........ 61
3.7. Requirement for DoD Hazard Classification. ......................................................... 62
Section 3B— Storage and Transportation Without DoD Hazard Classification 62
3.8. Storage and Transportation Without DoD Hazard Classification. .......................... 62
3.9. Explosives With DOE Hazard Classifications. ....................................................... 62
3.10. DoD-Owned Non-Stock-Listed Commercial Explosives. ...................................... 63
3.11. Manufacturing, R&D Items. ................................................................................... 64
3.12. Foreign Explosives. ................................................................................................ 65
3.13. Non-DoD-Owned Explosives. ................................................................................ 66
Section 3C— Hazard Classification of Unpackaged Items 67
3.14. Hazard Classification of Unpackaged Items. .......................................................... 67
Section 3D— Class 1 Divisions and Subdivisions 68
3.15. HD 1.1 – Mass-Explosion. ...................................................................................... 68
3.16. HD 1.2 – Non-Mass Explosion, Fragment Producing. ........................................... 69
3.17. HD 1.3 – Mass Fire, Minor Blast or Fragment. ...................................................... 70
3.18. HD 1.4 – Moderate Fire, No Significant Blast or Fragment. .................................. 70
6 AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017
3.19. HD 1.5 – Explosive Substance, Very Insensitive (With Mass Explosion Hazard). 70
3.20. HD 1.6 – Explosive Article, Extremely Insensitive (No Mass Explosion Hazard). 70
Section 3E— Compatibility Groups and Sensitivity Groups 70
3.21. Storage and Transportation Compatibility Groups. ................................................ 70
3.22. Sensitivity Groups. .................................................................................................. 71
Chapter 4— RISK ASSESSMENTS AND PROTECTION PRINCIPLES 73
Section 4A— Risk Assessments 73
4.1. Requirements for Risk Assessments. ...................................................................... 73
4.2. Risk Assessments. ................................................................................................... 73
4.3. Risk Management (RM). ........................................................................................ 74
4.4. System Safety. ........................................................................................................ 74
4.5. Professional Assistance for Risk Assessments and System Safety Analyses. ........ 74
Section 4B— Munitions Systems and Equipment 74
4.6. Safety Certification of Munitions Systems. ............................................................ 74
4.7. Risk Assessments for Explosives Equipment. ........................................................ 74
Section 4C— Explosives Operations and Facilities 75
4.8. Risk Assessment for Explosives Operations. .......................................................... 75
4.9. Risk Assessments for Explosives Facilities. ........................................................... 75
Section 4D— Glass Breakage Risk Assessments 75
4.10. Purpose of Glass Breakage Risk Assessments. ....................................................... 75
4.11. Requirements for Performance of Glass Breakage Risk Assessments. .................. 75
4.12. Methodology for Glass Breakage Risk Assessments. ............................................. 76
4.13. Engineering Mitigation Actions for Reducing or Eliminating Glass Breakage
Hazards to Personnel. .............................................................................................. 77
Section 4E— Health Hazard and Environmental Assessments 77
4.14. Health Hazard Assessments. ................................................................................... 77
4.15. Environmental Assessments. .................................................................................. 77
Section 4F— Protection Principles 77
4.16. Protective Shielding and Remotely Controlled Operations. ................................... 77
AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017 7
4.17. Intentional Ignition or Initiation of AE. .................................................................. 78
4.18. Protective Measures. ............................................................................................... 79
4.19. Emergency Operations. ........................................................................................... 79
Figure 4.1. 5-Step Risk Management Process. .......................................................................... 81
Chapter 5— GENERAL EXPLOSIVES FACILITY DESIGN, CONSTRUCTION AND
MAINTENANCE, AND EQUIPMENT DESIGN, MAINTENANCE AND
INSPECTION 82
Section 5A— Introduction 82
5.1. Applicability. .......................................................................................................... 82
Section 5B— Glass Panels 82
5.2. Glass Panels in Facilities Exposed to Explosives Hazards. .................................... 82
Section 5C— Hazardous Locations 83
5.3. Hazardous Locations. .............................................................................................. 83
5.4. Electrical Equipment in Hazardous Locations. ....................................................... 83
5.5. Interior Surfaces in Class II Hazardous Locations.................................................. 84
5.6. Hardware in Hazardous Locations. ......................................................................... 84
5.7. Static Electricity in Hazardous Locations. .............................................................. 84
5.8. Ventilation in Hazardous Locations. ....................................................................... 84
Section 5D— Electric Supply Systems 85
5.9. Electric Supply Systems. ........................................................................................ 85
5.10. Backup Power. ........................................................................................................ 85
Section 5E— Static Grounding and Bonding 85
5.11. Areas Requiring Static Grounding and Bonding Systems. ..................................... 85
5.12. Static Grounding and Bonding Requirements. ....................................................... 85
5.13. Permanent Static Grounding Systems. .................................................................... 86
5.14. Temporary Static Grounding or Bonding Cables. .................................................. 87
5.15. Static Grounding or Bonding Reels. ....................................................................... 87
5.16. Belting. .................................................................................................................... 88
8 AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017
Section 5F— Conductive Floors 88
5.17. Areas Requiring Conductive Floors. ....................................................................... 88
5.18. Requirements for Conductive Floors. ..................................................................... 88
5.19. Testing and Maintenance of Conductive Floors. .................................................... 88
5.20. Testing and Maintenance of Conductive Footwear. ............................................... 88
Section G— Installed Systems and Equipment Grounds 89
5.21. Installed Systems and Equipment Grounds. ........................................................... 89
Section 5H— Lightning Protection Systems 89
5.22. Facilities Requiring LPS. ........................................................................................ 89
5.23. LPS Design. ............................................................................................................ 90
5.24. LPS Inspection, Maintenance, Testing, and Training. ............................................ 93
5.25. LPS Exceptions. ...................................................................................................... 94
Section 5I— General Design Considerations for Explosives Facilities 95
5.26. Blowout-type Construction. .................................................................................... 95
5.27. Non-combustible Construction. .............................................................................. 95
5.28. Underground Explosives Storage Facilities. ........................................................... 95
5.29. Outdoor Explosives Storage Sites. .......................................................................... 95
5.30. Stairways. ................................................................................................................ 96
5.31. Fixed Ladders. ........................................................................................................ 96
5.32. Platforms, Runways, and Railings. ......................................................................... 96
5.33. Passageways. ........................................................................................................... 96
5.34. Walkways................................................................................................................ 96
5.35. Roads. ..................................................................................................................... 96
5.36. Gates. ...................................................................................................................... 97
5.37. Drainage. ................................................................................................................. 97
5.38. Drains and Sumps. .................................................................................................. 97
5.39. Tunnels.................................................................................................................... 98
5.40. Laundries. ............................................................................................................... 98
5.41. Steam for Explosives Processing or Facility Heating. ............................................ 98
AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017 9
5.42. Magazine Ventilation and Vermin-Resistance. ...................................................... 99
Section 5J— Emergency Exits for Explosives Buildings 99
5.43. General. ................................................................................................................... 99
5.44. Building Exits. ........................................................................................................ 99
5.45. Exit Doors. .............................................................................................................. 100
5.46. Safety Chutes. ......................................................................................................... 100
Section 5K— Explosive Dust Collection Systems 101
5.47. Vacuum Collection. ................................................................................................ 101
5.48. Location of Dry-Type Collection Chambers. ......................................................... 101
5.49. Location of Wet-Type Collection Chambers. ......................................................... 102
5.50. Design and Operation of Collection Systems. ........................................................ 102
Section 5L— Water Supply and Fire Suppression Systems for Explosives Facilities 103
5.51. Water Supply for Explosives Manufacturing Areas and Loading Plants. .............. 103
5.52. Automatic Sprinkler Systems. ................................................................................ 103
5.53. Deluge Systems. ...................................................................................................... 103
Section 5M— Monitoring of Design and Construction of Explosives Facilities 104
5.54. Monitoring of Design of Explosives Facilities. ...................................................... 104
5.55. Monitoring of Construction of Explosives Facilities. ............................................. 104
Section 5N— Maintenance and Repair of Explosives Facilities and Equipment 104
5.56. Removal of Explosives. .......................................................................................... 104
5.57. Requirements for Maintenance and Repair With Explosives Present. ................... 105
5.58. Maintenance of Explosives Facilities. .................................................................... 105
5.59. Maintenance and Repair in Hazardous Locations. .................................................. 106
5.60. Maintenance and Repair of Hazardous Location Equipment and Electrical
Installations. ............................................................................................................. 106
5.61. Maintenance and Repair of Electrical Equipment. ................................................. 106
5.62. Post-Maintenance and Repair of Explosives Facilities and Equipment. ................. 106
Table 5.1. Lightning Sideflash Policy for Nuclear Weapon Configurations. .......................... 107
10 AFMAN91-201_AFSPCSUP 13 SEPTEMBER 2017
Chapter 6— PROTECTIVE CONSTRUCTION AND SPECIFIC EXPLOSIVES
FACILITY DESIGNS 108
Section 6A— Introduction 108
6.1. General. ................................................................................................................... 108
6.2. Aboveground Magazines (AGM). .......................................................................... 108
6.3. Special Structures. .................................................................................................. 108
6.4. High Performance Magazines and Underground Explosives Facilities. ................. 108
Section 6B— Protective Construction 108
6.5. Purpose of Protective Construction. ....................................................................... 108
6.6. Requirements for Use of Protective Construction. ................................................. 109
Section 6C— Earth-Covered Magazines 111
6.7. Earth-Covered Magazines. ...................................................................................... 111
6.8. Earth-Covered Magazine NEWQD Limits. ............................................................ 111
6.9. Earth-Covered Magazine Design Load Criteria...................................................... 111
6.10. Earth-Covered Magazine Earth Cover Criteria. ...................................................... 111
6.11. Earth-Covered Magazine Drawings. ....................................................................... 112
Section 6D— Barricaded Open Storage Modules 112
6.12. Barricaded Open Storage Modules. ........................................................................ 112
6.13. Barricaded Open Storage Modules NEWQD and AE Type Limits. ....................... 112
6.14. Barricaded Open Storage Module Design Criteria. ................................................ 113
Section 6E— Barricades 114
6.15. Barricades ............................................................................................................... 114
6.16. Barricade Size and Orientation to Prevent Propagation Due to High-Velocity,
Low-Angle Fragments. ............................................................................................ 115
6.17. Barricade Size and Orientation for Barricaded ILD Protection. ............................. 115
6.18. Barricade Size and Orientation for Protection Against Overpressure. ................... 116
6.19. Barricade Construction Materials. .......................................................................... 116
6.20. Barricade Designs. .................................................................................................. 116
6.21. Natural Barricades. ................................................................................................. 116