The DOT, BATF, and DoD classification systems, when used in combination with other recognized tests, may be used to produce a systematic approach to classifying in-process explosive materials. In-process classifications are useful since an explosive will typically provide the same or greater level of hazard in a manufacturing operation than in a shipping or storage configuration, where the classification is known. Therefore, the manufacturer or processor of explosive materials may be under assessing the hazard of the explosives in their processes by solely using the transportation and storage classifications as a guide. Alternatively, an explosives manufacturer may assume that in-process operations always represent a high explosive hazard. This approach may lead to unwarranted restrictions or expense for some operations. Understanding the characteristics of the in-process material ensures that proper safety requirements are addressed early in the designing and planning stages of a production line.

This protocol is not intended to replace or modify BATF, DoD or DOT classification systems for storage or transportation, but to assist the manufacturer of explosives with proper facility design and siting of modified or new facilities.

In an explosives-manufacturing operation, the reactivity or sensitivity of the material may vary within the process. The in-process material characterization and classification requirements may therefore be different for various stages of a process. Therefore, the classification methodology developed should be applied to all stages and/ or configurations of the explosive. It is also important that a worst-case configuration, instead of a normal process upset or minimal-case configuration, be used when classifying in-process materials or articles. Generally, an over-test is performed rather than a minimum worst-case test, so that not every change in manufacturing procedures requires a re-test of the explosive substances or articles involved.

In-process classifications are determined by using a combination of the tests shown below. The Test Series 1-4 are for in-process classification of substances while Test Series 5 and 6 are for articles. See Terms and Definitions for an explanation of "substances" and "articles."

For testing consideration, SMS must be provided with information needed to understand your material and the objective of the testing, as specified in "Standard Required Information for Testing."