SUBCOURSE MM3671

EDITION 5

US Army Ammunition Inspector MOS 55X Skill Level 3 -Course

INSPECTION OF AMMUNITION RAILCARS, MILVANS, AND AIR SHIPMENTS

US ARMY ORDNANCE MISSILE AND MUNITIONS CENTER AND SCHOOL

MM3671 US Army Ammunition Inspector MOS 55X Skill Level 3 Course

INSPECTION OF AMMUNITION RAILCARS, MILVANS, AND AIR SHIPMENTS

*SUBCOURSE MM3671

US Army Ordnance Missile and Munitions Center and School

* This publication supersedes MM3671, Inspect Ammunition Transportation (Part II), Edition 1.

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MM3671 This publication is provided for nonresident instruction only. It reflects the current thought of this school and conforms to published Department of the Army doctrine as closely as possible. Users of this publication are encouraged to recommend changes and submit comments for its improvement. Comments should be keyed to the specific page and line of the text to which the change is recommended. Reasons will be provided for each comment to insure understanding and complete evaluation.

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30 DD Form 1387-2. 25 REVIEW EXERCISES. 30 Air Shipment Report-Identification Section. v Supplementary Requirements. 25 MILVAN Certificate. 36 Air Shipment Report-Inspection Section. 10 LESSON 2: INSPECTING A MILVAN (Task 093-404-3124). 1 Inspecting an Unloaded Railcar. 8 REVIEW EXERCISES. v LESSON 1: INSPECTING A RAILCAR (Task 093-404-3123). 25 Inspecting a Loaded MILVAN. 15 Container Inspection Report. v Credit Hours.MM3671 CONTENTS INTRODUCTION. 30 Hazardous Material Air Shipment Inspection Report. 12 Ammunition MILVAN. 12 Inspecting an Unloaded MILVAN. 38 REVIEW EXERCISES. 46 iii . 13 Container Damage Check List. 1 Inspecting a Loaded Railcar. 28 LESSON 3: INSPECTING MUNITIONS FOR AIR SHIPMENT (Task 093-424-3125).

MM3671 EXERCISE SOLUTIONS. 58 iv .

MM3670. Supplementary Requirements There are no supplementary requirements in material or personnel for this subcourse. you must know how to prepare such paperwork as the Air Shipment Report and DD Form 1387-2. Besides knowing the rejection criteria. and aircraft. covers the inspection of motor vehicles used to haul ammunition. For air shipments. MILVANs. You will need only this book and will work without supervision. The first subcourse. in addition to inspection criteria. Credit Hours Four credit hours will be awarded for the successful completion of this subcourse-a score of at least 75 on the end-of-subcourse examination. It covers the inspection of railroad cars.MM3671 INTRODUCTION This is the second of two subcourses on the inspection by a military ammunition inspector of vehicles used to haul ammunition. you must know how to inspect unloaded and loaded railcars. v . You must also know how to inspect MILVANs and prepare the necessary paperwork. you have to be able to fill out the Railcar Inspection Report and the Car Certificate and know where to look up inspection criteria. As an ammunition inspector.

PLEASE DISREGARD ALL REFERENCES TO THE 75% REQUIREMENT.MM3671 * * * IMPORTANT NOTICE * * * THE PASSING SCORE FOR ALL ACCP MATERIAL IS NOW 70%. vi .

If no certificate is required (Class B or C munitions). The carrier prepares three copies and keeps one. you should be able to describe the acceptance and rejection criteria for railcars used to transport munitions. have it removed before the car is used. you may be responsible for inspecting railcars before and after they are loaded with munitions. Item 3. Objectives. post them. You will have this subcourse book and work without supervision. make a notation to that effect in the Remarks column. If there are no placards on the unloaded railcar. Do not post placards on empty railcars. Item 2. The Car Certificate is required by the Tariff No. it must have a Car Certificate (figure 1-2) attached to each of its doors. Inspect a Railcar. This lesson is based on the following task from soldier's manual STP 9-55X34-SM-TG: 093-404-3123. Check the UNSAT column if it has not been met. you must know what makes a railcar serviceable or unserviceable. commonly known as BOE-6000.MM3671. then apply them again. Task. and to fill out the forms used to verify your inspection. The brakes should lock the wheels in place. You will check this when you make your outside inspection. Standards. release them. Apply the brakes. If the railcar is to carry Class A munitions. If there is too much oil or grease. An example of such a form is shown in figure 1-1. When you have completed this lesson. (Bureau of Explosives) BOE-6000. You must score at least 70 on the end-of-subcourse examination. The inspection is made using a locally produced form called the Railcar Inspection Report to record inspection results. 1 . To do so. The carrier must sign the first part of the certificate. Inspect the hand brake system to be sure it works properly and that there is no excess oil or grease. to select the proper placards and post them. You must also be able to select the right explosives placards. check SAT and print "unloaded railcar" in the Remarks column. Conditions. Lesson 1 Lesson 1 INSPECTING A RAILCAR As an ammunition inspector. This example will be used throughout this lesson. and complete a Car Certificate and a Railcar Inspection Report. Check the SAT column on the Report if this condition has been met. INSPECTING AN UNLOADED RAILCAR An ammunition inspector must inspect the interior and exterior of any railcar that will be used to transport ammunition. Item 1. Refer to it as you make an item-by-item inspection.

Lesson 1 Figure 1-1.MM3671. 2a . Railcar Inspection Report.

Item 5. Check SAT if the wheels are properly chocked. The first item you find that causes you to reject the railcar completes your inspection. Verify that the wheels are chocked to keep the car from moving accidentally. Make sure that the interior of the car is "broom clean. Item 4. Begin the inspection with the railcar's interior. Car Certificate. 2b ." This means that the railcar should look as if it has just been swept clean.Figure 1-2. See figure 1-3. Now you are ready to inspect the rest of the railcar safely.

See figure 1-4. When the interior inspection has been completed. Report unsafe conditions by checking the UNSAT column. They must operate freely and open all the way. such as decay in spots or overall or broken boards must be reported on the Railcar Inspection Report as an unsatisfactory condition and the defect must be corrected or the car must be rejected. If the doors do not operate properly.MM3671. To inspect the doors of the car. Check the SAT or UNSAT entry on the inspection report. Wheels Properly Chocked. or other protruding objects that could damage ammunition containers. Item 7. sides. If these conditions exist. Item 6. they must be covered with wood or fiber to keep the floor plates and explosives packages from touching. Any condition that could start a fire. Decay is recorded as an unsatisfactory condition. Lesson 1 Figure 1-3. If these conditions exist. begin your inspection of the railcar's exterior. it is a safety hazard. it is an unsatisfactory condition. or ends. Loose boards must be repaired before the car can be used. Look for nails or bolt heads. record them by checking the UNSAT column. record them as UNSAT on the Railcar Inspection Report. If satisfactory repairs are made (items are covered or removed) record them in the Remarks section. The doors must be repaired or the car must be rejected. open them. Inspect the roof and the running board. If there is no wood or fiber covering. Inspect the railcar floor for decay. If the railcar has metal floor plates. Another inspection point of the railcar interior is loose boards. 3 . Inspect the car interior for cracks or holes in the roof. Decayed wood will hold sparks that may result in a fire.

Close the doors. Make sure that they are closed tightly. record it under UNSAT on the inspection report. If the brakes will not set. or around the car or cars. If they do. If flags are not present. They should be fully operational so that the car can be secured. that the journal box covers were properly packed. Now inspect for contact between the brake pad and the wheel (figure 1-6). Blue flags must be placed at both ends of a car or a group of cars. They should close tightly. While the doors are closed. Item 10. on. If the springs do not hold the cover closed. it is an unsatisfactory condition. a "cut. check UNSAT on the inspection report. Lesson 1 Figure 1-4. The railcar cannot be used until stripping is installed to make the doors close tightly. inspect them again (figure 1-5). Item 9. under. Item 8. record this condition as UNSAT and reject the railcar. Even though the carrier representative certified. check SAT on the inspection report." The blue flags alert personnel that work is being performed in. See figure 1-7. If they do not close tightly. 4 . Railcar Roof with Running Board. inspect the hasp fastenings. oiled. record this safety violation on the inspection report by checking UNSAT. If the doors cannot be secured.MM3671. by signing the first part of the car certificate. and covered. You inspected the hand brake mechanism earlier.

MM3671. Brake Pad Properly Against the Railcar Wheel. Blue Flag Warning Signal. Lesson 1 Figure 1-5. 5 . Figure 1-6. Figure 1-7. Location of Journal Box.

Evaluate your inspection results (figure 1-9). Lesson 1 Item 11. If the condition is corrected on the spot. This item concerns loaded railcars only. In figure 1-8. If all unsatisfactory conditions have been corrected. 6 . Item 12. check UNSAT and note why in Remarks. note that in the Remarks section. Item 14. If you pass the railcar. Comments. Scrap Lumber Making It Unsafe to Work in and Around Railcars. This item concerns loaded railcars only. Your signature as ammunition inspector on the form will allow the car to be used or will reject it. check SAT. Decide from the entries you made on the inspection report. including the remarks and comments. Enter the date that you completed your inspection. scrap lumber and used strapping is scattered in the area. This item on the inspection report reminds you to note unsafe conditions that are not listed on the report form. this condition is entered and checked UNSAT in Item 13. for example. Figure 1-8. "All unsatisfactory items have been corrected.MM3671. Item 13. whether or not the car meets the standards for loading munitions." Date and Signature. the car may be released for loading. If not. Enter explanations such as.

7 . Lesson 1 Figure 1-9.MM3671. Evaluation of Inspection.

Make sure the wheels are properly chocked (see unloaded railcar inspection). DARCOM Drawing 4115 5PA 1002 is used as a guide for blocking and bracing in boxcars of boxed ammunition and ammunition on pallets. Using DARCOM Drawing 4115 5PA 1002 as a reference (figure 1-10). Item 11. Make sure that the proper placards were posted while the railcar was being loaded. notify the storage officer or NCO of this condition to have the loading deficiency corrected. You need explosives placards for Classes A and B munitions and placards for Class C. Improper blocking and bracing may allow the load to shift (figure 1-11). Figure 1-10. Item 1. A shifting load may result in an explosion. Item 10. Make sure the brakes are properly set (see unloaded railcar inspection).MM3671. inspect for proper blocking and bracing of the load. unitized with strapping. The placards should be on both ends and both sides of each railcar. Lesson 1 INSPECTING A LOADED RAILCAR An ammunition inspector must inspect any railcar that is loaded with ammunition and ready to be moved. Item 9. Item 2. Items 3 through 8. A Load Improperly Braced. The Railcar Inspection Report can also be used for the inspection of a loaded railcar (see figure 1-1). 8 . If the load is not properly blocked or braced. Make sure the car certificates are still on the doors (see unloaded railcar inspection). DARCOM Drawing 4115 5PA 1002 Figure 1-11. These items are for unloaded railcars.

If Class A munitions are loaded. This item concerns an unloaded railcar. Figure 1-13. Before sealing the car. use BOE-6000. Place the bill of lading and other documents pertaining to the munitions shipment inside a manila envelope. The railway employee will then sign Certification No. Comments.) Item 13. since there is no X at the point where the columns intersect. Attach the envelope with tape or staples to the inside of one of the railcar's doors. It is your responsibility when working with the BOE-6000 on the job to make sure you have the latest edition. An X at an intersection of horizontal and vertical columns shows articles that must not be loaded or stored together. You would be able to mark SAT. record the serial numbers of the seals on the Government bill of lading. This item concerns an unloaded railcar. Look these two items up on the extract. a railway employee must inspect the load blocking and bracing. If you compare the extracts in this subcourse with the latest edition of BOE-6000. Often both sign. Date and Signature Lines. (Note: BOE-6000 is always subject to change. Record the number on the Government bill of lading or shipping document. This item concerns an unloaded railcar. Lesson 1 Item 12.848 (see the extract in figure 112). date it and sign here. Certification No. Notify the chief inspector that the car can be released to the carrier for shipment. To check the compatibility of the load.MM3671. When you have finished your inspection. Item 14. Before the railcar can be closed and sealed. serial-numbered band around the handle of each door (figure 1-13). Suppose for example. you may find differences. Detonators (horizontal column d) and small arms ammunition (horizontal column 4) are compatible. If the load you are inspecting is not compatible. The ammunition inspector signs for the shipper. your cargo is small arms ammunition and detonators. 9a . make sure that required placards have been posted. paragraph 177. and see that the doors close tightly. Sealed Railcar Door Showing Closeup of Serial Numbered Seal. 2 on the Car Certificate (see figure 1-2) for the carrier. mark the item UNSAT and notify the control section. 3 of the Car Certificate will be signed by the shipper (or you acting for the shipper) or railway employee who supervised the loading and security. Seal the railcar by fastening a US Government.

Table 12-3 Loading and Storage Chart of Hazardous Materials for Land Transportation. 9b . Extract from BOE-6000. Lesson 1 Figure 1-12.MM3671.

(Cont) 9c . Extract from BOE-6000. Table 12-3 Loading and Storage Chart of Hazardous Materials for Land Transportation. Lesson 1 Figure 1-12.MM3671.

C. D. The metal plates are not warped. 10 . As it is loaded. The shipper. 1. c. A flashing red light. 4. A railway employee. A flashing green light.MM3671. After it is loaded. When are placards posted on a railcar that will be carrying hazardous material? a. b. d. 2. Lesson 1 REVIEW EXERCISES Circle the letter of the correct answer to each question. d. b. The ammunition inspector. d. Blue flags. Who signs Car Certification No. The receiver. c. B. c. Under what condition is a metal floor in a railcar acceptable? a." b. c. Red flags. 3. b. 5. b. 2 when the inspection has been completed on the loaded railcar? a. A. The car is "broom clean. c. What warning signal is put out when people are working around a railcar loaded with Class A munitions? a. d. There is no rust on the metal plates. Before it is loaded. A Car Certificate is required when what class of hazardous materials is being shipped? a. The metal floor is covered with wood or fiber.

b. c. Where is the Segregation and Separation Chart of Hazardous Material located? a. 2 and 3. What reference is used during inspection for proper blocking and bracing? a. d. you should retake the entire lesson. Recheck your answers to the Review Exercises. BOE-6000. b. check your answers against the Exercise Solutions. DA Pam 310-3. Proceed to have the car loaded and sign Certifications No. 1. d. 1 has not been signed. The Car Certificate must be signed and posted before Class A munitions can be loaded. When you are satisfied that you have answered every question to the best of your ability. c. Lesson 1 6. MIL-HDBK 138 (AR). 7. DARCOM Drawing 4115 5PA 1002. What should you do? a. c. d. BOE-6000. On the Car Certificate on the railcar received from the carrier. Reject the car.MM3671. Remove the Car Certificate and okay the use of the car for the next Class B shipment. TM 358-1. paying particular attention to the areas in which your answers were incorrect. If you missed three or more questions. Sign Certification No. MIL-HDBK 138 (AR). You are inspecting an unloaded railcar that will be used to carry Class A munitions. Certification No. 11 . b. DA Pam 310-3. 8.

After your inspection. AMMUNITION MILVAN The MILVAN used for carrying ammunition (figure 2-1) is a fabricated steel container with a mechanical loadbracing system that can be adjusted to meet most load requirements. Inspect a MILVAN. The MILVAN is the Army's primary ammunition container for both intra-theater and inter-theater distribution of ammunition. Lesson 2 Lesson 2 INSPECTING A MILVAN It may be one of your duties as an ammunition inspector to inspect MILVANs (military-owned demountable container). Conditions. you should be able to list the step-by-step procedures for inspecting a MILVAN. Container Inspection Report. A Military-Owned Demountable Container (MILVAN). This lesson contains the correct procedures for inspecting loaded and unloaded ammunition MILVANs. Task. You will have this subcourse book and work without supervision. Objectives.MM3671. you must accept the MILVAN for use as an ammunition shipping container or reject it. (Only MILVANs with load-bracing systems may be used to transport ammunition. Standard.) Figure 2-1. including proper placarding and Container Damage Check List. You must score at least 70 on the end-of-subcourse examination. When you have completed this lesson. and MILVAN Certificate completion. 12 . This lesson is based on the following task from soldier's manual STP 9-55X34-SM-TG: 09-404-3124.

MM3671. Figure 2-2. Container Damage Checklist. MIL-HDBK 138 (AR) contains two good forms. for example-unless local SOP designates a particular form. 13 . see figures 2-2 and 2-3. Lesson 2 INSPECTING AN UNLOADED MILVAN Any suitable form may be used to record the results of the inspection of a MILVAN-DA Form 2404 (Equipment Inspection and Maintenance Worksheet).

14 . Lesson 2 Figure 2-3. Container Inspection Report.MM3671.

MIL-HDBK 138 (AR) also contains detailed inspection criteria useful when actually inspecting a MILVAN (see extract at the end of the subcourse). One splice. Container Damage Check List Item 1-Rear (Exterior). A splice in a door sill is cause for rejection. Check the inner side of the doors for any damage that would interfere with their serviceability. 1. enter this information on your report form and continue the inspection. Lesson 2 These are the forms used in this lesson. Begin your inspection by checking the rear and the exterior of the doors of the MILVAN for any distortion. but not more than one splice. If the needed repair is postponed or will take considerable time to complete. reject the MILVAN and stop the inspection immediately.1 and 1. Enter the defect on the Container Inspection Report (figure 2-3) and notify maintenance personnel in accordance with local procedure. You will also need a MILVAN Certificate to complete after you pass a MILVAN (figure 2-4). holes. Door headers (above doors) and sills (below doors) must be inspected for any damage that would prevent proper door action or would weaken the structural strength of the MILVAN (figure 2-6). Figure 2-4.2. MILVAN Certificate. 15 . If the needed repair is made immediately. in a door header is acceptable. To continue would waste time. file your report with the surveillance section. Any damage or improper repair that results in failure of the doors to make the MILVAN watertight-or any other defect that threatens the safety and serviceability of the MILVAN-is a cause for rejection. or tears (figure 2-5). When you find a defect that renders the MILVAN unacceptable.MM3671.

1. Lesson 2 Figure 2-5. 1. 1.1. All repairs. Antirack hardware (keeps doors and panels aligned) should be properly attached to prevent doors from springing and getting out of alignment. 1. 1. If it is loose. All information must be accurate. Markings must be legible.17 . Make sure that the document holder is not loose (figure 2-7).14.4 . 1.8.13 and 1. Minor damage is acceptable (figure 2-6). attachments.20. and caulking are properly done.1. Where To Inspect for Door Headers and Sills. Have the necessary repair made. 1. 16 .1. There must be no major damage to the rain gutter.12. Corner posts and fittings and door panels must be structurally sound. if present. The handles and the handle retainers must not be distorted or be missing components that would interfere with their function. 1. Figure 2-6. The hinges must not be damaged or broken. and continue with the inspection. this would not be sufficient cause for rejection of the MILVAN.7. and there must be a readable data plate. and the doors must open and close freely (figure 2-9). including panel posts.3.16. Door seals must be intact to insure that the load is properly protected (figure 2-8).MM3671. Examples of Damage Bad Enough To Reject the MILVAN.15.9 . The locking bars must be in good condition.

17 . and Retainers. Figure 2-8. Locking Bar Retainers. Lesson 2 Figure 2-7. Figure 2-9. Where To Inspect for Hinges.MM3671. and Data Plate. Where To Inspect for the Document Holder. Handles. Where To Inspect for Door Seals.

Any condition that endangers the cargo. and 2. 2. 2. too. 2. Check the floor fasteners for any that are corroded. Example of Unacceptable Warping of MILVAN Floor. warping. Having made sure that the doors are thoroughly serviceable. Check all visible portions of the corner fittings and top rails for damage and distortion (figure 2-11).1. Inspect for any breaks or holes in the floor. as this.6. 18 .MM3671. turn your attention to the floor of the MILVAN. or rotting of the floor boards (figure 2-10).2. This would permit shifting of even well-braced cargo. Where To Inspect for Corner Fittings and Top Rails.3.7. Inspect for any splintering. you are ready to inspect the interior of the MILVAN. Inspect the mounting brackets for breaks and distortion. sheared. missing. This is an example of the sort of defect that can be reported to maintenance personnel for on-the-spot correction. Figure 2-10. Figure 2-11. The floor must be free of any debris. could damage the cargo. and 2. or loose. Lesson 2 Item 2-Interior. the equipment. Examine the floor of the MILVAN for any curvature. or personnel is sufficient cause for rejection. Floor stains and separation of joints also constitute a hazard to the shipment. 2.5. Now.

cracked.4. Inspect the roof bows for any that are torn loose from the top side rails. Roof bows that are damaged.MM3671. in depth. Check them for cuts and breaks. regardless of length. 19 . A poor. Closely inspect any frame members that are load bearers. breaks. Check them for distortion. Check for cracked or missing welds. 2. Figure 2-12. inspect the interior sides and front wall for any damage. If you find that the floor of the MILVAN is acceptable. holes. They should be properly made and intact. and separation. is a cause for rejection. Lesson 2 2.8. Small dents are acceptable. regardless of length. Any dent in any support member that exceeds 3/4 in. Inspect the interior of the roof panels for holes or severe dents. missing. both horizontal and vertical (figure 2-12). is cause for rejection. Any hole in the side or front wall is cause for rejection. Inspect all previous repairs and welds. or bowed are sufficient cause for rejecting the MILVAN. or missing weld will seriously weaken the structural strength of the MILVAN. Where To Inspect for Load Bearers. or punctures. deep. Dents in panels that do not affect support of corrugated ribs are acceptable. Any distortion of corner posts and any dent in top rails that exceeds 3/4 in. breaks. if the panels are not punctured and if the vertical support is not weakened.

Vertical slotted rails must be welded to the sides of the end frame (figure 2-14).10. Figure 2-13. Any of these defects is cause for rejection. and 25 independent load bracing crossbeams that interlock into the side rail slots. 20 . Defective crossbeams must be repaired or replaced before the MILVAN can be accepted. Figure 2-14. or bowed (figure 2-16). open the doors so that you can continue your inspection of the interior. 2. Vertical Slotted Rail. If light penetrates. here in position to illustrate their use.MM3671. Check the rails for distortion and for possible looseness. crushed. Close the doors from the inside and check for the penetration of light from outside. If it is a hole or a crack. it indicates that the MILVAN is unserviceable. Check for faulty or cracked welds. look for the source of entry. They are shown in figure 2-13. Lesson 2 2. Horizontal and vertical rails must not be damaged to the point that their slots would prevent the crossbeams from locking in the slots (figure 2-15). The cargo restraint system consists of eight horizontal slotted rails. This arrangement permits adjustment of the bracing to fit the loading requirements. Now. Inspect the load bracing crossbeams to make sure that the locking mechanism is operable and that the beams are not bent. Crossbeams in Place. intermittently spaced and welded on each side wall.9.

Bowed and Bent Crossbeams. 21 . Lesson 2 Figure 2-15. Where To Inspect for Slots.MM3671. Figure 2-16.

Curb Side (Exterior) Showing Inspection Points and Showing Unacceptable Damage to the Side. Item 6-Roof. and panels for any damage or distortion (figure 2-18). Climb on the roof and inspect it for holes and damage. or any condition that would make the MILVAN unserviceable. damage. you are determining the safety and the strength of the MILVAN with this inspection. Item 3-Curb Side (Exterior). The roof must be firm and watertight. go back outside and inspect the remainder of the exterior. Be sure to inspect every part of the interior for weakness. Lesson 2 Remember. corner fittings. such as an insecure weld or other improperly sealed patch. Remember that the corner fittings provide the means of handling. stacking. checking in particular the top and bottom rails. If you find no reason to reject the MILVAN from your inspection of the interior. and for any depression that would allow water to gather (figure 2-19). Check it for any unacceptable repair. Figure 2-17.MM3671. Items 4 and 5-Front and Road Side (Exterior). 22 . Pay particular attention to both the bottom and top rails and the corner fittings as you proceed. and securing the MILVAN. Inspect the curb side of the MILVAN for damage or distortion that would weaken the container or threaten its cargo (figure 2-17). Examine the road side of the MILVAN and the front.

MM3671. 23 . Lesson 2 Figure 2-18. Typical Not Acceptable MILVAN Roofs. Figure 2-19. Important Inspection Points for the Front and Road Side of the MILVAN.

MM3671, Lesson 2 Inspect the openings in the four top corner fittings to make sure they are undamaged and unobstructed. Item 7-Understructure (Exterior). Have the MILVAN raised and safely supported so you can inspect the bottom of the container (figure 2-20). Carefully check for any cracked or broken weld, or any weld that has been improperly made. Examine each frame member on the underside of the MILVAN for fractures, cracks, kinks, distortions, and separations. Remember, throughout the inspection, check for bad welds, and for broken, damaged, or improperly used bolts, rivets, and fasteners. Check the openings in the four bottom corner fittings for obstruction and damage. Remember to inspect for rust or corrosion that can weaken the floor assembly or its supporting structure. Carefully check the underside of the floor for any possible damage that was not visible from inside the container. Sum up the information from the check list on the Container Inspection Report.

Figure 2-20. MILVAN Suspended Making Inspection of Its Underside Possible. 24

MM3671, Lesson 2 Container Inspection Report Name of Lesson and Address. Enter the name and address of lesson. Container Number. Get this number off the upper right back door. In figure 2-1, it is USAA 0100574. Inspection Date and Hour. Enter the date and time of the inspection. Container Destination. Enter to where the container is being sent. Type. Enter the type of container. Munitions containers must be steel. Installation or Activity. Enter your installation or activity. Reports Control Symbol. Leave this blank; the Army does not use it. Conditions of Container Major Structures. For each entry under the Major Structures column, refer back to the check list you completed as you inspected the MILVAN. Use your judgment as to whether each entry under the Condition column is SAT. or UNSAT. Use the Remarks column for entries such as reporting repairs made changing UNSAT. to SAT. In the Conclusion section check off if the container has been accepted, conditionally accepted, or, rejected. You, the inspector, sign the lower left block. (Make sure the lower right block (lesson representative signature and title) is filled in.) MILVAN Certificate If your inspection of the MILVAN shows that it is serviceable, fill out the MILVAN Certificate (figure 2-4) and sign it. This certificate will indicate that the MILVAN is ready for loading. INSPECTING A LOADED MILVAN There is no official form to use when inspecting a loaded MILVAN. There may be local forms, however; or you may want to make up your own check list. Your first step is to verify that the items loaded are those listed on the shipping document, DD Form 1348-1 (DOD Single Line Item Release/Receipt Document). If the items are incorrect, notify the shipping section of the ASP of the error. Do not continue with the inspection until the proper items are loaded. If more than one type of ammunition is included in the load, check the compatibility by mode of transportation (water, air, rail, or motor). Use the tables for this compatibility check in BOE-6000 for water, rail, and motor shipments (see lesson 1), and TM 38-250 for air shipments. Inspect the load to insure that it is properly braced to prevent shifting, and check the distribution of the items in the MILVAN to insure load equalization. If the load is improperly braced or distributed in the MILVAN notify the shipping section of the ASP and have the loading defect corrected (figure 2-21). There is no standard for this, so you have to use your own judgment.

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MM3671, Lesson 2

Figure 2-21. MILVAN Load, Properly Braced.

After insuring the load has been properly braced and distributed (IAW DA Pam 75-5, not necessary for this subcourse) (figure 2-22) seal the doors. Use the same kind of band you use on a railcar. The MILVAN has two locks, and it requires two seals (figure 2-23).

Figure 2-22. MILVAN Load Distribution.

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File your inspection check list and report in the surveillance section. Lesson 2 Figure 2-23. The placarding of the MILVAN must be checked for correctness. put the number of the MILVAN and your signature on the MILVAN Certificate (figure 2-4). When you are satisfied that the load is authorized. properly secured. and placarded. according to the requirements of BOE-6000.MM3671. releasing the loaded MILVAN for shipment. Placards must be properly affixed to both sides and to the front and rear of the container while being loaded. Locking and Sealing Doors. 27 . Notify the shipping section of the ASP for correction if placarding is incorrect.

28 . b. c. 2. Light penetration. What part of an unloaded MILVAN is inspected first during an inspection? a. The roof. Holes on the sides. The braces. The coupling device. BOE-6000. c. What is being checked when the inspector gets in the MILVAN container and closes the doors? a. 4. Distorted top rail. d. A conditional acceptance is issued. What of the following defects is acceptable for a MILVAN container's interior sides and front wall? a. 5. A warning is issued. d. The ventilating system. c. The interior. b. 3. What reference contains MILVAN container rejection criteria? a. The level of light. b. Lesson 2 REVIEW EXERCISES Circle the letter of the correct answer to each question. MIL-HDBK 138 (AR). d. b. b. TM 385-1. d. The exterior doors. The inspector comes back and inspects only that one defect. The container is rejected. 1.MM3671. What is done if a MILVAN container defect is not corrected on the spot during an inspection? a. DA Pam 310-3. d. Cracked welds. c. Small dents. c.

Recheck your answers to the Review Exercises. c. What side of a MILVAN is inspected first after the interior has been inspected? a. The front. b. If you missed three or more questions. check your answers against the Exercise Solutions. b. Check the compatibility tables. you should retake the entire lesson. What is the first thing an inspector must do when inspecting a loaded MILVAN container? a. The rear. Where is a loaded MILVAN container placarded? a. c. d. Front and rear only. The road side. front. The curb side. 29 . 7. Rear only. Lesson 2 6.MM3671. Reconcile the load and DD Form 1348-1. When you are satisfied that you have answered every question to the best of your ability. b. Sides. 8. c. Placard the container. and rear. Sides only. d. paying particular attention to the areas in which your answers were incorrect. d. Determine how the container is to be shipped.

Lesson 3 Lesson 3 INSPECTING MUNITIONS FOR AIR SHIPMENTS One of the responsibilities of an ammunition inspector is to inspect munitions for air shipment. Standard. Item Nomenclature Block. You will have this subcourse book and work without supervision. is a locally produced form that must be completed by an ammunition inspector when munitions are to be shipped by air. It is your responsibility as the ammunition inspector to make certain that DD Form 1387-2 is correctly filled out. will be used throughout this lesson. Make sure there are five entries for the shipment. Hazard Class: Class A Explosive. When you have completed this lesson. Proper shipping name: Detonators. an example of a locally produced form. from the shipper. Class A Explosive. This lesson is based on the following task from soldier's manual STP 9-55X34-SM-TG: 093-424-3125. You must score at least 70 on the end-of-subcourse examination. You may be required to inspect pallets of ammunition at an ammunition supply point before they are transported to a military air base. Objectives. 30 . 2. Task. already filled out. commonly called the air shipment report. you should be able to describe what must be done to inspect ammunition prepared for air shipment. to approve or disapprove the shipment. The identification information needed to complete an air shipment report is taken from DD Form 1387-2 (Special Handling Data/Certification) (figure 3-2) and DD Form 1348-1 (figure 3-3). Inspect Munitions for Air Shipment. Conditions. DD Form 1387-2 Refer to figure 3-2 as you go through the form item by item. and to complete the Hazardous Material Air Shipment Inspection Report and the necessary tags and labels (DD Form 1387 and DD Form 1387-1). You receive DD Form 1348-1 from the ammunition accountable officer on your installation. The areas inspected are critical to the safe transport of ammunition by air. HAZARDOUS MATERIAL AIR REPORT SHIPMENT INSPECTION The Hazardous Material Air Shipment Inspection Report. You receive the original and six copies of DD Form 1387-2.MM3671. 1. as advance notice of the shipment. The form shown in figure 3-1.

31 . DOT label required: Explosive A. Lesson 3 Figure 3-1. DOD hazard class/division: 1. 4.MM3671. Shipment authorized via: Cargo Aircraft Only. Hazardous Material Air Shipment Inspection Report.1. 3. 5.

32a .MM3671. DD Form 1387-2 (Special Handling Data/Certification). Figure 3-3. DOD Form 1348-1 (DOD Single Line Item Release/Receipt Document). Lesson 3 Figure 3-2.

marked Hazard Class (figure 3-5).000 blasting caps is being shipped. the entry will be "Label None. is "1.1. Class A Explosives. you can find the proper shipping name. and cargo aircraft only symbol (+) to the left of the first column when it applies. It has an alphabetical listing of items in which you will find four of the required entries. Extract of Table 4-1. TM 38-250. marked Labels Required is blank or specifies none. a pallet of 180.MM3671." Note that the table in figure 3-4 states "See Detonators. Find "Blasting caps with metal clad mild detonating fuze. TM 38-250. figure 3-5. Look down the alphabetical listing in the first column in figure 3-4. Class A Explosives. as each package contains over 1. TM 38-250. The entry is "Explosive A. Summary of Quantity Distance Classification and Compatibility Groups. This is found in the fourth column of Table 4-1 in TM 38-250. The first entry in the Item Nomenclature block on DD Form 1387-2 is "Detonators. It is placed to the right of the hazard classification. the hazard class." See figure 3-6. 32b ." Continue looking down the alphabetical listing and find "Detonators. the Department of Transportation (DOT) classification is Class A Explosive. Table 5-21." The second entry is the hazard classification." See figure 3-5." See figure 3-5. In this lesson." Figure 3-4. use table 4-1. Lesson 3 To get the correct information for item nomenclature. Blasting Cap Entry. The entry is "Class A Explosive." The third entry is the DOD Hazard Class/Division. If the fourth column in figure 3-5. This is extracted from TM 9-1300-206. the label or labels required.000 blasting caps. The fourth entry is the label to be placed on the container or pallet shipped. Class A or Class C Explosives. in this case. The entry. In figure 3-4. You can find it in the second column of Table 4-1. For this shipment.

TM 38-250.MM3671. Lesson 3 Figure 3-5. 33 . Extract of Table 5-21. Extract of Table 4-1. TM 9-1300-206. Detonator Entry. Figure 3-6.

This block gives the total NEW (net explosive weight) in pounds per package or pallet. 34 . the entry would be "2. The information you need to check the entries for this shipment are found in Ammo Part VII-PackagingFiche 003 of the catalog. For this shipment. the entry will show only the NEW for one pallet or package. the entry will show only the NEW for the one pallet in pounds and the gross weight of the pallet. use the DOD Consolidated Ammunition Catalog.4 NEW.646 LBS 964.8 NEW. Cargo Aircraft Only Symbol. This indicates that passengers are not permitted. so you need a microfiche reader to use it. Lesson -3 The fifth and last item is to the right of the label requirement entry and is determined by the + immediately to the left of the column. An extract of this is shown in figure 3-8. This block gives the total gross weight of the pallet and total NEW of the pallet in pounds. Consignment Gross Weight Block." To see whether the explosive weights and consignment gross weight are correct. Extract of Table 4-1.323 LBS 482.MM3671. The entry for the one pallet is "1. Proper Shipping Name (figure 3-7)." If the shipment consisted of two pallets." Figure 3-7. and the entry "Cargo Aircraft Only" is placed in the label requirement entry. This catalog is in microfiche form. TM 38-250. the entry for the one pallet is "482.4 NEW. Net Quantity Per Package Block. No matter how many packages or pallets are in the shipment. For this shipment.

Ammo Part VII. 35a . Packaging. Extract of Fiche 003. Lesson 3 Figure 3-8.MM3671.

Packaging. (Cont. Extract of Fiche 003.MM3671.) 35b . Ammo Part VII. Lesson 3 Figure 3-8.

Also enter the NSN from the Stock for Part Number block of DD 1348-1 and to it add the Department of Transportation Identification Code (DODIC) from block W of the same form. and you do not need to double check it. Enter the gross weight in pounds from the Consignment Gross Weight block on DD Form 1387-2. Not used. This is found in the last column of table 4-1 to the right of Detonators. 36 . Enter the date you perform the inspection. Enter the name of the shipper from the block Address of Shipper on DD Form 1387-2. you do not need to double check it. Certification. Address of Shipper. From DD Form 1348-1. Signature. This block should be checked and the words Passenger Aircraft should be lined out. Check this block and enter the paragraph 5-15 as shown in Table 4-1 and the subparagraph of TM 38-250 that deals with the items being shipped. Enter the item nomenclature (Block X) from DD Form 1387-1. DOT Shipping Name. NEW Per PKG. Flash Point. Destination. the entry is 4. Installation. It was assigned by the form's originator. enter the Freight Classification Nomenclature (block U). See figure 3-5. a. (4). Paragraph 5-14. Load Storage (L/S) Group. Transportation Control Number (TCN). Enter the NEW from the Consignment Gross Weight block on DD Form 1387-2. The entry should be N/A as ammunition does not require this. You do not need to double check this except to be sure the form has been signed.MM3671. Typed Name. Enter the 17-digit Transportation Control Number from DD Form 1387-2. Date. (b) describes the packaging and marking for Class A explosive detonators. and Date. Destination. Enter the Destination from DD Form 1387-2. Air Shipment Report-Identification Section Refer to figures 3-2 and 3-3 as you go through the identification section of the report in figure 3-9 item by item. Item Nomenclature. This block was filled in by the form's originator. Lesson 3 Transportation Control No. NEW Per PLT. You do not need to double check this. The rest of the certification block is not filled in. You saw earlier in the lesson that this shipment was for cargo aircraft only. Class A Explosives. In this case. Gross Weight. You do not need to double check this.

Lesson 3 Figure 3-9. Hazardous Material Label(s). 37 . Enter the hazard class listed in the second line of the Item Nomenclature block on DD Form 13872. Approved Report Showing Defect Corrected.MM3671. Hazard Class. Enter the label(s) necessary from line three of the Item Nomenclature block on DD Form 1387-2.

38 . turn to page 2 of this appendix. Even a small amount of leakage is serious. You will note that this size pallet calls for 50 boxes containing 3. On it is the information you need to determine if the containers of blasting caps have been palletized correctly (see the extract in figure 3-12). containers in good condition. Figure 3-10. you would need TM 38-250.000 blasting caps. You can find this information in TM 38-250. Next. Extract from page 5-10. Appendix 121A (see the extract in figure 3-11). Preparation of Hazardous Materiels for Military Air Shipment. and authorized containers and packaging. begin the inspection itself. Item 1. Inspect the containers on each pallet to make certain they are authorized for the type of ammunition packed inside them.600 blasting caps per box. You will have automatically disapproved the shipment when you note an UNSAT finding. Refer to figure 3-9 as you go through the report item by item. Lesson 3 Air Shipment Report-Inspection Section After you have filled in the identification section of the air shipment report. You will find this information in Drawing 19-48-4116-20PA1002. Inspect each pallet to determine if it is the correct size for the quantity of items on the pallet. check the condition of the packaging as SAT on the air shipment report. If you find any packaging defects during your inspection. Inspect the containers on each pallet visually for leaking contents. but it is not needed for this subcourse. If you are satisfied with this part of your inspection and you have found correctly packed pallets. TM 38-250. Inspect wooden containers for such damage as broken or rotted wood. Item 2.MM3671. Report any defect to the control section so the defect can be corrected. no signs of leakage. Be extra careful when you inspect for explosive powder leakage. In an actual inspection. The total per pallet is 180. The authorized packaging for blasting caps is shown in the extract in figure 3-10. check the condition of the packaging as UNSAT and explain the defect in the Remarks column.

If not. and placement of strapping. placement of containers. check SAT. Appendix 121A. size of strapping. Extract: Page 1. Now inspect the pallet for damage. Lesson 3 Figure 3-11. Broken banding strips are also causes for rejection. The Bill of Material shows the total quantity of materials by size required to palletize one pallet. check UNSAT and explain in Remarks. 39 . Drawing 19-48-4116-20PA 1002. Broken skids and rotted skids are causes for rejection.MM3671. Follow the General Notes and Pallet Unit for determining pallet size. If everything passes.

Lesson 3 Figure 3-12.MM3671. 40 . Extract: Page 2. Drawing 19-48-4116-20PA 1002. Appendix 121A.

Be certain that the correct items are being shipped. It contains the 17-digit Transportation Control Number. The address label is DD Form 1387 (Military Shipment Label).MM3671. check SAT on the report. When your inspection shows that the markings are correct. DD Form 1387 (Military Shipment Label). Check the address label or address tag (figure 3-13). These markings are found on the top of the box. No label applied to the pallets can be put over any required identification on the containers. Item 4. Figure 3-13. 41 . Lesson 3 Item 3. Check the Department of Transportation (DOT) markings for the proper shipping name. the From and To airports. If you find that the markings are not correct. and other shipping information. The markings on the boxes that identify the item should agree with the shipping document pertaining to the shipment. check UNSAT and explain the defect in the Remarks column.

There are three types of explosives labels: Explosive A (Standard Form 400). four inches long on each side. If it is not correct. Make certain that the label is the correct one for the ammunition being shipped. check UNSAT and state your reason in the Remarks column. BOE6000). If you find that the explosive labeling is correct. Each pallet must have an explosives label on the same side as the consignee's name and address (figure 3-16). It is used when a label might crowd out the DOT markings or hazardous label you have just inspected. it should be applied to the lower two-thirds of the container (figure 3-15). Figure 3-14. If the explosive labels are NOT correct. TM 38-250. Item 5. DOD Form 1387-1 (Military Shipment Tag). If it is. See figure 3-17. Inspect to make sure that it is correctly applied with waterproof adhesive. All are orange. Find the correct label in Table 4-1. check SAT on the air shipment report. Inspect the air shipment for correct explosives labels. check UNSAT and explain the defect in the Remarks column. Make sure "Cargo Aircraft Only" label is also on the pallet (see page 169. Explosive B (Standard Form 401). Lesson 3 DD Form 1387-1 (Military Shipment Tag) is an address tag (figure 3-14). check this item as SAT on your air shipment report. 42 .MM3671. diamond-shaped labels. Make sure the address label or tag is correctly filled out and complete. and Explosive C (Standard Form 402). When the address label is used. See figure 3-18.

Proper Placement of Explosives Labels. Proper Placement of the Shipping Label. Figure 3-16.MM3671. 43 . Kinds and Sizes of Explosives Labels. Lesson 3 Figure 3-15. Figure 3-17.

Lesson 3 Figure 3-18. Extract: Location of Listing for Proper Explosives Labels in Table 4-1.MM3671. 44a . TM 38-250.

Extract: Location of Listing for Proper Explosives Labels in Table 4-1.) 44b . TM 38-250.MM3671. (Cont. Lesson 3 Figure 3-18.

(Cont. TM 38-250. Extract: Location of Listing for Proper Explosives Labels in Table 4-1.) 44c .MM3671. Lesson 3 Figure 3-18.

Check the SAT column for each defect acceptably corrected. for the required number of DD Forms 1387-2 and their distribution. Signature of Inspector Block. 45 . Item 7. In this space check appropriate block as determined by your inspection. Two copies are attached to the shipping document to be delivered to the air terminal with the shipment. This will require a total of one original and three copies of DD Form 1387-2 for the one-pallet shipment. Lesson 3 Item 6. Not used. Qualified personnel must complete one of the qualifying courses every 24 months. TM 38-250. refer to figure 13-3. you will reinspect the air shipment after the defect or defects have been corrected." and the envelope is taped to the pallet. In this space put such data as loading or unloading priority. "deliver by" date. For other types of shipments. Approved or Rejected Block.MM3671. etc. See figure 3-9. can certify the shipment. The distribution of signed copies of DD Form 1387-2 for a single pallet shipment (which has been the example in this lesson) is as follows: • • • The original copy is placed next to the address label on the pallet. Item 8. If the shipment has been rejected. TM 38-250. One copy is placed in a waterproof envelope marked "DD Form 1387-2. The official who certifies that the shipment complies with the requirements of TM 38-250 must sign the form in longhand above the typed name. Make a note that the defect has been corrected. Sign the air shipment report and give it to the chief ammunition inspector. Additional Information Block. then line out and initial the UNSAT check mark. DOD personnel who are qualified as a result of special training in accordance with paragraph 1-20.

Four. MILVAN certificate. TM 38-250. d. 1. 46 . b. In what publication is information on the correct label for ammunition being shipped? a. d. How many kinds of explosives labels are there? a. On what form does the inspector indicate SAT if approving pallets. c. Packer. Side. Driver. d. containers. c. c. Where can criteria for the packaging and marking of class A munitions be found? a. FM 55-70. b. FM 55-70. b. b. b. Lesson 3 REVIEW EXERCISES Circle the letter of the correct answer to each question. Where are DOT markings on the box? a. 5. 3. d. Table 121A. TM 38-250. Shipper. 4. Top and Sides. Three. Two. c. Table 4-1. Air shipment report. b. TM 38-250. and packaging for an air shipment? a. 6. Bottom. One. Senior inspector.MM3671. Table 121A. Table 4-1. TM 38-L69-11-1. DD Form 1387-2. Who provides the filled out copies of DD Form 1387-2? a. c. Top. 2. FM 55-70. c.

One original. four copies. One original. d.MM3671. 8. Average NEW for the whole shipment. Lesson 3 7. 47 . Total NEW for the whole shipment. check your answers against the Exercise Solutions. When you are satisfied that you have answered every question to the best of your ability. Total NEW per package or pallet. c. b. If you missed three or more questions. b. you should retake the entire lesson. How many copies of DD Form 1387-2 are needed for a single pallet shipment? a. c. paying particular attention to the areas in which your answers were incorrect. One original. Recheck your answers to the Review Exercises. What is the amount used in the entry for Net Quantity Per Package block on DD Form 1387-2? a. six copies. One original. three copies. five copies.

a (see page 41). 6. b (see page 1). 2. d (see page 15). b (see page 42). d (see page 9). 4. b (see page 30). 8. b (see page 4). 7. c (see page 25). c (see page 8). c (see page 32). b (see page 22). b (see page 7). a (see page 30). c (see page 27). 5. c (see page 3). c (see page 20). 4. 5.MM3671 EXERCISE SOLUTIONS LESSON 1 1. 3. 6. 4. 5. 2. b (see page 8). 3. 3. 2. b (see page 13). 7. 8. LESSON 2 1. c (see page 15). 8. b (see page 38). a (see page 34). LESSON 3 1. b (see page 1). a (see page 19). c (see page 42). 6. 7. 58 .