Military

10-1. Munitions maintenance planning must be aligned closely with the operational needs of supported units. Maintenance planners must be realistic when considering the availability of supplies and maintenance resources. A reduction in munitions maintenance increases the amount of ammunition taken from the supply system. Conversely, the inability of the supply system to replace unserviceable munitions requires a greater maintenance effort. Proper maintenance, storage, and handling of munitions enhance readiness, reduce replacement requirements, and conserve resources. The maintenance planner must recognize the interdependence of maintenance and munitions support.

10-2. Units need a constant supply of serviceable munitions. Munitions maintenance is a vital task that must be performed to sustain readiness. Maintenance includes everything from minor packaging and preservation operations (i.e., cleaning, removing rust and corrosion, repairing boxes and crates) to major operations (i.e., complete renovation). Provisions must be made to conduct as much maintenance as possible at the storage location. In some cases, munitions must be retrograded for maintenance. Since the movement of munitions requires transportation and personnel assets, it is inefficient to adopt a maintenance program geared totally to evacuation.

10-3. DS, GS, and modular ammunition units assume a more active role in conducting maintenance operations when operating in the corps and theater areas during combat or SASO. The primary focus in hostile, forward locations is issue and receipt activities; therefore, maintenance may be limited to packaging and preservation.

10-4. Munitions maintenance is divided into four categories: organizational, direct support, general support, and depot. Generally, Army munitions personnel only perform the first three categories of maintenance.

10-5. All activities that have munitions on hand perform organizational maintenance (generally packaging and preservation) to prevent deterioration from rough handling and exposure. Organizational maintenance in the using unit is usually performed with the technical assistance of ammunition units.

10-6. DS conventional ammunition companies in the theater of operations perform limited DS maintenance and surveillance of stocks under their control. Limits are defined by the capability of the unit and METT-TC. Besides packaging and preservation, DS maintenance may include replacing readily removable external parts and components; these include fuzes of artillery and mortar munitions, propelling charges and primed cartridge cases for semifixed and mortar munitions, grommets, and nose plugs. Maintenance at the DS level is largely due to turned-in munitions.

10-7. Conventional ammunition companies in the theater of operations that have GS capabilities perform maintenance above the DS level. Modular companies are designed with the capability to perform both DS and GS maintenance. GS maintenance includes, but is not limited to, the following:

• Removal of extensive rust/corrosion; painting and stenciling of Class V materiel; and fabrication of or major repairs to boxes, containers, and crates.
• Replacement of internal/external components that requires the use of operational shields or barricades.
• Demilitarization of ammunition, when directed.

10-8. All DS and GS companies with storage and issue missions are equipped to perform maintenance functions. The tools, equipment, and supplies needed to support maintenance at that particular level are included in each unit's supply and equipment list.

10-9. Depots perform more complicated maintenance (such as modification, explosive component replacement, or complete renovation) of munitions that are packaged and/or evacuated.

10-10. Care and preservation are terms often used to describe munitions maintenance at the organizational or DS level. Care stresses protection, and preservation stresses maintenance but includes protection. Care and preservation of munitions are essential for ensuring that stocks are available for combat missions.

10-11. Munitions returned by units can be held in the segregation area for up to 180 days. There, they are identified and segregated by type and lot number, checked for hazardous and nonstandard conditions, and repacked or palletized. Q-D, explosive, and personnel limits must comply with DA PAM 385-64.

10-12. Care and preservation lines may be established, if METT-TC and capability permit, where loose or opened munitions are visually inspected and properly identified. Containers are inspected to ensure that the contents match the information on the outside. Contents are inspected for serviceability, incompatibility, and hazardous conditions. Precautions must be taken when handling depleted uranium items (see TB 9-1300-278). Serviceable items are palletized. Unserviceable but salvageable items are sent for repair. Disposition instructions must be requested for suspended and nonrepairable items. Scrap material is placed in suitable containers and sent to a salvage area.

10-13. If inspection results in the need to repair or replace a container, the contents must be removed unless a new stencil or marking is all that is necessary. Munitions are returned to the container with enough filler material to allow a tight fit. Stencils or markings identical to the originals are placed on the new container. Seals and bands are replaced, and the container is ready for the palletizing area.

10-14. Munitions must be palletized IAW proper USAMC drawings and appendices. Some drawings may be designated as DARCOM drawings. No more than one lot is permitted on any one pallet in storage. Once inspected, pallets are transferred to a storage or shipping area.

10-15. If an explosive hazard exists, the destruction of unserviceable munitions and packaging is carried out only by, or under the supervision of, EOD personnel. Disposition instructions must be requested from higher headquarters prior to destruction. See DA PAM 385-64, DA Pam 738-750, and TM 9-1375-213-12 for more information.

10-16. All maintenance operations are performed IAW an approved maintenance SOP. TM 9-1300-250 contains guidelines for preparing maintenance SOPs and organizing maintenance activities. When local nationals are involved in maintenance operations, the SOP is written in their language as well as in English.

10-17. Munitions surveillance is the observation, inspection, and classification of munitions and their components for movement, storage, and maintenance. It includes the inspection of all equipment, facilities, and operations. Surveillance activities are conducted by all theater activities that store, maintain, dispose of, or ship ammunition and its components. Surveillance ends only when munitions are expended or destroyed.

10-18. The TSC is normally responsible for general supervision of munitions surveillance in the theater. The COSCOM is responsible for supervision within the corps. The ordnance battalion and CSB or CSG supervise this function in their commands. In established theaters, surveillance activities are under the control of DAC QASAS who are assigned to the appropriate Army headquarters IAW AR 702-6 and AR 740-1. In theater ammunition units, surveillance is performed by attached civilians and assigned military inspectors.

10-19. Battalion commanders must administer a quality assurance ammunition surveillance program that covers all munitions operations in their command. The QASAS in charge is responsible for this program and reports directly to the commander. Since the training required for the QASAS is more extensive than that of the military inspector, QASAS personnel perform most functional tests and the more complicated inspections. They certify the results of inspections and tests performed by the military inspectors. Some inspection results and functional test reports are signed only by a QASAS. Surveillance in an immature or developing theater is performed by 55Bs in a DS, GS, or modular ammunition company. Early deployment of QASAS personnel will ensure full surveillance capabilities.

10-20. Munitions inspectors are responsible for ensuring the reliability and serviceability of munitions. They perform their mission in plants, depots, storage areas, and on the battlefield. The surveillance mission encompasses the following duties:

• Inspecting storage facilities, field storage, and all types of storage sites to ensure compliance with storage standards.
• Inspecting surrounding areas for fire hazards and other nonstandard conditions.
• Checking for conditions that could speed up deterioration of items in storage.
• Teaching surveillance and munitions safety.
• Preparing and maintaining records and reports to cover all surveillance activities. (Surveillance records and reports are contained in SB 742-1.)
• Observing, inspecting, and investigating munitions and components for serviceability.
• Monitoring storage, handling, and maintenance operations and recommending changes to enhance safety and operational effectiveness.
• Recommending controls needed to maintain standards.
• Advising the commander on munitions surveillance matters.
• Inspecting munitions to determine quality, safety, and deterioration.
• Maintaining munitions drawings and specifications files and indexes.
• Maintaining munitions suspension files.
• Inspecting incoming and outgoing munitions shipments for compliance with existing instructions and regulations.
• Furnishing technical advice to the commander and supported units on munitions safety and compliance with munitions regulations.
• Ensuring that surveillance functions are performed according to SB 742-1 and applicable TMs and SBs.

10-21. Munitions inspectors provide an invaluable service to the commander and supported units. Inspectors assist in many activities including the following:

• Investigating ammunition malfunctions and accidents.
• Inspecting and testing lightning protection systems.
• Conducting unit basic load inspections.
• Preparing waivers for storage facilities.
• Planning construction of storage facilities.
• Planning field storage areas.
• Monitoring uploading/downloading of ammunition to/from combat vehicles.

10-22. Ammunition inspectors also help to plan, administer, and enforce the explosives safety program. This program includes the review, evaluation, and inspection of operations, procedures, equipment, and facilities used with munitions and explosives operations.

10-23. An active surveillance inspection program is vital to ensuring munitions reliability. IAW SB 742-1, the following surveillance inspections are performed by QASAS and military inspectors:

• Receipt, including depot transfers, field returns, and CEA.
• Periodic (cyclic).
• Storage monitoring.
• Special.
• Pre-issue.
• Verification.
• Munitions condition code.
• Ammunition in the custody of units.

10-24. The purpose of an inspection is to find deterioration and determine the serviceability of items. The inspector must be familiar with all information on the items, including components and packaging, as well as the characteristics of the weapons in which they are used. Serviceability standards are contained in SB 742-1.

10-25. Inspection procedures include observation, tests (such as gauging or strength tests), and functional tests. As a rule, munitions must not have defects that alter their characteristics, make them unsafe, or prevent them from performing as designed. The inspector must determine if defects can be corrected and at what maintenance level it must be done. Serviceability is not assumed from the fact that the item can be fired in the weapon for which it was designed. It must function correctly when fired.

10-26. The prime enemies of munitions are heat, moisture, and rough handling. Deterioration is faster when moisture is combined with a rise in temperature. Inspectors must look for indications of moisture, rust, or corrosion on projectiles and fuzes; corrosion and cracks on cartridge cases; deterioration of propellants; loose closing caps; and moisture or dampness inside containers.

10-27. Evaluating materiel that shows deterioration or damage is a decision based on the training, experience, and judgment of the inspector. Deterioration of materiel in storage is natural and varies depending on protective coating, packaging, and storage conditions. Deterioration is progressive. If maintenance is not performed, it progresses from an incidental stage, to minor, to major, and possibly to a critical stage. These four categories of deterioration are used to establish a uniform system of examination for deterioration or damage.

10-28. Further guidance on classifying metal, plastic, and rubber component deterioration; mixed ammunition; damaged packaging; and placing defects into one of the four defect categories can be found in SB 742-1 and other applicable SBs and TMs.

10-29. GMLR munitions, components, propellants (liquid and solid), protective clothing, packaging, and packing materials are inspected and tested using applicable SBs, TMs, drawings, and specifications.

10-30. Most mid-sized guided missiles are now certified as rounds and are maintained by the contractor at contractor facilities. Unit maintenance on guided missiles is limited to spot painting and replacement of items such as wings and elevons. Missile items identified by lot or serial number are inspected for serviceability. Materiel is sampled and inspected by individual lots. Missiles are inspected using the inspection table in the appropriate TM or SB.

10-31. Defects found in the sample are classified using the applicable SB, TM, or other specification. Where defects are not classified in these publications, the inspector classifies them according to SB 742-1. The results of the sample inspection are used to make serviceability decisions about the lot or group.

10-32. A technical history of each lot, serial number, or group of munitions is kept by surveillance personnel. This history includes results of all inspections, tests, investigations, and any unusual or changing conditions affecting the items. These records are used to evaluate the serviceability and reliability of munitions. Therefore, it is important that all information gathered be accurate and concise. The historical information needed for maintenance is usually more detailed as to the extent of the defect and the work required returning the item to service. The following information is needed to evaluate the reliability of the stockpile:

• Condition of the materiel.
• Quantity.
• Date of manufacture.
• Type of storage.
• Type of defects.
• Cause of defects.
• Results of tests.

10-33. Surveillance personnel are required to submit and maintain reports on materiel received or in storage. SB 742-1 provides guidance for preparing the following records and reports:

• DA Form 984, Munition Surveillance Report-Descriptive Data of Ammunition Represented by Sample.
• DA Form 2415, Ammunition Condition Report.
• DA Form 3022-R, Army Depot Surveillance Record.
• DA Form 3023, Gage Record.
• DA Form 3782, Suspended Notice.
• DA Form 4508, Ammunition Transfer Record.
• DD Form 250, Materiel Inspection and Receiving Report.
• DD Form 1575, Suspended Tag-Materiel.
• DD Form 1575-1, Suspended Label-Materiel.
• DD Form 1650, Ammunition Data Card.
• SF 361, Transportation Discrepancy Report.
• SF 364, Report of Discrepancy.
• Munitions inspection and lot number reports.
• Munitions suspension records, to include AMCCOM and MICOM suspension.
• Equipment logbooks and maintenance logs.
• Reports of explosions, chemical agent releases, serious accidents, and nuclear incidents.
• Small arms tracer reports.
• Storage monitoring records (local format).
• Others required by local/higher headquarters.

10-34. Safety in munitions maintenance is covered in AR 385-10, DA PAM 385-64, and maintenance manuals for specific munitions items. Explosives safety standards, the handling and storing of munitions, operational precautions, Q-D requirements, barricades, operational shields, personnel and explosives limits, and safety tools and equipment are discussed in Chapter 7 of this manual.

10-35. This chapter has provided only general information and guidance for personnel responsible for the maintenance of munitions. Detailed maintenance and surveillance procedures for specific munitions items are in TM 9-1300 series publications. Surveillance procedures are covered in SB 742-1.