DOE-STD-1212-2025, Explosives Safety

DOE TECHNICAL STANDARD EXPLOSIVES SAFETY DOE-STD-1212-2025 JANUARY 2025 MEASUREMENT SENSITIVE U.S. Department of Energy AREA SAFT Washington, D.C.20585 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. (This page left intentionally blank.) 2 DOE-STD-1212-2025 FOREWORD 1. This Department of Energy (DOE) Standard has been approved to be used by DOE, including the National Nuclear Security Administration, and their contractors. 2. Comments (recommendations, additions, and deletions) and data, that may be of use in improving this document, should be sent to: NA-ESH-23 U.S. Department of Energy National Nuclear Security Administration P.O. Box 5400 Albuquerque, NM 87185-5400 3. This technical standard is the successor to DOE-STD-1212-2019. 4. This technical standard provides explosives safety policies and requirements in accordance with 10 CFR 851, Worker Safety and Health Program. 5. This official version of the Standard may be found online at: https://www.standards.doe.gov/standards-browse 3 DOE-STD-1212-2025 https://www.standards.doe.gov/standards-browse (This page left intentionally blank.) 4 DOE-STD-1212-2025 Table of Contents 1 Scope/Purpose……………………………………………………….………….. 13 2 Applicability …..……………………………………………………..…………… 13 3 Administration and Management …..…………………………………............ 14 3.1 Office of Primary Responsibility (OPR) Designation …...…………………… 14 3.2 Exemption ………………………………………………..………….…………... 15 3.3 Equivalency ………………………………………..……………….…………… 15 3.4 Waiver ….….….……………………………………………………….…………. 16 4 Explosives Safety Program (ESP) Requirements ………………….............. 16 5 Roles and Responsibilities …..…………………………………….………...... 17 5.1 NNSA Associate Administrator for Environment, Safety, and Health……… 17 5.2 Central Technical Authority (CTA)…………………………........................... 17 5.3 Explosives Approval Authority (EAA)…………………………………………. 17 5.4 Head of DOE Field Element ……………………………………….................. 17 5.5 Federal Explosives Safety Subject Matter Expert (SME) (DOE/NNSA Sites) ……………………………………………………………………………… 18 5.6 DOE/NNSA ESC Chair ...……………………………………………………….. 19 5.7 Contractor Facility Manager ………………………………………………….... 19 5.8 Contractor Facility Management ………………………………………………. 19 5.9 Contractor Explosives Safety Program Manager ……………………………. 20 5.10 Contractor Explosives Safety Authority Having Jurisdiction (AHJ) ………… 20 5.11 Onsite Explosives Hazard Classifier ………………………………………….. 20 6 General Operational Safety ………………………….………………………… 21 6.1 Protection of Explosives……………………………………………………….. 21 6.2 Cardinal Principle…………………………………………………………..…… 21 6.3 Equipment Checks ……………………………………………………………… 21 6.4 Inspection Frequency …………………………………………………………... 22 6.5 Hazard Identification and Communication …………………………………… 22 6.6 Work Environment ……………………………………………………………… 22 6.7 General Explosives Area Controls ……………………………………………. 23 6.8 Concurrent Contact Operations …………………………………………......... 23 6.9 Contamination Prevention ……………………………………….…………..… 24 6.10 Low Concentrations of Explosives in Solution……………………………….. 25 7 Explosives Facility Design/Site Criteria ………………………….……........... 25 7.1 Explosives Facilities ………………………………………………………......... 25 7.2 Blast Resistant Design ………………………………………………………..... 25 7.3 Criteria for Lightning Protection Systems (LPSs)……………………............ 26 7.4 Unproven Facility Design ……………………………………………..……….. 26 7.5 Design of New Facilities ……………………………………………………..… 26 7.6 Site and General Construction Plans …………………………………..…….. 27 8 Hazard Analysis ………………………………..………………………..……… 28 8.1 Hazard Analysis ……………………………………………………………….... 28 8.2 Similar Processes ………………………………………………………………. 29 8.3 High Risk ………………………………………………………………………… 29 8.4 Electrical Hazard Classification Analysis …………………………………….. 30

5 DOE-STD-1212-2025 9 Operating Procedures ………………………………………………………...... 30 9.1 Procedures ………………………………………………………………………. 30 9.2 Approval …….……………………………………………………………………. 31 9.3 Operating Procedures Content ………………..………………………………. 31 9.4 Special or Experimental Procedures ………………………………………….. 32 10 Training …………………………………………………………………………… 33 10.1 Explosives Safety Training ……………………………………………………... 33 10.2 Training and Qualification Programs ………………………………………….. 33 10.3 Unexploded Ordnance (UXO) Qualification ………………………………….. 33 11 Quantity-Distance (QD)…………………………………………….….………... 34 11.1 Explosives Safety Site Plans (ESSPs) ……………………………………..… 34 11.2 Quantity-Distance (QD) Criteria …………………………………..…………… 36 12 Level-of-Protection (LOP) Criteria ……………………………………..……… 40 12.1 Required LOP…………………………………………………………..………… 40 12.2 Hazard Class 0 ………………………………………………………………….. 40 12.3 Hazard Class I …………………………………………………………………... 40 12.4 Hazard Class II ……………………………………..…………………………… 41 12.5 Hazard Class III …………………………………….………………………….... 42 12.6 Hazard Class IV ………………………………………..………………………... 43 13 Remote Operations ……………………………………..………………………. 43 13.1 Personnel Protection ……………………………………..……………............. 43 13.2 Access and Equipment Controls ………………………………………............ 44 14 Limits and Control ………………………………………………..……………... 44 14.1 Explosives Limits …………………………………………….………………….. 44 14.2 Personnel Limits ………………………………………..………………............. 45 14.3 Limit Control ………………………………………….………………………….. 45 15 Personal Protective Equipment ………………………………..….…………... 46 15.1 Clothing …………………………………………………………….…………….. 46 15.2 Footwear …………………………………………………………………………. 47 15.3 Wrist Straps………………………………………………………….…………… 47 16 Insensitive High Explosives (IHE) Qualification ………………..................... 47 16.1 IHE Test Description and Criteria ……………………………………………... 47 16.2 Revisions to IHE Test Description and Criteria …………………………….... 47 16.3 IHE Materials …………………………………………………………………….. 48 16.4 IHE Qualification Testing ……………………………………………………….. 48 16.5 IHE Qualification Process ………………………………………………........... 49 16.6 IHE Subassemblies Testing ……………………………………………............ 50 16.7 IHE Subassembly Qualification Process ……………………………………... 52 16.8 IHE Weapons ……………………………………………………………………. 54 16-1 Supplement 16-1 - IHE Qualification Background …………………………… 55 17 Laboratory Operations ………………………………………………………….. 57 17.1 Operational Requirements ……………………………………………………... 57 17.2 Blast Shields ……………………………………………………………………... 57 17.3 Laboratory Heating Operations ………………………………………………... 59 17.4 Laboratory Setups ………………………………………………………………. 60 6 DOE-STD-1212-2025 17.5 Laboratory Samples Consisting of Flammable Liquid/Explosives Mixtures…………………………………………………………………………… 60

17.6 Explosives Sample Control ……………………………………………………. 61 17.7 De minimis or Residual Quantities ……………………………………………. 61 17.8 Laboratory Electrical Equipment and Instrumentation………....................... 61 18 Inspection ………………………………………………………………….…….. 62 18.1 Inspections ………………………………………………………………………. 62 18.2 Inspection Methods …………………………………………………………….. 62 18.3 Inspection Equipment Design and Operation ……………………………….. 62 19 Explosives Development and Formulation Scaleup ………………………... 63 19.1 Contractor Explosives Development Committee (EDC)……………………. 63 19.2 Development Process …………………………………………………………. 63 19.3 Sensitivity Testing ……………………………………………………………… 65 19.4 Compatibility Testing …………………………………………………….......... 65 19.5 Phase I-Preliminary Development ……………………………………………. 65 19.6 Phase II-Experimental Characterization and Development ……………….. 66 19.7 Phase III-Full-Scale Testing and Production Development ………...……… 67 20 Synthesis and Formulation ……………………………………………………. 67 20.1 Synthesis ………………………………………………………………….......... 67 20.2 Formulation ……………………………………………………………….......... 70 21 Heating, Drying, and Thermal Conditioning …………………………………. 72 21.1 Hazards of Heating Explosives ……………………………………………….. 72 21.2 Critical Temperature and Thermal Analysis Methodology …………………. 72 21.3 Heating and Drying Equipment ……………………………………………….. 74 21.4 Heating and Drying Operations ……………………………………………….. 75 22 Dry Screening, Blending, and Melting ………………………………………... 76 22.1 Dry Screening ……………………………………………………………........... 76 22.2 Blending ………………………………………………………………………….. 77 22.3 Melting ……………………………………………………………………………. 77 23 Pressing and Extruding …………………………………………………………. 78 23.1 Pressing ………………………………………………………………………….. 78 23.2 Extruding …………………………………………………………………………. 81 24 Machining ………………………………………………………………………... 81 24.1 Equipment Requirements ………………………………………………............ 81 24.2 Contact or Remote Operations ………………………………………………... 82 24.3 Setup and Preparation Prior to Machining ……………………………........... 84 24.4 Operations Requirements ………………………………………………........... 85 24.5 Drilling …………………………………………………………………………….. 86 24.6 Coring …………………………………………………………………………….. 87 24.7 Sawing ……………………………………………………………………............ 87 25 Low Pressure Fluids …………………………………………………………….. 88 25.1 Use of Low Pressure Fluids ……………………………………………………. 88 26 Laser Ablation …………………………………………………………………… 88 26.1 Laser Ablation Operations …….……………………………………………….. 88 27 Hand Cutting and Finishing …………………………………………………….. 89 27.1 Hand-Cutting and Finishing Operations ………………………………............ 89 7 DOE-STD-1212-2025

28 Assembly and Disassembly ……………………………………………........... 89 28.1 Tools ……………………………………………………………………………… 89 28.2 Assembly Operations …………………………………………………………... 89 28.3 Loading Assemblies with Plastic or Extrudable Explosives ………………... 90 28.4 Disassembly Operations ……………………………………………………….. 90 28.5 Personnel Protection for Disassembly Operations ………………………….. 90 29 Testing ………………………………………………………………………….... 91 29.1 Test Planning ……………………………………………………………………. 91 29.2 Firing Areas ………………………………………………………………........... 91 29.3 Checkout of Dynamic Engineering Test Equipment ………………………… 92 29.4 Testing of Explosives and Hazardous Radioactive Materials ………........... 92 29.5 Heating of Explosives Test Specimens ………………………………………. 93 29.6 Instrumentation ………………………………………………………………….. 93 29.7 Explosives Accumulation Limits ……………………………………………….. 94 30 Test Firing ………………………………………………………………………... 94 30.1 General Range Standards ……………………………………………………... 94 30.2 Grass Fires ………………………………………………………………………. 95 30.3 Test Setup ……………………………………………………………………….. 96 30.4 Pin Switches and Other Non-initiating Circuits ………………………………. 96 30.5 Low-Energy Electro-explosive Devices ………………………………………. 97 30.6 Explosives Storage in Firing Areas ……………………………………........... 97 30.7 Firing Leads ……………………………………………………………………... 97 30.8 Unattended Test Assemblies ………………………………………................. 98 30.9 Firing Control Circuit Criteria …………………………………………………... 98 30.10 Test Firing in Containment Apparatus ………………………………………... 99 30.11 Gun Firings ………………………………………………………………………. 100 30.12 Drop Testing …………………………………………………………….............. 101 30.13 Post-firing Controls …………………………………………………………….... 101 30.14 Contamination of Firing Areas …………………………………………………. 102 31 Test Failures and Misfires ……………………………………………………… 103 31.1 Explosives Misfire ………………………………………………………………. 103 31.2 Misfire of a Remotely Fired Gun ………………………………………………. 103 32 Explosives Storage ……………………………………………………………... 104 32.1 Storage Magazine Facilities ……………………………………………........... 104 32.2 Storage Magazine Operations …………………………………………........... 105 32.3 Storage Review Program ………………………………………………………. 108 32.4 Storage Compatibility …………………………………………………………... 108 32.5 Onsite Containers ………………………………………………………………. 114 32.6 Storage in Buildings Other Than Storage Magazines ………………………. 116 32-1 Supplement 32-1 - Example Storage Review Program …………………… 120 33 Transportation …………………………………………………………………… 121 33.1 Explosives Transportation ……………………………………………………... 121 33.2 Onsite Shipments ……………………………………………………………….. 122 33.3 Materials Handling Equipment ……………………………………….............. 123 33.4 General Operation Requirements …………………………………………….. 124 33.5 Hazardous Conditions …………………………………………………............. 125 8 DOE-STD-1212-2025

33.6 EMR or RF Energy Emissions from Vehicles……………………………….. 126 34 Materials Receipt ………………………………………………………………... 126 34.1 Motor Vehicles …………………………………………………………………... 126 34.2 Damaged Shipments ……………………………………………………........... 127 35 Materials Handling ………………………………………………………………. 127 35.1 Material Handling ………………………………………………………………... 127 35.2 Manual Handling of Bare Consolidated Explosives …………………………. 128 35.3 Carts and Hand Trucks ………………………………………………………… 129 35.4 Vacuum Handling ……………………………………………………………….. 129 36 Electrical ………………………………………………………………………….. 130 36.1 Electrical Hazard Classification for Explosives Operations or Activities ….. 130 36.2 Electrical Equipment and Wiring………………………………………………. 132 36.3 Electrical Supply System…………………..…………………………………… 133 36.4 Electrical Equipment and Instrumentation…………… ………………………. 134 36.5 Hand-held, Battery-Powered Lights and Instruments………………………... 136 36.6 Non-Rated Extension Lighting …………………………………………........... 136 37 Electrical Test Instruments …………………………………………………….. 137 37.1 Terminology Specific to Section 37 …………………………………………… 137 37.2 Classification …………………………………………………………………….. 138 37.3 Approval and Certification ……………………………………………………… 138 37.4 Electrical Instruments for Use with Initiating Electrical Circuits ……………. 139 37.5 Electrical Instruments for Use with Non-Initiating Electrical Circuits ……… 139 38 Electro-Explosive Devices …………………………………………………….. 140 38.1 Protection from Electromagnetic Radiation ………………………………….. 140 39 Static Electricity …………………………………………………………………. 141 39.1 Bonding and Grounding of Equipment ……………………………………….. 141 39.2 Testing Bonded Equipment Grounds …………………………………………. 142 39.3 Conductive Floors, Shoes, Mats, and Wrist Straps………………………….. 142 39.4 Conductive Floor, Shoes, Work Surface, Wrist Strap, and Rubber Hose Specifications ……………………………………………………………............ 143 39.5 Conductive Floor, Shoes, Work Surface, and Wrist Strap Tests …….......... 144 39.6 Humidification ……………………………………………………………............ 145 40 Fire Protection ………………………………………………………………….... 145 40.1 Vegetation Control ………………………………………………………............ 145 40.2 Fire Protection Criteria ………………………………………………………….. 146 41 Facility Egress ………………………………………………………………….... 146 41.1 Personnel Protective Restrictions and Requirements ………………………. 146 41.2 Requirements for Existing Facilities …………………………………………... 147 41.3 Requirements for New Facilities ………………………………………………. 147 41.4 Single Exits ………………………………………………………………………. 148 41.5 Blast Resistant Doors …………………………………………………………... 148 41.6 Slide Escapes ……………………………………………………………........... 149 42 Lightning Protection …………………………………………………………….. 150 42.1 Lightning Protection Systems (LPSs)…………………………………………. 150 42.2 Conditions Where Lightning Protection Is Not Required ……………........... 151 42.3 Lightning Warning and Protection Plan ……………………………………….. 152 9 DOE-STD-1212-2025

42.4 Lightning Threat Actions ………………………………………………………... 152 42.5 Pause of Operations ……………………………………………………………. 154 43 Building and Equipment Maintenance ……………...……………………....... 155 43.1 Cleaning ………………………………………………………………………….. 155 43.2 Maintenance and Repair ……………………………………………………….. 155 43.3 Hot Work Permits ……………………………………………………………….. 156 44 Decontamination and Cleaning ………………………………………………... 157 44.1 Cleaning Operations ……………………………………………………………. 157 44.2 Cleaning Screw Threads ……………………………………………………….. 157 44.3 Final Decontamination and Disposal of Equipment …………………………. 158 44.4 Inspection ………………………………………………………………………... 159 44.5 Identification and Control of Decontaminated Items ………………………… 159 44.6 Termination of Explosives Facility Use ……………………………………….. 160 45 Collection Systems …………………………………………………………….... 161 45.1 Vacuum Equipment ……………………………………………………………... 161 45.2 Explosives Dust Exhaust Ventilation and Collection Systems ……………... 161 46 Drains and Sumps ……………………………………………….………........... 163 46.1 Collection …………………………………………………………………........... 163 46.2 Effluent ……………………………………………………………………........... 164 47 Waste Collection ……………………………………….………………………... 164 47.1 Removal of Explosives Waste …………………………………………………. 164 47.2 Solid Wastes …………………………………………………………………….. 165 47.3 Vacuum Collection of Explosives Dusts ………………………………........... 165 47.4 Explosives Slurries ……………………………………………………………… 167 47.5 Metal Scrap ………………………………………………………………………. 168 47.6 Salvaged Explosives ……………………………………………………………. 168 48 Waste Disposal ………………………………………..……………………….... 168 48.1 Disposal Operations………… ………………………………………………….. 168 48.2 Preparation for Open Burning …………………………………………………. 169 48.3 Destruction by Burning or Flashing ……………………………………........... 171 48.4 Ignition System Malfunctions …………………………………………………... 172 48.5 Post-burn Operations ………………………………………………………….... 172 48.6 Destruction by Detonation …………………………………………………….... 172 48.7 Use of Solvents ………………………………………………………………….. 173 49 Emergency Control ………………………………………..……………………. 173 49.1 Fire Symbols …………………………………………………………………….. 173 49.2 Emergency Plans ……………………………………………………………….. 173 50 Federal/Contractor Protective Force Ammunition …………………………… 173 50.1 Federal/Contractor Protective Force Vehicles and Personnel Carrying HD 1.1/1.2 Ammunition ……………………………………………………………. 173 50.2 Federal/Contractor Protective Force Ammunition Surveillance …………… 174 50.3 Pre-positioned Ammunition …………………………………………………… 174 50.4 DOE Canine Explosives Training Aids ………………………………………. 174 50-1 Supplement 50-1 - Recommendations for Federal/Contractor Protective Force Vehicles and Personnel Carrying HD 1.1/1.2 Ammunition …………. 175 10 DOE-STD-1212-2025 Appendix A: Acronyms …………………………………………………………………… 176 Appendix B: Definitions…………………………………………………………………… 179 Appendix C: Measurement Abbreviations ………………………..……………………. 190 Appendix D: References ………………………………………….………….................. 192 11 DOE-STD-1212-2025 (This page left intentionally blank.) 12 DOE-STD-1212-2025 1 SCOPE/PURPOSE 1.1 This technical standard provides the basic technical requirements for an explosives safety program necessary to ensure safe operations involving explosives, pyrotechnics, propellants, and assemblies containing these materials. 1.2 This technical standard establishes safety controls and standards not addressed in other existing DOE or non-DOE regulations and is intended to close the safety gap created by DOE’s unique activities to govern the DOE explosives safety process and ensure explosives safety is commensurate with the risk.

1.3 This technical standard is based on managing the risks associated with explosives by controlling energy inputs (stimuli) to explosive materials and mitigating explosive effects. 2 APPLICABILITY 2.1 This technical standard applies to all DOE sites engaged in any of the following activities involving explosives, pyrotechnics, or propellants as well as assemblies containing these materials: • Developing • Manufacturing • Handling • Storing • Transporting • Processing • Testing 2.2 Existing facilities that do not meet the requirements of this technical standard may continue to be used for the balance of their functional lives if the following two conditions are met and documented: 2.2.1 The current operation presents no significantly greater risk than that assumed when the facility was originally designed. 2.2.2 It can be demonstrated clearly that a modification to bring the facility into compliance is not feasible. 2.3 With the exception of explosives storage and transportation, this technical standard does not apply to commercial activities such as routine construction or routine tunnel blasting. 13 DOE-STD-1212-2025 3 ADMINISTRATION AND MANAGEMENT 3.1 Office of Primary Responsibility (OPR) Designation 3.1.1 NA-ESH-23 Worker Safety and Health Division is the National Nuclear Security Administration (NNSA) OPR for this technical standard. 3.1.2 The OPR shall act as the Preparing Activity for this technical standard. 3.1.3 The DOE/NNSA Explosives Safety Committee (ESC) shall review, evaluate, and recommend proposed changes to this technical standard. Note: Changes to this Standard approved by the DOE/NNSA ESC and published in their approved minutes can be implemented at DOE/NNSA Sites prior to this Standards next update as determined and documented by the Contractor Explosives Safety AHJ. 3.1.3.1 The changes shall be consonant with state-of-the-art technical changes in the field and include lessons learned from DOE/NNSA, other Governmental, and Industry experience and mishaps. 3.1.4 The OPR shall evaluate proposed changes to this technical standard on an annual basis. 3.1.4.1 The OPR may decide to submit a section into RevCom for review and approval. 3.1.4.2 The DOE/NNSA ESC shall evaluate proposed changes at the request of the OPR. 3.1.5 Throughout this Standard, requirements are denoted by the words “shall” and “should.” 3.1.5.1 “Shall” requirements are mandatory. 3.1.5.1.1 Relief from a "shall" requirement requires an exemption (see section 3.2). 3.1.5.1.2 A contractor may use an approved equivalency as an alternative approach to meet a "shall" requirement, (see section 3.3). 3.1.5.2 “Should” requirements are mandatory. 3.1.5.2.1 Relief from a “should” requirement requires a waiver (see section 3.4). 14 DOE-STD-1212-2025 3.1.5.3 The use of the word “may” with reference to application of a procedure or method denotes an acceptable means of performing the task. 3.1.5.4 “Notes” are clarifying statements which add context, background, examples, exceptions, etc. and may be used to convey additional information about a requirement. 3.2 Exemption 3.2.1 Exemptions are the release from requirements in this Standard. 3.2.2 Exemptions are approved by the Head of DOE Field Element, and documented for the OPR in a memorandum.

3.2.3 Central Technical Authority (CTA) concurrence is required prior to the granting of exemptions for nuclear safety directives or successor documents identified in the current version of DOE O 410.1, Central Technical Authority Responsibilities Regarding Nuclear Safety Requirements. CTA concurrence is required for exemptions involving hazard category 1, 2, or 3 nuclear facilities. 3.2.4 Exemptions are processed by the Head of DOE Field Element. Follow DOE O 251.1 for the Exemption Process. 3.3 Equivalency 3.3.1 Equivalencies represent an alternative approach to meeting a “shall” requirement of the Standard intended to achieve an equivalent level of safety. 3.3.2 Required documentation for an equivalency: • Description of the condition. • Requirement(s) being affected. • Reason why requirement cannot be achieved. • Alternate approach. • Contractor Explosives Safety Authority Having Jurisdiction (AHJ) determination of equivalent safety. • Contractor Explosives Safety AHJ explanation of additional risk (if applicable). 3.3.3 The Contractor Explosives Safety AHJ shall evaluate, determine, and document that the proposed alternate approach complies with the intent of the provisions of this Standard. 3.3.4 The Contractor Explosives Safety AHJ shall provide a determination of equivalent safety. 15 DOE-STD-1212-2025 3.3.4.1 If the equivalency introduces additional risk, the Contractor Explosives Safety AHJ shall include an explanation of the additional risk. 3.3.5 Equivalencies shall be coordinated with the Federal Explosives Safety Subject Matter Expert (SME) (DOE/NNSA Sites). 3.3.6 Equivalencies that do not introduce additional risk are approved by the Contractor Facility Manager. 3.3.6.1 Equivalencies that introduce additional risk are approved by the Head of DOE Field Element. 3.4 Waiver 3.4.1 A waiver provides relief from a “should” requirement. 3.4.2 A waiver is where the conditions, practices, means, methods, or processes to be used are determined to be safe and necessary. 3.4.3 The Contractor Explosives Safety AHJ shall evaluate, determine, and document that the proposed waiver complies with the intent of the provisions of this Standard. This documentation shall include a determination regarding the safety and necessity of the waiver. 3.4.4 Waivers are approved by Contractor Facility Management. 3.4.5 Required documentation for a waiver: • Description of the condition. • Requirement being affected. • Reason why compliance is not achieved. • Compensatory measures taken to provide protection. • Any proposed corrective actions and schedule. • Contractor Explosives Safety AHJ determination. • Duration of the waiver. 4 EXPLOSIVES SAFETY PROGRAM (ESP) REQUIREMENTS 4.1 All DOE sites within the scope of this technical standard shall establish and maintain a site-specific ESP based on the requirements in this technical standard and 10 CFR 851.24. ESPs shall address all applicable explosives operations and activities. The ESP shall include: 4.1.1 The organizational structure for site explosives safety operations and activities. Address the following committees as they apply: 16 DOE-STD-1212-2025 4.1.1.1 A Contractor Explosives Development Committee (EDC) to approve each phase of an explosives development program. 4.1.1.2 A Contractor Explosives Storage Review Committee (SRC) to establish and approve storage review intervals for all bulk explosives stored at the facility.

4.1.2 The process to resolve technical conflicts between explosives safety requirements and other functional area technical requirements. 4.1.3 The process to apply specific explosives safety provisions to meet Level-of-Protection (LOP) criteria (see section 12). 4.1.4 The process to interact with other safety disciplines supporting explosives operations and activities performed at the site. 4.1.5 The hazard analysis process in support of explosives operations and activities, with a graded approach. 4.1.6 The training and qualification program to support explosives operations and activities. 5 ROLES AND RESPONSIBILITIES 5.1 NNSA Associate Administrator for Environment, Safety, and Health 5.1.1 Designates the Explosives Approval Authority (EAA) to approve qualification of Insensitive High Explosive (IHE) Material and/or Subassembly. 5.1.2 Exercises responsibilities delegated by the Administrator under this Standard. 5.2 Central Technical Authority (CTA) 5.2.1 Concurs with exemptions to this technical standard involving hazard category 1, 2, or 3 nuclear facilities. 5.3 Explosives Approval Authority (EAA) 5.3.1 Approves Qualification of Insensitive High Explosive Material and/or Subassembly. 5.4 Head of DOE Field Element 5.4.1 Verifies that the facilities, activities, and programs under their purview operate in compliance with the requirements of this technical standard. 17 DOE-STD-1212-2025 5.4.2 Approves exemptions to this technical standard. 5.4.2.1 Exemptions involving hazard category 1, 2, or 3 nuclear facilities require CTA concurrence. 5.4.3 Approves equivalencies to this technical standard that introduce additional risk. 5.4.4 Approves Explosives Safety Site Plans (ESSPs). 5.4.5 Approves site and general construction plans for explosives facilities. 5.4.6 Provides oversight of the Contractor ESP. 5.4.7 Appoints a primary and alternate field element representative to the DOE/NNSA ESC. Ensures an appointed member attends each DOE/NNSA ESC Meeting. 5.5 Federal Explosives Safety Subject Matter Expert (SME) (DOE/NNSA Sites) 5.5.1 Reviews and recommends approval or disapproval to the Head of DOE Field Element for: 5.5.1.1 Exemptions to this technical standard. 5.5.1.2 Equivalencies to this technical standard that introduce additional risk. 5.5.2 Reviews ESSPs and recommends approval or disapproval to the Head of DOE Field Element. 5.5.3 Performs assessments of the Contractor ESP in accordance with DOE O 226.1, Implementation of Department of Energy Oversight Policy (current version). 5.5.4 Familiarizes themselves with the Contractor ESP and the explosives operations and activities under their contract. 5.5.5 Shall complete the DOE-STD-8002, Functional Area Qualification Standard for Explosives Safety. The Head of DOE Field Element may apply a graded approach by issuing a documented Job Specific Qualification Standard. 18 DOE-STD-1212-2025 5.6 DOE/NNSA ESC Chair 5.6.1 Performs duties identified in this technical standard and the approved DOE/NNSA ESC Charter. 5.7 Contractor Facility Manager 5.7.1 Establishes and maintains a site-specific ESP. 5.7.2 Assigns a Contractor Explosives Safety Program Manager. 5.7.3 Appoints a primary and alternate Explosives Safety SME as the Contractor Explosives Safety AHJ and Voting Member on the DOE/NNSA ESC. Ensures an appointed member attends each DOE/NNSA ESC Meeting. 5.7.4 Approves equivalencies that do not introduce additional risk. 5.8 Contractor Facility Management

5.8.1 Implements the explosives safety requirements of this technical standard into operations and activities involving explosives. 5.8.2 Verifies that the site training and qualification program addresses explosives workers. 5.8.3 Verifies that explosives-related activities performed onsite by entities other than DOE/NNSA contractors/subcontractors are coordinated through the Contractor Explosives Safety AHJ. 5.8.4 Transmits the ESSP to the Head of DOE Field Element for review and approval. 5.8.5 Selects hazard analysis methodology and addresses the results. 5.8.6 Approves explosives area electrical hazard classification analyses. 5.8.7 Establishes the levels of approval required for operating procedures, based on the operation’s inherent risk. 5.8.8 Establishes the frequency/interval of inspections, operational checks, storage review, and other items as identified in this technical standard. 5.8.9 Approves waivers. 19 DOE-STD-1212-2025 5.9 Contractor Explosives Safety Program Manager 5.9.1 Assists Contractor Facility Management in implementing the requirements of this technical standard. 5.9.2 Performs site-specific explosives safety assessments to verify compliance with the requirements of this technical standard. 5.9.3 Recommends approval of the ESSP to Contractor Facility Management. 5.9.4 Designates Authorized Onsite Explosives Hazard Classifier(s). 5.10 Contractor Explosives Safety Authority Having Jurisdiction (AHJ) 5.10.1 Assists Contractor Facility Management to assure that the level of explosives safety provided to site-specific explosives operations and activities is commensurate with the requirements of this technical standard. 5.10.2 Provides site-specific determinations, interpretations, and clarifications to the requirements of this technical standard. 5.10.3 Interfaces with other disciplines to resolve site-specific conflicts between national codes and standards and this technical standard. 5.10.4 Reviews and recommends approval of electrical hazard classification analyses. 5.10.5 Provides documented determinations and recommendations to Contractor Facility Management regarding proposed equivalencies and waivers to the requirements of this technical standard. 5.11 Onsite Explosives Hazard Classifier 5.11.1 Provides onsite explosives hazard classification for the purpose of onsite transportation and storage. 20 DOE-STD-1212-2025 6 GENERAL OPERATIONAL SAFETY 6.1 Protection of Explosives 6.1.1 Explosives are energetic materials that react when exposed to suitable stimulus, which generally occurs through one or more of the following mechanisms: • Heating • Electrical Discharge • Friction • Pressure • Impact • Shock • Chemical Incompatibility 6.1.2 Explosives shall be protected from exposure to unintentional or uncontrolled stimulus. 6.2 Cardinal Principle 6.2.1 Mitigation of explosive effects to personnel and facilities is based on the Cardinal Principle of explosives safety, which is to limit exposure to a minimum number of personnel, for a minimum amount of time, to a minimum quantity of explosives, consistent with safe and efficient operations. In practice, the Cardinal Principle is applied through activity- specific requirements such as: • Access Control • Personnel Limits • Explosive Limits • Quantity-Distance • Level-of-Protection 6.2.2 The Cardinal Principle shall be observed at any location or in any operation involving explosives. 6.3 Equipment Checks

6.3.1 Before being used in the explosives process, and at established intervals, processing and test equipment shall be checked for: • Proper design • Proper function • Specified clearances between parts in relative motion • Abnormal metal-to-metal rubbing of moving parts potentially contacting explosive materials • Cracks, voids, or screw threads where explosives may accumulate • Contamination that is incompatible with the process materials 21 DOE-STD-1212-2025 6.3.2 This checkout may require the use of mock explosives in process or test conditions. 6.3.3 Explosive materials shall not be pinched or confined between equipment lids or covers and their mating surfaces. These surfaces shall be cleaned before cover placement. This includes pressing operations. 6.4 Inspection Frequency 6.4.1 When this technical standard calls for an inspection, but the inspection interval is not specified, Contractor Facility Management shall establish the inspection interval. 6.4.2 Inspection intervals shall be modified when operational experience dictates a need. 6.5 Hazard Identification and Communication 6.5.1 Contractor Facility Management shall identify and maintain a current list of explosives and other hazardous materials used in conjunction with their operations. 6.5.2 Contractor Facility Management shall educate and train employees in the hazards and precautions required for handling explosives and materials used in conjunction with explosives. 6.6 Work Environment 6.6.1 Where solid bare explosive pieces are handled: 6.6.1.1 The floor should be resilient or covered with a resilient material. 6.6.1.2 All hard objects that explosives could strike in a handling incident should be covered with a resilient material where practical. Note: Physical safety systems demonstrated to preclude the explosives from being dropped or struck could meet these requirements. 6.6.2 A procedure should be established to account for hand tools that may be inadvertently dropped into an explosives processing operation, thus creating a hazard. 6.6.3 Personnel shall be assigned in such a manner that each worker’s presence is monitored frequently and assistance can be provided or aid summoned in the event of an emergency. 22 DOE-STD-1212-2025 6.7 General Explosives Area Controls 6.7.1 Smoking, Matches, Lighters, Metal Articles 6.7.1.1 There shall be no smoking in explosives storage, processing, or test areas, except in designated locations. 6.7.1.2 No matches, lighters, or other fire, flame, or spark producing devices shall be taken into an explosives control area except with written authorization. If authorized to be carried, matches shall be contained in a metal carrying device too large to fit into pockets. “Strike anywhere” matches shall not be used. 6.7.1.3 Operating personnel should not carry metal articles (e.g., keys, jewelry, knives, coins) in explosives processing areas where such items could constitute a hazard if dropped into the process. 6.7.2 Cooking and Eating 6.7.2.1 Food or beverages shall not be consumed in explosives buildings, except in designated areas. 6.7.2.2 There shall be no personal dishes or utensils in an explosives building, except in designated eating areas. 6.7.2.3 Coffee pots, hot plates, ovens (including microwaves), and portable electric heaters shall not be permitted in rooms where: • Explosives may be present. • Flammable vapors or combustible dust may be present. • Electrical classification of appliances is not compatible with the area.

6.7.3 Access to Explosives Areas 6.7.3.1 Access control procedures shall be established for entry to all explosives areas. 6.8 Concurrent Contact Operations 6.8.1 The preferred setup for explosives operations is to perform each operation in a separate location to preclude any adverse operation interaction. Because such an arrangement is frequently impractical, concurrent operations may be permitted if the following conditions exist: 6.8.1.1 Potential equipment-operator interactions between the two operations have been analyzed and the risk is not appreciably greater than that for both operations considered separately. 23 DOE-STD-1212-2025 6.8.1.2 Explosive materials in either operation are not exposed to stress conditions such as elevated temperature (melting or heat conditioning), elevated pressures (pressing or extruding), or deformation/shear (machining or cutting). 6.8.1.3 Mixing of materials in the concurrent operations does not create compatibility problems. 6.8.1.4 Each operator is aware at all times of concurrent operations in his or her area. 6.9 Contamination Prevention 6.9.1 Precautions shall be taken to avoid mutual contamination when two or more incompatible explosives or materials are handled on a single line or within one building or room. Note 1: This includes vacuum systems and explosives scrap collection. Note 2: Inadvertent mixing of incompatible explosives materials can be hazardous not only to manufacturing facilities and personnel but also to the user if such materials are loaded into explosives devices. 6.9.2 When two or more explosives are used in a line or within a building and mixing is not intended, the materials shall be segregated in separate locations. 6.9.2.1 Containers of explosives shall be marked or labeled in accordance with section 32.5.7. 6.9.2.2 Care shall be exercised to properly segregate material in service magazines and in operating buildings. 6.9.3 When a different explosive is to be used in process equipment, the equipment shall be thoroughly cleaned, and excess explosive from the previous job should be removed from the bay. Note: This eliminates the hazards caused by mixing materials. 6.9.4 In any explosives operation, permanent service lines shall be labeled as to their contents. 6.9.4.1 Valves and switches on service lines whose operation can result in a hazardous situation shall be labeled as to their function. 24 DOE-STD-1212-2025 6.10 Low Concentration of Explosives in Solution 6.10.1 After explosives are in dilute solution (less than 25% explosives by weight), the primary hazard shall be considered as that associated with the solvent and not the explosive. Note: Where supported by technical data and approved by the EDC, a solvent/ explosives solution greater than 25% may also be similarly classified. 6.10.2 If the explosive recrystallizes or precipitates out of solution, safety requirements for explosives shall apply. 7 EXPLOSIVES FACILITY DESIGN/SITE CRITERIA 7.1 Explosives Facilities 7.1.1 Permanent explosives facilities shall comply with Unified Facilities Criteria (UFC) 3-340-02. 7.1.1.1 DOE/TIC-11268 may be used as a supplement as it often resolves some special DOE design considerations and may result in a more economical design. Note: As an example, it describes how to reduce blast overpressure from an explosion due to a high-altitude location. 7.1.2 Portable magazines should be ventilated and resistant to water, fire, and theft.

7.1.2.1 Portable magazines may be made of any material that meets these requirements. Note: Type 2 portable magazines that comply with 27 Code of Federal Regulations (CFR) Part 555.208 meet these criteria. 7.1.3 Portable magazines shall be sited per Department of Defense Explosives Safety Regulation (DESR) 6055.09 as aboveground magazines. 7.2 Blast Resistant Design 7.2.1 Blast-resistant design for personnel and facility protection shall be based on the TNT (Trinitrotoluene) equivalency of the maximum quantity of explosives and propellants. 25 DOE-STD-1212-2025 7.2.2 TNT equivalency shall be increased by 20% for design purposes in accordance with UFC 3-340-02. 7.3 Criteria for Lightning Protection Systems (LPSs) 7.3.1 Lightning protection shall be designed in accordance with National Fire Protection Association (NFPA) 780, Standard for the Installation of Lightning Protection Systems, and Section 42 of this technical standard. 7.4 Unproven Facility Design 7.4.1 For an unproven facility design, either a validated model or full-scale test is required to validate structural adequacy unless a high degree of confidence can be provided by calculations or other technical bases. 7.4.1.1 Prior to full-scale testing, test plans shall be provided to the Head of DOE Field Element for concurrence. 7.5 Design of New Facilities 7.5.1 The design of new explosives facilities and major modifications to existing explosives facilities shall conform to the following: 7.5.1.1 The requirements established in this technical standard. 7.5.1.2 The methods of analysis and design, as well as protective design features specified in UFC 3-340-02. Note: It is not intended that existing facilities be changed to comply with these provisions, except as required by law. 7.5.1.3 The following documents may be used to assist the design and analysis of blast-resistant design. The most current and updated version should be used. • DOE/TIC-11268 • Department of Defense Explosives Safety Board (DDESB) TP-12 • DDESB TP-13 • DDESB TP-15 • DDESB TP-16 • DDESB TP-17 7.5.2 Studies necessary to provide the technical basis for location, engineering, design, and operation (under normal and potential design basis accident conditions) of buildings shall follow the stricter of this technical standard or DESR 6055.09 for establishing explosives quantity-distance (QD) separation. 26 DOE-STD-1212-2025 7.5.3 To maintain maximum, long‐term flexible use of facilities, Contractor Facility Management is encouraged to consider installing dual‐rated (i.e., Class I, Division 1 and Class II, Division 1) permanent wiring and equipment in explosives operating rooms. As a minimum, installation should allow for easy conversion to dual‐rated wiring and equipment. 7.6 Site and General Construction Plans 7.6.1 Site and general construction plans for explosives facilities, as well as plans for changes in utilization of facilities or mission changes that adversely affect the explosives QD requirements, shall be submitted to the Head of DOE Field Element for review and approval. Plans shall be forwarded for: 7.6.1.1 New construction or major modifications of facilities for explosives activities. Note: When modifications or rehabilitation plans for existing facilities do not introduce additional hazards or do not increase the net explosives capacity or chemical agent hazard for which the facility was designed or sited, site and general construction plans are not required to be submitted to the Head of DOE Field Element for review.

7.6.1.2 Facilities for activities not involving explosives that are in such proximity to explosives as to be exposed to hazards or for which a reasonable doubt may exist regarding possible exposure to hazards. 7.6.1.3 Facilities for activities not involving explosives that become exposed to blast, fire, or fragment hazards; or potential toxic chemical agent release due to change in facility mission or facilities usage. 7.6.2 When the review of site and general construction plans is required, Contractor Facility Management shall: 7.6.2.1 Indicate specifically in the letter of transmittal its approval of the proposal, along with changes, modifications, or specific precautionary measures considered necessary. 7.6.2.2 Comply with applicable requirements of DESR 6055.09 for site plan submission. 7.6.2.3 Retain a copy of the complete site plan and the final safety submission, together with DOE Field Element letter(s) of approval, as a permanent record at the facility/site of origin. 27 DOE-STD-1212-2025 7.6.2.4 Keep facility maps current with the latest site plan approval and reconciled with the facility master planning document. 7.6.3 DESR 6055.09 identifies minimum distances for protection from fragment hazards and blast overpressure. 7.6.3.1 The methods of calculation presented in DDESB TP-13 may be used to establish a smaller fragment exclusion zone. Note: It is not intended that these minimum fragment distances be applied to operating facilities or dedicated support functions within an operating line. For these exposures, the DOE criteria presented in this technical standard for Class I, II, III, or IV LOP activities with appropriate QD separations are the required protection levels per section 12. 7.6.4 In addition to this technical standard, the following are resource documents for the siting and design of explosives facilities: • DOE Order 420.1 • DOE Order 430.1 • 10 CFR Part 830 • UFC 3-340-02 • DOE/TIC-11268 • DESR 6055.09 • DDESB TP-13 • DDESB TP-26 • AMCR 385-100 • TR-828 • AFWL-TR-74-102 • HNDM-1110-01-2 • CEHNC-EDS-F-21-02 8 HAZARD ANALYSIS 8.1 Hazard Analysis 8.1.1 Before starting any operation involving explosives, a documented hazard analysis shall be performed per 10 CFR 851.21. 8.1.1.1 Hazard analyses shall be performed using a graded approach applicable to the specific explosives operation. 8.1.2 When an explosives operation changes, new hazards shall be addressed in a supporting hazard analysis which then becomes part of the original hazard analysis. 28 DOE-STD-1212-2025 8.1.3 When modifying facility or process equipment, a documented analysis shall be performed to validate uniform standards are adhered to throughout the facility. 8.1.4 Contractor Facility Management shall address the results of a hazard analysis. 8.1.4.1 Hazard prevention and abatement shall be conducted per 10 CFR 851.22. 8.2 Similar Processes 8.2.1 A single hazard analysis may be performed for similar processes performed in a single facility, provided that the worst-case process is the basis for the hazard analysis. 8.2.1.1 Selection criteria for the worst-case process are: • Sensitivity of materials; • Quantity of materials; • Number of personnel potentially affected; and • Impact on other operations and activities. 8.2.1.2 As a new process is considered for inclusion under an existing hazard analysis, each step of the new process shall be evaluated to determine if it is within the scope of the existing hazard analysis, and to identify any hazards not addressed in the existing hazard analysis.

8.3 High Risk 8.3.1 Hazard analysis supporting explosives synthesis, formulation, manufacturing, testing, or disposal operations shall be performed and revalidated as a team effort. The team shall consist of a minimum of three personnel, to include at least one technical member and one operator. The following makeup is recommended: • Team Leader who is familiar with the analysis methodology used. • Technical Member(s) who is familiar with the process being analyzed. • Scribe who writes notes of meetings and interviews and drafts reports. • Operator(s) who actually performs the work being analyzed. • Explosives Safety SME. Note: A technical member is an individual who has expertise in a particular technical discipline (e.g., engineering, chemistry, physics, and safety). 29 DOE-STD-1212-2025 8.3.2 Contractor Facility Management shall select the analysis methodology used (e.g., What if Analysis, Fault Tree Analysis, Event Tree Analysis). 8.3.3 Employees and employee representatives shall be consulted on the hazard analysis. 8.3.4 The result of the hazard analysis shall be provided to employees involved in or affected by the operation. 8.3.5 The hazard analysis shall be updated and revalidated at least every five years. 8.4 Electrical Hazard Classification Analysis 8.4.1 If a documented analysis is used to determine the electrical hazard classification for areas where explosives operations or activities are conducted, the analysis shall be reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 8.4.2 The scope of the analysis shall identify the specific location and specific explosives operation or activity. 8.4.3 The analysis should be limited to the following: • Enclosed areas, (e.g., rooms, bays, chambers). • Normal operating conditions. 8.4.4 The analysis should consider the following: • The physical configuration of the explosives, (encased, bare, consolidated, powder, packaged, unpackaged). • The explosives operation or activity being conducted. • Other activities or operations being conducted in the same area. • Migration of explosive or ignitable gases, vapors or dust mixtures to or from adjacent areas. 8.4.4.1 The analysis shall be updated and revalidated if any of these change. 9 OPERATING PROCEDURES 9.1 Procedures 9.1.1 Operating procedures shall be written and approved for each operation involving explosives. 9.1.2 Operating procedures shall implement all applicable controls derived from supporting hazard analysis prior to the procedure being approved for use. 30 DOE-STD-1212-2025 9.1.2.1 Operating procedures that were not prepared using the current hazard analysis shall be evaluated to verify that all applicable controls (new or revised) derived from the current hazard analysis are implemented prior to the procedure being approved for use. 9.2 Approval 9.2.1 New or revised operating procedures shall be reviewed and approved prior to use. 9.2.2 Contractor Facility Management should establish levels of approval based on the operation’s inherent risk. 9.2.3 The review and approval process shall include line and safety organizations. 9.3 Operating Procedures Content 9.3.1 The introduction to the procedure should include the following: 9.3.1.1 A statement of the scope, nature of the operation and its objectives, and defining what facilities and equipment are covered. 9.3.1.2 The name of the department responsible for the operation and the procedure.

9.3.1.3 If the procedure serves as the basis for an exemption, equivalency, or waiver from the requirements of this technical standard, a statement to this effect and a specific reference shall be included. 9.3.2 The materials and equipment section should present the following information: 9.3.2.1 All significant tools, supplies, chemicals, and equipment necessary to perform the operation should be listed in the procedure or in a separate required document. 9.3.2.2 Specifications for approved chemicals, supplies, tooling, and equipment should be referenced where applicable. 9.3.2.3 An explanation of any specific hazard involved in the handling of chemicals or explosives, or a reference to a document that describes the hazards. 31 DOE-STD-1212-2025 9.3.3 The safety section of the procedure should present the following information or reference a safety document that specifies the requirements: 9.3.3.1 General safety rules to be observed and techniques to be applied that verify safety of operations, prevent personnel injury or illness, and prevent equipment damage. 9.3.3.2 Additional or specific emergency controls not addressed by the facility emergency plan. 9.3.3.3 Protective equipment used during the operation. 9.3.3.4 The number of personnel (workers and casuals) and explosives weight limits associated with the operation being conducted. 9.3.4 The operations section should consist of sequential directions written or pictured in clear, concise steps that describe how to perform a particular operation: 9.3.4.1 General directions for operation of all major explosives handling equipment. 9.3.4.2 Particular emphasis should be placed on safety interlocks and controls, and their proper use. 9.3.4.3 If a particular operation requires that no other operation be performed concurrently in the same work area, this requirement shall be stated clearly in the procedure. 9.4 Special or Experimental Procedures 9.4.1 In addition to the applicable requirements listed for operating procedures, the following shall also be addressed: 9.4.1.1 Field operations (remote to normally occupied areas) shall include procedures to verify prompt response of both fire and emergency medical services. 9.4.1.2 Personnel involved with the operation shall be briefed or trained on any unique aspects of the operation and emergency procedures. 9.4.2 When a special or experimental operation shall be conducted a number of times, an operating procedure should be written and approved. 32 DOE-STD-1212-2025 10 TRAINING 10.1 Explosives Safety Training 10.1.1 Personnel shall be properly trained before they are assigned to explosives operations or operate any explosives transport vehicle. 10.1.2 The training for explosives work serves to assist in conducting work safely and developing safety awareness and shall verify that personnel: • Develop and maintain a safe attitude towards work with explosives. • Define and understand the potential hazards involved. • Learn correct skills to perform tasks safely. • Are prepared for unexpected hazardous conditions. • Read and understand the appropriate operating procedures. 10.2 Training and Qualification Programs 10.2.1 Each site's Training and Qualification Program shall address explosives safety training. 10.2.1.1 Personnel responsible for administering a site’s Explosives Safety Program shall be supported by a site-approved Training and Qualification Program.

10.2.2 An employee shall not be permitted to continue working with explosives if their supervisor, with counsel from medical personnel, determines that they are unable to perform the task safely. Possible reasons include: • Physical injury or illness. • Disease. • Mental or emotional disturbances. 10.3 Unexploded Ordnance (UXO) Qualification 10.3.1 Personnel in charge of UXO removal/disposal should be U.S. citizens and have successfully completed training at a U.S. Military Explosives Ordnance Disposal (EOD) school. 10.3.1.1 Personnel shall provide documentation of completed training and have a minimum of 18 months operational EOD experience. 10.3.2 Personnel performing UXO removal or disposal shall have completed training at a U.S. Military EOD school or have equivalent training or experience. 10.3.3 All other personnel engaged in UXO operations shall be trained thoroughly in applicable UXO recognition and explosives safety. 33 DOE-STD-1212-2025 10.3.4 Personnel requiring access to areas known or suspected to contain UXOs shall be required to complete UXO awareness training and comply with any site-specific additional UXO area access requirements. 10.3.5 Sites containing UXOs shall establish site-specific UXO awareness training. 11 QUANTITY-DISTANCE (QD) 11.1 Explosives Safety Site Plans (ESSPs) 11.1.1 Explosives facilities shall be supported by an approved ESSP. 11.1.1.1 The ESSP shall be approved prior to the introduction of explosives. 11.1.2 Contractor Facility Management shall verify that ESSPs are submitted to the Head of DOE Field Element for review and approval. 11.1.3 Where there is an increase in risk that affects QD criteria under an existing ESSP, the ESSP shall be updated, re-submitted, and approved prior to start of affected operations. Examples include: • New construction of a potential explosion site. • New construction of an exposed site. • Facility modifications, change of mission, or change of operations that increase explosives hazards (e.g., personnel exposures, Net Explosive Weight (NEW), change in Hazard Division (HD), nature of operation). • Change of use of non-explosives-related facilities that requires application of more stringent explosives safety criteria. 11.1.4 Risk based explosives siting, as described in DDESB TP-14 is another tool to address explosives QD determinations of equivalency of safety. 11.1.5 CEHNC-EDS-F-21-02 may be used as a technical basis to determine QD for non-fragment-producing small quantities of explosives. 11.1.6 The site plan package shall contain the following: 11.1.6.1 A QD Chart containing the following: • Each sited facility Potential Explosion Site (PES) listing maximum NEW for each applicable HD. • Actual and required distance to Exposed Sites (ES). • QD criteria used for siting each PES - ES relationship. 11.1.6.2 Map(s) showing each PES, its clear zone, and all ESs within the clear zone. 34 DOE-STD-1212-2025 11.1.6.3 Personnel limits for the explosives facility. 11.1.6.4 Description(s) of explosives and non-explosives operations within the clear zone. 11.1.6.5 Justification(s) for facilities not meeting current criteria for the operation that address: • Bringing the facility up to current standards is not feasible, and • Operations present no significantly greater risk than that assumed when the facility was originally constructed. 11.1.7 If the siting has any unique characteristics, explain what they are and what criteria is being applied.

Note: If a facility is built to contain blast effects and fragments, QD to exposed sites does not apply. 11.1.8 A letter of transmittal shall accompany each site plan or group of site plans. The letter shall contain the following: 11.1.8.1 Reason for submittal (preliminary or final siting of new facility, site plan/plans for grandfathered facility/facilities, change in operation with increased or decreased QD requirement). 11.1.8.2 Request for ESSP approval. 11.1.8.3 For a grandfathered facility, note whether the facility meets current criteria for the operation being conducted. 11.1.9 Situations where an ESSP is not required. 11.1.9.1 An ESSP is not required for de minimis or residual quantities of explosives (see section 17.7). 11.1.9.2 An ESSP is not required for storage and associated handling of HD 1.4S. 11.1.9.3 An ESSP is not required for facilities presenting only localized, minimal hazards as determined by the Contractor Explosives Safety AHJ. Note 1: The Contractor Explosives Safety AHJ can designate these facilities as non-explosives facilities. Note 2: Examples of excluded items may include user quantities of small arms ammunition, commercial distress signals, or cartridges for cartridge actuated tools. 35 DOE-STD-1212-2025 11.2 Quantity-Distance Criteria 11.2.1 QD criteria shall account for the types and severity of hazards each explosive material presents, the construction and orientation of facilities to which the criteria are applied, and the degree of protection desired for personnel and facilities adjacent to the explosives operations. Note: The United Nations (UN) hazard classification system defines the types and severities of explosives hazards. 11.2.2 Hazard Divisions 11.2.2.1 Explosives shall be classified based on their reactions to specific initiating influences. 11.2.2.2 Personnel shall use the UN hazard classification system for DOE explosives classification, Table 11.1 lists the hazard divisions of Class 1. Table 11.1 Hazard Divisions of Class 1 HD Designators Hazards 1.1 Mass detonating 1.2.1 Non-mass explosion, fragment producing with NEW for QD > 1.6 lbs 1.2.2 Non-mass explosion, fragment producing with NEW for QD ≤ 1.6 lbs 1.2.3 Non-mass explosion, fragment producing based on single package test only No reaction greater than burning from the external fire test, bullet impact test or slow cook-off test 1.3 Mass fire, minor blast or fragment 1.4 Moderate fire, no significant blast or fragment 1.5 Explosive substance, very insensitive (with a mass explosion hazard) 1.6 Explosive article, extremely insensitive 11.2.2.3 Classification tests (described by TB 700-2) and additional tests (as desired), including UN ST/SG/AC/10/1 and UN ST/SG/AC/10/11, shall be used to assign energetic materials to the appropriate HD SCG (Storage Compatibility Group). Supplemental tests may be used for additional characterization when material properties or anticipated material environments are expected to significantly influence the explosives classification. 11.2.2.4 Although Department of Transportation (DOT) hazard classifications require the use of the Bureau of Explosives' (BOE) Impact Apparatus to 36 DOE-STD-1212-2025 determine impact sensitivity, other impact apparatus may be used, providing: • Test results for at least two reference explosives are compared to results for the reference explosives on the BOE Impact Apparatus; and • A minimum of 10 trials each is run for the reference explosives and the explosives being classified.

11.2.3 The principles and tables presented in DESR 6055.09 shall be used to determine the total quantities of explosives in adjacent magazines, operating buildings, or other explosive facilities that shall be applied to QD tables, and inert storage locations. Note 1: The minimum separation distances required for the facilities are based on the desired LOP and total quantities of explosives. Note 2: The total quantity of explosives is determined by defining and examining the Maximum Credible Event (MCE). If an explosives event occurs, the MCE is the largest credible amount of explosives that could be involved (not necessarily the total quantity of explosives present). Note 3: Requirements for onsite de minimis or residual quantities of explosives can be found in Section 17.7. 11.2.3.1 When the LOP (see section 12) required by this technical standard differ from the requirements of DESR 6055.09, this technical standard shall take precedence. 11.2.4 Transport Vehicles 11.2.4.1 Explosives loaded vehicles in holding yards are considered aboveground magazines for QD purposes. They shall be kept in groups, and each group shall be limited to a maximum of 250,000 lbs (113,398 kg) of high explosives (HE). 11.2.4.2 When a classification yard, interchange yard, inspection station or specified location is the site where explosives are interchanged between the common carrier and facility transportation, QD provisions do not apply provided that vehicles are moved expeditiously to a suitable location. 11.2.5 Utilities Installations 11.2.5.1 Permanent DOE controlled underground utilities installations (excluding building service lines) should be separated from explosives locations containing HD 1.1 materials (see Table 11.2). 37 DOE-STD-1212-2025 Table 11.2 QD Separation for Protection of Underground Service Installations Quantity of explosives (Maximum) Distance Pounds Kilograms Feet Meters ≤ 10,000 ≤ 4,535.9 80 24.4 20,000 9,071.8 85 25.9 50,000 22,679.6 110 33.5 100,000 45,359.2 140 42.7 250,000 113,398.1 190 57.9 Note: If the potential donor building is designed to contain the effects of an explosion, the formula: D=3.0 W1/3 can be used to determine separation distances for less than 20,000 lbs (9,071.8 kg). 11.2.5.2 Privately owned or operated utilities installations (aboveground and underground) shall be separated from explosives locations by at least Public Traffic Route Distance (PTRD). Installations that include structures should be separated from explosives facilities by Inhabited Building Distance (IBD). 11.2.5.3 Certain auxiliary power facilities, transformer stations, etc., present fire hazards to explosives facilities. Transformers and associated electrical switching apparatus serving one explosives facility or complex that do not present a fire hazard to the facility (i.e., dry type, "less flammable" oil insulated) shall be located as specified in NFPA 70 and FMDS 5-4/14- 18. 11.2.5.4 Normal oil insulated transformers shall be located at least 50 ft from an explosives facility or as specified in DESR 6055.09. Note: See section 36.3 for additional electrical supply system requirements. 11.2.5.5 Electric and hybrid-electric vehicles with energy storage devices based on lithium battery chemistries shall not be parked within fire protection distance of explosives facilities (100 ft which may be reduced to 50 ft for buildings of non-combustible construction). Charging stations and parking areas for electric and hybrid-electric vehicles shall be sited not closer than fire protection distance from explosives facilities. This does not apply to facilities with 1.4S materials (e.g. small arms ammunition).

Note 1: These distances may be modified when supported by a documented analysis (e.g., Fire Hazard Analysis, Fire Protection Facility Assessment) by a qualified Fire Protection Engineer (see DOE-STD- 1066), reviewed by the Contractor Explosives Safety AHJ, and approved by Contractor Facility Management. 38 DOE-STD-1212-2025 Note 2: These distances may be increased where deemed necessary to ensure full accessibility of fire and emergency services to explosives facilities. 11.2.6 Storage Tanks for Petroleum and Hazardous Materials 11.2.6.1 Storage tanks for petroleum and hazardous materials shall be sited using Storage Tanks for Hazardous Materials criteria as specified in DESR 6055.09. 11.2.6.1.1 Above ground tanks containing 500 gallons or less of petroleum that serve equipment (such as oil heaters or diesel generators) located in or near explosives buildings shall be located a minimum of 50 ft from explosives locations and comply with NFPA 30. 11.2.6.1.2 Tanks located near intentional detonation areas should be barricaded. Similar underground tanks complying with NFPA 30 do not require separation from explosives facilities. 11.2.6.1.3 In both cases (11.2.6.1.1 and 11.2.6.1.2), the tanks shall be equipped with an anti-siphoning device, unless siphoning is impossible. 11.2.7 Small Quantities of HD 1.1 Explosive Substances 11.2.7.1 Use Table 11.3 to determine distances for small quantities of explosive substances. Note: For many situations, it can be demonstrated that adequate personnel protection is provided at distances considerably less than those distances identified in DESR 6055.09. Table 11.3 Minimum QD Requirements for Small Amounts of Explosive Substances Having HD 1.1 Classification Net Explosive Weight Inhabited Building Distance Public Traffic Route Distance Intraline Distance < 0.0066 lb 0 ft 0 ft 0 ft (0.003 kg) (0 m) (0 m) (0 m) 0.0066 lb – 0.022 lb 16.4 ft 9.8 ft 6.6 ft (0.003 kg – 0.01 kg) (5 m) (3 m) (2 m) 0.022 lb – 0.55 lb 49.2 ft 29.5 ft 16.4 ft (0.01 kg – 0.25 kg) (15 m) (9 m) (5 m) 39 DOE-STD-1212-2025 12 LEVEL-OF-PROTECTION (LOP) CRITERIA 12.1 Required LOP 12.1.1 The LOP required for an explosives activity is based on the hazard class (accident potential) of the explosives activity involved. 12.1.2 Each bay that houses an explosives activity shall have a LOP based on the hazard class determined for the activity. 12.1.3 LOP may be provided by equipment design, structural design, operation separation, or provision of operational shields. 12.2 Hazard Class 0 12.2.1 Explosives operations involve the intentional initiation of explosives materials or articles. Note: Examples are explosives testing, firing activities associated with training, and destruction of explosives by detonation. 12.2.2 Areas used to conduct Class 0 activities shall protect all personnel from injury due to blast, fragments, and structural collapse of buildings. This protection may be achieved by measures (or combination of measures) to include control of fragments and overpressure by suppression, containment, or distance (location) as follows: 12.2.2.1 No structural damage to any facility due to overpressure, fragments, or debris. 12.2.2.2 No fragment or debris impact to operators. 12.2.2.3 Operator protection from any injurious thermal flux. 12.2.2.4 Overpressure, fragment, and debris impact to surrounding areas limited to approved site plans and DESR 6055.09 for intentional detonation of explosives criteria.

12.3 Hazard Class I 12.3.1 Explosives operations involve activities with a high accident potential where: (1) energies approach the upper safety limits, (2) loss of control of interfacing energy is likely to exceed safety limits, and (3) research and development where safety implications have not been fully characterized. 40 DOE-STD-1212-2025 Note: Examples are screening, blending, pressing, extrusion, drilling of holes, dry machining, machining explosives and metal in combination, some environmental testing, new explosives development and processes, explosives disposal by burning and some destructive testing. 12.3.2 Operations shall be conducted remotely because any personnel exposure is unacceptable. 12.3.3 Bays for Class I activities shall comply with the requirements for Class II bays, and, in addition, provide protection to prevent serious personal injuries to personnel performing the activity and personnel in other occupied areas. This protection can be achieved by controlling blast and debris through suppression, containment, or establishing an exclusion area with positive access control. Serious injury prevention is satisfied when personnel are not exposed to: 12.3.3.1 Overpressures greater than 5 psi maximal effective pressure, which should not exceed 2.3 psi peak positive incident pressure (2.3 psi is specified in the DESR 6055.09 as required protection for all personnel exposed to remote operations). 12.3.3.2 Structural collapse of a facility or building from overpressure or debris impact. Structural collapse is a structural component’s failure as a direct result of loss of structural integrity. This collapse does not result in explosion propagation, fatalities, or severe personal injuries. 12.3.3.3 Hazardous fragment or debris having an impact energy greater than 11 ft-lbs. 12.3.3.4 Thermal fluxes are limited to prevent the onset of second-degree burns. This value is specified in DESR 6055.09, as required protection for all personnel assigned to perform remote operations. 12.3.3.5 Transients shall be protected as specified in DESR 6055.09 using “Accidental Ignition or Initiation of Explosives” criteria. 12.4 Hazard Class II 12.4.1 Explosives operations involve activities with moderate accident potential due to the explosives type, condition of the explosives, or nature of the operations. These activities involve energies that do or may interface with the explosives are normally well within the safety boundaries for the explosives involved, but where the loss of control of these energies could approach the safety limits. 41 DOE-STD-1212-2025 Note: Examples are weighing, some wet machining, some multi-port gravity blending, assembly and disassembly, some environmental testing, and some packaging operations. 12.4.2 Class II activities have an accident potential greater than Class III activities, but personnel exposure in contact operations is acceptable. 12.4.3 For Class II operations, access ramps and site roads are not considered occupied areas. 12.4.4 Bays for Class II activities shall comply with the requirements for Class III bays, and, in addition, provide protection to prevent fatalities and severe personnel injuries in all occupied areas other than the bay of occurrence. Prevention of fatalities and severe injuries is satisfied when personnel in occupied areas other than the bay of occurrence are not exposed to the following:

12.4.4.1 Overpressures greater than 15 psi maximal effective pressure. The threshold pressure for eardrum rupture is 5 psi; one-half of the threshold pressure for lung damage is 15 psi (see chapter I-11.1 of UFC 3-340-02). 12.4.4.2 Structural collapse resulting from overpressure or debris impact. Structural collapse is a structural component’s failure as a direct result of a facility losing structural integrity. This collapse does not result in explosives propagation, fatalities, or severe personnel injuries. 12.4.4.3 Hazardous fragments or debris generated in acceptor-occupied areas having an impact energy of 58 ft-lbs or greater, (see chapter I-11.3 of UFC 3-340-02). 12.5 Hazard Class III 12.5.1 Explosives operations involve activities with low accident potential. Note: Examples are activities during storage and operations incidental to storage or removal from storage. 12.5.2 Bays for Class III activities shall provide protection from explosion propagation from bay to bay within buildings and between buildings that are located at intraline or intermagazine distance. 12.5.3 If intermediate storage of explosives is within an operating building containing Class II or Class I operations, the intermediate storage or staging bay shall require Class II LOP. 42 DOE-STD-1212-2025 12.5.4 Minimum separation distances may be reduced when explosives bays are designed to adequately contain the effects of an accident (blast pressures and missiles). 12.6 Hazard Class IV 12.6.1 Explosives operations involve activities with IHE or IHE subassemblies where the probability of accidental initiation or transition from burning to detonation is negligible. Note: Examples are processing and storage activities with IHE and IHE subassemblies. 12.6.2 The following explosives activities with IHE and IHE subassemblies shall remain Class I: • Pressing. • Some machining (see section 24.2.4). • Dry blending. • Dry milling. • Dry screening. 12.6.3 Bays for Class IV activities shall provide protection from fire hazards effects. 12.6.3.1 This protection may be achieved by HD 1.3 aboveground magazine distance separation or by a design that contains the effects of an accident. 12.6.3.2 Because accidental detonation is not considered credible, Class IV bays shall be sited and designed as acceptors rather than donors for the effects of blast overpressure, structural collapse, and missiles (hazardous fragments). 13 REMOTE OPERATIONS 13.1 Personnel Protection 13.1.1 Explosives operations that present a high accident potential as defined in section 12.3.1 shall be performed remotely. 13.1.2 Personnel involved in remote operations shall be provided the required LOP for the hazard class of the operation. 13.1.3 Transient personnel shall be provided protection in accordance with the requirements in DESR 6055.09. 43 DOE-STD-1212-2025 13.2 Access and Equipment Controls 13.2.1 Administrative and/or engineered controls shall be used to prevent entry into a hazardous location in which a remote operation is occurring or to prevent the operation from proceeding when personnel enter. 13.2.1.1 Roads shall be blocked at a minimum PTRD (K24) or hazardous fragment distance from buildings where hazardous (remote) operations are being performed, whichever is greater. Note: Hazardous fragment distance may be satisfied by providing equivalent protection. 13.2.1.2 Corridors leading to bays in which hazardous (remote) operations are being performed shall be marked to warn of the danger with established barriers.

13.2.1.3 When practical, visual methods should be used to monitor remote operations to enable viewing of the operating area conditions before entering. Audio monitoring and video recording should also be considered. 13.2.1.4 Remote operating equipment should be interlocked to access doors for each remote operation. 13.2.1.5 Lights or similar warning devices shall conspicuously identify locations where remote operations are performed to indicate when remote operations are under way. 14 LIMITS AND CONTROL 14.1 Explosives Limits 14.1.1 The quantity of explosives at an operating location shall be the minimum necessary to carry out the operation safely and efficiently. 14.1.1.1 When practical, this quantity shall be subdivided and separated to prevent propagation of detonation. 14.1.1.2 Supplies exceeding this minimum quantity shall be removed from the operating area. 14.1.2 In no case shall the quantity of explosives permitted in an operating building exceed the maximum permitted by QD criteria. 44 DOE-STD-1212-2025 14.1.3 QD criteria and requirements for application of these criteria are presented in section 11. 14.1.4 IHE limits for pressing, dry blending, dry milling, dry screening, and certain machining operations (see section 24.2.4) should be the same as those established for HE operations. 14.2 Personnel Limits 14.2.1 The number of personnel at an operating location shall be the minimum consistent with safe and efficient operation. 14.2.2 Only jobs necessary to the performance of a hazardous explosives operation should be performed in the same location as the hazardous operation. 14.2.3 Only personnel needed for hazardous operations shall be allowed in hazardous locations. 14.2.4 Personnel limits shall allow for necessary casuals. 14.2.5 Sufficient personnel shall be available to perform a hazardous operation safely and to obtain help and aid the injured if an accident occurs. 14.2.6 Contractor Facility Management shall specify explosives activities that may be performed alone. 14.2.6.1 No person shall perform explosives work with a high risk of serious injury alone. 14.2.6.2 Prompt and easy communications with other employees shall be provided. 14.3 Limit Control 14.3.1 Posting and Recording 14.3.1.1 All rooms, bays, and buildings containing explosives shall have, posted in a conspicuous place, a standardized posting stating the maximum amount of explosives and the maximum number of workers and casuals permitted in the controlled area at any one time. 14.3.1.2 Maximum explosives and personnel limits for all buildings and bays for each explosives area shall be documented and maintained on file. 45 DOE-STD-1212-2025 14.3.2 Limit Review and Approvals 14.3.2.1 Contractor Facility Management personnel with authority and jurisdiction over an operating bay or building shall review explosives and personnel limits for each location periodically and recommend changes as required. 14.3.2.2 When the use of a location changes, personnel and explosives limits shall be reviewed and limits reestablished as required. 14.3.2.3 Changes in explosives and personnel limits shall be reviewed and approved in the same manner as operating procedures (see section 9). 14.3.2.4 A procedure shall be established for the approval of temporary changes in explosives and personnel limits for an operating location. 14.3.3 Personnel Controls 14.3.3.1 A system shall be established to control the presence of personnel within explosives operating areas.

14.3.3.2 The movement of transients in the vicinity of an explosives operating area should be controlled when their presence creates a congestion problem or other safety concern. 14.3.4 Explosives Controls 14.3.4.1 A verifiable system shall be established to control the amount of explosives present in an explosives facility. 15 PERSONAL PROTECTIVE EQUIPMENT 15.1 Clothing 15.1.1 Flame-retardant clothing may be desired for explosives operations with the potential for flash fire. 15.1.1.1 The clothing shall not have cuffs. 15.1.1.2 The clothing should not have metallic fasteners. 15.1.2 Operating procedures shall include protective clothing requirements. 46 DOE-STD-1212-2025 15.1.3 15.2 15.2.1 15.2.1.1 15.2.2 15.2.3 15.3 15.3.1 16 16.1 16.1.1 16.2 16.2.1 Cotton or other antistatic outer and undergarments, including socks, should be worn where generation of static electricity would create a hazard. Footwear Personnel working in areas where electrostatic sensitive explosive powders or materials are handled shall wear conductive, non-sparking footwear. Exception: Personnel working on electrical or electronic equipment shall not wear conductive footwear unless protected by insulated mats, ground fault circuit interrupters (GFCI), etc. When conductive footwear is worn, the conductivity shall be tested immediately prior to each use. Personnel working in areas where explosives contamination may be present shall wear non sparking footwear or bootie shoe coverings. Wrist Straps When electrostatic discharge (ESD) wrist strap and cord are worn, the resistance shall be tested immediately prior to each use. INSENSITIVE HIGH EXPLOSIVES (IHE) QUALIFICATION Note: The qualification and approval process described in LLNL-TR- 679331/LA-UR-15-29238 "IHE Material and IHE Subassembly Qualification Test Description and Criteria" is limited to DOE and nuclear weapons applications. IHE Test Description and Criteria IHE Material and IHE Subassemblies qualification criteria are outlined in LLNL-TR-679331/LA-UR-15-29238 and this technical standard. Revisions to IHE Test Description and Criteria Revisions to LLNL-TR-679331/LA-UR-15-29238 shall be approved by the proponent organizations (Lawrence Livermore National Laboratory, Los Alamos National Laboratory, Sandia National Laboratory, and Pantex) and shall be reviewed for concurrence by the DOE/NNSA ESC. Once concurrence is obtained, the Chair shall issue a letter of concurrence to the submitting organization. 47 DOE-STD-1212-2025 16.3 IHE Materials 16.3.1 In scales that are conservative to the relevant nuclear weapon application, IHEs shall meet the following requirements: Note: For more information refer to Supplement 16-1, IHE QUALIFICATION BACKGROUND 16.3.1.1 Does not transition from deflagration to detonation (DDT). 16.3.1.2 Does not transition from shock to detonation (SDT). • Under 3.5 GPa, 3 µs 1-dimensional shock insult at ~25°C. • Under 5.3 GPa, 0.5 µs 1-dimensional shock insult at ~25°C. • Under 1.5 GPa, 3 µs 1-dimensional shock insult when heated to 10°C below the cook-off temperature of the explosive. 16.3.1.3 Passes IHE criteria for Skid test outlined in LLNL-TR-679331/LA-UR- 15-29238. 16.3.1.4 Passes IHE criteria for Bullet test outlined in LLNL-TR-679331/LA-UR- 15-29238. 16.4 IHE Qualification Testing 16.4.1 Any explosive that is a candidate for classification as an IHE shall be subjected to the DOE qualification tests listed in Table 16.1.

Note: This includes three tiers of tests. Test procedures are contained in LLNL-TR-679331/LA-UR-15-29238. Table 16.1 Required Testing to Qualify IHE Materials Tier 1: Prerequisites Tier 2: IHE Material Qualification Tier 3: Demonstration Tests Interim Hazard Classification DDT Test and SDT Test Skid Test and Bullet Test 16.4.2 Some or all of the test requirements of this section may be met by analogy as indicated below: 16.4.2.1 The DOE/NNSA ESC determines the acceptability of analogy in lieu of test data. 16.4.2.2 Analogy submitted in lieu of test data shall include rationale. 16.4.2.3 Approved IHEs (listed in Table 16.2) with complete test data shall be used for baseline comparison purposes. 48 DOE-STD-1212-2025 16.4.3 The DOE/NNSA ESC may request additional information depending on circumstances surrounding the analogous information submitted. 16.4.4 A candidate IHE can be placed in one of the following analogy categories to define required tests depending on the type and extent of change in the candidate IHE relative to the baseline IHE and the potential effects of these changes on specific initiation mechanisms (shock, thermal, mechanical, impact): 16.4.4.1 If the analogy can be fully credited, no testing is required. Note: For example; the candidate IHE involves the same energetic and inert components as the approved baseline IHE, the only change being a volume-percent decrease in the energetic component content. 16.4.4.2 If the analogy can be partially credited, partial testing is required. Sufficient testing is required to verify that no chemical or physical incompatibilities have been introduced that would de-stabilize the base IHE. Note 1: For example; the candidate IHE formulation modifies an inert component of the approved baseline IHE. Note 2: In this case, test data normally generated by the requesting facility during their explosive development scale-up phasing process may be submitted in lieu of the qualification tests of Table 16.1. Note 3: During the development phase, the Contractor EDC, or equivalent, may dictate restrictions consistent with an IHE that are internal to their facility only. 16.4.4.3 If the analogy cannot be credited, full testing is required. Note: For example; the candidate IHE involves the addition of an untested (IHE tests) energetic component to the approved baseline IHE. 16.5 IHE Qualification Process 16.5.1 IHE Materials qualified by previous methods shall remain qualified and are listed in Table 16.2 Table 16.2 Approved IHEs TATB TATB/KEL-F (or equivalent) Formulations 49 DOE-STD-1212-2025 16.5.2 The organization with the need for IHE determination (hereafter shall be referred to as the Requestor) shall perform or have performed the appropriate tests in accordance with the requirements of LLNL-TR- 679331/LA-UR-15-29238, after coordinating need for material qualification with the appropriate Headquarters (HQs) Program Office (e.g., NA-11, NA-12, or NA-19). 16.5.3 The Requestor submits the test data, for the candidate explosive, to the DOE/NNSA ESC Chair. 16.5.4 The DOE/NNSA ESC Chair assigns a Task Group for review and recommendation of approval/disapproval of the candidate explosives material. 16.5.5 If the request is not recommended for approval, the Task Group documents the rationale and requirements that were not met and provides this information to the DOE/NNSA ESC Chair who then communicates with the Requester through the DOE/NNSA ESC Chair.

16.5.6 If the request is recommended for approval, the Task Group assembles the test data and provides this information to the DOE/NNSA ESC Chair with a recommendation to approve the candidate explosive. 16.5.7 The DOE/NNSA ESC Chair prepares a written recommendation on the approval of the candidate explosive, and submits it along with the supporting explosives package to the NNSA/NA-ESH Associate Administrator for Environmental, Safety, and Health; the EAA. 16.5.8 The EAA approves or denies the candidate explosive for qualification as an IHE, and provides written documentation of their decision to the DOE/NNSA ESC Chair. 16.5.9 The DOE/NNSA ESC Chair provides documentation of the EAA's decision to requestor, and if approved, the IHE is added to Table 16.2. 16.6 IHE Subassemblies Testing 16.6.1 IHE Subassemblies are composed of IHE hemispheres or spheres with booster charges, with or without detonators that, as an assembly are so insensitive that the probability of accidental initiation or transition from burning to detonation is negligible, and therefore meet IHE criteria at a system-relevant scale. 50 DOE-STD-1212-2025 16.6.2 Main charge materials that do not qualify as IHE materials in section 16.3 may be used as main charges in an IHE Subassembly, provided they meet IHE criteria at a smaller, system-relevant scale. 16.6.3 Any explosive Subassembly that is a candidate for classification as an IHE Subassembly shall be subjected to DOE qualification tests as listed in Table 16.3. These tests shall be planned with consideration of worst-case scenarios. Testing approaches and methods are contained in LLNL-TR- 679331 / LA-UR-15-29238. The qualification approach evaluates each material in the assembly as follows: 16.6.4 Verify main charge is incapable of DDT and therefore meets IHE criteria for a material. 16.6.4.1 Verify main charge meets IHE material criteria for SDT, as shown in Table 16.1, Tier 2 and defined in LLNL-TR-679331/LA-UR-15-29238. 16.6.4.2 Verify detonator material is incapable of DDT in a scale conservative to its relevant application. Note: Electrical threat to detonator is not part of this qualification. 16.6.4.3 Verify booster is incapable of DDT in a scale conservative to its relevant application. 16.6.4.3.1 The test plan shall specify applicable testing for cased and/or uncased configurations with or without detonators. Table 16.3 DOE Qualification Tests for IHE Subassemblies* Test Results DDT No DDT in main charge, booster, and detonator materials tested at scales relevant to application, plus margin for conservatism. SDT No SDT in main charge material per tests in Table 16.1 for both ambient and heated materials. Multiple Bullet Impact No detonation or violent reaction of main charge with a 3-round bullet impact burst in worst-case configuration. Skid Test No burning or violent reaction of main charge (as evidenced by visible fireball) up to a specified height and test angle using Subassembly configuration modified for impact in worst-case geometry. *Tests are not required for subassemblies when main charge and booster charge explosives have been qualified as IHE by tests in Table 16.1. 16.6.5 Some or all of these test requirements may be met by analogy as indicated below: 51 DOE-STD-1212-2025 16.6.5.1 The DOE/NNSA ESC determines the acceptability of analogy in lieu of test data. 16.6.5.2 Analogy submitted in lieu of test data shall include rationale.

16.6.5.3 Approved IHE Subassemblies with complete test data shall be used for baseline comparison purposes. 16.6.6 The DOE/NNSA ESC may request additional information depending on circumstances surrounding the analogous information submitted. 16.6.7 A candidate IHE Subassembly can be placed in one of the following analogy categories to define required tests depending on the type and extent of change in the candidate IHE Subassembly relative to the baseline IHE Subassembly and the potential effects of these changes on specific initiation mechanisms (shock, thermal, mechanical, impact): 16.6.7.1 If the analogy can be fully credited, no testing is required. Note: For example; materials and scales remain the same and only minor changes that do not affect explosive characteristics. 16.6.7.2 If the analogy can be partially credited, partial testing is required. Note: For example; minor changes to explosive materials or components. 16.6.7.3 If the analogy cannot be credited, full testing is required. Note: For example; a significant change to materials or configurations. 16.7 IHE Subassembly Qualification Process 16.7.1 IHE Subassemblies qualified by previous methods shall remain qualified and are listed in Table 16.4. 16.7.2 The Requestor submits a test plan to the DOE/NNSA ESC Chair and the test plan shall be coordinated with the appropriate DOE/NNSA site, after coordinating need for subassembly qualification with the appropriate HQs Program Office (e.g., NA-11, NA-12, or NA-19). 16.7.3 The DOE/NNSA ESC Chair assigns a Task Group for review and approval/disapproval of the test plan. 52 DOE-STD-1212-2025 16.7.4 The ESC Task Group reviews the test plan for compliance with the IHE subassembly requirements and provides input (if necessary), and approves/denies the test plan. They then communicate their decision to the DOE/NNSA ESC Chair. 16.7.5 The DOE/NNSA ESC Chair communicates the approval/disapproval to the Requestor. 16.7.6 If the test plan is approved, the Requestor submits the test data, for the candidate subassembly, to the DOE/NNSA ESC Chair. 16.7.7 The DOE/NNSA ESC Chair submits the test data to the Task Group for review and recommendation of approval/disapproval of the candidate subassembly. 16.7.8 If the request is not recommended for approval, the Task Group documents the rationale and requirements that were not met and provides to the Requestor through the DOE/NNSA ESC Chair. 16.7.9 If the request is recommended for approval, the Task Group provides the DOE/NNSA ESC Chair with recommendation to approve the candidate subassembly. 16.7.10 The DOE/NNSA ESC Chair prepares a written recommendation on the approval of the candidate subassembly, and submits it along with the supporting subassembly package to the EAA. 16.7.11 The EAA approves or denies the candidate subassembly for qualification as an IHE subassembly. 16.7.12 The EAA provides written documentation of their decision to the DOE/NNSA ESC Chair. 16.7.13 If approved, the DOE/NNSA ESC Chair provides documentation of the EAA's decision to requestor. If approved, the IHE Subassembly is added to Table 16.4. Note: Any redesign that dimensionally increases the booster size requires resubmission of an experimental plan and additional testing as another IHE Subassembly. Table 16.4 Approved IHE Subassemblies B61*3/4/6/7/8/10/11/12 W80* W81* B83* W84 W87 W89 *Approval limited to boosters of the size tested or smaller. 53 DOE-STD-1212-2025 16.8 IHE Weapons

16.8.1 IHE weapons are those weapons listed in JNWPS TP-20-7, and are exempt from storage and transportation limits when stored or transported alone or in combination with each other. Note: This classification is valid only if storage containers provide adequate spacing between individual units. JNWPS TP-20-7 specifies the spacing requirements for materials stored or transported out of containers. 54 DOE-STD-1212-2025 Supplement 16-1 – INSENSITIVE HIGH EXPLOSIVES (IHE) QUALIFICATION BACKGROUND BACKGROUND The DOE IHE definition differs from that of Department of Defense (DoD)/UN Extremely Insensitive Substance (EIS) due to different risks and consequences associated with nuclear weapons application. The critical difference in risk is the possibility of special nuclear material (SNM) dispersal. Detonation is the response that impacts nuclear safety. Inadvertent nuclear yield should not be possible in modern weapons, so SNM dispersal requires shock from explosive in close proximity, according to DOE-HDBK-3010-94 and NUREG/CR-6410. Absence of a detonation greatly reduces the likelihood of dispersal. A shock from deflagrations would be weak. Prompt Shock-to-Detonation Transition (SDT) cannot be excluded under all conditions because an IHE shall detonate to function as designed. The threshold should be clearly defined because nuclear safety requires that we know the SDT characteristics of an explosive. It is also important to confirm that the SDT characteristics are reasonably consistent across the lifecycle temperature range. SDT insults are generated with a gas gun which develops a sustained, 1D, shock pulse. These 1D shock pulses do not have a system-relevant scale, so all IHE materials and subassemblies undergo the same test. Deflagration-to-Detonation Transition (DDT) is the build-up of a burning reaction to a detonation. Ignition is a complex phenomenon governed by many competing processes. We assume ignition of a burning reaction in qualification testing since we cannot guarantee that ignition shall never occur in the various relevant hazard scenarios. Whether the ignited materials transition to a detonation is equally complex but is controlled by a few key variables, including the strength of confinement, charge size, and the state of the explosive. The DDT test is a large test with high confinement, and large margin. Deliberate ignition verifies DDT is not possible in the material in any scale relevant to a nuclear weapon. The inclusion of DDT testing eliminates the need for many standard ignition and reaction violence tests like ODTX, Susan, Spigot, Friction, Bonfire, and Slow Cookoff. Unknown to Detonation Transition (XDT). In some hazard scenarios with detonable solid rocket motors, initiation has been observed under conditions that are insufficient to develop either an SDT or DDT initiation. This response mode is termed XDT, where “X” stands for the unknown transition to detonation. It is believed that the XDT mechanism is the result of a process that includes severe damage and break-up of a bare energetic material in an unconfined space, expansion of this damaged material, and subsequent re- compaction of damaged material to develop ignition or initiation. The process is known to be highly complex and geometry dependent. There are no credible threats to nuclear weapons that include a geometry that allows this process to progress. Also, the final stage of both DDT and XDT is facilitated by the same underlying mechanism, shock initiation of damaged explosives. If an HE passes a conservatively-designed DDT test, then we can be

55 DOE-STD-1212-2025 confident that XDT is not a possibility under similar stimulus and geometry. Therefore, a test for XDT does not need to be included as a qualification test. High explosive violent reaction (HEVR) is a commonly used term to describe an unacceptable level of reaction. There is, however, no clear definition, either theoretically or empirically, of HEVR. DOE O 452.1F and the D&P Manual both refer to HEVR as “ranging from a fast deflagration of the high explosive up to and including a detonation of the high explosive”. There is no threshold for what might constitute a fast deflagration. In other cases, including dispersal of material outside a facility perimeter, HEVR is essentially being defined in terms of causing a secondary effect rather than in terms of the phenomenon itself. Without a clear or consistent definition, it is impossible to define one or more tests with meaningful criteria to evaluate the candidate explosive for its propensity to undergo HEVR. Hence the absence of that specific term in the definition of IHE. Historical IHE test definitions similarly did not exclude the possibility of HEVR in an IHE. We can make some observations on the implications of the new definition to the potential for HEVR: the material properties that underlie DDT behavior also underlie HEVR responses, including the propensity for thermal ignition, deflagration rate, and shock sensitivity. Therefore, an explosive that meets the DDT criteria in the new definition is likely to be relatively benign in any HEVR. DEFINITIONS Scales conservative to a relevant nuclear weapon application: The scale of a given experiment is related to HE configuration in U.S. nuclear weapons. This is related to the main charge with a margin of conservatism. The scale is not the same as classified scaled weapons experiments. Scales conservative to its relevant application: The scale of a given experiment is related to the HE configuration and confinement of the given application. For example, a booster application has a shorter run length and lower confinement relative to a main charge. REFERENCE DOCUMENTS The following documents set forth some of the procedures to be referenced when planning the IHE and IHE subassembly testing required by Table 16.1 and Table 16.3: • TB 700-2 • MHSMP-84-22 Rev.1 • UN ST/SG/AC.10/11/Rev.1 • LLNL-TR-679331, LA-UR-15-29238 • DOE HDBK-3010 • NUREG-1320 • JNWPS TP-20-7 56 DOE-STD-1212-2025 17 LABORATORY OPERATIONS 17.1 Operational Requirements 17.1.1 Laboratory personnel shall conduct work involving explosives materials in accordance with approved operating procedures supported by documented hazard analysis. 17.1.2 The quantity of explosives present in a laboratory shall be the minimum required for the operations and should be at or below assigned limits. 17.1.3 Storage of explosives not in process is allowed provided the explosives are secured when the laboratory is unoccupied. 17.1.4 Explosives shall be configured to preclude exceeding the MCE. 17.1.5 Open flames shall be prohibited in laboratories where explosives or flammable solvent vapors are or may be present unless allowed by an approved hazard analysis or procedure. 17.1.6 Disposal of explosives through laboratory drains shall be forbidden unless the drain plumbing has no traps and is designed to handle explosives (i.e., is provided with a sump or other device for the collection of solids).

17.1.6.1 Even if a drain is designed to handle explosives, deliberate disposal of explosives in these drains should be avoided. These drains should be used only to clean up explosives spills. 17.1.6.2 Special care should be exercised to prevent entrance of compounds into drains that may react with iron or rust to form sensitive salts (e.g., picrates and picric acid). 17.1.7 Suitable guards shall be provided for all glass or fragile equipment intended to withstand reduced or elevated pressure. 17.2 Blast Shields 17.2.1 If determined through a documented hazard analysis that a laboratory operation presents a credible risk of explosives initiation, controls shall be incorporated, such as the use of blast shields or performing the operation remotely. Table 17.1 lists shields that have been tested and found acceptable for the indicated quantities of explosive. 57 DOE-STD-1212-2025 17.2.2 If an experiment poses a metal-fragment hazard (as opposed to a glass-fragment hazard) and the experiment cannot be conducted remotely, the proposed shield should be tested and approved under conditions simulating an explosion in the experimental setup but with at least 125% of the anticipated explosive content. 17.2.3 The shield shall be anchored to the hood frame or bench top when it is being used for protection against more than 0.16 oz (5 grams) of TNT equivalent. Note: Shields listed in Table 17.1 were not tested for metal-fragment penetration (unless specifically indicated) and thus may not offer effective protection when the explosive is closely confined in a heavy-walled metal container (“heavy-walled” is defined here as wall thickness to diameter ratio greater than 0.01). 17.2.4 Other blast shields may be approved for use after successfully passing a test of 125% of the rated explosive charge. 17.2.5 For confined areas, a blast vent having less strength than the shield should be provided. 17.2.6 When explosives operations require personnel to reach around a shield to manipulate equipment, exposure shall be minimized. 58 DOE-STD-1212-2025 Table 17.1 Blast Shields for Laboratory Operations Shield Minimum distance from explosive Explosives limit Leather gloves, jackets, or coats, and plastic face shields ---- 50 mg 3 mm tempered glass 8 cm 50 mg 7 mm Lucite/equivalent material 15 cm 2.5 g 20 mmLucite/equivalent material 15 cm 10 g 15 mm laminated resistant glass 20 cm 20 g 25.4 mm Lexan/Lexguard 30 cm 50 g 2 units each of 25.4 mm plate glass laminated with 12.4 mm polycarbonate with a 9.5 mm air gap between units (glass sides facing the explosive) 30 cm 50 g (steel confined) Note 1: Blast testing has shown that laminated tempered glass is superior to monolithic tempered glass, and polycarbonate is superior to acrylic plastics, such as Lucite. Laminated tempered glass is recommended instead of monolithic tempered glass and polycarbonate is recommended in lieu of acrylic. Note 2: The shields are recommended to be of equal or greater thickness than those listed in the table. Note 3: Proof testing is highly recommended. Note 4: When designing and/or replacing a blast shield with a polycarbonate, it should be UV stabilized, treated for abrasion resistance, and have met A-A-59502. Note 5: When designing or replacing a blast shield with laminated glass, it should be coated with a 0.1 mm fragment-resistant film on the viewer’s side to minimize spalling. Note 6: The shield, shield frame, and anchoring system shall be designed to resist maximum credible overpressure and fragments.

17.3 17.3.1 17.3.2 17.3.3 17.3.4 17.3.5 17.3.5.1 Laboratory Heating Operations During synthesis, formulation, or experimental work, heat may be applied to initiate or maintain reaction, to increase solubility, etc. Heat shall be applied indirectly using steam, a water bath, oil bath, or an approved laboratory electrical heating device such as a mantle. Caution shall be exercised to verify that reactive material does not come in direct contact with the heating elements. If an experiment requires a blast shield, any heating device shall be mounted so that temperature can be controlled from the operator side of the shield. If an experiment requires a blast shield, any heating device should be mounted so it can be separated quickly from the reaction vessel without operator exposure. During design of the experiment, consideration should be given to providing emergency cooling for the reaction vessel or its contents. 59 DOE-STD-1212-2025 17.3.6 Heating systems that are operated unattended shall have dual controls, an override shutoff, or some other protection against failure of the primary heating control. 17.3.6.1 Heating of explosives with devices without these controls shall be monitored at all times 17.3.6.1.1 If the operator leaves for any reason, the heating device should be turned off. 17.3.7 Requirements in section 17.3.6 may not apply to systems capable of totally containing the effects of an explosion. 17.3.8 Periodic checks should be made to verify that an experiment is proceeding satisfactorily and that the apparatus is not boiling dry, malfunctioning, etc. 17.3.9 In the case of remotely controlled operations, provisions shall be made for observation using mirrors, television monitors, etc. 17.4 Laboratory Setups 17.4.1 Equipment and apparatus shall be clean, in good condition, and in good working order. 17.4.2 All glassware and apparatus shall be inspected for cracks, defects, etc., before use. 17.4.3 Defective or damaged equipment shall be removed from service. 17.4.4 Setups shall be geometrically and structurally stable. 17.4.5 Work areas should be neat and uncluttered. 17.5 Laboratory Samples Consisting of Flammable Liquid/Explosives Mixtures 17.5.1 When flammable liquid/explosives mixtures are less than 25% explosives by weight, the predominant hazard may be considered as that associated with the flammable liquid and not the explosive. Note: Where supported by technical data and approved by the EDC, a flammable liquid/explosives mixture greater than 25% may also be similarly classified. 60 DOE-STD-1212-2025 17.5.1.1 In-process flammable liquid/explosives mixtures that meet section 17.5.1 criteria, (to include those that may contain explosive precipitants) may be placed in a designated flammable storage cabinet with other flammable liquids. 17.6 Explosives Sample Control 17.6.1 Samples shall be delivered to a laboratory only at specific designated locations. 17.6.2 Each sample shall be properly identified and labeled. 17.6.3 Upon completion of required tests or analyses, the sample should be removed from the laboratory. 17.6.4 A safety information sheet should accompany all samples of new experimental explosive material submitted to a laboratory for analysis. 17.7 De minimis or Residual Quantities

17.7.1 Based on a total mass size less than the critical diameter, primary explosives 1 mg or less and secondary explosives 10 mg or less are considered non-detonable by abnormal stimuli or environment (see section 6.2.1). Locations with explosives in these quantities are therefore exempt from the following requirements. • Electrical equipment requirements. • Posting of fire symbol signs and placards. • Quantity-Distance requirements. • Posting of explosives limits. • Personnel Limits. 17.8 Laboratory Electrical Equipment and Instrumentation 17.8.1 Laboratory electrical equipment and instrumentation that comes into direct or indirect contact with explosives shall be evaluated for suitability of use with explosives. 17.8.1.1 This evaluation shall address the risk of the laboratory electrical equipment and instrumentation presenting an unintentional initiation stimulus to explosive materials. 17.8.2 Laboratory electrical equipment and instrumentation determined suitable for use in direct or indirect contact with explosives should be appropriately documented and/or labeled. 61 DOE-STD-1212-2025 18 INSPECTION 18.1 Inspections 18.1.1 Explosives shall be inspected to verify proper identification. 18.1.2 Incoming explosives raw materials shall be inspected for foreign bodies that could cause operating or safety problems in processing operations. 18.1.3 Pressed explosive billets shall be inspected for foreign bodies, voids, or cracks that could cause operating or safety problems in processing operations. 18.1.4 Explosives pieces and assemblies shall have their physical parameters measured where improper dimensions could cause safety problems in processing operations. 18.2 Inspection Methods 18.2.1 The following are examples of acceptable inspection methods: • Screening • Visual inspection • Magnetic separation • Radiography • Chemical analysis • Physical dimension 18.3 Inspection Equipment Design and Operation 18.3.1 Pinch points shall be eliminated or steps taken to preclude explosives contamination of pinch points. 18.3.2 Threaded fasteners or threads of measuring equipment shall be protected from explosives contamination. 18.3.3 Care shall be taken to prevent parts of the measuring or handling equipment from becoming loose and getting into the explosives. 18.3.4 Inspection fixtures shall be designed to secure the explosives piece or assembly effectively to prevent toppling, rolling, or dropping during measurement operations. Note: This is especially critical if the explosives assembly is in motion (e.g., spinning, vibrating) during measurement. 62 DOE-STD-1212-2025 19 EXPLOSIVES DEVELOPMENT AND FORMULATION SCALEUP 19.1 Contractor Explosives Development Committee (EDC) 19.1.1 A committee shall be established at each DOE/NNSA facility engaged in explosives development to be the approving authority for each phase of an explosives development program. 19.1.2 This committee is referred to in this technical standard as the EDC, but it may have a different name at each DOE/NNSA facility. 19.1.3 Individuals selected to serve on the EDC should have considerable experience in explosives handling, processing, chemistry, sensitivity and safety. 19.1.4 The EDC shall approve phase-by-phase, modified formulations and sensitivity data as follows: 19.1.4.1 Shall review and approve data generated in each phase of a development project that involves a new explosive or new explosive formulation before the next phase begins.

19.1.4.2 Shall review and approve compositional modifications to previously evaluated explosive formulations and may approve minor modifications to the explosives formulation for a given phase of development without requiring all of the developmental steps and tests. 19.1.4.3 May waive some developmental phase tests if comparable sensitivity data for the subject material are available from another source. 19.2 Development Process 19.2.1 All DOE/NNSA explosives handling facilities shall establish an administrative process that defines the basic steps for developing and evaluating new explosives and explosive formulations. 19.2.2 The process shall require that each development effort proceed in phases from small to large quantities. The quantities of materials that may be handled in each phase shall be limited. 19.2.3 The EDC shall be responsible for establishing criteria for acceptable explosive behavior in each test of each phase of the explosives development process. 63 DOE-STD-1212-2025 19.2.4 The development process should consist of three phases plus sensitivity and compatibility testing, when required. Guidelines for establishing this procedure are contained in Table 19.1. Table 19.1 Scaleup Process Guidelines for New Explosives and Formulations Quantity of New Materiala Recommended Dataa Data Desired Additional Recommendations Synthesis Specified by the lab performing the synthesis Impact, friction, spark, thermal stability Before using the new ingredient in a formulation ---- Formulation Compatibility Testing: 2 g Thermal compatibility of new ingredient with other ingredients of formulation Before proceeding to Phase I Materials should be processed remotely Phase I 10 g Impact, friction, thermal stability Before non-remote processing and handling in Phase I or scaleup to Phase II Materials should be processed remotely before passing sensitivity and stability tests Phase II 500 gb Compatibility c, impact, friction, spark, thermal stability, thermal characterization before elevated temperature pressing d, e f Phase III Specified by EDC Compatibility, high-speed machining, drop, skid Before Phase III machining or handling of billets 7 kg or greater Composition of formulation shall be fixed a. Quantities and recommended data apply to both new formulations and explosive ingredients. b. The EDC may allow more than 500 g in Phase II where larger quantities are needed for some tests. c. Compatibility of explosives and formulations with materials contacting the explosives in test and production assemblies. d. Before proceeding to Phase II if the composition of a formulation is modified so that the composition is no longer within the limits specified by the EDC. e. Before proceeding to Phase III if: 1. The formulation to be scaled up to Phase III differs from that tested in Phase I, or 2. The explosive or formulation prepared for Phase II development is produced by techniques different from those used in Phase I. f. Materials investigated in this phase should be produced by techniques similar to those that shall be used to produce larger batches in a subsequent phase. 64 DOE-STD-1212-2025 19.3 Sensitivity Testing 19.3.1 Before mixing a new explosive with other materials, the sensitivity and stability of the explosive should be determined and should comply with the criteria set by the EDC. Recommended tests include the following: • Drop-weight impact • Friction • Spark • Thermal stability

19.3.1.1 Thermal stability tests should include two or more of the following: • Differential Thermal Analysis (DTA) or Differential Scanning Calorimetry (DSC) • Thermal Gravimetric Analysis (TGA) • Gas evolution rate at elevated temperature (Chemical Reactivity Test (CRT), Vacuum Stability Test (VST)) • Time-to-explosion analysis 19.4 Compatibility Testing 19.4.1 If a proposed formulation contains new ingredients (explosive or non- explosive), the new ingredients should be tested for compatibility with the other ingredients before preparing batches for Phase I testing. 19.4.2 Compatibility tests should include any of the stability tests listed under section 19.3.1.1. 19.4.3 No more than 2g of the new formulation should be prepared, handled, or stored before compatibility testing. 19.4.4 Formulations for compatibility testing should be processed remotely, whenever possible. 19.5 Phase I—Preliminary Development 19.5.1 Whenever possible, material should be processed remotely. 19.5.2 The total quantity of material that may be processed, handled, or stored at any one time in Phase I should not exceed 10g. 19.5.3 The new explosive or formulation should be subjected to sensitivity and stability tests. Note: Thermal stability testing need not be performed here if one or more of the compatibility tests listed under section 19.3.1.1 have already been conducted on the new formulation. 65 DOE-STD-1212-2025 19.5.3.1 As a minimum, drop-weight impact, friction, spark sensitivity, and thermal stability tests should be performed. 19.5.4 If the new explosive or formulation has acceptable sensitivity and compatibility results, it may be scaled up to Phase II. Note: The EDC may impose handling or processing restrictions or precautions on the material if its performance in any of the above tests is questionable. 19.5.5 After Phase I testing of a formulation is complete, the EDC shall define, on the basis of the test results, what variations in composition are permissible during Phase II development without retesting. 19.6 Phase II—Experimental Characterization and Development 19.6.1 The total quantity of materials processed or handled at any one time in Phase II should not exceed 500g. Note: No limit exists on the quantity that may be stored, other than the storage facility limits for SCG L explosives. 19.6.2 Materials investigated in Phase II should be produced by techniques similar to those that shall be used to produce larger batches in a subsequent scaleup phase. 19.6.3 A thermal characterization test and evaluation should be run before pressing the new material at elevated temperature. 19.6.4 The Phase I sensitivity and stability tests should be rerun in Phase II if any of the following conditions apply: 19.6.4.1 The formulation to be scaled up to Phase III differs from that tested in Phase I. In this case, testing should be completed before Phase III scaleup. 19.6.4.2 The explosive or formulation prepared for Phase II development is produced by techniques different than those used in Phase I. 19.6.4.2.1 Testing should be completed before Phase III scaleup. 19.6.4.3 During Phase II, the composition of a formulation is modified to an extent that the composition is no longer within the limits specified by the EDC (see section 19.5.5). Testing should be completed before proceeding with Phase II. 66 DOE-STD-1212-2025 19.6.4.4 The compatibility of explosives and formulations with materials contacting the explosives in test and production devices shall be evaluated before any such device is assembled.

19.6.4.4.1 If compatibility testing is required, one or more of the tests listed under section 19.3.1 should be recommended. 19.7 Phase III—Full-Scale Testing and Production Development 19.7.1 The maximum quantity of materials processed or handled in Phase III shall be defined in the EDC grant of authorization to proceed with Phase III. Note: No limit is imposed for storage facilities except the limits imposed by the QD tables. 19.7.2 All additional testing necessary to define Storage Compatibility Group (SCG) should be completed before committing bulk quantities of the material to storage (see section 32.4). 19.7.3 During Phase III development, the composition of all formulations should be fixed. 19.7.4 Any new explosive material that is to be contact machined shall be subjected to a machining overtest. 19.7.4.1 Reaction threshold should be determined if possible. 19.7.5 If billets of 7kg or greater are to be produced in Phase III, skid testing should be performed and EDC criteria for this test should be met. 19.7.6 Section 19.6.4 should also apply to Phase III development. 20 SYNTHESIS AND FORMULATION 20.1 Synthesis 20.1.1 Synthesis operations are conducted both on laboratory and pilot scales. The EDC shall approve new operations and materials. In the laboratory, the new material shall initially be prepared on a small scale and characterized as to sensitivity, physical, and explosive properties. Also, the laboratory shall develop processing techniques for the material. If laboratory studies determine that the explosive is of continuing interest, it may be advanced to the Pilot Plant where processing techniques shall be refined and scaled up. The Pilot Plant 67 DOE-STD-1212-2025 shall produce sufficient material for larger scale physical, explosive, and sensitivity characterizations. 20.1.2 Laboratory Scale Synthesis 20.1.2.1 Before initiation of work, the SME who is directing or conducting the synthesis shall analyze each explosives or potential explosives experiment for the type and magnitude of hazards. They shall be responsible for planning the proper selection of conditions, quantity of explosives, and safety devices to be employed. 20.1.2.2 Experiments should be designed to minimize the amount of explosives involved and to use the mildest conditions that yields the desired information. 20.1.2.3 New explosives materials shall be afforded extra protection against impact, pinching, friction, pressure, sparks, contamination, and deterioration. 20.1.2.3.1 If it is necessary to subject explosives to any of these conditions, the operation shall be conducted remotely or adequate personnel shielding shall be provided. 20.1.3 Pilot or Processing Scale Synthesis 20.1.3.1 Alarms should be provided for coolant flow to the reactor, for reaction vessel agitation, and for reactor temperature. These alarms should be energized whenever coolant supply or agitation is critical to prevent a runaway reaction. 20.1.3.2 When agitation is critical, the reactor should be equipped with at least two sources of power to maintain agitation in the event of failure. For example, a reactor might employ an air or inert gas bubble tube as a backup for a mechanical agitator. 20.1.3.3 The reaction vessel should be equipped with an emergency system that automatically cools the vessel or opens or closes a vessel dump valve as required by the process. 20.1.3.3.1 Contact operations should be conducted with a means to activate the emergency system manually.

20.1.3.4 An alarm or monitor should be provided for the critical exhaust ventilation system to warn operating personnel if airflow rates drop below a predetermined level. 68 DOE-STD-1212-2025 20.1.3.5 Emergency plans shall be established for the synthesis area, specifying action to be taken in the event an alarm sounds. 20.1.3.6 Before operations begin, all equipment shall be set up and checked for proper function. 20.1.3.7 Prior to use with any hazardous material, new or infrequently used equipment shall be tested in a dry run. 20.1.3.8 Before starting any process operation, the transfer lines to be used should be properly labeled and their function specified in the operating procedure. 20.1.3.9 All control valves shall be correctly identified according to function. 20.1.3.10 Safety equipment and clothing shall be worn as defined in operating procedures. 20.1.3.11 Explosives warning signs shall be conspicuously displayed on any processing vessel in which explosive materials are to be left overnight. 20.1.3.12 All explosives synthesis process equipment shall be maintained routinely. 20.1.3.13 Equipment with defects that could affect safe operations shall be tagged to prevent its use until repairs are completed. 20.1.3.14 Transfer hoses and portable equipment not involved in the process shall be removed from the work area and stored in their proper places. 20.1.3.15 Agitator blades on reactors and mixers shall be inspected regularly for proper clearance to verify that there is no pinch point or metal-to-metal contact. 20.1.3.16 Any vessel that can be sealed and that can operate above atmospheric pressure shall be equipped with overpressure protection. 20.1.3.17 All closed vessels should be purged with inert gas before flammable liquids are introduced. 20.1.3.18 Inert gas pressure should be used to transfer flammable liquids when gravity flow or pumping is not practical. 69 DOE-STD-1212-2025 20.2 Formulation 20.2.1 Formulation operations considered in this section involve combining compounds or mixtures when one or more of the ingredients are explosive. 20.2.2 Explosives should be loaded into mixers, mills, and deaerators as an operator attended, contact operation. However, the starting, operating, and stopping of such equipment with explosives present shall be accomplished remotely. As an exception, mixing type operations involving a low-energy transfer may be allowed as a contact operation (e.g., slurry coating and melt agitation). 20.2.3 Equipment used for explosives formulation shall be checked for proper operation before adding explosives. 20.2.4 Equipment shall be examined for proper clearances and for metal-to- metal rubbing of moving parts with the potential to contact explosives. 20.2.5 Bearings should be sealed to preclude explosives contamination. 20.2.6 Fast action deluge systems shall be considered for equipment (e.g., mixers, mills, and deaerators) used for easily ignitable explosives formulations. 20.2.7 Hot water, cold water, or steam may be applied to mixers and mills. Heating fluid temperatures shall not exceed known safe operating temperatures for the explosives involved. When roll milling, allowance shall also be made for viscous shear heating of the explosives in process. Heated systems shall comply with the requirements of section 21.3.1 and section 21.3.4. 20.2.8 Mixing 20.2.8.1 Mixer seals and gaskets shall be checked on a regular schedule and cleaned or replaced as required.

20.2.8.2 Checks should be made to verify that maximum particle sizes of ingredients or hard agglomerates of proposed mixes are less than the blade to blade or blade to bowl clearances. 20.2.8.3 Initial cleaning with solvents used for dissolving or suspending the explosives residues shall be done remotely (except for melt mix or slurry coating vessels). 70 DOE-STD-1212-2025 20.2.8.4 Explosive powders and plastic bonded explosives formulations should be mixed wet in a contact operation. This can be accomplished if the wet mixture cannot be initiated with energy sources available, the viscosity is kept low, and the possibility of isolated portions of the mix becoming dry is precluded. 20.2.9 Ball or Jar Milling 20.2.9.1 Balls that are porous or contain cavities shall not be permitted in mills for grinding explosives. 20.2.9.2 Grinding media contaminated with explosives slurry shall be protected from excessive impact when emptying of the mill. 20.2.9.3 After grinding, a careful inspection shall be made to verify that the explosive is free of grinding media. Dispose of any explosives contaminated with broken media. 20.2.9.4 After separating the explosive, the grinding media shall be thoroughly cleaned and inspected before reuse or disposal. 20.2.10 Roll Milling 20.2.10.1 Positive stops should be installed on roll mills to prevent rolls from rubbing against each other. 20.2.10.2 Before starting a milling operation on a roll mill, the contact of the scraper blade with the roll should be adjusted to the minimum pressure necessary to perform the operation. 20.2.10.3 Roll gaps should be set as wide as possible while still allowing adequate working of the material. The minimum gap setting shall be 0.1 mm. 20.2.10.4 Roll rpm should be held at the minimum required to process the material adequately. 20.2.10.5 All roll mills that should be contact operated (e.g., with non-explosive materials) shall be equipped with emergency stop devices (breaker bar or chain) within easy reach of the operator. 71 DOE-STD-1212-2025 21 HEATING, DRYING, AND THERMAL CONDITIONING 21.1 Hazards of Heating Explosives 21.1.1 Elevated temperature may increase an explosive’s sensitivity to other stimuli such as impact, shock, friction and static electricity. Note: A runaway chemical reaction may occur at or above the explosive’s critical temperature that can produce an explosion or fire. 21.1.2 Elevated temperature of an explosive in a sealed container may cause gas generation and pressure rupture of the containment even at temperatures below the critical temperature. 21.1.3 Chemically incompatible or reactive materials, which may be present as accidental contaminants, as components of the formulation, or in external contact with the explosive, may intensify the preceding dangers or cause them to occur at lower temperatures. 21.1.4 Non-uniform heating can cause excessively hot regions in the explosives. Causes may include inadequate agitation of fluid explosives, non-uniform heaters, and non-uniform heat conduction. 21.2 Critical Temperature and Thermal Analysis Methodology 21.2.1 Critical temperature is a system property that depends on a combination of the explosive’s chemical decomposition reactions, its mass and shape, heat transfer and other thermal characteristics of the system, and the confinement or pressure of decomposition products, especially gases. Several different methods of thermal analysis may be used to determine or estimate the critical temperature. The process is typically quite complex because of the complexity of normally occurring chemical reactions.

21.2.2 For operational safety, a conservative estimate (i.e., lower limit) of the critical temperature for a heating operation shall be made (uncertainties of 18°F to 45°F (10°C to 25°C) being common). 21.2.2.1 Analogy of one explosive or system to another similar system with a reliable thermal analysis should be used to determine safe heating temperatures and heating times (heating limits). 21.2.3 The DTA, DSC, or other comparable techniques may be used to measure the temperature of the onset of an exothermic reaction in an explosive. The test results may be used to rank the thermal stability of explosives and as part of a thermal analysis. Because of the complexity 72 DOE-STD-1212-2025 of chemical decomposition, however, the DTA/DSC exotherm has no systematic relationship to the critical temperature and is unreliable for estimating safe heating limits. Exotherm temperature is always considerably above critical temperature and usually increases with the heating rate of the test. 21.2.3.1 Where the DTA/DSC exotherm is specified as a standard for temperature control, the test heating rate shall not exceed 18°F (10°C) per minute. 21.2.3.2 DTA/DSC shall not be used as a sole means for establishing heating limits. 21.2.4 Each facility shall conduct or obtain thermal analysis of any explosives system before the explosive is heated in a contact operation or in association with hazardous radioactive materials as described in section 29.4. 21.2.5 From this analysis, a heating limit for the explosives system shall be established which the EDC shall approve. 21.2.5.1 All factors in section 21.1 and section 21.2 shall be considered. 21.2.5.2 Any significant change in the geometry or an increase in mass should be considered a new explosives system. 21.2.5.3 For a contact operation, the maximum temperature should be set at least 18°F (10°C) below the critical temperature. 21.2.5.4 For heating explosives in association with hazardous radioactive materials, the maximum temperature should be set at least 36°F (20°C) below the critical temperature. 21.2.5.5 Contractor Facility Management should approve heating to a temperature greater than the above specifications if a documented analysis of the explosive’s thermal characteristics indicates that an acceptable time or temperature safety factor is still present for a specific operation. 21.2.5.6 These operations shall be conducted remotely. 21.2.6 Heating controls for each operation shall be established and specified in written operating procedures. 73 DOE-STD-1212-2025 21.2.6.1 Specified conditions should be set at the lowest temperatures and heating times to do the job efficiently. Temperatures should not exceed the heating limit for the explosives system. 21.2.6.2 Factors to consider when establishing heating controls include: • The heating limit and accuracy of the estimated critical temperature. • Accuracy of the temperature control equipment. • The likelihood of incompatible chemical contamination and other operational parameters. 21.3 Heating and Drying Equipment 21.3.1 Heat should be supplied by steam, hot water, friction air, electrically heated transfer fluid, or electrical resistance elements. 21.3.2 Redundant, automatic heat controls shall limit temperatures. 21.3.3 Explosives heated using electrical resistance elements shall be separated from electrical resistance elements to avoid any possible contact.

21.3.4 In systems heated by steam only, the requirements for redundant, automatic heat controls shall be satisfied if a pressure reducing valve, pressure relief valve, and thermostatic valve on the system control the steam pressure. 21.3.5 In electricity heated systems, a manual reset secondary over- temperature system consisting of a controller, failsafe sensor, and an interrupting device shall be provided to interrupt the heat supply source if the primary system fails. 21.3.5.1 The secondary interrupter shall be separate from the primary interrupter. 21.3.5.2 The upper limit of the primary controller is determined by the desired operating temperature limit. 21.3.5.3 The secondary (override) controller is set at a higher temperature but should not exceed the maximum temperature determined by the heating limit specified for the explosives system as determined in section 21.2.4. 21.3.6 Visual and/or audible alarms should be provided to alert operating personnel to abnormal temperature conditions. 21.3.6.1 The heating of explosives should be monitored at all times. 74 DOE-STD-1212-2025 21.3.7 The air or gas used to condition exposed explosives shall not be recirculated if directly heated by electrical resistance elements. 21.3.8 Drying or heating ovens should be vented to a safe location outdoors. Water wash or filtration of the exhaust may be required. 21.3.8.1 If exhaust fans are used, they shall be interlocked with the heat source. 21.4 Heating and Drying Operations 21.4.1 Heating and drying shall be performed under the mildest set of conditions to accomplish the task safely and efficiently. 21.4.2 A thermal analysis shall be made and a written procedure prepared consistent with section 21.2. 21.4.3 The operating procedure shall include controls on the mass and geometry (thickness of the layer) of the material that may be heated. 21.4.4 Except as described in section 21.4.5, drying shall be achieved by circulating a warm, dry gas—either air or inert—over or through the material. 21.4.5 Small samples may be dried by placement in desiccators or by subjecting them to vacuum. 21.4.5.1 Vacuum drying of larger items should be preceded by drying at atmospheric pressure to remove quantities of moisture or solvent before vacuum is applied to remove the final traces of moisture or solvent. 21.4.5.2 Explosives having a vapor pressure exceeding 0.013 Pa (1 x 104 mm Hg) at the drying temperature shall not be subjected to vacuum drying. 21.4.5.3 A cold trap shall be used for vacuum drying where the vapor pressure of the explosives is unknown. 21.4.6 A vapor air mixture within explosive concentration limits shall be avoided. 21.4.6.1 Such a vapor air mixture can be controlled by providing sufficient airflow to maintain a vapor concentration well below the lower flammability limit or by using an inert atmosphere. 75 DOE-STD-1212-2025 21.4.6.2 For inert atmosphere, positive purge shall be used to preclude oxygen leakage into the unit. 21.4.6.3 If vapor concentrations approaching a flammable level are anticipated, they shall be monitored. 21.4.6.4 Airflow shall be controlled to prevent dusting. 21.4.7 When heating explosives whose vapor pressure may cause undesired condensation of explosives on equipment parts, heating shall be conducted in a manner to control condensation of the explosive material. 21.4.7.1 This control should be accomplished by heating the exhaust system or by circulating the air at a rate that shall keep the explosives concentration below the level at which condensation could occur.

21.4.8 The proper operation of heater controls shall be verified on a regular schedule established by Contractor Facility Management. 22 DRY SCREENING, BLENDING, AND MELTING 22.1 Dry Screening 22.1.1 Use of magnetic separators is often advisable to remove ferrous materials that may have passed through the screens. 22.1.2 Operations using mechanical screens shall be performed remotely. 22.1.3 Screening small samples may be performed as a contact operation in accordance with approved operating procedures. 22.1.4 Operating areas and equipment therein shall be cleaned frequently to avoid accumulation of explosives dust. 22.1.5 Operations and equipment shall be set up to minimize and control dust generation. 22.1.6 Equipment shall be designed and operations performed to avoid subjecting explosive materials to pinching, friction, or impact. 22.1.7 Precautions shall be taken to prevent metals from rubbing together when the screens vibrate. 22.1.8 Vibrating equipment shall be inspected frequently for developing cracks subject to contamination by explosives. 76 DOE-STD-1212-2025 22.1.9 Equipment shall be electrically bonded and grounded. Resistance to ground shall be 10 ohms or less and shall be inspected as established by Contractor Facility Management. 22.1.10 Equipment used to transfer electrostatic sensitive explosives to or from screens shall be conductive or static dissipative and electrically bonded to the screen during transfer. Resistance values for conductive or static dissipative materials are found in ESD ADV1.0. 22.2 Blending 22.2.1 Dry blending of explosives shall be performed remotely. 22.2. Dry, hand blending of small samples may be performed as a contact operation in accordance with approved operating procedures. 22.2.3 Equipment should be designed and operations performed to minimize generation and dispersion of explosives dust. 22.2.4 Equipment shall be electrically bonded to provide a continuous path to ground. 22.2.4.1 Resistance to ground shall be 10 ohms or less and shall be inspected as established by Contractor Facility Management. 22.2.5 Equipment used to transfer electrostatic sensitive explosives to or from blenders shall be conductive or static dissipative and electrically bonded to the blender during transfer. Resistance values for conductive or static dissipative materials are found in ESD ADV1.0. 22.3 Melting 22.3.1 The heat for melting explosives shall be supplied by saturated steam, hot water, or another temperature controlled medium. 22.3.1.1 The steam pressure shall be controlled in accordance with section 21.3.4. 22.3.2 Temperatures for contact melting of TNT based explosives (except those containing PETN (Pentaerythritol Tetranitrate), e.g., pentolite) and keeping them molten shall not exceed 249.8°F (121°C). 22.3.2.1 The temperature limit for TNT explosives containing PETN shall be 228.2°F (109°C). 77 DOE-STD-1212-2025 22.3.3 Alarms shall be provided on the melt temperature and on melt kettle agitation when the operation is left unattended. 22.3.3.1 Alarms shall sound if the temperature exceeds the specifications of section 22.3.2 above, or if agitation ceases. 22.3.4 Provisions should be made for emergency emptying of melt kettles in the event of temperature control problems or power failures. 22.3.5 Feeding of the melt kettle and the melting operation shall be controlled or regulated to prevent the formation of large chunks of explosives.

22.3.6 Wherever possible, valves, piping, and threaded bolts and fasteners should be eliminated from melted explosives handling systems. 22.3.7 Melt kettles shall be constructed with corrosion resistant materials. 22.3.7.1 Construction shall not contain blind holes, threads, or cracks in areas exposed to melted explosives. 22.3.7.2 Welds shall be inspected and found free of cracks and porosity. 23 PRESSING AND EXTRUDING 23.1 Pressing Note: Explosives pressing operations subject explosives to high pressures to achieve a physical change. Pressing of explosives formulations is done routinely to consolidate explosive materials into configurations required for test assemblies or weapon systems. Two common types of pressing operations commonly performed are isostatic/hydrostatic and punch and die. The following requirements apply to these types of pressing operations. 23.1.1 Explosives pressing operations shall be conducted remotely. 23.1.2 The correct functioning of press interlock systems shall be verified at intervals established by Contractor Facility Management. 23.1.3 Pressing mandrels, punches, and dies used in explosives operations shall be examined regularly during periods of use for evidence of structural failure. 23.1.3.1 Suitable nondestructive test methods shall be used to perform the examination. 78 DOE-STD-1212-2025 23.1.3.2 Contractor Facility Management shall establish intervals between inspections for each tooling design before committing the tooling to use. 23.1.3.3 The inspection interval and updating should be based on experience with similar tooling designs and configurations. 23.1.4 All new or modified mandrels, punches, and dies shall be inspected before their first use. 23.1.4.1 At least one pressing cycle shall be completed with mock explosives before proceeding to explosives. 23.1.5 Pressure controllers and indicators shall be calibrated periodically to verify accurate control and monitoring of pressing operations. 23.1.6 Press parts that contact explosive materials shall be cleaned thoroughly to remove residual explosives before use with a different explosive formulation. 23.1.7 Temperature control for heated presses and dies shall comply with the requirements of section 21.3.1 and section 21.3.4. 23.1.8 All pressing assemblies shall be designed or have procedural controls established to minimize or eliminate the extrusion of explosives between two mating metal surfaces during the pressing operation. 23.1.9 Operations with explosive powders should be performed in a manner that reduces the release of explosives dust and thereby reduces operator exposure and general room contamination. 23.1.9.1 For operations involving large amounts of powders, local exhaust ventilation with a dust collection system should be provided. 23.1.9.2 Respiratory protection to prevent inhalation of explosives dust may be required when adequate ventilation is not available. 23.1.10 Isostatic/Hydrostatic Pressing 23.1.10.1 Before an elastomeric container or mandrel constructed of a new material is introduced into a pressing operation (where it contacts explosives), the material shall be evaluated for compatibility with the explosives. 23.1.10.2 All pressing vessels shall be examined for evidence of cracking or other signs of incipient structural failure at regular use intervals by suitable 79 DOE-STD-1212-2025 nondestructive test methods. Contractor Facility Management shall establish examination intervals.

23.1.10.3 Before large scale pressings of new explosives or explosives formulations, the materials shall be evaluated for thermal stability (see scaleup procedures in section 19). Note: “New explosives or explosives formulations” refer to those that are new to large scale pressing. 23.1.10.3.1 Stability test results shall be used to assist in establishing safe pressing conditions for the specific pressing size. 23.1.10.4 For isostatic pressing, procedural controls shall be established to validate that: • An acceptable vacuum can be obtained on the mandrel assembly to prevent adiabatic heating during pressing; and • Air is bled out of the press before pressurization. 23.1.10.5 Consideration should be given to the use of fire-resistant hydraulic fluids. 23.1.10.5.1 New fluids shall be checked to verify compatibility with the explosives used. 23.1.11 Punch and Die Pressing 23.1.11.1 All pressing punches and dies shall be inspected visually for damage, deformation, and cleanliness before installation on a press. 23.1.11.1.1 Any questionable condition shall be resolved before the pressing proceeds to verify that the operation’s safety is not compromised. 23.1.11.2 All punches, dies, and press attachment fixtures shall be designed to minimize the possibility of the punch being misaligned with the die (resulting in gouging of a die surface during pressing). 23.1.11.2.1 Press setup procedures shall provide for operator verification of proper alignment before pressing. 23.1.11.3 The responsible user of a gauging section capable of performing the necessary measurements shall control punches and dies. 23.1.11.3.1 Punches and dies should be maintained in matched sets. 80 DOE-STD-1212-2025 23.1.11.4 A group other than the user shall check critical punch and die dimensions before initial use and at suitable intervals thereafter. 23.1.11.4.1 Suitable check intervals for each punch and die design should be determined as in section 23.1.4. 23.2 Extruding 23.2.1 Extrusion operations shall be conducted remotely. Note: Contact extrusion may be performed when hand extruding small quantities with no metal-to-metal contact. 23.2.2 Precautions shall be taken to prevent personnel from being injured by the rupture of pressurized equipment. 23.2.3 The explosive shall be protected against extrusion beyond the tooling cavity. 23.2.4 Precautions shall be taken to prevent foreign material from entering the explosives. 23.2.5 New designs and significant design changes in equipment, tooling or components shall be tested by mock explosives extrusion before actual explosives extrusion. 23.2.6 Pressure controllers and indicators shall be calibrated periodically to validate that proper sealing and extrusion pressures are maintained. 23.2.7 Extrusion press parts shall be cleaned thoroughly of residual explosives remaining from the previous operation before the press is loaded with a different explosive formulation. 23.2.8 Hand loading of extrudable explosives is covered in section 28.3. 24 MACHINING 24.1 Equipment Requirements 24.1.1 Interlocks shall be provided for wet machining operations to verify coolant flow before machine operation. 24.1.1.1 The coolant flow shall be monitored and the equipment automatically and safely shut down if loss of coolant flow is detected. 81 DOE-STD-1212-2025 24.1.1.2 The coolant interlocks shall be protected from tampering and unauthorized disabling by physical means, or supervisory control.

24.1.2 The vacuum-on-vacuum chuck holding fixtures shall be monitored and interlocked with the equipment for automatic shutdown of machining in the event of vacuum loss. 24.1.3 Tool path controls (stops, limits, design patterns) shall be provided to prevent the unplanned travel path of a tool or work piece. 24.1.4 Positive means or secondary verification shall control and limit equipment speed and feed rates. 24.1.5 Pressure-relief devices should be installed on pneumatically or hydraulically powered equipment to provide for safe operation. 24.1.6 Metal chip waste from machining operations should be kept separate from explosives waste. 24.1.6.1 When this is not possible, mixed explosives and metal waste should be completely segregated from unmixed waste and held for separate disposal. 24.1.7 A cutting tool inspection and control program shall be established for explosives machining operations. 24.1.8 Dull or damaged tools shall not be used. 24.1.9 Consideration shall be given to additional safety control devices (e.g., design patterns, safety templates, chip thickness sensors, tool pressure sensors), depending on the type of machining operations, size of explosives pieces, types of explosives, and other factors. 24.1.10 The “machining over-test” shall be considered a testing operation (see section 24.4.13) and is exempt from equipment requirements. 24.2 Contact or Remote Operations 24.2.1 The following explosives may be contact machined if a compatible, nontoxic, noncombustible coolant is used. Explosives not listed below shall be machined remotely. • Amatol • Baratol • Boracitol • Explosive D 82 DOE-STD-1212-2025 • Octol with no more than 75% HMX (Cyclotetramethylene Tetranitramine) • Pentolite with no more than 50% PETN • RDX/TNT compositions with no more than 75% RDX (Cyclotrimethylene Trinitramine). These compositions include Composition B, Composition B-3, and 75/25 Cyclotol • TATB (Triamino Trinitrobenzene) and TATB compositions with an inert plastic binder • TNT 24.2.2 Explosive assemblies composed of any combination of explosives listed in section 24.2.1 and the following non-explosive materials may be contact machined if a compatible, nontoxic, noncombustible coolant is used: • Foamed plastics • Solid plastics • Adhesives • Amorphous graphite • Calcium sulfate casting powder • Explosives mockup 24.2.3 If an assembly contains an explosive not listed in section 24.2.1 or a non-explosive material not listed in section 24.2.2, the assembly shall be machined remotely. 24.2.4 On any explosive, with certain exceptions for TATB and TATB/KEL-F (or equivalent) formulations and explosives machined by fluid jet (see section 24.2.6), the following operations shall be performed remotely: • Drilling of holes smaller than 5 cm in diameter (except for TATB and TATB/KEL-F (or equivalent) formulations, where drilling of holes smaller than 4 mm). • Coring operations (except contact operations on those explosives listed in section 24.2.1, when the requirements of section 24.6 are met and a coolant is used). • Machining of any metal/explosives interface. • Machining TATB and TATB/KEL-F (or equivalent) formulations subassemblies with HD 1.1 boosters installed. • Machining of explosives in Phase II or earlier stage of scaleup (see section 19). • Dry machining Note: TATB and TATB/Kel-F (or equivalent) formulations booster pellets may be contact machined provided a dust collection system is used. 83 DOE-STD-1212-2025

24.2.4.1 For TATB and TATB/KEL-F (or equivalent) formulations contact machining of holes 4 mm to 8 mm, through coolant drills shall be used applying the set-up, flute length, and depth of hole requirements specified in section 24.5.1-3. Coolant flow shall be verified prior to drilling operations. 24.2.5 Machining of primary explosives shall be avoided. Consider other methods, such as forming or pressing to final dimensions, to achieve the desired shape. 24.2.6 IHE, PBX 9404 (Plastic Bonded Explosive), and LX-10 may be contact machined by high-pressure fluid jet. 24.2.6.1 The fluid jet system pressure shall not exceed 20,000psig. 24.2.6.2 The velocity of the fluid jet shall not exceed 520m/sec (theoretical). 24.2.6.3 The jet nozzle orifice diameter shall not exceed 0.01in. 24.2.6.4 The system machining fluid shall be water and shall not contain any abrasives. Note: See section 25 for use of low-pressure fluids. 24.2.7 Concurrent contact machining operations in the same bay should not be permitted. However, concurrent TATB and TATB/KEL-F (or equivalent) formulations contact machining is permitted when other explosives are not present. 24.2.8 Provisions shall be made to monitor remote machining operations visually. Consideration should be given to video recording and audio monitoring. 24.3 Setup and Preparation Prior to Machining 24.3.1 Before setting up the explosive work piece, the equipment shall be checked for proper function and the absence of interference between stationary and moving parts. 24.3.2 An inert shape (e.g., wax, Lexan (polycarbonate), or mock explosive) should be used to test the equipment function of any operation using new tooling or new part programs. 24.3.3 The explosive component to be machined shall be inspected by radiography or other suitable nondestructive test methods for cracks, voids, and high-density foreign objects. 84 DOE-STD-1212-2025 24.3.4 The explosive component shall be checked for proper size. 24.3.5 Caution shall be exercised during setup and adjustment to avoid pinching, dropping, crushing, or otherwise applying abnormal forces to explosives present. 24.3.6 Special care shall be given to mounting and centering a part on a vacuum chuck. 24.3.7 Special attention shall be given to the proper functioning of the vacuum system and its surface holding area. 24.3.8 Limits on machine speed, depth of cut, and feed rate shall be set before the machine is activated. 24.3.9 Interlocks shall be functional before the machine is used to machine explosives. They should be tested once per shift. 24.4 Operations Requirements 24.4.1 The minimum tool speed necessary for safe and efficient operation should be maintained. The following maximums shall apply: • The relative velocity between the explosives surface and the cutting tool shall not exceed 250 m/min; • Work pieces or cutting tools shall not be rotated at speeds exceeding 1050 rpm; and • The feed rate of the cutting tool or work piece shall not exceed 1mm per revolution. 24.4.2 The work piece, fixture, cutting tools, equipment, floor, troughs, drains, etc., should be cleaned frequently to prevent accumulation of explosive wastes. 24.4.3 Approved measures should be taken to prevent rust and minimize deterioration of precision surfaces. 24.4.4 All tools, equipment, fixtures, and parts should be cleaned before removal from the work area for storage. 24.4.5 Coolant shall be used to aid in removing heat and cutting waste for contact machining operations.

24.4.6 Coolant should be used for remote operations when practical. 24.4.7 Coolant should be used on explosives/inert assemblies. 85 DOE-STD-1212-2025 24.4.8 When the explosives portion is included in the cut, coolant shall be used for contact machining. 24.4.9 Coolant is not required if the explosives portion of the assembly is contained (no bare explosives) and is not included in the cut, or the machining is conducted remotely. 24.4.10 Spray mist coolant may be used during machining of the explosive-containing assemblies if the explosives portion is not included in the cut. 24.4.11 All visible explosives shall be removed from the machine before maintenance or repairs. 24.4.12 No safeguards or interlocks shall be removed or made inoperative, except by authorized personnel. 24.4.13 Before submitting an explosive for contact machining approval, a machining over-test shall be conducted to identify the machinability and associated hazards. 24.4.13.1 Machining over-test should be performed in facilities set aside for this purpose. 24.4.13.2 Machining over-test shall be conducted remotely. 24.4.13.3 Operations performed during sample preparation may include gaging and assembly, but shall not include any contact cutting, scraping, or other material-removing operations on explosives specimens. 24.5 Drilling 24.5.1 Drilling operations should be set up to maximize the ease of achieving and maintaining proper alignment and to facilitate removal of explosives chips, fines, and powder. 24.5.2 The fluting length on the drill bit shall exceed the depth of the hole to be drilled by a minimum of 1.3 cm or one-hole diameter, whichever is greater. 24.5.3 The depth of a hole shall not be extended more than 1.5 times the hole diameter (up to a maximum of 2 cm) during a single insertion of the drill into the material. 86 DOE-STD-1212-2025 Note: After each insertion, it may be advisable to withdraw the drill completely and remove loose explosives from the cavity and drill bit before reinserting. 24.5.4 Coolant flow (when used) shall be directed to the explosives/cutting edge interface. 24.5.5 Drill bits larger than 0.25 in (6mm) should have a coolant channel to the tip of the drill. 24.5.5.1 Bits 0.25 in (6 mm) or less in diameter do not need coolant channels, but should limit the depth of each pass to no more than ½ the diameter of the bit to verify that the coolant flow is capable of keeping the hole clean. 24.5.6 Pulsating pressure types of coolant supplies are recommended for drills of 0.25 in (6 mm) diameter or less to remove drill fines. 24.6 Coring Note: A machining operation that removes material in the form of a cylinder by cutting at the circumference to create a hole or recover the material from the center of the cut. 24.6.1 Coolant flow (when used) shall be directed at the explosives/cutting edge interface. 24.6.2 If the hole is not positioned to provide continuous breakout, the coring shall be accomplished incrementally. 24.6.3 When done in increments, no more than 1.5 times the diameter of the hole shall be cored at one time. 24.6.3.1 Before the maximum distance has been cored, the tool shall be totally retracted from the hole and cleaned. 24.6.3.2 The hole shall be flushed with coolant. 24.7 Sawing 24.7.1 The feed rate of the saw blade or work piece shall not exceed 30 cm/min. 24.7.2 For band saws, coolant flow should be directed onto the saw blade at the cutting interface, guide rollers, and the drive wheel/saw blade interface.

87 DOE-STD-1212-2025 24.7.3 For circular saws, the coolant flow should be directed at the explosives/cutting edge interface. 25 LOW PRESSURE FLUIDS 25.1 Use of Low Pressure Fluids 25.1.1 Low pressure fluids may be handled in explosives contact operations to aid in the following: • Dissolution • Rinsing • Flushing, or • Similar operations 25.1.2 The fluid system shall have a pressure relief device installed to prevent system over pressurization. 25.1.3 Low pressure fluid operations may be used with those explosives whose impact sensitivity is less than PETN. Note: Such operations may be used on other explosives only after analyzing the energies involved. 25.1.4 Solvents shall be compatible with the explosive material. 25.1.4.1 Controls for their use shall be specified in operating procedures. 26 LASER ABLATION 26.1 Laser Ablation Operations 26.1.1 Laser ablation shall be conducted as a Hazard Class 1 LOP Activity. 26.1.2 During set-up, when personnel are exposed to the explosives hazard, the ablation laser beam shall not be able to reach the explosives or assembly containing explosives. Note: Low-power alignment lasers may be used. 26.1.3 Before setting up the explosive work piece, the equipment shall be checked for proper function and the absence of interference between stationary and moving parts. 26.1.4 Caution shall be exercised during setup and adjustment to avoid pinching, dropping, crushing, or otherwise applying abnormal forces to explosives present. 88 DOE-STD-1212-2025 26.1.5 Interlocks shall be functional before the laser is used to ablate explosives. 26.1.6 During laser ablation operations, the operator should be provided an immediate means to block the laser beam from reaching the explosives. 27 HAND CUTTING AND FINISHING 27.1 Hand-Cutting and Finishing Operations 27.1.1 Hand-cutting and finishing of explosive materials shall be performed using the mildest energy input that accomplishes the task safely and efficiently. 27.1.2 These activities may include: • Cutting • Trimming • Coring • Lapping (surface polishing) 27.1.3 The Contractor EDC shall review and approve the safety of hand-cutting and finishing operations, which shall then be incorporated into an operating procedure before starting the operation. 28 ASSEMBLY AND DISASSEMBLY 28.1 Tools 28.1.1 Hand tools and electrical and pneumatic tools that may subject the explosives to abnormal frictional forces, pinching, or excessive pressure, or cause significant deformation, shall not be used during assembly or disassembly. Note: Tools may be used on non-explosive components. 28.2 Assembly Operations 28.2.1 Operators need to be alert for mismated parts and misaligned components during assembly operations. 28.2.2 Hard surfaces that contact explosives shall be precisely machined to mate with the explosives, lined with cushioning material, or otherwise configured to keep sharp corners or projections from being forced into explosives. 89 DOE-STD-1212-2025 28.3 Loading Assemblies with Plastic or Extrudable Explosives 28.3.1 Contamination of these explosives with abrasive or foreign substances shall be avoided. 28.3.2 The assembly shall be loaded with small increments of explosives and may be tamped with suitable nonmetallic tools to eliminate air voids. 28.3.3 Plastic explosive compositions C-3 and C-4 may be softened by warming to between 69.8°F (21°C) and 100.4°F (38°C) before working.

28.3.4 Extrudable explosives LX-13 and XTX should be kept as cool as practical to prevent premature curing. 28.4 Disassembly Operations 28.4.1 Before beginning disassembly, the device’s condition shall be assessed to determine if it can be safely handled. 28.4.2 Disassembly operations shall be planned before actual disassembly. Possible problem areas caused by method of construction or physical condition shall be considered. 28.4.3 Approved operating procedures shall be used for each unique disassembly. 28.4.4 If disassembly would normally cause release of pressure or if a credible hazard exists of pressure causing components to fly apart, before beginning disassembly, pressurized units shall be thoroughly depressurized. 28.4.5 If approved for use, compressed air shall be applied cautiously during disassembly to avoid causing device components to fly apart. Note 1: This may require remote operation. Note 2: Use hydraulic pressure if possible. 28.5 Personnel Protection for Disassembly Operations 28.5.1 Operators and all other personnel shall be provided complete protection from disassembly operations involving conditions known or expected to require the use of abnormal force. 28.5.1.1 Such operations require either remote operation or the use of an operational shield. 90 DOE-STD-1212-2025 28.5.2 When required, shielding shall be designed to protect personnel at other operations or locations from blast and fragments arising from a possible explosion. 28.5.3 When disassembly requires that the operator be protected by an operational shield, disassembly shall be defined as complete separation (threads or other connections) of component parts. 28.5.3.1 Parts shall not be loosened or separated while the operator is unprotected. 29 TESTING 29.1 Test Planning 29.1.1 All explosives testing involving the intentional initiation of explosives materials or articles shall be considered Class 0 operations and shall comply with the requirements of section 12 of this technical standard. 29.1.2 Proposed testing programs shall undergo a hazard analysis based upon the maximum credible event. 29.1.2.1 This shall be done with knowledge of the construction and operation of all standard and nonstandard equipment to be used, as well as the type of explosives involved. 29.1.3 Large-scale tests with the potential to propel fragments off DOE testing locations shall receive a formal risk analysis of the worst-case conditions for each test type. 29.1.3.1 Such analysis shall address the probability and potential severity of hazards with respect to injury and property damage. 29.2 Firing Areas 29.2.1 A secured firing area (danger zone) shall be established for each test to protect personnel from hazardous blast overpressure, firebrands (burning or hot fragment), fragments, or projectiles from an explosives shot or gun firing. 29.2.1.1 The danger zone shall be determined by the application of the principles outlined in DESR 6055.09. 29.2.2 Selected firing areas shall minimize the potential for secondary fires and adverse effects to the environment. 91 DOE-STD-1212-2025 29.3 Checkout of Dynamic Engineering Test Equipment for Explosive Assemblies 29.3.1 To minimize the possibility of an incident during dynamic testing of explosive assemblies, load-bearing members of the test equipment or explosive assembly should be proof-tested and examined if: 29.3.1.1 The test equipment is new or has undergone a design modification;

29.3.1.2 Existing test equipment is to be used under unusually severe test conditions (i.e., conditions of velocity, vibration, pressure, load); or 29.3.1.3 A new or modified explosive assembly is to be tested that affects the loading characteristics of the equipment. 29.3.2 Proof-testing of the explosive assembly or test equipment should be conducted before running tests involving systems with explosives. 29.3.3 At a minimum, proof-testing should consist of the following sequence of checkouts: 29.3.3.1 Check out load-bearing members (lifting devices, hold-down mechanisms, fixtures, vehicle cases) to at least 125% of rated load using simulated loads. 29.3.3.2 “Dry run” tests of actual systems with mock materials in place of explosives and hazardous radioactive materials. 29.3.4 If a part failure occurs in either of the checkout tests in sections 29.3.3.1 or 29.3.3.2, tests involving explosives or radioactive material shall not be run until additional checkout tests have demonstrated that the cause of failure has been eliminated. 29.4 Testing of Explosives and Hazardous Radioactive Materials 29.4.1 Explosives and hazardous radioactive materials (e.g., plutonium, enriched uranium) shall not be included in the same test or operation if the test or operation is not contained and involves any of the following: Note 1: Depleted uranium and natural thorium are not considered hazardous radioactive materials for this purpose. Note 2: Nuclear Explosive Operations, covered by DOE O 452.2 are exempted from this requirement. 92 DOE-STD-1212-2025 29.4.1.1 Application of high-energy stimuli (e.g., high shock, impact, or friction levels) to the explosive. 29.4.1.2 Heating the explosive to within 18°F (10°C) of the heating limit determined for the explosive system without hazardous radioactive materials consistent with section 21.2.4. 29.4.1.3 Intimate contact of incompatible material with the explosive as determined by compatibility testing. 29.5 Heating of Explosives Test Specimens 29.5.1 Before heating an explosive, a thermal analysis shall be conducted and a written procedure prepared consistent with section 21.1. 29.5.2 For requirements on heating equipment see section 21.3. 29.5.3 Contact operations on explosives specimens undergoing thermal conditioning may be permitted if: 29.5.3.1 The specimen is not subjected to excessive friction, impact, or spark stimuli during normal operations or during a credible accident scenario. 29.5.3.2 The explosive involved has satisfied appropriate scale-up sensitivity and stability criteria (see section 19) and has sufficient handling history to reveal any special characteristics affecting safe use. 29.5.4 If an explosives test specimen in a contact operation is discovered to have exceeded the established heating limit for the explosive system, the test shall be terminated and the specimen cooled to ambient temperature. 29.5.4.1 An operating procedure should be prepared and approved for the required corrective action (i.e., disassembly or disposal). 29.6 Instrumentation 29.6.1 Instrumentation directly applied to explosives in a test specimen shall be physically disconnected, isolated, or grounded before personnel may enter the test cell. 29.6.1.1 Only instrumentation channels that contain devices that limit the current below the level capable of initiating the explosive are exempt. 93 DOE-STD-1212-2025

29.6.2 Environmental control transducer leads, not attached to the test specimen and permanently installed in an approved control system, do not need to be grounded or disconnected. 29.7 Explosives Accumulation Limits 29.7.1 Explosives specimens shall not be permitted to accumulate in a test cell beyond the quantity required to sustain the test. 29.7.1.1 For short-term testing (less than one day), specimens present shall not exceed a 4-hr supply. 30 TEST FIRING 30.1 General Range Standards 30.1.1 Each DOE explosives test site shall establish procedures to verify that personnel are not exposed to firebrands (burning or hot fragment), fragments, or excessive blast overpressure from a test shot. 30.1.2 During test operations, personnel access to each test site shall be controlled. 30.1.2.1 Unattended roadblocks, gates, or doors used to prevent personnel from entering the danger zone during a test should be interlocked or locked with specially controlled keys. Note: In locations where interlocks or locks are not practicable, appropriate barriers and signage may be applied. 30.1.3 Before test firing, all firing site personnel and visitors shall be accounted for and in a safe place. 30.1.4 A visual inspection of the danger zone shall be performed immediately before each test shot or series of shots as applicable, to verify that no transients are present. 30.1.5 The danger zone shall be free of service personnel (e.g., telephone repairmen, surveyors, road maintenance crews) during test operations. 30.1.6 The control point shall notify service personnel of the specific requirements under which they may safely work in the area when testing is not in progress. 30.1.7 The control point shall notify firing site personnel of the presence and location of service personnel in their areas. 94 DOE-STD-1212-2025 30.1.8 Clearance for a test or test series shall be coordinated with all test sites and other areas that could be affected. 30.1.9 A warning shall be provided to every affected area to warn personnel of an impending test firing. Note: Detonation of very large explosive shots, numerous smaller shots, or gun firings could exceed the DOE allowable limits for impulse noise. 30.1.9.1 This warning shall include standard audible signals. 30.1.10 During test operations, all personnel assigned to the test area shall be continuously alert for movement of personnel, vehicles, and aircraft. 30.1.11 Test firings often create hazardous conditions for aircraft operating in the airspace near the danger zone. If this airspace is subject to air traffic, precautions shall be taken to verify that the airspace is clear of traffic at the time of firing. 30.1.12 Each firing site shall establish personnel limits based on the number of people actually needed to conduct an operation and the number of casuals that should be present. The responsible person at the firing site shall enforce these personnel limits. 30.1.13 Detonation clouds should be allowed to disperse before personnel leave protective bunkers. Note 1: Testing of explosives can result in personnel exposure to toxic decomposition products such as carbon monoxide, hydrogen chloride, hydrogen fluoride, hydrogen cyanide, and nitrogen oxides. Note 2: Danger zone distances may be adequate to allow cloud dispersal and protect outside personnel from excessive exposure. 30.1.14 For testing that can result in abnormally long hazardous conditions following the test, the procedure shall require a suitable waiting period before personnel leave their shelter or safe haven area.

30.2 Grass Fires 30.2.1 Before conducting a test shot at an outside firing pad, an evaluation shall be made to determine the need to control grass fires that the test may initiate. 95 DOE-STD-1212-2025 30.3 Test Setup 30.3.1 Test setup work should be done before receipt of explosives. When possible, the following activities should be performed: 30.3.1.1 Firing site safety devices (at both the bunker and remote from the firing bunker) shall be checked as established by Contractor Facility Management. Note: Safety devices include warning lights, door and gate firing circuit interlocks, emergency firing circuit cutoff switches, and grounding. 30.3.1.2 Firing pad and shot stand setup work that require power tools or other potential spark-producing devices should be completed. 30.3.1.2.1 Special precautions and procedures shall be developed and implemented if power tools or other spark producing devices are needed after explosives are delivered to the firing pad. 30.3.1.3 The firing pad shall be cleared of all unnecessary equipment. 30.3.1.4 When possible, all diagnostic equipment shall be set up, checked, and tested in a “dry run.” 30.3.1.5 If a special structure is required, as much work as possible should be accomplished on the structure, including assembly of all materials. 30.4 Pin Switches and Other Non-initiating Circuits 30.4.1 Whenever pin switches and other non-initiating circuits are checked (such as for charging current or leakage) and are in contact with or in close proximity to explosives, the check should be performed remotely. 30.4.2 Other non-initiating electrical circuits include strain gauges, pressure transducers, thermocouples, etc., that may be affixed to or close to the explosives within an assembly. 30.4.2.1 A continuity-only (resistance) check may be accomplished as a contact operation with an electrical instrument approved for use with the particular explosive device. 30.4.3 When low-firing-current actuators are involved, consider conducting these tests remotely (see section 37.4). 96 DOE-STD-1212-2025 30.5 Low-Energy Electro-explosive Devices 30.5.1 Procedures shall be established to verify that Radio Frequency (RF), Frequency Modulation (FM), and television transmitters with sufficient output energy to initiate an electro-explosive devices (EED) at the test site are either restricted to a safe distance from the site or not operated. 30.5.2 Appropriate separation distances from Electromagnetic Radiation (EMR) transmitters shall be determined per section 38.1.3. 30.5.3 Low-firing-current igniters or detonators shall be kept separate from explosives at all times, except during actual test charge assembly and setup. 30.5.4 At all times, wiring systems for the explosive charge and any low-firing-current initiators shall be kept insulated from all sources of extraneous current unless the weapon components have an exposed electrical ground by design. 30.5.5 Connections made using weapon wiring connectors or cables are acceptable without further modification. 30.5.6 Shunts shall be left on low-energy initiators or lead wires until connections are made. 30.5.7 Connections shall be taped or otherwise insulated. 30.5.8 Test units containing low-firing-current actuators or detonators shall be clearly marked. 30.5.8.1 No contact operations involving electrical testing shall be permitted on this type of unit unless an electrical meter for the specific application is used. 30.6 Explosives Storage in Firing Areas

30.6.1 Explosives or ammunition storage at a firing area shall be located such that ignition, explosion, or detonation is improbable if a fire, unplanned explosion, or detonation occurs in the area. 30.6.2 Tests that require storage of explosives or ammunition at the firing site beyond a day’s event shall conform to the requirements of section 32. 30.7 Firing Leads 30.7.1 All detonator lead wires shall be electrically insulated. 97 DOE-STD-1212-2025 30.7.2 During setup on the firing point, firing leads or cables of low-energy detonators for explosive assemblies shall be kept shorted. 30.8 Unattended Test Assemblies (during off-shift hours, when necessary) 30.8.1 If explosives are present, appropriate safety warning signs shall be displayed at all entrances to the firing pad. 30.8.2 Protective services and fire department personnel shall be notified of the explosives location. 30.8.3 This location shall be in a controlled-access or secured area. 30.8.4 If low-energy detonators are present on the assembly, their leads or cables shall be shorted. 30.9 Firing Control Circuit Criteria 30.9.1 The criteria in this section apply to electrical circuits used to initiate EEDs used for test firing. Note: These criteria apply regardless of whether the circuit is energized using an internal or external power source. 30.9.1.1 A Firing Circuit shall be treated as capable of firing without warning as soon as it is coupled to an EED. 30.9.1.2 A Firing Circuit that is connected to explosives shall not be armed during contact operations. 30.9.2 Firing Control Circuits shall be documented, reviewed, and approved for safety and operational control purposes. 30.9.2.1 Documentation shall include complete wiring diagrams, electrical schematics, and cable function lists. 30.9.3 All Firing Control Circuits, including changes and modifications, shall be reviewed for safety and compliance with section 30.9, and approved by Contractor Facility Management prior to use with explosives. 30.9.4 Firing Control Circuits not meeting the safety criteria of section 30.9 may be used with explosives only if equivalent safety is provided as determined by a documented analysis reviewed by the Contractor Explosives Safety AHJ, and approved by Contractor Facility Management. 98 DOE-STD-1212-2025 30.9.5 Firing Control Circuits shall include both an arm and a fire control. 30.9.5.1 For low-energy EEDs, the safe mode of the arming circuit shall interrupt the firing circuit, short-circuit the EED terminals, and should ground the EED terminals. Note: Manual shorting and grounding is permitted. 30.9.6 Each Firing Control Circuit shall include an interlock device which prevents unauthorized or inadvertent energization of a firing circuit. 30.9.6.1 The interlock device shall be unique for its application. 30.9.6.2 If key-operated controls are used, they shall be designed to lock in the safe (Off) position when the control key is removed. 30.9.6.3 Duplicate keys, safety plugs, or other interlock devices shall not be permitted in any single test area. 30.9.6.4 During shot preparation, the key, safety plug, or other interlock device, whichever is used, shall be in the control of the lead operator at all times. 30.9.7 Each Firing Control Circuit shall be isolated from all other circuits so as to prevent inadvertent energization by other circuits. 30.9.8 Firing Control Circuits shall be failsafe. Failure of any single component shall not result in inadvertent initiation of the EED prior to arming.

30.9.9 Firing Control Circuits shall be marked clearly or otherwise distinctively identified. 30.9.10 Developmental and/or Self-Contained Firing Circuits designed to initiate EEDs shall meet the requirements of section 30.9 before being used with explosives. 30.10 Test Firing in Containment Apparatus (Tanks, Chambers, or Vessels) 30.10.1 Explosives may be detonated in containment apparatus. 30.10.2 All containment components shall be capable of withstanding and confining the effects of the explosion. 99 DOE-STD-1212-2025 30.10.3 When new firing containment apparatus are designed and put into service, a safety factor to their operational explosives weight limit shall be included during certification testing. 30.10.3.1 This over-test load should be based on a percentage of the operational explosives weight limit. 30.10.3.1.1 For example, a certification test should be performed with an appropriate explosive material weighing at least 125% TNT equivalency of the intended operating limit. 30.10.4 The firing circuit should be interlocked with the containment apparatus access door latch. 30.10.5 Qualified engineering personnel shall periodically inspect the containment apparatus to verify that its structural integrity is maintained after repeated detonations. 30.10.6 Test firing is often conducted inside large containment apparatus that allow personnel entry but provide a confined working space and limited egress. 30.10.6.1 The operating procedure shall include requirements for ventilating and evaluating the containment apparatus’ atmosphere before personnel entry. 30.11 Gun Firings 30.11.1 The gun shall be rigidly mounted so that the impact area is defined and controlled. 30.11.2 The target shall have an adequate backstop. 30.11.3 Provision should be made to remotely move the gun, remotely remove the propellant charge, or remove the explosives from the line of fire if the gun misfires, unless the hazardous effects of an accidental detonation of the explosive target is contained or effectively shielded from personnel. 30.11.4 Provisions shall be made to collect and remove undetonated explosives from the chamber or area. 30.11.5 Work, adjustment, or observation shall not be permitted on a gun while a live round is in the firing chamber. The only exception is to check azimuth and elevation. 100 DOE-STD-1212-2025 30.11.6 Precautions shall be taken to protect personnel or equipment against hazards resulting from errors in assembly or preparation of equipment and ammunition. In particular, the following areas shall be checked: • Fluid level of hydraulic recoil mechanisms. • Function of the firing mechanisms. • Absence of obstructions in the bore. 30.11.7 Firing mechanisms, particularly electric firing mechanisms, shall be tested before use to verify that merely inserting a round or closing of the breech does not result in firing. 30.11.8 Test weapons other than manually-fired small arms should be equipped for remote control of the safety and for remote cocking. 30.11.8.1 The safety shall not be advanced to the fire position and the weapon shall not be cocked until all personnel are in a safe location. 30.11.9 When using hydrogen gas to fire a light gas gun, the operation shall be remote while hydrogen is present in the gun pressure tanks or in the gun barrel and catch tank after firing. 30.11.9.1 The hydrogen shall be purged from the entire system with inert gas and the atmosphere checked before personnel are allowed to reenter the gun bay.

30.12 Drop Testing 30.12.1 After an explosives drop test, personnel shall wait a minimum of 5 minutes before leaving the control bunker to inspect the test pad. 30.12.1.1 If smoke or flame is observed at the drop test area, entry shall not be permitted until at least 30 minutes after all visual signs have disappeared. 30.13. Post-firing Controls 30.13.1 If the firing appears to be normal, test personnel shall remain in the protective shelter for a suitable waiting period. 30.13.1.1 The test procedure shall specify the waiting period, which shall be sufficient to verify adequate dissipation of smoke and dust. Note: In some cases, developing and analyzing the diagnostic film for misfires may be helpful. 101 DOE-STD-1212-2025 30.13.2 During the waiting period, all power to the firing units shall be turned off or disconnected. 30.13.2.1 Whenever possible, detonator cables should be disconnected from the firing units and shunted and grounded, and the firing unit capacitor grounded. 30.13.3 After the waiting period, one qualified person (or more, when required by a documented hazard analysis) shall physically inspect the firing pad to determine the results of the shot before other personnel leave the shelter. 30.13.3.1 When a partial detonation or a test misfire occurs or is suspected, the firing area shall be inspected for unreacted explosives (see section 31). 30.13.3.2 If the inspection confirms that safe conditions exist, the lead person shall signal “all clear.” 30.13.4 Recovered explosives from a destructive test shall be placed in an explosives storage magazine as SCG L unless a documented analysis determines that the explosives do not present a special risk. 30.14 Contamination of Firing Areas 30.14.1 A contamination zone for each firing area shall be established and permanently documented. 30.14.2 Personnel access to explosives-contaminated areas shall be controlled. Note: Unless determined unnecessary, through documented analysis reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 30.14.3 Service personnel shall not work in the area without the permission of testing-area management and only when supervised by a management-approved person. Note: Unless determined unnecessary, through documented analysis reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 102 DOE-STD-1212-2025 31 TEST FAILURES AND MISFIRES 31.1 Explosives Misfire 31.1.1 If no audible detonation is heard after once pulsing the firing circuit, the firing circuitry and detonators may be checked for continuity. These checks shall be accomplished from within the control bunker or from a protected location. If the firing circuits and detonators appear operative, additional attempts to fire may be made. 31.1.2 If the shot still does not fire, the following precautions shall be taken: 31.1.2.1 Disconnect and de-energize all electrical power sources connected to the shot. 31.1.2.2 Verify that all personnel in the danger zone are aware of the misfire and that they shall remain under cover until released. 31.1.2.3 Before personnel are permitted to leave the cover of the bunker, a pre- established waiting period shall be observed. Note: A minimum 30-minute waiting period is advised. 31.1.2.4 A carefully prepared review of the situation should be initiated in consultation with another knowledgeable person.

31.1.2.5 After an agreement has been reached and before other personnel are permitted to leave the cover of the bunker, one qualified person should carefully approach and examine the setup to verify that it is safe. 31.2 Misfire of a Remotely Fired Gun 31.2.1 When a misfire occurs, several more attempts to fire the gun may be made. If subsequent attempts are also unsuccessful, the following precautions should be taken: 31.2.1.1 Disconnect all electrical circuitry to the gun so the firing system cannot be energized. 31.2.1.2 Before approaching a light-gas-driven gun, verify that it is in a safe condition by venting all pressure in the gun breech. 31.2.1.3 To reduce the risk of a gas explosion if the driving gas is flammable, the gun breech shall be purged with inert gas after venting. 103 DOE-STD-1212-2025 31.2.1.4 A minimum waiting period of 10 minutes shall be observed before permitting personnel to approach to the gun. 31.2.1.5 When approaching the gun, if there is any indication that powder is burning, personnel shall return to a safe area and observe an additional waiting period of at least 20 minutes. 31.2.1.6 The gun shall not be approached within the known recoil distance behind the breech or from the front. Approach to and work on the gun shall be from the sides. 31.2.1.7 For separate loading guns (i.e., propellant charge is loaded separate from projectiles), the propellant igniter shall be disconnected from the firing mechanism and removed from the gun before any other gun operations. 31.2.1.8 If possible, the powder chamber of the gun shall be checked for the presence of pressure and vented to the atmosphere before opening the chamber. 31.2.2 If an unforeseen failure situation arises (e.g., the explosive projectile is stuck in the bore), an emergency procedure shall be prepared and followed to resolve the situation. 32 EXPLOSIVES STORAGE 32.1 Storage Magazine Facilities 32.1.1 Permanent Facilities and Portable Magazines 32.1.1.1 New permanent explosives facilities shall comply with UFC 3-340-02, Unified Facilities Criteria. Note: DOE/TIC-11268 may be used as supplemental guidance. 32.1.1.2 Legacy facilities with an approved QD site plan may continue to be used as explosives facilities (see section 11). 32.1.1.3 Portable magazines should be ventilated and resistant to water, fire and theft. They may be made of any material that meets these requirements. Note: Portable facilities that comply with 27 CFR Part 555.203, 27 CFR Part 555.207, 27 CFR Part 555.208, 27 CFR Part 555.209, 27 CFR Part 555.210, or 27 CFR Part 555.211 meet these requirements. 104 DOE-STD-1212-2025 32.1.1.4 Portable magazines shall be sited per DESR 6055.09 as above ground magazines. 32.1.2 Placards shall be posted on or near each magazine door, specifying explosive and personnel limits and general safety precautions that should be observed during work in the magazine. 32.1.3 Vegetation around storage magazines should be controlled to minimize potential damage to the magazine (see section 40.1). 32.1.4 At least two fire extinguishers, minimum rating 2A-10BC should be provided for immediate use by personnel working around a magazine. 32.1.5 Rated telephone or other emergency communication equipment should be provided in magazine storage areas. 32.1.6 All communication equipment located outdoors should be protected from the weather. 32.1.7 Temperature control.

32.1.7.1 In general, storage magazines should not be heated unless heating is necessary to prevent damage caused by sudden temperature changes or when dimensional changes of components are undesirable. 32.1.7.2 Magazines requiring heat should be heated with steam, hot water, or electrically heated hot water. 32.1.7.3 Magazines with temperature control requirements, may require both heating and air conditioning. 32.1.7.4 Electrical systems with forced air through ducts may be allowed if the systems are located exterior to any explosive hazard. 32.1.7.5 Heating coils shall be arranged so that explosives material cannot come into contact with the coils. They shall be equipped with covers designed to prevent storage of materials on top of the coils. 32.1.7.6 Maximum and minimum temperature monitors should be provided in all heated magazines. 32.2 Storage Magazine Operations 32.2.1 Explosives items shall be properly packaged and stored in either DOT-approved manufacturers’ containers/packages or in approved onsite containers (see section 32.5). 105 DOE-STD-1212-2025 32.2.2 Explosives may be stored on magazine shelves. 32.2.2.1 The bottom of the container should not be more than 2m off the floor, except as permitted by section 32.2.3. 32.2.3 Explosives and explosives containers in storage shall be positioned safely and securely. If explosives containers are stacked, they shall be placed in stable arrays. 32.2.4 Load limits shall be established for shelving in magazines. 32.2.4.1 If overloading is possible, the loading conditions shall be posted. 32.2.5 Materials shall not be left suspended by booms, cranes, or hoists in any explosives storage facility. 32.2.6 Stacks of explosives should be arranged so that air freely circulates to all parts of the stack. 32.2.6.1 To prevent moisture accumulation, pallets or appropriate dunnage should be used so containers are not stacked directly on the magazine floor. 32.2.7 Aisles shall be wide enough to accommodate inspection, inventory, sampling, and materials handling operations of the stored explosives containers. 32.2.8 Crews shall not be permitted to work in a position that requires passing the work aisle or the position of a second crew to reach the exit. 32.2.9 Each crew working in a magazine shall have their own exit route that does not interfere with exit routes for other crews (see section 41). 32.2.10 Magazines shall be locked at all times except when permissible operations are in progress or when opened for ventilation. 32.2.11 Personnel shall be present while the magazine is open for ventilation. 32.2.12 All exit doors shall be unlocked and open when personnel are working in the magazine. 32.2.13 Each magazine shall be inventoried at least annually to determine the total weight of explosives present. Note: For the purpose of inventories, “annually” refers to the one-year anniversary of the last inventory or inspection plus or minus 30 days. 106 DOE-STD-1212-2025 32.2.13.1 Materials that are not properly identified or labeled shall be dispositioned. 32.2.14 The liquid level in storage containers for wetted explosives shall be checked and replenished as necessary at least once a year. 32.2.14.1 A log of the checks shall be maintained. 32.2.15 Empty containers, tools, conveyors, lift trucks, skids, etc., should not be stored in a magazine containing explosives. 32.2.16 Combustible materials such as excess dunnage, packing material, and boxes shall not be stored in a magazine containing explosives.

32.2.17 Flammable liquids shall not be stored or used in explosives magazines unless the liquid is an explosive, is needed as an explosives-wetting agent, or is an integral part of an explosives device. 32.2.18 Explosives-handling operations shall not be performed when magazine entranceways are icy or do not provide adequate footing for any other reason. 32.2.19 Operations involving hazardous materials other than those incidental to storage or removal from storage shall not be permitted in any magazine with the following exceptions: Note: The handling involved when removing explosives from storage magazines and transporting them to other facilities for the purpose of inspection, surveillance, adding liquid, limited repair or minor modifications may expose the explosives to a greater risk of accidental initiation than performing these limited activities in the storage magazine. 32.2.19.1 Inspection and surveillance sampling of SCG D materials, and SCG C materials consisting of bulk propellants and IHE, provided that each storage container sampled is in good condition (i.e., the container is not leaking, no evidence exists of explosives contamination at the closure or of seal failure, and the closure is mechanically sound and free of excessive corrosion). 32.2.19.1.1 Only one container of explosives shall be opened at one time in a magazine. 32.2.19.2 Adding liquid to adjust the liquid composition level in which a SCG D explosive is stored (water and alcohol mixtures may be used). If only water is added to the explosive, the water should be distilled or de- 107 DOE-STD-1212-2025 ionized (bacteria present in untreated water may produce gas during storage). 32.2.19.3 Limited repairs and minor modifications of containers and fully assembled end items, (e.g., minor surface repair, cleaning, and stenciling). 32.2.19.4 Other limited operations, supported by a documented risk assessment, that indicate the risk of moving the explosives to another facility is greater than the risk of performing the work in the storage location, reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 32.3 Storage Review Program 32.3.1 Contractor Facility Management shall establish a program to review stored explosive materials. Explosives may degrade during prolonged storage, increasing the hazards of handling or use. Note: An example storage review program is provided in Supplement 32-1, Example Storage Review Program. 32.4 Storage Compatibility 32.4.1 Explosives shall not be stored with materials or items that increase the risk of initiation or decomposition. Note: Examples are mixed storage of explosives with flammable or combustible materials, acids, or corrosives. 32.4.2 Different types of explosives may be stored in the same magazine if they are compatible. 32.4.2.1 Explosives shall be assigned to a SCG when they can be stored together without significantly increasing either the probability of an accident or, for a given quantity of explosive, the magnitude of such an accident. 32.4.3 Each type of explosive shall be assigned to an appropriate SCG (A through G, L, and S) for the purpose of storage at DOE facilities. The groups are defined in the following sections. Note 1: These definitions and Table 32.1 are in accordance with the principles and tables in DESR 6055.09. 108 DOE-STD-1212-2025 Note 2: Table 32.1 presents some examples of commonly used materials that are assigned to each storage compatibility group. This list does not enumerate all materials that may be included in each group. Table 32.1 Storage Compatibility Groups (SCGs) for Explosives and Explosive-Containing Devices SCG A Initiating explosives. • CP (5-Cyanotetrazolpentaamine Cobalt III Perchlorate) • HMX (Cyclotetramethylene tetranitramine) (dry) • PETN (Pentaerythritol tetranitrate) (dry) • Lead azide • RDX (Cyclotrimethylene trinitamine) (dry) • Lead styphnate • TATNB (Triaziodotrinitrobenzene) • Me