TM-38-400

• JOINT SERVICE MANUAL (JSM) FOR STORAGE AND MATERIALS HANDLING
• Table of Contents
• Table of Contents (Cont)
• Chapter 1. GENERAL
• Explanation of Terms.
• Chapter 2. STORAGE SPACE MANAGEMENT
• Figure 2-2. Ground-Level General Purpose Warehouse
• Refrigerated  warehouse.
• Flammable/hazardous
• Figure 2-5. Flammable Warehouse
• Figure 2-6. Hazardous Materials Facility
• Figure 2-7. Floor Plan of a Flammable/Hazardous Materials Facility
• Figure 2-8. Typical Examples of Sheds
• Above-ground magazine.
• Figure 2-10. Typical Earth-Covered Magazines
• Dry tank
• Transitory shelter.
• Nontraditional  storage  structures.
• Figure 2-14. Example of RELMS
• Open Storage Space.
• Scope.
• Figure 2-19. Floor Load Limitation
• Commodity characteristic
• Development of Data for Use in Space Requirement Computations.
• Figure 2-21. Space Occupancy Effectiveness
• Cubic Foot computation.
• Figure 2-23. Dollar Value Per Cubic Foot
• Figure 2-25. Square Feet Required to Store Additional Inventory
• Figure 2-26. Factors of Consideration in Computing Storage Support Space Requirements
• Section IV. Planning the Storage Layout
• Figure 2-27. Storage of Stocks by Popularity
• Working Aisles.
• Preparation of Layout Plan.
• Figure 2-29. Space Layout for Large Lot
• Figure 2-31. Example Direction of Storage Arrangements
• Figure 2-32. Bin Shelving Plan Sheet
• Figure 2-33. Shelf Box, Small, One and Two Compartment
• Figure 2-34. Large Metal Shelf Box
• Figure 2-35. Large Corrugated Shelf Box
• Figure 2-36. Typical Bin Shelf Box Arrangement
• Basin bin, shelf, and rack layout criteria.
• Figure 2-37. Metal Pallet Rack for Storage of Small Lot Items
• Open storage layout criteria.
• Figure 2-39. Example Layout for Open Storage Area
• Figure 2-40. Example of Open Storage Area Layout
• Utilization of Floor Plan in Stock Layout.
• Figure 2-41. Example Stock Layout
• Flexibility.
• Section V. Space Control and Reporting
• Space recapitulation record.
• Space Reporting Guidance.
• Figure 2-45. Sample Space Recapitulation Record
• Measuring covered storage space
• Measuring open storage areas.
• Calculating gross space for storage operations in square feet.
• Reporting net storage space.
• Figure 2-49. Determining Cubic Capacity in Covered Storage Areas
• Open improved storage areas.
• Figure 2-50. Honeycombing-Type A Potential Vacant Space
• Figure 2-52. Type A Potential Vacant Space Recouped Through Rewarehousing
• Figure 2-54. Type B Potential Vacant Space
• Figure 2-55. Type B Potential Vacant Space Recovered Through Rewarehousing
• Figure 2-56. Combination of Types of A and B Potential Vacant Space
• Guide for computing occupied and vacant Space
• Using the storage space survey worksheet
• Collection of cubic data.
• Preparation of survey to determine cubic occupancy
• Figure 2-60. Example of Bulk Planograph Worksheet
• Table 2-1. Determination of Sample Size
• Table 2-2. Table of Random Numbers
• DOD Storage Space Reporting.
• Reporting requirements.
• Figure 2-61. SSMR (DD Form 805)
• Preparation of the DD Form 805.
• Figure 2-62. Example of a Completed DD Form 805
• Header section.
• Figure 263. Example of a SSMR Output Product
• Section A-Gross Space Available
• Section B-Net Space Available.
• Section B-Net Space Available. (Cont)
• Section  C-Occupied  Storage Space
• Table 2-3. Format 1, Header
• Table 2-4. Format 2, Detail
• Chapter 3. STORAGE PROCEDURES
• Unloading Operations.
• Figure 3-1. Unloading and movement to storage using forklift truck
• Figure 3-2. Unloading and movement to storage using tractor-trailer train
• Figure 3-3. Unloading and movement to storage-mixed car lots
• Checking Incoming Material.
• Table 3-1. Pallet Pattern Selection Table (40- by 48-Inch Pallet)
• Table 3-1. Pallet Pattern Selection Table (40- by 48-Inch Pallet) (Cont)
• Table 3-1. Pallet Pattern Selection Table (40- by 48-Inch Pallet) (Cont)
• Table 3-2. Pallet Pattern Outline Table (40- by 48-Inch Pallet)
• Table 3-2. Pallet Pattern Outline Table (40- by 48-Inch Pallet) (Cont)
• Table 3-2. Pallet Pattern Outline Table (40- by 48-Inch Pallet) (Cont)
• Table 3-2. Pallet Pattern Outline Table (40- by 48-Inch Pallet) (Cont)
• Receipt Documents.
• Shipment Planning.
• Section III. Stock Location
• Location Site Identification.
• Figure 3-4. Example of stock location layout for large lot bulk storage
• Figure 3-5. Example of stock location layout for medium lot bulk storage
• Figure 3-6. Example of stock location layout for retail bin or shelving and small lot bulk storage
• Figure 3-7. Example of view of a pallet rack-type stock location layout
• Maintaining the Location System.
• Stock locator file.
• Section IV. Pest Management
• Inspection.
• Information Report Requirements.
• Section V. Inventory
• Principles of Inventory Control.
• Bar Code Utilization.
• Physical Inventory Guidelines.
• Section VI. Care of Supplies in Storage (COSIS)
• Basic COSIS Program Actions.
•  Special Considerations in Care of Stored Material
• Table 3-4. Listing of Material Condition Tags, Labels, and Instructions
• Section VII. Operations in CH Space
• Criteria for Facility Selection.
• Material Protection Factors.
• Figure 3-10. A dessicant-type dehumidifier
• Figure 3-11. Auxiliary door actuated by contact with MHE
• Section VIII. Security of Materials in Storage
• Responsibilities.
• Storage of Small Arms.
• Inspection.
• General.
• Loading Rules for Rail Carriers.
• Actions of Pressures on Cargo.
• Lateral pressures.
• Floating Loads
• Figure 3-16. Snubbing machine.
• Mixed Loads.
• Bagged Commodities in Closed Cars.
• Palletized Loads in Closed Cars.
• Boxcar information.
• Loading on Pallet.
• Loading factors.
• Figure 3-22. Palletized loads.
• Cylindrical Containers in Closed Cars.
• Loading wooden barrels.
• Figure 3-26. Loading diagrams cylindrical containers.
• Machinery and Machine Tools.
• Figure 3-28. Frontloader forklift truck equipped with toplift attachment.
• Figure 3-29. Sideloader truck equipped with toplift attachment.
• Figure 3-30. Mobile crane equipped with toplift attachment.
• Loading.
• Load Movements.
• Forward movement.
• Rearward movements.
• Figure 3-36. Rear gate.
• Figure 3-37. Rear gate positioned in truck.
• Lateral movement.
• Types of Loading.
• Figure 3-40. Loading.
• Palletized loads.
• Freight Loss and Damage.
• Use and Maintenance of Pneumatic Dunnage.
• Disposable pneumatic dunnage.
• Dunnage.
• Placement.
• Figure 3-45. Single void pneumatic dunnage bracing pattern.
• Figure 3-46. Larger dunnage units bracing higher loads.
• Figure 3-48. Pneumatic dunnage units in various void arrangements.
• Figure 3-50. Pneumatic dunnage stays load laterally and longitudinally.
• Operational procedures.
• Removal.
• Policy.
• Types of Unit Loads.
• Advantages of Unit Loads.
• Unitizing Loads by Shrink Wrapping.
• Shrink-film characteristics.
• Determining film bag size and thickness.
• Unitizing Loads by Stretch Wrapping.
• Equipment.
• Stretch-wrap films.
• Advantages and disadvantages of stretch wrap.
• Chapter 4. MHE AND PRINCIPLES
• Containers.
• Material Movement.
• Section II. Materials Handling Equipment.
• Handtruck, platform, four-wheel.
• Dollies.
• Lifting-Type Vehicles.
• Tiering truck, electric, narrow-aisle.
• Truck, reach, narrow-aisle.
• Truck, forklift, counterbalanced.
• Figure 4-15. Truck, forklift, solid, semisolid rubber, or pneumatic tires, 2,000-pound, 130-inch lift.
• Figure 4-17. Truck, forklift (3-wheel) pneumatic tires, 3,200 pound, 144-inch lift.
• Application.
• Truck, front side-to-side loader.
• Gantry Crane.
• Bridge Cranes
• Crane Truck.
• Horizontal Transport Equipment.
• Tractor, warehouse, gasoline, pneumatic tires, 4,000-pound drawbar pull.
• Hoist, straddle, mobile.
• Conveyors
• Conveyor,  roller  gravity.
• Conveyor, horizontal-slider bed, belt.
• Conveyor,  gravity-extendable.
• Conveyor, live-storage.
• Conveyor, power-driven belt, portable.
• Conveyor, towline.
• Automatic guided vehicles (AGVs).
• Sortation Systems.
• MHE Accessories.
• Drum-handling attachment.
• Lifting arm bar
• Clamp.
• Retriever trailers.
• Pallet sling.
• Figure 4-61. Pallet sling.
• Figure 4-62. Safety pallet specifications.
• Dock Related Equipment.
• Flip ramp dock board.
• Mobile vehicle loading ramp.  
• Portable platform.
• Section III. Storage Aids.
• Horizontal dunnage
• Collars for compressed gas cylinders.
• Containers.
• Pallets.
• Figure 4-81. Pallet, 40 by 48 inches, flush-end, three-stringer, two-way entry, hardwood.
• Figure 4-84. Pallet, 40 by 48 inches, four-way (partial) wing, softwood.
• Wire basket.
• Figure 4-87. Wire basket.
• Bins.
• Pallet storage racks (adjustable.)
• Rack, drive-in, drive-through.
• Rack, flow-through
• Cantilever racks.
• Box pallets
• Storage and Retrieval Systems (SRSs).
• Types of SRSs.
• Section IV. Selection of MHE
• Forklift Truckload Ratings.
• Special Equipment Considerations.
• Mechanical Alterations.
• Section V. MHE Requirement Factors
• Figure 4-98. Types of equipment that effectively serve supply operations under varying conditions.
• Planning the Operation.
• Figure 4-100. Tractor-trailer shipping operation.
• Figure 4-101. Graduated sequence of experienced operations improvement.
• Figure 4-103. Example timing of a bulk shipping or receiving operation.
• Computing MHE Requirements.
• Figure 4-105. Formula to be applied in computing MHE requirements.
• Computing Pallet Requirements.
• Considerations in Requirements for Fixed Equipment.
• Fleet Management.
• Maintenance.
• Reports and reports procedure.
• Section VI. On-The-Job Training (OJT) Course for Operators of MHE
• Vision, Hearing, and Reaction Tests.
• Figure 4-111. Driver testing and training device.
• Physical Examination.
• Instructions on Types of Equipment.
• Figure 4-112. The mast or upright is the elevating assembly of a fork lift truck.
• Fundamental Operational Instructions for Fork Truck
• Advanced Training in Fork Truck Operation.
• Load handling maneuvers for trainees.
• Figure 4-118. After crossing in front of the stack, the operator spots a pallet load adjacent to another
• Figure 4-119. A double pallet load must be tiered with an overhang of no more than 2 inches in any direction.
• Figure 4-121. Typical floor pattern. Proper stacking procedure is shown at left.
• Figure 4-122. Loading a freight car.
• Fundamental Operational Instructions for Industrial Tractors
• Course in Operation of Industrial Tractor-Trailer Trains
• Operational Instructions for Truck Straddle Carry (or Gantry Trucks).
• Operating Rules.
• Fork trucks.
• Examinations for Fork Trucks.
• Examinations for Other Equipment.
• Grading Examinations.
• Preparation of Additional Courses.
• Chapter 5. STORAGE OF SPECIAL COMMODITIES
• Handling Methods.
• Formation of Lumber Drafts.
• Assembling a lumber draft.
• Anchoring of butt boards.
• Placement/alignment of stickers.
• Stickering requirements.
• Binding of Lumber Drafts.
• Open Storage.
• Foundations, general.
• Figure 5-9. Diagram of yard and shed layout.
• Portable lumber foundations.
• Stack Spacing and Roofing Protection.
• Vertical spacing.
• Covered Storage.
• Storage of Special Items.
• Measuring Moisture Content.
• Section III. Vehicles (Tracked and Wheeled) and Artillery
• Open storage areas
• Storage Patterns.
• Figure 5-15. The back-to-back storage pattern.
• Selection of the proper pattern
• Methods for Storage, Receipt, and Issue.
• Stacking
• Figure 5-18. Roll-through racks for stacking vehicles in storage.
• Figure 5-20. suspension-type racks for stacking vehicles in storage.
• Figure 5-22. Metal stands for stacking vehicles in storage.
• Towing equipment.
• Figure 5-24. Example of a wheeled prime mover.
• Towing aids.
• Exercising.
• Figure 5-28. An exerciser for use on recoil mechanisms.
• Receipt and issue.
• Figure 5-30. Parts boxed and attached to end item for shipment.
• Figure 5-31. Windshield boxed for protection during shipment.
• Truck-mounted crane.
• Wheel-mounted  crane
• Crawler-mounted crane.  
• Section IV. Subsistence
• Transport and Storage Compatibility of Fresh Fruits and Vegetables.
• Perishable Subsistence Compatibility Group
• Chill injuries to certain products.
• Table 5-1. Storage Life of Frozen Subsistence
• Table 5-1. Storage Life of Frozen Subsistence (Cont)
• Table 5-1. Storage Life of Frozen Subsistence (Cont)
• Table 5-1. Storage Life of Frozen Subsistence (Cont)
• Table 5-2. Storage Life of Perishable Subsistence
• Table 5-2. Storage Life of Perishable Subsistence (Cont)
• Table 5-2. Storage Life of Perishable Subsistence (Cont)
• Table 5-2. Storage Life of Perishable Subsistence (Cont)
• Table 5-2. Storage Life of Perishable Subsistence (Cont)
• Table 5-2. Storage Life of Perishable Subsistence (Cont)
• Table 5-2. Storage Life of Perishable Subsistence (Cont)
• Semiperishable Subsistence in Dry Storage
• Causes of spoilage.
• Physical factors for canned products.
• Table 5-3. Storage Life of Semiperishable Subsistence
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Table 5-3. Storage Life of Semiperishable Subsistence (Continued)
• Section V. Miscellaneous Commodities
• Batteries.
• Storage facilities.
• Handling precautions.
• Electronic Materiel.
• Photosensitized Materiels (Film and Paper) and Flash Bulbs.
• Hazards.
• Self-Sealing Fuel Cells.
• Lubricating Oils and Greases.
• Wire Rope.
• Navigation Timepieces.
• Machine Tools and Production Equipment
• Figure 5-42. Typical storage layout of machine tools.
• Tires, Tubes, and Rubber Products.
• Over-the-road and industrial vehicular tires and Tubes
• Figure 5-43. Typical storage in pallet support sets.
• Figure 5-44. Block stack of 11.00X15 tires.
• Figure 5-45. Tires unitized by stretch-wrap method.
• Abrasive or Grinding Wheels.
• Glass.
• Musical Instruments.
•  Brushes: Feather, Wool, Bristle, and Hair.
• Clothing and textiles.
• PVC Plastic Pipe.
• Radioactive Material.
• Section VI. Packaged Petroleum Products
• Standards for Storage of 5-Gallon Military Gasoline Containers (Blitz or Jerry).
• Standards for Storage of Packaged Fuels, Lubricants, and Greases.
• Storage of Empty Containers.
• Quality Surveillance.
• Section VII. Metal Products
• Figure 5-48. Pigeonhole-type metal storage rack.
• Figure 5-49. Nesting-type rack with automatic grab hook attachment.
• Figure 5-51. Lightweight sheet or strip racks.
• Handling Equipment.
• Figure 5-53. Tree frame racks mounted on warehouse trailer.
• Figure 5-55. Automatic grab hook and spreader beam.
• Handling Methods.
• Figure 5-57. Storage of materials in pigeonhole- type racks.
• Figure 5-60. Crane positioning rack into storage.
• Figure 5-61. Fork truck operation in open storage.
• Figure 5-62. Open storage area.
• Figure 5-66. Use of horizontal dunnage in flat storage of armor.
• Figure 5-67. Open storage of metal shapes.
• Safety.
• Section VIII. Cable Storage and Handling
• Figure 5-70. Pyramid stacking of cable reels.
• Handling of Cable.
• Cable Rereeling.
• Figure 5-73. Hand operated cable reeling unit and measuring device.
• Protection of Cable Ends.
• Chapter 6. SAFETY
• Section IV. Accident Prevention Program
• Section V. Safety Equipment and Clothing
• Section VI. Fire Protection (29 CFR 1910.156)
• Sprinkler system.
• Section VII. Fire Suppression Equipment (Portable Fire Extinguishers, 29 CFR 1910.157)
• Selection by hazard.
• Inspection, maintenance, and hydrostatic tests
• Table 6-3. Hydrostatic Test Interval for Extinguishers
• Section VIII. Housekeeping as Related to General Storage (29 CFR 1910.14)
• Table 6-5. Characteristics of Extinguishers
• Table 6-5. Characteristics of Extinguishers (Continued)
• Wash and locker rooms.
• Section IX. Rules for Safe Storage
• Spontaneous combustion.
• Safe handling and disposal of fluorescent lamps
• Section X. Size of Storage Blocks, Clearances, Heights, and Limitations
• Clearances.
• Section XI. Signs and Color Code Markings in Relation to Safety in Storage.
• Figure 6-4. Stack clearance at exterior walls (nonhazardous materials).
• Directional arrows (OSHA 1910.145).
• Color code markings.
• Fire prevention devices.
• Forklift truck safety rules (29 CFR 1910.178).
• Straddle carry trucks safety rules.
• Warehouse crane safety rules.
• Section XIII. Safety Practices for Non-powered MHE
• Section XIV. Manual Handling
• Section XV. Safety in Loading and Unloading Railroad Cars/Trucks and Trailers
• Section XVI. Building and Physical Equipment
• Section XVII. National Defense Stockpile.
• Chapter 7. ON-THE-JOB TRAINING FOR STORAGE PERSONNEL
• The Three Phases of Instruction.
• Qualifications of Trainers.
• Section II. Training Program
• The Requirements for a Successful Storage and Materials Handling Training Program.
• Section III. Conference Leader
• Key Ideas and Questions.
• Facility Characteristics.
• Shipping and receiving platforms.
• Pillars, posts, and columns.
• Commodity Characteristics.
• Aisles.
• Layout.
• Fire aisles.
• Stock Locator.
• Section IV. Storage of Materials
• Objectives.
• Types of Stacks and Their Use.
• Orderliness.
• Honeycombing.
• Storage Aids.
• Floor dunnage.
• Short dunnage.
• Pallets (general).
• Box pallets/pallet support sets.
• Summary for Storage Aids.
• Section V. Principles of Materials Handling
• Materials Handling Efficiency.
• Various Types of and Advantages in Using Mechanical Equipment.
• Types of equipment.
• Movement Factors.
• Factors to be considered in vertical movement.
• Principles of Materials Handling.
• Principle of continuous flow.
• Principle of concentration of operation.
• Applied to manual handling.
• Applied to mechanical handling.
• Balance in an operation.
• Summary.
• Chapter 8. STORAGE MANAGEMENT TECHNIQUES
• Directing
• Manpower and Equipment.
• Production.
• Analysis of Methods.
• Use of Incentive Awards Program.
• On-site Reviews and Checks.
• Appendix A: REFERENCES
• Appendix A: REFERENCES (cont)
• Appendix A: REFERENCES (cont)
• Appendix B: FORMS
• Appendix C: METRIC/TEMPERATURE CONVERSION CHARTS CHEMICAL INDEX
• Appendix C: METRIC/TEMPERATURE CONVERSION CHARTS CHEMICAL INDEX (CONTINUED)
• GLOSSARY
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• GLOSSARY (Cont)
• TM-38-400
• Distribution:
• Recommended Changes to Equipment Technical Publications
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