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Iowa Army Ammunition Plant

Iowa Army Ammunition Plant is a Group Technology Center for missile warheads, tank ammunition, artillery rounds and demolition charges. The plant is a one-of-a-kind national resource that provides "total munitions solutions" for the Defense industrial base, which includes research, development, production, inspection, testing, assembly, packing and demilitarization. The Iowa AAP's 1,500 building facility is built on 19,300 acres in southeast Iowa. Less than a third of the IAAAP's 19,015-acre (30-square-mile) property is occupied by active or formerly-active production or storage facilities. The remaining land is evenly divided between leased agricultural acreage and woodlands.

Public access to the installation is restricted by contractor security measures, including perimeter fencing, but various recreational activities are allowed in some non-industrial, on-site areas. These recreational activities include hunting and fishing. Public access to many on-site contaminated areas, however, is prevented by secondary fencing surrounding installation facilities and industrial areas.

Production at the ammunition plant began just before Japan attacked Pearl Harbor in December 1941. In 1947, Mason & Hanger, Silas Mason Co., Inc., became the first operating contractor to produce nuclear weapons for the Atomic Energy Commission. The IAAP manufactured high-explosive components for nuclear weapons as well as performed the final assembly of the weapons during the years 1949-1975. The nuclear production ended in 1975, but the plant still produces conventional ammunition.

Iowa AAP's current capabilities cover the full range from prototype to high rate manufacturing, including the casting and pressing of explosive components. State-of-the-art microprocessor controllers virtually eliminate variation in larger hydraulic pressing operations. The plant provides customers a one-stop-shop of scientists, engineers and technicians to develop systems from conception through production. Iowa AAP has also been designated as the Midwest demilitarization facility. Iowa AAP, called "Team Iowa" by employees, has received significant recognition for its dedication to quality. Most notably, Iowa AAP was a semifinalist in both the 1993 and 1994 Malcom Baldrige National Quality Award Competitions

Iowa Army Ammunition Plant (IAAAP) is operated by American Ordnance LLC, a joint venture company owned by Day & Zimmermann and General Dynamics Ordnance Systems. Day & Zimmermann Inc., a privately held company based in Philadelphia, made the Mason Co., parent company of IIAP contractor Mason & Hanger, a wholly owned subsidiary under an agreement announced 14 April 1999. Under the merger agreement, Mason's businesses were folded into similar business units of Day & Zimmermann. Mason & Hanger combined with Day & Zimmermann's Government Systems Group based in Philadelphia.

In business since 1827, Mason & Hanger-Silas Mason Co., Inc. was the country's longest-existing engineering and construction company. Originally involved in large construction and landmark infrastructure projects, Mason & Hanger accomplishments included: the Grand Coulee Dam; the Lincoln, Boston, and Brooklyn-Battery automotive tunnels; and New York City subway tunnels.

Mason & Hanger entered the ordnance plant construction arena during World War II and set industry standards for blast resistant structures and explosive safety procedures. Its engineers developed new technologies for automated processing and new methods for melting, curing, and shaping explosives in the load/assembly and pack operations. In 1947, Mason & Hanger began construction of a Nuclear Weapons line at the Iowa Army Ammunition Plant in Middletown, Iowa for the Atomic Energy Commission. Mason & Hanger became the Iowa Army Ammunition Plant operating contractor for the U.S. Army in 1951. It continued to operate this government-owned, contractor-operated facility and refine its ability to efficiently manufacture products critical to national defense.

The Iowa Army Ammunition Plant is a 19,000-acre load, assembly, and pack facility that provides munitions and high explosives development, processing, production, testing, and demilitarization. The plant encompasses 1.7 million square feet of manufacturing space and 1.9 million square feet of warehouse area, for a total of over 4.3 million square feet within the confines of the facility. Also included are 142 miles of roads and 103 miles of railroad tracks. These efforts are supported by almost 900 personnel.

On 30 September 1999 American Ordnance announced a strategic planning initiative to investigate commercial opportunities for the Iowa Army Ammunition Plant. The new initiative focused on how the assets at the plant, including land, buildings and equipment, can be used to develop new business opportunities for the region. American Ordnance LLC (AO) has a facility use contract allowing the use of the 19,000 acre government-owned facility. AO retained Pendulum Management Company LLC (PMC) to coordinate the study and to work with state and local officials as well as the U.S. Army to maximize the value of the Iowa facility.

The Iowa Army Ammunition Plant facility is recognized as a leader in the high, medium, and low volume production of pressed or melt-poured warheads such as Hellfire, TOW, Patriot, Stinger, Javelin, and Hawk. The facility also produces 120mm battle tank ammunition and a variety of mines, mortars artillery rounds, demolition charges, and blanks. Named as the Midwest Area Demilitarization Facility in 1992, the Iowa Army Ammunition Plant now has an additional mission of disposing of old and/or obsolete ammunition in an environmentally- conscious manner.

The Inert Landfill encompasses an area of approximately 14 acres and consists of six trenches, which were filled primarily with sanitary landfill materials. The Inert Landfill operated from 1941 to 1990. In the early 1980's, the northern section of Trench 5 also received ash from an explosive waste incinerator and from the open burning of explosives. The area was then covered with a weather-resistant clay "cap", designed in accordance with EPA guidance for hazardous waste landfills. In the fall of 1997, trenches 1 through 5 of the Inert Landfill were covered with a multi-layer geomembrane cap. This new cap included the already-capped northern section of Trench 5, providing even greater long-term protection. 62,218 cubic yards of "lightly" contaminated soil from the Line 1 and Line 800 sites was placed on the existing landfill as gradefill material. The gradefill material is located below the protective geomembrane and soil cover materials. This reduced the environmental "threat" from the contaminated material and minimized disposal costs. It resulted in a significant cost savings for the Inert Landfill cap because it reduced the need to import clean borrow to bring the landfill to proper grade for capping.

The Agency for Toxic Substances and Disease Registry (ATSDR), a public health agency of the U.S. Department of Health and Human Services, released on 05 January 2004 the final version of a public health consultation concerning the health effects from environmental releases of beryllium and depleted uranium at the Iowa Army Ammunition Plant (IAAP) in Middletown, Des Moines County, Iowa. The health consultation found that the environmental releases of beryllium and depleted uranium (DU) from the plant and from the Burlington Atomic Energy Commission Plant in Burlington, Iowa, are not at levels that would result in adverse human health effects to facility residents or to those living nearby.

The Commerce Center of Southeast Iowa invites businesses to take full advantage of generous Armament Retooling Manufacturing Support (ARMS) financial incentives, a comprehensive support infrastructure, and plentiful space opportunities for new or expanding business. Available facilities include locations for warehousing, distribution, manufacturing and office space to support your business needs. Development sites exist for those who have unique requirements or desire to design and construct a new building. The facility, in America''s heartland near Burlington, Iowa, has convenient rail and highway connections, and air and water access is nearby. A favorable business climate coupled with ARMS incentives and local and state level development initiatives make the Commerce Center of Southeast Iowa the ideal environment for a new business.

BRAC 2005

In its 2005 BRAC Recommendations, DoD recommended to close Kansas Army Ammunition Plant (AAP), KS and would relocate 105MM HE, 155MM HE, and Missile Warhead functions to Iowa AAP. Capacity and capability for Artillery, Mortars, Missiles, and Pyro/Demo existed at numerous munitions sites. There were 8 sites producing Artillery, 5 producing Mortars, 9 producing Pyro/Demo, and 13 performing Demilitarization. To reduce redundancy and remove excess from the Industrial Base, the closure would allow DoD to create centers of excellence, avoid single point failure, and generate efficiencies.

In another recommendation, DoD recommended to close Lone Star Army Ammunition Plant (AAP), TX. It would relocate Mines and Detonators/Relays/Delays functions to Iowa AAP. Capacity and capability for Artillery, Mortars, Missiles, Pyro/Demo, and Storage existed at numerous munitions sites. There were 8 sites producing Artillery, 5 producing Mortars, 9 producing Pyro-Demo, 15 performing storage, and 13 performing Demilitarization. To reduce redundancy and remove excess from the Industrial Base, the closure would allow DoD to create centers of excellence, avoid single point failure, and generate efficiencies. Goal is to establish multi-functional sites performing Demilitarization, Production, Maintenance, and Storage. Lone Star primarily performed only one of the 4 functions.

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Page last modified: 05-07-2011 02:42:03 ZULU