A213293 Shell Tests Prop BLDG AEF
A213293 Shell Tests Prop BLDG AEF
A213293 Shell Tests Prop BLDG AEF
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DEPARTMENT OF DEFENCE
DST0O 4DEFENCE SCIENCE AND TECHNOLOGY ORGANISATION
89 9 18 058
UNCLASSIFIED
DSTOb
TECHNICAL REPORT
WSRL-TR-01/89
ABSTRACT
A series of trials was conducted in October 1988 to assess the pvimary fragment
containment and secondary fragment generation characteristis of explosives
buildings when subjected to HD 1.1 and HD 1.2 charges detonating within the
building. A number of other fragment protection devices were tested and the
results enabled the conclusion that the double brick cavity walls of these
buildings plus 25 nun mild steel sheetirg are acceptablecontainment to stop the
fragment spread from charges up to 2.5 kg TNT equivalent. Care needs to be
taken to provide adequate stand-off from walls and to ensure that the elevation
angle of the containment exceeds 50.
0 Commonwealth of Australia
Author's address:
Programs and Management Support
Weapons Systems Research Laboratory
PO Box 1700, Salisbury
South Australia
UNCLASSIFIED
WSRL-TR-01/89
TABLE OF CONTENTS
Page
1. INTRODUCTION
1.1 Background
2.2 Explosives 2
2
2
2.4 Stand-off distance
2
2.5 Steel plate
2
2.6 Test chamber section
2.7 Walls 2
11
2.8 Rope Mantle
11
3. DETAILS OF TRIALS
11
3.1 105 mm test preparation
11
3.2 105 mm fragment distribution
11
3.3 Screening of openings
11
3.4 2.5 kg bare charge preparation
I/
3.5 700 g bare charge preparation
12
4. RESULTS AND OBSERVATIONS
Acceson For 12
4.1 105 mm test reslts
NT 12
71 12
4.1.1 Steel plate
j, : . . - 12
4.1.2 Test chamber and ropemantle
4;
WSRL-TR-01 /89
Page
23
5. DISCUSSION OF RESULTS
23
5.1 The haz- 'd
23
5.2 Collapse of walls
23
5.3 Securement of screens ?
•' 23
5.4 Rope mantles and test chambers 23
23
6. CONCLUSIONS AND RECOMMENDATIONS
24
7. ACKNOWLEDGEMENTS
25
REFERENCES
LIST OF FIGURES
3
1. Plan view of containment test Albion Explosives Factory
5
2. Component layout - isometric view
6
3. Steel plate unit
7
4. Test chamber wall sample (Artillery Shell Test)
9
5. Artillery Shell Detonation - effect on walls
13
6. Results of Artillery Shell Detonation - rope mantle and chamber wall
15
7. Artillery Shell Detonation - continued
17
8. Artillery Shell Detonation - continued
19
9. Results of 2.5 kg bare charge detonation
21
10. Results of 700 g bare charge detonation
27
ANNEX A
32
ANNEX B
WSRL-TR-01/89
1. INTRODUCTION
1.1 Background
Explosives storage and processing locations are potentially hazardous to people within their
immediate vicinity. The four potentially lethal effects of an inadvertent explosion, used in the
assessment of safe separation, arise from the blast wave, the radiated heat from the fire ball, the
projected primary fragments if not contained, and secondary fragments (rock, building material etc).
The potentially lethal effects of blast and radiated heat are predictable from a knowledge of the
quantity of explosives and the distance to receptors, but more needs to be known to predict fragment
effects. Factors difficult to predict, such as the fracture mechanics of typical HD 1.1 processing
equipment or the fragment polarisation pattern of some HD 1.2 explosives under test or in storage,
require that a conservative approach be taken to safety distances where fragments may be involved.
Accordingly, minimum safety distances of 270 m for quantities above 50 ,g or 200 m (< 50 kg)
respectively are applied when it cannot be shown that fragments can be contained(ref.1,2).
The experiments to be reported here follow successful tests on reinforced concrete modules designed to
contain the fragments from a 10 kg TNT equivalent source used in propellant manufacture(ref.3).
Reinforced concrete modules are too bulky to be used in some locations where smaller quantities of
explosives are being used. A cost effective approach was considered to be an adequately supported
25 mm steel plate.
Accordingly, three tests were performed wherein a 105 mm HE shell was detonated to simulate the
effects of a 2.5 kg NEQ explosives incident with primary fragments, and bare plastic explosive
charges at 2.5 kg and "0 g NEQ were detonated to assess secondary fragment generation.
Although US safety tables infer that quantities below 5 lb (2.27 kg) can be contained in their
explosives buildings, tests on the Australian explosives buildings, mainly erected during the second
world war, had not been done before the tests reported here. There was an additional requirement to
test proposals for internal fragment screens for this quantity. Accordingly, a task was planned which
aimed at testing the containment of fragments from a 2.5 kg source against a number of structures,
including building walls, suppressive screens and a duplication of a test chamber section.
The test site (made available by the Operational Safety Committee (Explosives)) was Building 255
at the Albion Explosives Factory (AEF). It had been planned to demolish the building as part of the
current activity in relocating of the facility.
The structural detail of the building, which had a double cavity brick external wall and a double
brick, no cavity, inner dividing wall, is shown in figures 1 and 2. These figures also show the layout of
the three tests and an isometric view of the test involving the artillery shell (105 mm HE).
4
WSRL-TR-01/89 2
This particular building was located in an area allowing effective control of access, and the clearance
distances met the demolition requirements. Prior to the tests, the asbestos cement roof had been
removed to prevent dispersion of asbestos dust as a result of the explosions. Construction and site
preparation for the tests, including removal of the roof and fabrication and positioning of target
structures was performed by AEF personnel.
2.2 Explosives
The source of a uniformly fragmenting explosive was an Artillery Shell (105 mm HE M) fitted with a
nose closure plug (no fuse, but booster in fuse well), supplied by the Australian Army. Stemmed with
Plantee Explosive No 4 (PE4) and initiated with a No 8 Detonator and fired by a RAAF Service
Condenser Exploder, it constituted a 2.5 kg TNT equivalent RD 1.2 source.
Additional PE4 used to construct bare charges of 2.5 kg and 700 g initiated and fired in a similar
manner to the 105 mm shell, made up Tests 2 and 3 of the trial sequence.
2.3 Targets
The targets or fragment containment proposals included double brick walls of both cavity and solid
style, a 25 mm steel plate, a replicated section of an environmental test chamber and a traditional
rope mantle. These are shown in figures 1 and 2.
The possibility of production of secondary fragments and/or spalling or scabbing off external walls
from charges of 2.5 kg and smaller, was also to be investigated. In making these tests, it was decided
to take the crater diameter (discussed in reference 4), as the minimum stand-off distance between
explosive and containing walls. The required stand-off distance was calculated from the formula
D - 0.8 Q 1/3, Q being the TNT equivalent quantity in kilograms, D in metres and taken as 1.3 m for the
2.5 kg tests reported.
Experience from the 10 kg trials(ref.3) indicated that rigid attachment to the floor of any fragment
shields was probably the reason for the very large forces generated at the securement points and
potential was considered to exist for the shield to become a missile. As a result of this consideration,
flexible securement was devised for the steel plate. The arrangement used in the securement of the
plate is shown in figure 3. The flanges of the heavy-walled pipe, which were slotted and welded to
the plate, were designed to be flush with the floor but free to move in the close fitting diamond saw
recesses cut into the floor. Vertical movement of the plate, under impulsive blast loading, was
restrained by the bending of the single taper flange beam attached to one side and the back of the
plate. The plate and method of securement were compatible with the layout of the experimental
propellant manufacturing plant in which it was proposed to be employed.
A drawing of the test chamber section is shown in figure 4. Essentially the chamber was two 18 gauge
mild steel plate sections separated by soft insulating material.
2.7 Walls
To assess the possible production of secondary fragments from the outer walls of the building, the
outside surfaces immediately adjacent to the location of the shell were painted black and wood
battens were attached to the walls at these locations for securing white painted 'canite' sheets. Any
spalling or scabbing of the outer walls would be recorded as marks on the canite.
3 WSRL-TR-01 /89
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5 WSRL-TR-01/89
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The detailed construction of the rope mantle was not recorded but it was a typical rope mantle, used
but serviceable and supported on two RSJ beams set into the floor at the prescribed distance. The base
of the mantle may be seen in the top right hand photograph of figure 1, and the dismembered
remnants on the lower left photograph of figure 5.
3. DETAILS OF TRIALS
The three tests were carried out during 11 to 13 October 1988 in accordance with the procedures at Annex A.
All the explosives functioned on the first firing pulse.
In the test of the shell it was considered important to prevent it from toppling before or during
detonation. The shell remaining vertical would ensure a uniform spread of fragments to the
surrounding targets and, in accordance with the results of a study conducted by Materials Research
Laboratory (MRL), discussed in the next paragraph, would ensure that most fragments struck a target
within the building. This requirement was satisfied by the ring and rod attachment shown in figure 1,
top left photograph.
The data provided by MRL is at Annex B. The pattern distribution was the result of a computer
modelling program based on a lethality study carried out by the UK's Royal Armament Research and
Development Establishment (RARDE). The distribution of fragments indicated by RARDE were in
general agreement with the fragment spread from a detonating shell given in munitions effects
manuals. The pattern of fragments were anticipated to fall inside an elevation angle of 450 with the
maximum concentration at the centre points of the targets. As a substantial target existed in all
directions to 550 above the nose of the shell, it was assessed that most fragments would remain close to
the building. A search of the area after the trial proved these assumptions correct.
The door and window openings were screened by the type of reinforced cement blocks used in the 10 kg
Woomera-based trial(ref.3).
The 2.5 kg bare charge was constructed of sticks of PE4 moulded around a central wooden rod in rough
semblance to the artillery shell.
It was located in the next bay of the building at the same stand-off distance to both types of building
walls. The concrete wall modules blocks, as well as providing protection at the door and window
openings, created a similar confining effect to that provided for the 105 mm shell.
The 700 g bare charge was formed in the shape of a sphere and set on a platform representing a wooden
bench such as might be found in explosives laboratories. The charge was located 30 cm away from a
corner of the double brick cavity walls of the building.
Photographs of the three test sites, before initiation, are shown in figure 1.
WSRL-TR-01/89 12
The blast following the firing pulse was observed on a TV recorder. Small window fragments were
seen being projected from the building. Later examination of the building showed that most of the
wired-glass window sections imploded and were scattered around the bay in which the test was
conducted, probably as a result of the negative pressure phase of the blast wave.
The results showed that the shell detonated in the vertical position and sent fragments equally in all
directions in azimuth. The distribution in the vertical plane can be assessed, in a general way, by the
impact marks shown on the steel plate and the environmental test chamber section shown in the
photographs comprising figure 6. The remains of the white pressure sensitive tape, originally
marking the projected vertical and horizontal axes of the shell can be seen, even though the test
chamber section was blown off its mounts.
The number of fragments which struck the steel plate was assessed to be between 400 and 500. Of
these three had sufficient energy to penetrate the plate and were found imbedded in the wall (as
had many others which by-passed the fragment screens).
The large recovered fragments and a number of pin sized marks on the targets showed that there
was a much wider distribution of masses from the ruptured shell case than indicated by the stated
or desired weapon characteristics, Annex B refers. A detailed exarmination of the steel plate has
begun in order to measure the impact area of the fragment strikes and their depth of penetration of
this plate, to compare the fragment distribution mass and velocity with the model provided by
MRL.
Both the representative test chamber section and the rope mantle were penetrated easily by the
fragments. Erosion of the walls behind these targets and on the cement blocks was no different in
appearance to that caused by unimpeded shell fragments.
4.1.3 Walls
The double brick outer wall under severe fragment attack, collapsed against the canite sheets and
pushed their securing battens outwards. However, no marks of primary or secondary fragments
from the walls were found on any of the canite sheets, other than rubbing marks from black painted
sliding bricks.
The double brick internal wall, no cavity, produced what was considered to be a typical
saucer-shaped spall, directly adjacent to the charge on the outer side of the wall. However it did
not fall away until the canite was removed, and as for the outer wall, no primary or secondary
fragment impacts were found in the soft canite sheets placed against this wall.
4.1.4 Illustrations
4The effects described in the previous paragraphs are illustrated in the photographs comprising
figures 5, 6, 7 and 8.
t The detonation of the 2.5 kg bare charge was accompanied by an impulse sound and fire ball, as
observed on the TV monitor, considerably greater than that of the shell. A door was seen flying off
the building, which on closer examination was due to the projection of an unsecured cement block,
located to protect the door opening.
13 WSRL-TR-01 /89
Of
19 WSRL-TR-01/89
23 i'RL-Ri-0I189
Although the inner surface of the wall had been scorched by the fire ball and the outer walls bowed
under the pressure, no spalling or scabbing of bricks from the outer wall or the outside of the inner wall
were recorded. These results are illustrated in the photographs comprising figure 9.
The effects of detonating a 700 g charge placed 30 cm from the outer walls of the magazine are shown
in the photographs comprising figure 10.
Although an existing internal crack was opened and burn marks were left on the plaster coating the
insides of the wall, there was no projection of bricks or fragments from the outer surfaces.
5. DISCUSSION OF RESULTS
When the chemical energy of a detonating explosive disrupts its primary containment there is a wide
distribution of kinetic energy in the primary fragments, unless specific steps are taken to control the
break-up. When the pressure wave from a detonating explosive is reflected from the surface of a
large container, such as a building, sections of the outer wall can be ejected with considerable kinetic
energy producing secondary fragments. Both types of fragment constitute a hazard unless controlled.
The results of the tests reported here showed that the primary fragments from detonating sources of
2.5 kg TNT or less can be effectively reduced to an acceptable minimum by the typical double brick
walls of the explosives building. Where the stand-off distance of the wall meets the crater diameter
criterion, no spalling or scabbing or secondary fragments of the wall will occur. Door and window
openings may be screened by reinforced cement traverses or structures closer in, such as the 25 mm mild
steel plate construction tested in this trial.
It was observed that the 25 mm steel plates had been lifted vertically approximately 12 mm by the
explosion and the support leg basins had also been disturbed. Allowing the steel plat securement
devices to yield elastically under the blast impulse seems to be a viable method of retaining fragment
screens in place in the event of an inadvertent detonation.
The rope mantle was not effective against the smaller high energy fragments produced in the test.
The test chamber section results showed that environmental tests on HD 1.2 munitions huld always
require the use of additional fragment screens.
It is concluded that, for HD 1.2 situations up to 2.5 kg NEQ, effective primary fragment containmn'nt can be
expected from typical double brick walls provided that;
WSRL-TR-01/89 24
(a) charges are located at, or further than 0.8 Q 113 m from the wals,
(b) the wall is of sufficient height, relative to the charge, to intercept all low angle fragments,
(c) adequate precautions are taken to ensure that door and window openings are screened.
It is concluded that 25 mm mild steel plate, suitably mounted to allow some yielding movement under
shock1loading of the explosion, will provide adequate fragment containment at a separation distance of
0.8 Q /3 m from the charge.
Rope mantles do not provide containment for primary fragments, and their use is not recommended in such
situations.
7. ACKNOWLEDGEMENTS
The authors wish to recognise the cooperation and supportive effort extended by staff at both Albion
Explosives Factory and Materials Research Laboratory, and particularly to Mr Ray Sweetman (AEF) and
Mr John Donaldson (MEF) for their participation.
25 VSLT-18
REFERENCES
ANNEX A
FileRet: W6068/3/5
Sec OSC(E)
For information:
Sec ESTC
R.B. CROCKART
Task Manager
Encl
Oct 88
2. Area Security
Area Security over the trial period has already been discussed with
Mr Tom Barnes, Officer in Charge of the area who has made the initial
arrangements to ensure the area out to 400m is cleared of people and that
any people between 400m and 800m are under cover during the trials (and for
any period after if there is a misfire). in addition the access roads into
the firing site will be controlled at the points marked C on the enclosed
map of the area, also showing the 400 and 800m zones.
5. Area Preparation
Although advice from Albion indicates that the test items are in place in
Building 255, checks will be made on fragment containment geometry and
floor securement from the explosion site of the 105nm shell.
.12
29 WSRL-R-01/89
1. Equipment Requirements
g. Red Flags
h. 104mm Shell
i. 35mm Camera
k. Safety Ohmmeter
2. Trial Personnel
c. Remove nose closure plug and tamp PE4 into the fuse well in
accordance with the enclosed drawing. Rectify a cavity for the
detonator.
A
L_ --
WSRL-TRI-01 /89 30
NQ6 DETONATOR
PROJECTILE Mi
ALUMINWUM LINER
BASE COVER
31 WSRL-TR-O1/89
1. Equipment
2. Personnel
3. Initial Preparation
a. Weigh and mould 500 gm of PE4 into a ball; rectify a hole for the
detonator.
b. Place on wooden spoke on table E9.5cms from double brick and from
cavity brick walls.
4. Proceed with final preparation and firing as for the 105 mm shell test.
-et
WSRL-TR-01 /89 32
ANNEX B
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33 WSRL-TR-oi/89
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WSRL-TR-01/89
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4 TITLE
THE FRAGMENT CONTAINMENT CHARACTERISTICS
OF EXPLOSIVES
BUILDINGS AND OTHER FORMS OF FRAGMENT PROTECTION FOR HD 1.1
AND HD 1.2 CHARGES UP TO 2.5 kg TNT EQUIVALENT
7.2 NUMBER OF
REFERENCES 4
8.2 DOCUMENTSERIES
and NUMBER 10 COST CODE
Technical Report
01/89
No limitation
b. Non -Thesaurus
Terms
SUMMARY OR ABSTRACT
(ifthis is security classified, the announcement of thi report will be similarly dassifed)
id