Download - Baffle Range Procedures_TBRL

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GOVERNMENT OF INDIA

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TBRL / PAMPHLET /B.R.01 / 2006

BAFFLE RANGE PROCEDURES

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DISTRIBUTIONS

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COPY NO.

1. DIRECTOR OF ARMAMENTS , DRDO HQ, DRDO BHAWAN, NEW DELHI-110011

1

2. DIRECTOR MT-5, INTEGRATED HQ OF MOD(ARMY), ARMY HQ, NEW DELHI-110011

2,3

3. DIRECTOR, CTEC, DRDO BHAWAN NEW DELHI-110011

4,5

4. DIRECTOR, TERMINAL BALLISTICS RESEARCH LABORATORY, SECTOR-30, CHANDIGARH-160030

6

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CONTENTS

PREFACE vii

PART-1 INTRODUCTION

SECTION Para I GENERAL

Need of Baffle Range 2. Policy 5.

PART-2

DEVELOPMENT OF BAFFLE RANGE II BAFFLE RANGE

Baffle range-Mark(I) 7. Baffle range-Mark(II) 9.

III EVALUATION OF BAFFLE RANGE PERFORMANCE

General 13. Feasibility of ground barriers concept 15. Feedback on Baffle Range Performance 16. Findings of performance studies 17.

PART-3

BAFFLE RANGE PLANNING & DESIGN CONSIDERATIONS IV PLANNING & LAYOUT OF BAFFLE RANGE

General 18. Determination of user needs 23. Baffle Range Layout Considerations 25.

V SELECTION OF SITE FOR BAFFLE RANGE

General 26. Feedback form for evaluation of site 28.

Guidelines for selection of site for Baffle range 29. Orientation 29.

Ground characteristics 30. Direct fire zone 31.

No-man land 32. Surrounding structures 33.

Minimum land area dimensions for Baffle range 35. Preliminary site plan 36. Before assembly of the BOO 39. Approval of Baffle range site 40.

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VI GUIDELINES FOR BAFFLE RANGE CONSTRUCTION General 42. Design Parameters 44.

Construction Considerations 45. Side Wall Pair 45.

Baffle walls 46. Stop Butt 47. Ground Barriers 48. Direct fire zone 49. Support Facilities 50.

Weather Protections 51. Approval of construction drawings 52. Construction Inspection 53. Test Fire in Baffle range 54.

PART-4

BAFFLE RANGE OPERATION & MAINTENANCE VII BAFFLE RANGE OPERATION & SAFETY

General 55. Baffle Range Control Considerations 57. Cost effective, safe Baffle range design 61. Range officers can make Baffle ranges safer 63. Avoid Accidents 64. Performance assessment of Baffle range 65. (Logbook and Digital Photograph)

VIII BAFFLE RANGE MAINTENANCE General 66. Fitness for use 67. Scheduled Maintenance 68.

IX SAFETY AUDIT OF BAFFLE RANGE IN SERVICE

Safety audit of Baffle Range (Half yearly) 74. Annual Monitoring of Baffle Range 76.

PART-5

SALIENT FEATURES X IMPORTANT POINTS ON BAFFLE RANGE

General 77. Firing Practice 81. Baffle Range safety 82.

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PART-6 GLOSSARY

XI DEFINITIONS XII THE 4 ES FOR BAFFLE RANGE

PART-7

ARCHITECTURAL LAYOUTS OF BAFFLE RANGE

DRAWING-01. BAFFLE RANGE -300M DRAWING-02. BAFFLE RANGE -300M ISO SHADED DRAWING-03. BAFFLE RANGE -300M ISO DRAWING-04. BAFFLE RANGE -300M PLAN& SECTION DRAWING-05. 100M SEGMENT OF 300 M BAFFLE RANGE DRAWING-06. BAFFLE RANGE- 100M PLAN & SECTION DRAWING-07. 50 M SECTION OF 300 M BAFFLE RANGE DRAWING-08. BAFFLE WALL DRAWING-09. BAFFLE WALL-ARMOUR PLATE FIXING DRAWING-10. SIDEWALL DRAWING-11. STOPBUTT DRAWING-12. MARKERS GALLARY, SIDE WALL & BAFFLE WALL DRAWING-13. MARKERS GALLARY DRAWING-14. GROUND BARRIER DRAWING-15. FIRING POINT DRAWING-16. BAFFLE RANGE -500M PLAN

LIST OF FIGURES Para A typical conventional classification firing range 1. Baffle range-Mark(I) at Infantry School Mhow 8. Model of 100m Baffle range-Mark(II) 10. Computer model of 300m Baffle range-Mark(II) 11. LIST OF FORMS /FORMATS Feedback form for evaluation of site 28. Baffle range usage logbook format 65. Baffle range safety audit form 76.

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PREFACE

This Pamphlet provides guidelines for planning & layout design of a Baffle Range, a reduced danger area range for practice firing with small arms. A safe Baffle range results if and only if it is operated safely, the firers are controlled by the rules and safety policies and its fitness is maintained. Therefore recommendations regarding Baffle range construction design, maintenance, fitness certification, usage and safety audit are also included herewith. These guidelines/ recommendations are based on literature survey, feedback received on performance of already constructed Baffle ranges and extensive data generated through trials at TBRL in recent years.

The 4 Es (Evaluate, Engineer, Educate, and Enforcement) must be used at every step during development and usage of a Baffle Range. The design guidelines/recommendations, safety rules and safety policies stated in this Pamphlet and in Pamphlet No.33, Infantry Training , Volume III, Range and Courses, Range Construction and Regulation (All arms) must be enforced on the Baffle range construction and usage so as to ensure required safety and service life. The attention of users is especially required in Part-4 of this pamphlet Baffle range operation & maintenance so as to ensure safe firing practices and longer service life for Baffle range.

It is hoped that the users will find these guidelines helpful in planning Baffle ranges which are cost effective, while affording safer service.

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PART-1

INTRODUCTION

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TBRL / PAMPHLET / BR01/ 2006; Oct 2006; Copy: 06; Sheet 1

SECTION-I

GENERAL

1. Small Arms Firing Range is a live-fire training facility for practice firing with small arms. Conventional Classification Ranges (CCR) used for firing practice with small arms are provided a danger area extended up to 1830 m behind the stop butt. The danger area provides a safe zone for the misdirected bullets resulting from possible errors made by soldiers in both horizontal and vertical directions during practice firing. It must be free from buildings, roads, footpaths, etc. These ranges were not very safe and several accidents have been reported because free flight rifle bullet can travel up to 3 Kms.

A TYPICAL CONVENTIONAL CLASSIFICATION FIRING RANGE

Need of Baffle Range 2. The area required for a classification range with full danger area is around 500 acres which is quite huge. There is an overall shortage of classification ranges primarily due to non availability of adequate and suitably situated land for constructing safe and efficient ranges. Troops have to travel long distances for practice firing. Therefore it has become necessary to explore an alternative means whereby land requirement for classification ranges can be minimized and yet the firing practice is carried out without compromise. 3. The requirement of danger area for classification ranges can be reduced up to 20 acres by providing suitably designed ballistic protection structures (such as baffle walls, side walls, ground barriers, bullet catchers, stop butt etc) at specified locations, properly conditioned impact surfaces, regular upkeep of impact area and strict enforcement of safety rules/ precautions in the range. 4. Such a great saving of land creates a possibility of having practice firing ranges at cantonments with short availability of land due to increasing population and very high estate cost. Keeping this in view, TBRL Chandigarh has been indigenously developing concept/layout design of a range with reduced danger area requirements, termed as Baffle range, as an alternative effective and safe facility for small arms practice firing. Policy 5. In view of increasing density of civilian population in and around Cantts, construction of Baffle range assumes greater importance with a view to avoid accidents and consequent litigation cases. Keeping in mind present commitments of army and likely pattern of

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operations, it has been agreed that construction of Baffle range up to 300m would meet training requirements of army. However, where possible, scope for extending the Baffle range up to 500m at a later date should be created. 6. In order to ensure timely action: (a) HQ Commands will project Baffle ranges in MWP. (b) QMG Br. will plan allotment of funds for each Command. (c) E-in-C Br. will monitor construction of each Baffle range from BOO stage onwards till

completion. (d) DG MT will process the case to obtain In Principle approval for construction of

Baffle ranges from MOD, and monitor progress of allotment of funds and construction of Baffle ranges on quarterly basis.

(e) Board of Officers (BOO) detailed by concerned formation at a given site will invariably have a member from TBRL, Chandigarh.

(f) A copy of preliminary site plans, technical data including zoning maps, aerial photographs, topographic maps and duly filled feedback form for site evaluation (para-28.) relevant to each site should be forwarded to TBRL Chandigarh two weeks before assembly of the BOO at a given site. The four corners of proposed sites must be flag-marked and access to site must be ensured at the time of clearance for Baffle range site. Wherever required, representatives of TBRL will visit specific site for according site clearance.

(g) Representatives from each Zonal Chief Engineer under whose jurisdiction, work on Baffle ranges has been sanctioned, will report to TBRL Chandigarh with detailed engineering drawings specific to each site for final clearance, before execution of work. The construction design & drawings of Baffle range should be in accordance to architectural design layout and recommendations given in this pamphlet and Pamphlet No.33, Infantry Training , Volume III, Range and Courses, Range Construction and Regulation (All arms).

(h) Each HQ Division/Area will constitute a standing board of officers to inspect the baffle ranges under their jurisdiction. A report will be forwarded to respective HQ command for the period ending 01July and 31Dec every year. Inspection will cover the parameters given in Baffle range safety audit form in para 76. of this pamphlet. HQ commands will forward a consolidated report to Army HQ/MT-5 giving only the relevant points, for further action.

(i) An evaluation committee comprising representatives of QMG, E-in-C, DG Inf, DGMT, HQ DRDO, TBRL and Col GS (Training) HQ command will annually monitor and evaluate the maintenance and performance of one baffle range to be selected by DGMT/MT-5. The committee will prepare a report for perusal of DGMT/DCOAS(IS&T).

(j) For initial two years usage of each Baffle range quarterly feedback data and digital photographs (refers para-65) should be forwarded by respective user units to TBRL Chandigarh so as to access effectiveness of Baffle range and need for further improvements.

(k) Pamphlet on Baffle range and any amendment in future will be issued by TBRL to DGMT. These will be further issued to HQ Commands and down to Brigade level.

(l) A set of typical architectural drawings showing necessary details required for preparation of estimates and site specific construction drawings of Baffle range-Mark(II) will be provided by TBRL rep at BOO stage.

PART-2

DEVELOPMENT OF BAFFLE RANGE

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BAFFLE RANGE PROCEDURES TBRL / PAMPHLET / BR01/ 2006; Oct 2006; Copy: 06; Sheet 3

SECTION-II

BAFFLE RANGE Baffle range-Mark(I) 7. First Baffle range was constructed at Infantry School Mhow, in 1995. 8. Baffle range-Mark(I) comprised of nineteen baffle walls (33m wide 8.5m high and with 22m wide, 2.5m -4.2m high opening from GL) and one Stop-butt (33m wide10m high). It is used by 6 firers at a time. It has firing points at100m, 200m, 300m. This design has been modified and number of baffles has been reduced from 6 per 100m to 2 per 100m making it cost effective.

BAFFLE RANGE-MARK(I) AT INFANTRY SCHOOL MHOW

Baffle range-Mark(II) 9. Since these early beginnings continuous studies were conducted at TBRL using trial data and user feedback. These studies revealed need of modifications in the Baffle range-Mark(I) through an improvised concepts of a system of ground barriers, side walls, baffle walls and stop butt to arrest the misdirected bullets. The new concept requires lesser number of baffle walls as compared to Baffle range-Mark(I) 10. The modified Baffle range-Mark(II) provides improved performance with reduced risk, enhanced overall safety, ricochet reduction, reduced overall construction cost and accommodates six firers in lying, kneeling and standing in trench positions. It has a number of ground barriers to eliminate ricochets from ground surface.

MODEL OF 100M BAFFLE RANGE-MARK(II)

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11. According to army units the Baffle range should provide safety for error of 14 deg in horizontal plane and 11 deg in vertical plane from all firing point. The required safety of the range was achieved in Baffle range Mark-II by (a) Providing baffle walls with more width [35.8m(6.9+22+6.9)] and more height [9.1m]. (b) Increasing vertical clearance of 22m wide opening in all baffle walls to 4.1m above GL. (c) Providing 6.9 m wide x 9.1 m high side wall pairs at 44m, 55m, 85m in every 100m

segment. (d) Increasing the width of side wall pair at target gallery to 8.2 m (e) Enclosed type Stop Butt for maximum safety [12 m high & width (9+22+9) 40m].

COMPUTER MODEL OF 300M BAFFLE RANGE-MARK(II)

12. Detailed layout drawings for Baffle Range-Mark(II) are place at Part-7 of this pamphlet. Site specific construction design must be in accordance to these detailed layout drawings as well as the guidelines in this pamphlet & Pamphlet No.33, Infantry Training , Volume III, Range and Courses, Range Construction and Regulation (All arms) .

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SECTION-III

EVALUATION OF BAFFLE RANGE PERFORMANCEGeneral 13. Baffle Range-Mark(II) has been made at few places. A 100m Baffle range-Mark(II) was constructed at TBRL, Ramgarh Range for field trials to collect feedback on range performance, firearms testing, and as a means of developing accurate ammunition. 14. The range was studied theoretically & experimentally as well as shown to various perspective users for valuable suggestions so as to achieve a design with enhanced safety. Feasibility of ground barriers concept 15. Feasibility of ground barriers concept was evaluated through preliminary trials at the Baffle range at TBRL and by exhaustive trials in form of simulated test firings at a layout prepared at Infantry School, Mhow. Feedback on Baffle Range Performance 16. TBRL is in the continuous process of getting feedback about the performance of these Baffle Ranges. Extensive theoretical and practical studies are being carried out using feedback from user and trials so as to achieve continuous improvements in Baffle range concept like greater range safety, longer life, minimum maintenance etc. Findings of performance studies 17. These studies revealed following: (a) Cost effective, safe, low maintenance Baffle range design can result only if safe,

controlled firers are an assumption. There is no possibility of any bullet escaping Baffle range if practice firing is executed with in permissible firing errors. In case of aimed firing the probability of a bullet hitting some RCC ballistic structure is very less.

(b) A RCC structure meeting a bullet hit develops local damage which must be repaired using suitable repair material as soon as possible.

(c) If a local damage to RCC structure is not repaired quickly, multiple bullet hits at the same location can cause very heavy damage / damage beyond repair. Consequently huge maintenance costs may be involved as well as the effective service life span of such Baffle range will get reduced considerably.

(d) The concept of ground barriers although useful, but can result in ricochets if soil slopes are not maintained properly.

(e) The performance and utilization of the present Baffle ranges Mark-II can be improved manifolds by providing partial lining of rifle grade material of hardness 480 BHN/ sacrificial material like SIFCON (Slurry Infiltrated Fiber Concrete) panels of suitable thickness on baffle walls and stop butt. The armour steel plates of hardness 480 BHN can be supplied by PEC Ltd.(A Government of India Enterprise), Hansalaya, 15 Barakhamba Road, New Delhi-110 001, Tel 011-2331 4727, Fax no. 011-23315279, 23314797 & 23313664, E-mail: [email protected], Web:www.peclimited.com. The randomly selected sample of armour plates should be ballistically evaluated at TBRL Chandigarh

(f) Longer service life and higher safety with very less maintenance can be achieved by using suitably inclined overhead baffles made of rifle grade material and angled side walls. The new concept is being analysed at TBRL Chandigarh. The cost of implementing this new concept will be almost same as that of the present design of Baffle range-Mark(II) incorporating partial lining of armour plate.

PART-3

BAFFLE RANGE PLANNING & DESIGN CONSIDERATIONS

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SECTION-IV

PLANNING & LAYOUT OF BAFFLE RANGE General 18. A new range is planned, designed, and constructed based upon the needs of the specific user. 19. All decisions in planning, designing and construction of a baffle range are based on proven engineering practices. 20. Individual units may establish design criteria exceeding the minimums specified in this pamphlet and pamphlet-33. Various agencies should jointly develop site-specific designs. 21. The range design must also address noise control and environmental hazards resulting from the use of ammunition containing lead. 22. Planning should be logical so that nothing is overlooked or left to chance. Suggested guidelines are outlined below. Determination of user needs 23. The first decision is to identify the types of practice firing necessary to meet the needs of the user unit. 24. The range type, size, and configuration is based upon the training needs of individual units, weapon-specific training requirements, land availability, location of range, length of range, firing line & target line requirements, climatic & ground conditions, soil type etc. Baffle range layout considerations 25. Various consideration specified in the Pamphlet No.33, Infantry Training , Volume 3, Range and courses must be satisfied for following: (a) Range area: There are certain basic and optional considerations used to layout ranges.

Among these are: terrain features, site dimensions, type of range, soil structure, surrounding inhabitants, access and utilities.

(b) Direct fire zone The ground between the targets and firing line must be free of any hardened surface, such as rocks or other ricochet producing materials, up to 30cm depth.

(c) Firing line area: Firing points , firing point numbering scheme, firing line enclosure or cover, space for support activities, walkways etc.

(d) Target line area: Target carriers spacing for small arms practice firing ranges is determined by the size of the carrier used, and may vary from a minimum of about 2.5 mtrs up to a maximum of 3.65 mtrs (centre to centre).

(e) Backstop: Backstop construction must meet certain specific criteria: be wider than the target area; provide clean earthen surface material to a depth of 450-600mm at a slope >400.Horizontal bullet catchers provide maximum use of the exposed surface area.

(f) Baffles and other safety barriers Vertical, overhead, ground and side baffles are barriers used to keep errant bullets confined to a restricted area of the range. Adding these barriers is often expensive, but properly installed they can reduce land requirements. Baffle ranges over 300 meters in length is not practical.

(g) Side Containment Side berms may be in the form of earthen embankments, concrete walls or wooden crib/earth embankment combinations.

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SECTION-V

SELECTION OF SITE FOR BAFFLE RANGE General 26. A suitable internal board of officers including officers from user unit and MES should be constituted to identify several sites because one or more may prove unsuitable or construction costs may be prohibitive. 27. The BOO should collect technical data including zoning maps, aerial & normal photographs, topographic maps, relevant to each site. The on-site information should be gathered both on the ground and in the air. Feedback form for evaluation of site 28. Suitability of a site is determined on the basis of feedback on each site in a format placed below.

FEEDBACK FORM FOR EVALUATION OF SITE1 Access:

( Dedicated right-of-way, Dirt road, Paved road Gravel road or No access). Poor Access necessitates construction of roadway to site.

Location: (Travel distance for firers) Locate the range as convenient to the users as possible.

2

Orientation The ideal orientation is with firing conducted from South to North to minimize glare.

3 Utilities available Electricity Phone Water Sanitary Sewer etc.

4 Residential area Noise complaints are likely when residential areas exist within 360m from the Baffle range.

5 Size An area large enough to accommodate the appropriate disciplines and projectile containment as modified by existing topographic features, and/or additional range features.

6 Area geology (Clay, Sand, Heavy rocks etc.) Affects cost of conditioning the site

7 Vegetation (Cleared , Scrub brush, Light timber, Heavy timber etc.)

8 Topography (Desert, Plains, Hilly, Mountainous, Flood Plain) Affects cost of Construction

9 Weather Dry, Semi-Dry, Wet, Heavy Snows etc.

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10 Water bodies in Baffle range area Lakes , Ponds, Rivers, Falls etc.

11 Zoning Rural, Residential, Light industrial, Heavy industrial, Agriculture, Conservation, Recreational, Airport.

12 Environmental Restrictions Necessitate approvals in these matters. During the site selection phase, every effort should be made to minimize any adverse impact on the surrounding environment.

Endangered Species Act Wilderness Act Air and water pollution Health department requirements Sound Transmission Zoning regulations Soil conservation standards

13 Explosive storage magazines & Hazard Classification STEC Pamphlet No.1 Quantity Distance Regulations for Military Explosives, 1993 of DRDO is relevant.

14 No-man land Minimum 50m no-man land (with sufficient greenery)on sides and back of the direct fire zone/ range area

15 Future expansion

16 Character of ground (i) Character of ground in rear of targets, height, slope and so on. (ii) Character of ground in front of targets, if rising or falling towards target line. (iii) Is there a clear line of sight from all firing points to all targets. If not, what work will be required to obtain a clear line of sight?

17 Safety Precautions What arrangements exist or are proposed to prevent persons entering the danger area while firing is in progress? Full details should be given and positions of sentries, flag poles, and so on shown on the map.

Any other information: Station: Place: Prepared by: Approved by:

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Guidelines for selection of site for Baffle range 29. Orientation A Baffle range should be sited facing NORTH. 30. Ground characteristics As a general rule a site on level dry ground is the best. (a) Sites on rocky, uneven, rising or falling ground cause difficulties in construction and

usage and also tend to decrease the safety of the Baffle range. (b) A hollow site is unsatisfactory. (c) An uphill line of sight must be avoided. 31. Direct fire zone (a) The direct fire zone must be stone free up to 30 cm depth. (b) Soil additives must be tested to ensure that they will not cause cementing or hardening

of the soil surface. (c) Direct fire zone should not be in wetlands or in locations subjected to frequent

flooding. 32. No-man land (a) There must be at least 50m no-mans land on sides and back of Baffle range. (b) The no-man area must be maintained green through protecting existing trees &

vegetation and plantation of suitable trees not higher than 15 feet. (c) A 3.6 m high boundary wall of RCC/brick must be constructed around the direct fire

zone at 15m distance from the edges of the stop butt & direct fire zone. Facilities like target store & workshop , troop shelters, facilities for maintenance, rest rooms, observers shade, range complex, toilets, stores, vehicle parking shades, underground water storage etc, can be constructed at safe & suitable locations in no-man area and within range boundary.

(d) Any facility within the Baffle range boundary should not be constructed exactly behind firing point.

33. Surrounding structures: (a) The range line of fire should not be in the direction of residential areas or upwind of

residential areas. (b) Distance of residential area from the Baffle range should be at least 360 m in view of

noise pollution from the Baffle range, (c) No multistory complex be allowed within 100 m on sides only of the range body. (d) Any magazine for explosive storage must be located as per STEC Pamphlet No.1

Quantity Distance Regulations for Military Explosives, 1993 of DRDO. (e) No airport should exist within 400 m of the Baffle Range. 34. Site a Baffle range with the prevailing wind blowing from the firers back toward the

target line. 35. Minimum land area dimensions for Baffle range (six firers): (a) 100m Baffle range-140m x 195m . (b) 300m Baffle range-140m x 395m . (c) 500m Baffle range-140m x 595m .

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Preliminary site plan 36. The internal board of officer should collectively review the compatibility of proposed land/ location for Baffle range usage based on the information collected as per 27. & 28. above. 37. After identifying suitable site(s) the information gathered under previous steps is applied to the rendering of preliminary site plan drawings in following steps: (a) Prepare preliminary layout sketches for each site. (b) Applicable zoning, environmental, building code, and other pertinent restrictions must

be included in the draft document specifications. (c) Prepare alternative preliminary site plans showing different layouts. (d) Prepare a safety plan for each specific site. (e) To flag-mark four corners of proposed sites (f) To ensure access to sites. (g) Take digital photographs of each site from suitable positions (like from 4 flag-marked corners) so as to have a clear idea of the site as well as surrounding structures during documentation. 38. On the preliminary site plan, surrounding structures should be located and intervening distances highlighted. These plans should be drawn to scale so that they can be utilized with topographic maps or aerial photographs. Before assembly of the BOO 39. Before assembly of the Board of Officers detailed by concerned formation at a given site: (a) A copy of preliminary site plans, technical data including zoning maps, aerial and

normal photographs, topographic maps, feedback formss for site evaluation relevant to each site should be forwarded to TBRL Chandigarh for study and comments.

(b) If possible, at least one officer of the internal board should visit TBRL Chandigarh for technical discussions on preliminary site plans.

Approval of Baffle range site 40. At this point, all elements necessary for final site selection should be in place. The four corners of proposed sites must be flag-marked and access to site must be ensured. 41. Preliminary site plans along with previous documentation, should provide enough information to make the final site selection by the Board of Officers detailed by concerned formation at a given site.

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SECTION-VI

GUIDELINES FOR BAFFLE RANGE CONSTRUCTION General 42. Construction plans should follow the usual format used by architects and engineers detailing specifications for a builder. These plans should include at a minimum a layout of the proposed range in cross section and top view. The necessary professional help, such as, a consultant, an engineer, an architect, a surveyor, a draftsman should be hired to complete the plans for the construction phase. 43. The Baffle range and its support facilities, when completed, must satisfy or exceed the requirements of this pamphlet and . Pamphlet No.33, Infantry Training , Volume III, Range and Courses, Range Construction and Regulation (All arms) Design Parameters 44. Loading to be considered during design of structures comprises of dead load, wind load, earthquake load, snow load, impact load due to minimum two bullets (weight 10gms each moving at 850m/sec) Construction Considerations 45. Side Wall Pair comprises of two 9.1m high (above MGL-made up ground level) 6.9m wide walls separated by 22m. Side walls may be minimum 230 mm Brick envelop with suitable beams and columns of M25 RCC. 46. Baffle walls comprises of a pair of side wall [9.1m high(above MGL) & 6.9m wide] integrated with a 22m x 5m horizontal baffle 4.1m above MGL. (a) In horizontal baffle

lower 3m band is minimum 300mm thick M25 RCC and Upper 2m band may be minimum 230 mm Brick envelop with suitable beams

and columns of M25 RCC. (b) Integrated vertical side wall may be minimum 230 mm Brick envelop with suitable

beams and columns of M25 RCC. (c) The lower 2m band of the baffle is exposed to severe bullet impact and must be

provided extra reinforcement by using Sacrificial lining of minimum 75mm thick SIFCON panels in 24m x 2m area

as shown in drawing of baffle wall. The sacrificial lining need to be replaced before it is damaged to exposes the RCC surface of the baffle. Approximately 3.8 m3 of SIFCON will be required per baffle.

Non-sacrificial lining of 10mm thick armour plate of hardness 480 BHN covered with 30mm soft wood in 24m x 2m area as shown in drawing of baffle wall. The non-sacrificial lining need only protection from weather to last for the life of baffle if aimed firing is assumed. Approximately 3.85 ton of armour grade steel of hardness 480 BHN will be required per baffle.

47. Stop Butt (a) Stop butt is 40m wide 12m high (minimum 300mm thick M25 RCC) with stone free

(to a minimum depth of 450-600mm) soil compacted at a slope of minimum 40deg inside a 22m wide 6m high 7.5m deep box (minimum 300mm thick M25 RCC).

(b) The stop butt must be provided extra reinforcement by using a 10mm thick armour plate of hardness 480 BHN covered with 30mm soft wood in 24m wide lower 2m band of the horizontal baffle and on upper 2m band of rear wall of soil box as shown

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in drawing of stop butt. Approximately 7.4 ton of armour grade steel of hardness 480 BHN will be required for stop butt reinforcement.

48. Ground Barriers A Ground barrier comprise of 0.35m high (above GL)wooden boxes made of 30mm soft wood filled with washed gravel and closed on top with a 0.25m(min) wide 0.15m high right angled triangle cap of soft wood. These wooden boxes are backed on side facing stop butt by compacted stone free soil (refer drawing). The total height of ground barrier above OGL must not exceed 0.55m (so as to keep it 50 mm below top of firing points and target gallery). 49. Direct fire zone (a) Firing points & trenches, Markers gallery & Mantlet must be constructed in

accordance to Pamphlet No. 33. (b) The ground in 50m segment of direct fire zone near target line is to be given a

downward slope of 1 towards the target gallery. As the top level of Baffle walls and sidewalls is the same, the height of various structures in this 50m segment will increase as per the made up ground level.

(c) Top level of firing points and target gallery should be same (i.e. 0.6m above GL). (d) The ground between the targets and firing line must be free of any hardened surface,

such as rocks or other ricochet producing materials, up to 30cm depth. Ideally, surface areas should be nearly level, sloping only enough to provide drainage. The range floor or ground surface should be planted with low growing ground cover (a healthy quality grass mixture suited to the area). Grass reduces heat on Baffle range and enhances its appearance.

50. Support Facilities

As per the requirements of the user unit support facilities like target store & workshop , troop shelters, maintenance areas, rest rooms, observers shade, range complex, toilets, stores, vehicle parking shades, underground water storage etc, can be constructed at safe & suitable locations in no-man area and within range boundary. Weather Protections 51. Weather effects should be addressed by applying weather proof coatings on RCC structures and steel, treating wood for weather and termites, providing suitable drainage/ pumping for rain water etc. The frontal area of all structures will have a fiber plaster of thickness not less than 15mm. Approval of construction drawings 52. To conclude the project: (a) Follow through with all commitments and requirements identified (b) Prepare final construction plans, specifications and cost estimates. (c) Obtain all necessary approvals.

Detailed plans showing specific dimensions and locations are needed to obtain approval of final construction drawings from TBRL Chandigarh before commencement of construction..

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Construction Inspection. 53. Validate that the proper materials have been used and construction complies with the specifications and drawings. (a) The materials, distances, and angles are critical to safety and must be verified

according to this pamphlet and Pamphlet No.33, Infantry training volume III, Ranges and courses.

(b) Distances from the firing lines to target lines are critical and must be measured during construction and on completion of the range.

(c) Availability of required no-man land must be ensured. (d) All barriers, fences and signs must be erected, Test Fire in Baffle range 54. In a newly constructed baffle range controlled test-firing must be accomplished using tracer ammunition before conducting practice firing operations. An expert board will act as observers. The most experienced firers available will use the most powerful ammunition authorized for use on the range, for the test.

PART-4

BAFFLE RANGE OPERATION & MAINTENANCE

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SECTION-VII

BAFFLE RANGE OPERATION & SAFETY General 55. The conventional classification range accommodates the controlled and supervised discharge of weapons and has sufficient land area to ensure that the discharged projectile does not exit the safety fan comprising of surface danger zone (SDZ) and vertical danger zone (VDZ). 56. Direct-fire rounds and ricochets are unimpeded and may fall anywhere within the safety fan. The conventional classification range requires a safety fan equal to 100 percent of the maximum range of the most powerful round to be used on the range. Baffle Range Control Considerations 57. Proper and efficient range operations are vital to the success of any practice firing Baffle range. Basic and advanced schools must be conducted to familiarize firers/ trainers with the Baffle range and how to set up and conduct a practice firing. Copies of all practice firing program guidelines, rule books & TBRL pamphlet Baffle Range Procedures should be included in the range library. 58. Smooth functioning of Baffle range requires equipment like phone systems, public address systems. flags, radios etc. Proper use of equipment has a great effect on how long it will last. Firers must be trained for operating target carriers & equipment, target preparation etc. 59. Range control serves to provide rules and supervision that encourage safe, healthful and proper use of a small arms practice firing Baffle range. To be considered are: (a) Posting rules, regulations & signs, use of safety devices etc., (b) Provision of administrative facilities such as statistical office, communication system, (c) Provision of range optional features like waiting areas, restrooms, portable toilets,

trash receptacles etc. (d) Landscaping is an important means of making the Baffle range attractive. 60. A general safety consideration for small arms Baffle ranges is based on the maximum range of ammunition authorized for use on the facility. Cost effective, safe Baffle range design 61. A Safe Baffle range results if and only if it is operated safely and the participating firers are controlled by the rules and safety policies which must be enforced while using the Baffle range. 62. Cost effective, safe Baffle range design can result only if safe, controlled firers are an assumption. As per experienced range designers and range operators: A completely safe Baffle range cannot be designed. Though barriers are installed to limit bullets to a specific area, each user must be made aware of limitations of Baffle range and the reasons for them. Rule violations must have consequences.

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Range officers can make Baffle ranges safer 63. Range officers can create safer Baffle ranges by focusing on the following in addition to the safety rules already specified during practice firing on conventional ranges. At Baffle range, range officer must insist - (a) Fitness of Baffle range prior to conduct of any practice firing, (b) Firers to be aware of the administrative and safety rules at Baffle range, (c) Firing as a process of aiming and hitting the target (d) Firers to execute only aimed fire, (e) No firing at baffles, sidewalls, ground barriers, backstops or wooden frames, which

will destroy property, (f) Authorized number of firers at a time during practice firing, (g) Use of only authorized arms and ammunitions on Baffle Range, (h) Firing from authorized firing points, (i) Use of only authorized targets/ target materials, (j) Proper gun handling on the firing line by the firers, (k) Type of firing in relation to the distance to the target, (l) No firing when aircraft approach the danger area at heights less than those given for

the various weapons. Avoid Accidents 64. The great majority of accidents on ranges are due to carelessness and poor range discipline rather than to structural defects in the ranges. No set of safety rules is comprehensive, safety is not guaranteed by compliance with above. The individual range officers should take strict steps to ensure safety. Performance assessment of Baffle range (Logbook and Digital Photograph) 65. A logbook on Baffle range usage should be maintained in following format by Range officers so as to access its effectiveness and to provided feedback data for further improvements:

BAFFLE RANGE USAGE LOGBOOK FORMATDate User

Details No.of Firers

Firing Point

Firing position

Small arms used

Ammunition used

No. of rounds fired

Remarks & signature of Range officer-in-charge

Digital photograph of baffle walls, ground barriers, target gallery, stop butt, and

intermediate firing points should be taken every three months or as and when necessary.

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SECTION-VIII

BAFFLE RANGE MAINTENANCE

General 66. General maintenance starts when the Baffle range is planned. Proper maintenance of ballistic structures & ground, equipment and fixtures protects the long-term investment. Fitness for use 67. The range officer must insist range fitness for use through routine range maintenance comprising of- (a) Conditioning of range ground by grass cutting, trimming grass, removing any hard

object from direct fire zone, cleaning up litter etc. (b) Conditioning of ballistic protection structures through quick repairs (c) Restoring ground barriers regularly, (d) Restoring soil fill contours at backstop & berm, (e) Painting of important areas and signs Scheduled Maintenance 68. A good rule is to conduct maintenance chores regularly, rather than just before an event. Perform small tasks each time the Baffle range is used rather than wait until major repairs are needed. 69. Paste a maintenance checklist in the Baffle range and outline check-off blocks, so soldiers can indicate that they have completed a specific task. In addition, same checklist could be published in the Range newsletter. This checklist should also point out where tools and materials are stored at the facility. 70. Installation of underground telephone and electrical cables inside PVC pipe allows easy removal and replacement. 71. All steel used in constructing target carriers be hot dipped galvanized or painted with rust preventive paint. Such measures will ensure long-term, low maintenance use. It may require grease fitting or applicators at all wear points. Target carrier maintenance often consumes a great deal of time in a maintenance program. When carriers are poorly designed, the result is often frequent and expensive repairs. Therefore, before any practice firing event or during routine activities, any dirt or rust should be removed from the wear points, tighten loose fittings, weld or replace any broken parts. 72. To guarantee long-term use of range equipment, especially items subjected to weather related deterioration, a preventive maintenance program is required for repairing ballistic protection structures, cleaning storm water systems, repairing electrical systems, painting important areas, signs & parking lots etc., edging sidewalks, maintaining buildings, recovery of lead from soil fills etc. 73. Sufficient inventories including consumables and repair materials needed for maintenance during Baffle range usage should always be on hand.

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SECTION-IX

SAFETY AUDIT OF BAFFLE RANGE IN SERVICE Safety audit of Baffle range (Half yearly) 74. Each HQ Division/Area will constitute a standing board of officers to inspect the baffle ranges under their jurisdiction half-yearly as per check sheet placed below. 75. A report will be forwarded to respective HQ command for the period ending 01July and 31Dec every year. Inspection will cover the parameters given in check-sheet below. HQ commands will forward a consolidated report to Army HQ/MT-5 giving only the relevant points, for further action. Annual Monitoring of Baffle Range 76. An evaluation committee comprising representatives of QMG, E-in-C, DG Inf, DGMT, HQ DRDO, TBRL Chandigarh and Col GS (Training) HQ command will annually monitor and evaluate the maintenance and performance of one baffle range to be selected by DGMT/MT-5. The committee will prepare a report for perusal of DGMT/DCOAS(IS&T).

BAFFLE RANGE SAFETY AUDIT FORMSl. No.

Description Action Status

Is soil fill slope maintained? Is cleaning of lead required? Is there any serious damage to roof/ wing walls?

1 Stop Butt

Is reinforcement lining intact? Is there any water logging inside pit? Are trolleys working properly?

2 Target Gallery

Is mantlet maintained as per pamphlet-33? Whether trenches are OK? 3 Firing Points Is their any water logging inside OK? Is turfing OK? Are their any pebbles, hard surfaces, stones observed?

4 Range surface

Is ground slope maintained? Is there any serious damage? 5 Baffles walls & Side

walls Is reinforcement lining intact? Is there any serious damage? Are wooden boxes & caps intact? Is their any pebbles observed? Is soil surface slope maintained?

6

Ground Barriers

Is washed gravel filling OK? Is target storage area properly used? Is range complex properly used? Is range complex provided with basic facilities? Are proper roads and parking area provided? Is 50 m wide no-man area around range direct fire zone maintained green?

Is communication facility OK?

7 Support facilities

Is boundary wall around range OK? Remarks: (Member) (Member) (Member)

PART-5

SALIENT FEATURES

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SECTION-X

IMPORTANT POINTS ON BAFFLE RANGE General 77. Any general details (firing point, trench, target gallery etc.) may be taken from Pamphlet No. 33, Infantry Training , Volume III, Range and Courses, Range Construction and Regulation (All arms). 78. The Baffle range Mark(II) design provides a safety of 14 in the horizontal plane and 12 in the vertical plane. 79. Board of Officers detailed by concerned formation at a given site will invariably have a member from TBRL, Chandigarh. 80. Plan of action for construction of Baffle range should be in accordance to policy and directives issued at times by Integrated HQ of MOD(Army), General Staff Branch, MT-5. 81. Firing Practice (a) The Baffle range has firing points at 500,400,300,200,100 and 50m. The firing

practice for 50m will be for standing position only. (b) The Baffle range is to be used strictly for six firers only. (c) Ground in direct fire zone must be leveled, dry, stone free and turfed. (d) Before any practice firings the soil fill & slope at firing points, ground barriers, target

gallery and stop butt must be checked, conditioned and correctly made up. (e) The practice firings must be conducted under the supervision of trained personnel who

are fully conversant with the operation of Baffle Range. (f) Weapons authorized on the Baffle range include 9mm Carbine & Pistol; 5.56mm

INSAS Carbine, Rifle & LMG; 7.62 Gun Machine MAG58; 7.62mm Sub Caliber for 106 RCL; 9mm Sub Caliber for 84mm RCL; 7.62mm SLR, AK-47.

82. Baffle Range safety (a) The targets must be placed correctly (especially height) in the trolley system as

mentioned in Pamphlet No.33. Incorrect placement of targets will result in increased bullet hits on various structures.

(b) A 50m wide No-man land with barbwire fence and sufficient green trees (not higher than 15 feet) must be provided on sides and back of the Baffle range.

(c) A brick/stone masonry boundary wall of 3.6 m height is to be provided around the full range. Keeping in view the conventional range discipline, no movement of personnel to be allowed within the range boundary wall when the firing is in progress.

(d) It is evident that the misdirected shots will cause some damage to various structures. Hence fitness of all the structures must be periodically checked and repaired using appropriate repair material.

(e) A protective lining should be provided in the line of fire on front face of RCC structures to prevent heavy damage to it.

For more details contact: The Director, TBRL, Chandigarh.

PART-6

GLOSSARY

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SECTION-XI

DEFINITIONS Backstop: A device constructed to stop or redirect bullets fired on a range. Baffles: Barriers to contain bullets and to reduce, redirect or suppress sound waves. Baffles are placed either overhead, alongside or at ground level to restrict or interrupt errant or off-the-target shots. Barrel: The metal tube of a gun made from iron or steel, through which the bullet or shot charge passes when the gun is fired. Berm: An embankment used for restricting bullets to a given area, or as a protective or dividing wall between ranges. Bullet: A single projectile fired from a firearm. Bullet Trap: A device designed to trap or capture the entire bullet and fragments as opposed to redirecting the projectile into a sand pit. Cartridge: A self-contained unitized round of ammunition that is made up of a case, a primer, powder and a bullet. The case is usually made from brass but may be steel, metal alloy or plastic. Chamber: The enlarged portion of the barrel at the breech in which the cartridge is placed ready for firing. Direct Fire Zone: The area between stop butt and most distant firing line. Firing Distance: The distance between the firing line and the target line. Firing Line: A line parallel to the targets from where firearms are discharged. Firing Position (Point): An area directly behind the firing line having a specified width and depth that is occupied by a firer, his equipment and, if appropriate, an instructor. Firing Range: A facility designed for the purpose of providing a place on which to discharge firearms, shoot air guns and/or archery equipment. Firing Range Complex: It may include offices, classrooms, club houses, parking facilities and other related structures. Horizontal Bullet Catcher (Eyebrow Catcher): A device installed along a backstop, a berm, or on the range floor, and designed to capture ricocheting projectiles. More frequently used on backstop areas where the slope does not positively contain bullets. Impact Area: That area in a backstop or bullet trap directly behind the target where bullets are expected to impact. The term may also refer to an area down range of a Baffle range from first firing point towards stop butt where bullets will impact. Line of Sight: An imaginary straight line from the eye through the sights of a firearm to the target. Muzzle: The forward end of a barrel. Muzzle Velocity: The velocity of a projectile as it exits the muzzle of a firearm. Noise: Unwanted sound is referred to as noise. Criteria for elimination of ricochet from ground

The ricochets from ground can be eliminated by ensuring bullet impacting soft soil at an angle exceeding 30deg, so that it gets either embedded in the soil or simply splashes back after loosing most of its energy as a result of impact. The absorption of bullets misdirected towards ground can be achieved by constructing ground barriers ahead of firing point satisfying following requirements minimum possible number of ground barriers must be used. minimum maintenance requirements for shape of ground barriers. height of ground barriers must not interfere with bullet trajectory and allows easy

movement of soldiers, and also the requirement of ground slope is minimized.

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Rules and Regulations: Standards used in the operation of a firing range. Rules and regulations are set up to govern the method of range operation to include health and safety. The violation of range rules and regulations generally carries penalties enforced by range officer. Safety Baffles: Vertical or sloping barriers designed to prevent a projectile from traveling into an undesired area or direction. Most often used to prevent bullets from leaving a confined area. Small Arms: Firearms that may be both carried and discharged by one person, as opposed to artillery pieces. Small arms are not subject to precise definitions, but the term usually includes rifles, handguns (pistols), shotguns, submachine guns and machine guns. Small Arms Range: Small Arms Firing Range is a live-fire training facility for practice firing with small arms to improve the marksmanship skills of soldiers, and certifying personnel in the use of handguns, shotguns, rifles up to 7.62mm. Surface Danger Zone (SDZ): The portions of the range in the horizontal plane that are endangered by firing a particular weapon. The SDZ includes the area between the firing line and the target line, an impact area, a ricochet trajectory area, and a secondary danger area. The SDZ may also include a weapon back-blast area. The SDZ must be located completely within the boundaries of Armed force -owned or -leased properties. Target Line: A line parallel to the firing line along which targets are placed. Trajectory: The path a projectile travels from the muzzle to the point of impact. Venetian Blind Trap: A steel trap that has a series of angled plates, 45 degrees or less, sloping to the rear and toward the bullet impact area and installed in a vertical fashion as to resemble a Venetian Blind. The bullets are directed upon impact into a chamber located at the bottom of the device, where remaining velocity and energy are expended. The chamber provides easy access for lead removal. Vertical Danger Zone (VDZ): The VDZ is the volume of airspace above the SDZ between the ground surface and the maximum ordinate of a direct-fired or ricochet round. The height of the VDZ varies with the weapon and ammunition fired.

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SECTION-XII

THE 4 ES FOR BAFFLE RANGE

The 4-Es must be used at every step of developing a Baffle range. The 4-Es are: evaluate, engineer, educate and enforcement. (a) Evaluate the needs of the prospective user and identify the specific firing activities to

be conducted on the Baffle range. Evaluate how many firing activities will be conducted on the same piece of ground, but not necessarily simultaneously.

(b) Engineer each Baffle range to accommodate the specific activities which are to be

conducted on the same piece of ground/range. Intimate knowledge of each activity and a rule book specifying the detailed requirements (if applicable) of each activity is essential. Each activity's requirements will have to be considered in detail to ensure no conflicts in firing line design, target line location, target placement and target set up, etc. Once the design criteria have been established, it will be important for the user to truly understand that there will be very little room for change in use without returning to the evaluation phase with a view toward additional engineering to retrofit the range to accommodate the new activity.

(c) Educate the range officers and those who will be using the facility (firers) in the

specific actions that are acceptable. Firearms, firearm calibers, positions that can be used (standing, sitting/kneeling, prone), types of firing (slow fire only, rapid fire, etc.) are few topics that should be taken into consideration from inception as to how the range will or may be used. Briefings on the etiquette of firearms safety, how and when to approach the firing line, how and when to change targets, commands that will be used-and their meanings, range officer authority, etc. Careful consideration in this area will reasonably ensure that the Baffle range will never be used outside of its design criteria and thereby cause problems.

(d) Enforcement is the final phase of the 4-Es and ultimately is the glue that will hold all

these considerations together into one cohesive package. Enforcement solidifies the safety plan. The user must consider the specific methods and actions that will be employed to ensure the Baffle range is always used within the design criteria. Ultimately, it will be the responsibility of the range officer to determine the method to be used, assuring adherence to the rules and regulations established.

PART-7

ARCHITECTURAL LAYOUTS OF BAFFLE RANGE

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Part-7 Architectural Drawings of Baffle Range-Mark(II) ofBaffle Range Procedures,TBRL/PAMPHLET/B.R.01/2006;Oct 2006; Copy: 06 Drawing -1

BAFFLE RANGE -300M

The no man land must be green. Plantation of normal trees (10 to 15 feet high) is recommended.

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BAFFLE RANGE -300M ISO (SHADED)

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BAFFLE RANGE -300M ISO

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BAFFLE RANGE -300M PLAN

BAFFLE RANGE -300M SECTION

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100M SEGMENT OF 300 M BAFFLE RANGE

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BAFFLE RANGE - 100M PLAN & SECTION

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50 M SECTION OF 300 M BAFFLE RANGE

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BAFFLE WALL

75mm

75mm

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BAFFLE WALL-ARMOUR PLATE FIXING

Direction of fire

Left side view

Wood covering with two layers of 20mm & 15mm thick

RCC Baffle Wall

Screw- Flat head

20M SS Bolt 10cm in RCC, 9 mm projecting

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A 6 mm thick cap of armour grade steel should be placed above nut before fixing wood covering to avoid any damage to bolt due to bullet impacts.

Nut

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SIDEWALL

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STOP BUTT

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MARKERS GALLARY, SIDE WALL & BAFFLE WALL

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MARKERS GALLARY

Please refer Pamphlet No.33 for more construction details.

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GROUND BARRIER

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FIRING POINT

Height of any surface in firing point above ground level should not be more than 0.6m (including wood lining). Please refer Pamphlet No.33 for more construction details.

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Part-7 Architectural Drawings of Baffle Range-Mark(II) ofBaffle Range Procedures,TBRL/PAMPHLET/B.R.01/2006;Oct 2006; Copy: 06 Drawing -16 of 16

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BAFFLE RANGE -500M PLAN (kindly refer A2 size drawing on next page )

DISTRIBUTIONSCONTENTSPREFACEPART-1INTRODUCTIONPART-2DEVELOPMENT OF BAFFLE RANGEPART-3BAFFLE RANGE PLANNING & DESIGNCONSIDERATIONSPART-4BAFFLE RANGE OPERATION & MAINTENANCEPART-5SALIENT FEATURESPART-6GLOSSARYPART-7ARCHITECTURAL LAYOUTS OF BAFFLE RANGELAYOUT OF 500m BAFFLE RANGEfgsd-A2.pdfA2

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