1. Storage and Handling
STORAGE AND HANDLING - INTRODUCTION: (1 SLIDE, 4 MIN)
SLIDE 1 of 1: INTRODUCTION (4 min)
The safe and effective storage of ammunition and explosives is expensive in terms of storage infrastructure and stock maintenance requirements.
To get maximum cost efficiency, we need to get maximum storage efficiency - commensurate with safety and other practices that should occur in an ammunition facility.
And to optimise the storage - we need to plan.
Maximum use should be made of the available units of space (UOS) in covered storage to reduce the requirement for superfluous buildings or for field or temporary storage of ammunition and explosives.
IATG 06:20 provides guidance on the general practical considerations for storage space planning. Note that reference to this IATG should be done with equally due reference to the other IATG documents which provide more specific safety advice for storage, handling, processing, special safety precautions and equipment requirements.
We have already encountered the concept of Units of Space.
(Instructor: pose these questions to the students):
Q. What is a unit of space? (Answer: A 1m x 1m x 1m cubic area – a ‘notional’ space. This is based on a ‘standard (ie NATO standard) pallet which measures these dimensions. This standard pallet also measures 1 tonne (1000kg).
Q. Why do we use this concept? (Answer: It simplifies planning for storage).
What happens if the permitted NEQ for a PES is less that the number of pallets it can hold? (Answer: Only the maximum NEQ can be stored. This
might mean that there is free space left in the site, ie it is only physically part full. However, we can’t exceed the NEQ limit. This is called being NEQ’d out”).
Q. What happens if we can fill up the site without breaching the NEQ limit – ie there is still available NEQ on the licensable limit”? (Answer: we can’t physically put more into the site than it will hold. We would have to accept that we haven’t fully utilised the NEQ limit. This I called being “bulked out”.

2. Calculation of Storage Space Requirements
Default distances from packages to walls and ceiling (or attachments on walls such as heaters): 500mm If 500mm is impractical, absolute minimum is: 150mm If less than 500mm, review periodically – aim to adjust stock to achieve a 500mm gap
CALCULATION OF STORAGE SPACE REQUIREMENTS: (4 SLIDES, 8 MIN)
SLIDE 1 of 4: CALCULATION OF STORAGE SPACE REQUIREMENTS (2 min)
Other than the NEQ limit, there are some basic constraints that we must always remember when calculating how much we can fit into an ESH.
These gaps are to safeguard against flashover from a lightning strike on an ESH.
Spacing requirements of packages of ammunition and explosives in an ESH:
The default separation between the outer face of any explosive package (including those stored on racks or trolleys) and the inner face of any adjacent structural wall or from metallic fittings such as heaters and luminaries should normally be at least 500 mm. This includes the distance from the top of the top package to the roof. As well as providing protection against flashover from lightening strikes, this distance allows good natural airflow around stacks and good access for visual inspection, etc.
When explosives are packaged in containers larger than the standard NATO pallet and it is impractical to observe the standard 500 mm separation distance, then a lesser separation may be used after consultation with the national technical authority. However, under no circumstances must the separation distance be less than 150 mm. Where the separation is less than 500 mm, the storage arrangements should be periodically reviewed with the aim of re–establishing the standard 500 mm separation distance.
The exception to these rules is for correctly packaged small arms ammunition (SAA) in Hazard Division (HD) 1.4.

3. Calculation of Storage Space Requirements
100mm from the floor
Aisles wide enough for handling
(Usually 2m for MHE, 1m for a palletiser)
20mm air gap around each pallet
CALCULATION OF STORAGE SPACE REQUIREMENTS: (4 SLIDES, 8 MIN)
SLIDE 2 of 4: CALCULATION OF STORAGE SPACE REQUIREMENTS (1 min)
Additional spacing requirements are that:
All ammunition should be raised 100mm off the floor by the use of pallet bases or wooden dunnage;
Aisles should be wide enough to permit the operation of mechanical handling equipment (MHE) (usually 2.0m) or for hand pallet transporters (usually 1.2m)
A 20mm air gap should surround each pallet

4. Calculation of Storage Space Requirements - Example
ESH DETAILS
FIGURES
COMMENT
ESH width 6m
ESH length 8m
ESH height
3.7m
ESH volume
177.6m3
Height of dunnage
0.1m
From the floor
MHE gangway 2m
Up the middle
Gap from walls
0.5m
From each face
Gap from ceiling
From top package
Available ESH width 3m
6-(2x0.5)-2
Available ESH length 7m
7-(2x0.5)
Available ESH height
Rounded down to nearest meter/pallet
Maximum theoretical UOS
63 UOS
3x7x3
CALCULATION OF STORAGE SPACE REQUIREMENTS: (4 SLIDES, 8 MIN)
SLIDE 3 of 4: CALCULATION OF STORAGE SPACE REQUIREMENTS – EXAMPLE (3 min)
The table shows an example of calculating UOS.
(Instructor: take the students through the table to demonstrate how the 63 UOS is derived)

5. Calculation of Storage Space Requirements - Example
CALCULATION OF STORAGE SPACE REQUIREMENTS: (4 SLIDES, 8 MIN)
SLIDE 4 of 4: CALCULATION OF STORAGE SPACE REQUIREMENTS – EXAMPLE (2 min)
The illustration show this graphically.
(Instructor: take the students through the GRAPHIC to demonstrate how the 63 UOS is derived).

6. Stacking STACKING: (3 SLIDES, 8 MIN) SLIDE 1 of 3: STACKING (1 min)
The term ‘storage and handling’ refers to those procedures and activities regarding safe storage and handling of ammunition and explosives.
We are now aware that, in principle, ammunition may be stacked - that is to say, one pallet may be placed on top of another, and potentially another on tops of that, and so on.
The criteria on the screen are important because they detail the principles of stacking that should be followed to ensure safety and the serviceability of packages and their contents, and to achieve efficiency in storage, accounting and handling.
These criteria also apply to palletised packages.
The national technical authority shall be responsible for detailing specific stacking heights or restrictions and these should be stated in a "safe system of work" document.
Note particularly that the ability to stack ammunition, whether it be palletised or not, will largely be determined by the condition and strength of the floor.

7. Stacking Criteria Storage surfaces should be firm and level
Packages dry, clean and serviceable
Stacked by Lot or batch numbers
Identification markings can be easily seen
Constraints stock marked and segregated
Spaces for easy extraction of single packages
Space for rapid evacuation of personnel
Wooden battens may be used to ensure stability
STACKING: (3 SLIDES, 8 MIN)
SLIDE 2 of 3: STACKING CRITERIA (4 min)
The criteria are:
Storage surfaces should be firm and level
All packages and unpackaged items should be dry, clean and serviceable before being placed in storage
Lot or batch numbers should be stacked by mark or model number, filler / manufacturer, date and lot or batch/Batch Key Identification (BKI) number
Pallets and loose packages should be stacked so that identification markings can be easily seen and identified without moving the ammunition packaging
Ammunition subject to constraints should be suitably marked or labelled and segregated from other stock
Spaces between ammunition stacks should be wide enough to permit easy extraction of single packages or pallets, using mechanical handling equipment (MHE) if necessary, and to permit the checking of package markings. There should be sufficient space to allow for rapid evacuation of personnel in the event of an emergency
Wooden battens may be used between tiers of packaged and unpackaged stores to ensure stability

8. Stacking Criteria (cont)
Stacks should be square or pyramidal in shape
The top of stacks should be easily reached by MHE with the minimum of stock movement.
The height of a stack should not prevent the free air circulation from another stack
Stacking requirements and heights may vary to suit individual ammunition nature requirements, restrictions and local conditions
STACKING: (3 SLIDES, 8 MIN)
SLIDE 3 of 3: STACKING CRITERIA (CONT) (3 min)
The criteria are:
Stacks should be square or pyramidal in shape
The top of stacks should be easily reached by MHE with the minimum of stock movement. Dismantling of a stack in order to reach certain lot or batch numbers should be achievable with the minimum of logistic effort
The height of a stack should not prevent the free air circulation from another stack
Stacking requirements and heights may vary to suit individual ammunition nature requirements, restrictions and local conditions
There are also a number of specific requirements relating to stacking of loose packages, unpackaged ammunition items, unboxed shell, aircraft bombs, white phosphorous and also inert items. These are covered in detail in IATG 06:30, along with the topic of racking…

9. Racking Sufficient load bearing capacity Stable
Not present a trip hazard
Load from the bottom up
Risk to people reaching up high
Risk of dropping packages from a height
Non-flammable or fire retardant material
RACKING: (1 SLIDE, 3 MIN)
SLIDE 1 of 1: RACKING (3 min)
Stacking heights may be increased by the use of racking.
Racking of sufficient load bearing capacity should be employed. Once again however, the strength of the floor may be a limiting factor.
Racking shall be stable and shall not present a tip hazard when fully loaded.
Loading should be from the bottom up to preclude a high centre of gravity.
Consideration should be given to overreach for people trying to get items at height. The additional risk involved should a package be dropped from height should also be considered.
Racking should be of a non-flammable or fire retardant material whenever possible.

10. Stack Tally Cards ESH 3 12202-01 Rd 9mm Ball IMI 10-09 009 A1
Ammunition Stack Tally Card
IATG Form 03.10
ESH
ADAC
Ammunition Description
Lot/Batch
Condition Code
Remarks
Date
Issue/Receipt Voucher Number
Received
Issued
Balance
Signature
Name
Grid Locator Reference
ESH 3
Rd 9mm Ball
IMI A1
1 May 2012
Bob Smith
XY-1011
230,400
230,400
K3, K4
15 May 12
John Brown
XY-1056
30,400
200,000 K3
STACK TALLY CARDS: (1 SLIDE, 5 MIN)
SLIDE 1 of 1: STACK TALLY CARDS (5 min)
The use of Stack Tally Cards are vital control measures in the accounting and control of ammunition in storage, even if an advanced electronic ammunition control system is in use. In the absence of an electronic system their use is essential.
Stack Tally Cards shall be placed on or otherwise attached to each stack of explosives. Each Tally Card format shall show clearly the contents of the stack.
Small stocks of differing ammunition natures with different lot/batch numbers may be stacked together providing each lot/batch is easily identifiable and CG mixing rules are applied.
Where pallets are concerned, a 'Pallet Contents Sheet' may be used - this is essentially the same as a stack tally card but refers to a pallet.
Worked Example: We will now do a worked example.
This stack of ammunition is in ESH 3. (Instructor: click mouse to reveal entry onto Stack Tally Card on the screen).
The ADAC is a codification system that some countries use to help with stock management. For the sake of argument, lets say we are operating the system and the ADAC number is This is 9mm ball ammunition. (Instructor: click mouse to reveal entry onto Stack Tally Card on the screen).
The Lot is IMI (Instructor: click mouse to reveal entry onto Stack Tally Card on the screen).
It is in good condition and there are no constraints against it. The condition code for this is, say, Condition Code A1. (Instructor: click mouse to reveal entry onto Stack Tally Card on the screen).
There are no remarks to enter, although for example this could relate to bans or constraints. (Instructor: No click required here, as there is no entry to make).
(Instructor: click mouse to reveal entry onto Stack Tally Card on the screen).
Let us say that the stock was received at the depot and put into the ESH on 1 May This was done on issue voucher serial number XY There were 230,400 rounds on the voucher (and in the consignment, as the consignment matched the cargo manifest!).
As there was none of this stock in the stack beforehand, the balance is now therefore 230,400 rounds. The name of the individual who received the ammunition and completed the stack tally card was Bob Smith. He has a poor signature! The grid locator reference within the ESH is K3 and K4, as this stock arrived on two pallets which means two units of space, which generally means 2 separate notional grid squares.
On the 15 May 2012, there are 30,400 rounds issued from the depot to a training unit. John Brown enters the details for this transaction, which was done under voucher XY It brings the stock balance in the stack down to 200,000 rounds.
On the 30th May, the training unit returns 2000 rounds which they did not use. Bob Smith again handles this transaction, the voucher code being XY-1102 this time. This brings the balance in the stack to 202,000 rounds.
30 May 12
Bob Smith
XY-1102
2,000
202,000 K3

11. Storage Temperatures More than 1 temperature restriction:
Use the maximum restriction
Nitrate ester based propellants:
Do not store for over 1 month if temperature is likely to remain below 5ºC
Coolest temperature ESH for:
Ammonium Nitrate/TNT or TNT
Incendiary, White Phosphorous or tear-producing compositions
Propelling charges or items containing propellant
STORAGE TEMPERATURES: (1 SLIDE, 5 MIN)
SLIDE 1 of 1: STORAGE TEMPERATURES (5 min)
When considering the storage of ammunition the following should be taken into account:
Any explosive having more than one class of temperature restriction shall be regarded as being in the class with the maximum restriction
To prevent the exudation of nitro-glycerine, nitrate ester based propellants (or articles containing such propellants) should not be kept in explosive storehouses for a continuous period of more than one month if the temperature in any part of the building is liable to remain below 5 degrees C. If the stipulated minimum temperature conditions cannot be met consideration should be given to fitting artificial heating to an approved standard
The efficiency, storage life and safety of some explosives, particularly propellants, are also adversely affected by storage at high temperatures. The use of adequate ventilation, approved air conditioning, or insulation, should be considered in order to keep temperatures in storehouses to a minimum. The ammunition natures listed below should be stored in the coolest accommodation possible:
Ammunition containing Ammonium Nitrate/TNT (Amatol) or TNT
Incendiary ammunition
Propelling charges or ammunition containing propellant
Ammunition containing white phosphorus (WP) or tear-producing compositions
Temperature recording:
Maximum/minimum thermometers or approved temperature data loggers should be installed in storehouses where temperature susceptible explosives and articles are stored, handled or processed and the readings recorded. Humidity and other environmental considerations are covered in IATG

12. Storage and Handling Confirmatory Test
CONFIRMATORY TEST: (1 SLIDE, 7 MIN)
SLIDE 1 of 1: CONFIRMATORY TEST (7 min)
(Instructor: Hand out the test papers and get the students to answer the questions. Give them 4 minutes for this).
(Instructor: After 4 minutes, take 2 – 3 minutes to review the answers with the students. You may wish to get them to mark each others’ papers).
Answers:
1. What is the default gap to be left between ammunition packages and the walls and ceiling of an ESH? mm   
2. If this distance has to be reduced, for example if there odd-shaped/sized large munitions such as guided missiles in their containers, what is the absolute minimum distance between the packages and the walls? mm
3. Why is this requirement in place? To prevent flashover from lightening strikes to the building, to allow good airflow, and to allow someone to get round the stack to check the stocks.
4. What type of ammunition does this restriction not apply to? The exception to these rules is for correctly packaged small arms ammunition (SAA) in Hazard Division (HD) 1.4.
   
5. What is a Unit of Space (UOS)? A notional area of 1 cubic meter and 1 metric tonne.
6. State one advantage and one disadvantage of stacking ammunition. There are many, if necessary refer to previous slides for ideas.
7. Bob Smith’s 7.62mm ammunition problems. Firstly, he issued training ammunition to an operational unit. Secondly, he got his maths wrong when he issued the stock, the balance should have read 12,000 rounds.
 8. You have to store some ammunition. One type is a mortar bomb containing white phosphorous. The other is a propellant which you know contains nitrate esters. You have 2 ESH available. On tends to get quite warm up to 20ºC, and one is usually below 5ºC. Which ESH would you use for which ammunition? The WP should go into a cooler ESH. The nitrate ester propellant should not go into an ESH that remains below 5ºC for more than one month.

13. Questions
Are there any questions? 1 slide, 5 minutes