Consulting
TCI leverages unmatched experience across all three perspectives – Military, AE Industry, and Regulatory – to guide your organization through the complexities of DoD Manual 4145.26 compliance. Our consulting services include site feasibility assessments, virtual program reviews, process risk management, and hazard analyses. With a structured, efficient approach, TCI helps organizations achieve compliance, reduce risk, and optimize operational performance.
Subcontractor Flow-Down Compliance Audits
Most U.S. Government DoD AE procurement contracts reference DFARS 252.223-7002, “Safety Precautions for Ammunition and Explosives,” which assigns prime contractors the responsibility of ensuring all subcontractors comply with DoD explosive safety requirements. TCI helps organizations develop, maintain, and perform these compliance audits, ensuring subcontractor networks meet the highest safety standards.
Comprehensive Explosives Safety Programs
Contractors must maintain a comprehensive, documented AE Safety Program in compliance with DoD regulations, as well as a robust Process Safety Management (PSM) program per 29 CFR 1910.119. TCI integrates these programs with broader industrial safety requirements—including lockout/tagout, confined space entry, PPE, and electrical safety—ensuring your explosives safety and PSM programs are complementary, practical, and fully compliant.
Process Hazards Analysis (PHA)
A comprehensive PHA is essential for designing safety into AE operations. Effective PHAs involve collaboration across management, production, engineering, maintenance, and safety teams—they are not solely a safety team activity. TCI guides organizations in conducting data-driven, high-quality PHAs in alignment with DoD Manual 4145.26, helping identify inherent risks and improve operational safety.
Explosives Safety Site Plans (ESSP)
The ESSP is central to any robust Explosives Safety Program. It documents safe operational and storage distances, handling procedures, SOP and PHA references, critical infrastructure, emergency response protocols, and inclement weather procedures. TCI assists in developing ESSPs that comply with DoD Manual 4145.26, while providing practical guidance to maintain the safest possible work environment.
Quantity Distance (QD) Assessments
An integral component of any AE contractor’s Explosives Safety Site Plan, QD assessments evaluate explosives hazards—incorporating hazard divisions and net explosive weights—to determine safe operational and storage distances. TCI assesses separation requirements to prevent sympathetic propagation protecting personnel, facilities, and the surrounding community.
Blast analysis and modeling
Sometimes, adhering to the Cardinal Principle of Explosive Safety—minimum number of personnel, minimum amount of time, and minimum quantity of energetic material—is not enough due to site constraints. When distance alone cannot meet QD criteria, TCI provides engineering solutions using blast mitigation techniques. Our engineers employ DDESB-approved methodologies to model overpressure and fragmentation hazards which inform facility design ensuring maximum protection in constrained environments.
Site Feasibility Assessments
Evaluating whether a site meets AE production safety requirements can be complex. TCI’s streamlined assessment process can typically be completed in a one-day site visit with input from key process owners, providing actionable guidance for informed, efficient decision-making.
Corrective Action Request (CAR) Review and Response Development
Even in highly controlled environments, deficiencies can occur. Regulatory oversight may trigger a Corrective Action Request (CAR). TCI analyzes deficiencies, designs process improvements, and assists in preparing compliant CAR responses, helping organizations refocus on safe, effective operations.