Method1 Us
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TN-10
TN-10
Significance: During World War II, the Holston Army Ammunition Plant
made several significant contributions to
explosives-manufacturing technology. It was the first
large-scale facility to implement the nearly developed
Bachmann process in the manufacture of the explosive
RDX. At the same time, it streamlined the Bachmann
method by instituting a slurry-based, continuous
manufacturing process, and it also developed important
new cooling and packaging procedures for composition
#
B. As a result of these innovations, Holston became
the world's largest producer of Composition B, the
most powerful explosive until the development of
nuclear weapons.
Historical Report
Prepared by: Jeffrey A. Hess, 1984.
Prepared for
Transmittal by: Robie S. Lange, HABS/HAER, 1985.
Holston Army Ammunition Plant
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EXECUTIVE SUMMARY
The Holston Army Ammunition Plant (HSAAP) is part of the Army's Armament,
Munitions and Chemical Command (AMCCOM). It is the only American
manufacturing facility for RDX- and HMX-based high explosives. Its chief
following V-J Day, the facility has been in continuous production since its
initial construction in 1942-1944. Of the 470 buildings maintained by the
period.
Because of their great technological and historical importance, the ten RDX
and Ccmposition-B manufacturing lines (Buildings Bl, S3, B5, 87, B9, Cl,
C3, C5, C5, C7, C9, D1-D10, E1-E10, G1-G10, Hl-HlO, 11-110, Jl^JlO, K1-K10,
L1-L10, M1-M10, 01, 03, 05, 07, 09, N1-N10) at Plant B are Category I
CONTENTS
Executive Surmary
PREFACE 1
1. INTRODUCTION 3
Scope 3
Methodology 4
2. HISTORICAL OVERVIEW 14
Background 14
World War II 17
Korean War . 45
Vietnam War 48
Recent Developments 50
3. PRESERVATION RECOMMENDATIONS 59
Background 59
BIBLIOGRAPHY 83
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PREFACE
Holston Army Ammunition Plant. Prepared for the United States Army
to assist the Army in bringing this installation into compliance with the
National Historic Preservation Act of 1966 and its amendments, and related
federal laws and regulations. To this end, the report focuses on the
and the U.S. Department of the Army. The program covers 74 DARCOM
Headquarters DARCOM, directed the program for the Army, and Dr. Robert J.
Engineering Record (HABS/HAER) directed the program for the National Park
Service. Sally Kress Tompkins was program manager, and Robie S. Lange was
Holston Army Ammunition Plant
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and Jeffrey A. Hess. The author of this report was Jeffrey A. Hess. The
author gratefully acknowledges the help of Lt. Col. Willis Seguin, Plant
Commander; William D. Miller and Susan P. Cole of the government staff; and
T.W. Goodwin, Jerry Blair, Henry Hurd, Roy S. Eastern, Robert Brewer, Jr.,
Chapter 1
INTRODUCTION
SCOPE
the Holston Army Ammunition Plant. The survey included the following
tasks:
installation.
of Congress.
METHODOLOGY
1. Documentary Research
Arsenal.
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Army records used for the field inventory included current Real
2. Field Inventory
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lines), and Robert Wicker (Plant-B acid area and utilities). The
production equipment.
Field inventory forms were prepared for, and black and white 35 nsn
represent all buildings of that type. Field inventory forms were also
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3. Historical Overview
appropriate.
installation.
workmanship, feeling, and association, and that they meet one or more
4
of the following:
7
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nation's past.
distinction.
Regulation 420-40:
categorization level for each Army property. These criteria were used
built and put into service during World War II, as well as of
The four criteria were often used in combination and are as follows:
and functionality.
X
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World War II, and special attention was given to their evaluation.
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circumstances required.
5- Report Review
NOTES
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Chapter 2
HISTORICAL OVERVIEW
BACKGROUND
air miles apart on the Holston River in northeastern Tennessee (Figure 1).
produces raw materials for and processes by-products from Plant B, which is
situated upstream on about 5,900 acres in rural-suburban Hawkins County.
During World War II, the HSAAP made several significant contributions to
explosives-manufacturing technology. It was the first large-scale facility
result of these innovations, the HSAAP became the world's largest producer
X
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of Composition B, the most powerful explosive known until the development
"maggie unit,"
Shortly after V-J Day, the HSAAP suspended manufacturing operations and
expanding and contracting during and after the Korean and Vietnam Wars.
also maintains and operates one of the country's few remaining producer-gas
X
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installation's three major production periods: World War II, the Korean War
and the Vietnam War. Whenever the available data permits, the discussion
WORU) WAR II
that ran the gamut from amphibious vehicles to rocket propellants. But
by the British, and this was particularly true in the area of high
explosives.
During the 1930's, British stategists had learned that German submarine
the British Admiralty began seeking a more effective explosive, and its
known to be almost twice as powerful as TNT but also several times more
X
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anonymity, they chose the name of "Composition B" for the desensitized
mixture of 60% RDX and 40% TNT that was to be widely used in Allied naval
Although the British were the first to tame cyclonite, they were less
for eleven pounds of strong nitric acid for every pound of RDX produced,
and operate. While the Bridgewater plant was still under construction, the
project. Despite his personal distaste for the work, Bachmann threw
himself into the study with such energy that within three months he had
85% while doubling the RDX yield from hexamine. The new process, however,
of weak acetic acid contaminated with RDX. Before the Bachmann method
Tennessee.
Tennessee Eastman to join its RDX task force, and three months later, the
The firm was then asked to design and operate two pilot plants in
the other to combine RDX and TNT into Composition B. Both plants were in
production by the end of April 1942. Highly impressed with the company's
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contract to this effect was signed by Tennessee Eastman and the United
The Kingsport area was selected as the site for the HSAAP primarily because
satisfied the following basic criteria that governed the selection of other
World-War-II explosives plants:
When the government began its acquisition of land for the HSAAP in the
summer of 1942, the Plant-A site, immediately adjacent to the Tennessee
predominantly crop and pasture land that had long been used for dairying.
It contained at least thirty-eight standing structures, including
farmhouses, servants' quarters, garages, stables, barns, and a schoolhouse.
2ef
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None of these buildings survive within the present boundaries of the
HSAAP.9
Construction
*
Construction work on the HSAAP commenced in the summer of 1942 under the
special "Holston District" to administer the project. Since the HSAAP was
contract was awarded to the New York architectural and engineering firm of
Fraser-Brace Co., Inc., which had just completed a series of design and
Throughout World War II, the HSAAP was officially designated as the
Holston Ordnance Works. The plant's current name, which dates from
1963, is used throughout this report for the sake of brevity and
clarity.
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Camp Edwards in Massachussets. At the HSAAP site, the Boston firm was
three firms, the Corps of Engineers had hoped to promote flexibility and
construction crews remained at the site until mid-March 1944, when "the
project was finished, cleaned up and 100% in the hands of the operators."
At this time the Corps of Engineers took inventory of the new installation,
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into six major areas according to their general function. The most
sition B (Figure 4). Bordering the manufacturing area on the north was a
shop area and, further north, an administration area, which contained the
HSAAP's Main Administration Building (Building b-1) (Figure 5), Personnel
Telephone Building (Building b-5), and Fire Station (Building b-7). Due
west of the manufacturing area was a Steam Plant (Building b-200), and an
west was a storage area for ammonium nitrate, a main ingredient for the
* After World War II, there were gradual reductions in the size of the
HSAAP until, by the early 1930s, Plant A comprised about 120 acres and
Plant B about 5,900 acres.
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explosives. Separated from the rest of Plant B by the Holston River, and
located about two miles southwest of the manufacturing area, this facility
the widespread use of brick, which was generally considered too costly for
After the completion of the expansion program in the spring of 1944, the
HSAAP experienced little new construction during World War II. The only
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facilities were located in the acid area of Plant B and conformed to the
18
prevailing utilitarian-industrial architectural style.
Technology
materials, the HSAAP manufactured the first three. We will consider each
in turn.
as the starting point for acetic-anhydride manufacture. The weak acid from
Plant B was shipped to Plant A in tank cars over the inter-plant railroad;
it was then delivered to Building a-2 for concentration into glacial
acetic.
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Although dilute acetic acid could have been concentrated by simple
concentrate the dilute acid. With only minimal loss, the entraining fluid
21
was recovered from the waste water and continuously recycled. The
Since the glacial acetic produced from the Plant-B dilute acid was
insufficient to meet the installation's total acetic-anhydride production
requirements, the HSAAP also had the capability to manufacture new acetic
acid. Until the early 1930s, almost all glacial acetic produced in the
British procedure for producing acetic acid by catalytic methods from ethyl
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alcohol. This procedure was the one adopted at the HSAAP. A Tennessee
equipment. The new acid was concentrated into glacial grade at the
acetic.
Production of glacial acetic acid was the first step in the manufacture of
ketene. Next, the ketene was "scrubbed" with fresh glacial acetic acid to
form a crude mixture of acetic anhydride and dilute acetic acid. This
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crude solution was then refined and separated into pure anhydride and
23
glacial acetic by repeated distillation in a rectifying column.
a-7 and a-20 prepared the crude anhydride solution, and Building a-6
housed sixteen gas-fired furnaces and eight scrubbing trains; and Building
24
a-6 had nine rectifying columns. Since the Kingsport area had no
natural-gas facilities, the cracking furnaces at Buildings a-7 and a-20
Acetic anhydride was only the first of three RDX ingredients manufactured
at the HSAAP. The second principal raw material was nitric acid, which was
ammonia was vaporized and mixed with heated compressed air in the presence
of a platinum catalyst to form nitrogen oxides. The nitrogen compounds
were then further oxidized with air and fed into an absorption tower, where
they combined with water to form 60% nitric acid. At the HSAAP, air
Building b-302.25
Like most industrial uses of nitric acid, the manufacture of RDX required
the HSAAP used the time-honored technique of concentrating the 60% nitric
dehydration towers at Building b-303. The spent sulfuric acid, now diluted
it, in turn, was dehydrated by blasts of hot gases from oil-fired furnaces.
nitric-acid operation.
The third, and last, RDX ingredient produced at the HSAAP was ammonium
nitrate. Until the summer of 1944, _the installation purchased its ammonium
nitrate from the Kansas-Ordnance Works and the Wolf Creek Ordnance Works,
operation was that the HSAAP could not manufacture enough nitric acid to
meet the production requirements of both RDX and ammonium nitrate. This
/
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works that had excess capacity. In 1945, however, increased demands for
RDX ingredients during World War II, the installation did host some
important experimental work in the area of nitric-acid concentration.
nitrate. The pilot plant (Building b-303-B) was built and in operation by
Although this pilot project never moved beyond the experimental phase, it
laid the groundwork for the development, during the 1950s, of the
preparation of RDX by the Bachmann method was quite another matter. When
Tennessee Eastman first began its work on a pilot plant for RDX in early
both dry and liquid ingredients that were reacted in a two-stage batch
Second, a production system was devised whereby the RDX was transferred
from one processing building to another in slurry form through the use of
one end of a production line, and RDX rolling off at the other.
RDX and TOT into Composition B. As one observer noted, "The British
shovel in wet RDX and stir until the water evaporated. The molten mix was
then poured into trays something like biscuit pans where it cooled and
solidified. With only a few pounds per tray, this was a real labor hog.
32
Besides, the workers were constantly exposed to poisonous TOT fumes." To
continuous pelleting procedure that used "an agitated casting pot with
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33
multiple holes in the bottom" to extrude the warm Composition B mixture
onto a cooling conveyor belt (Figures 10/ 11). "The process was simple,
ingenious and safe. It eliminated the TNT fume problem and reduced labor
34
by a very large factor."
In its final design, the Plant-B manufacturing area was organized into ten
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The HSAAP's first production line for RDX and Composition B went into
operation in April 1943, and by the end of that year, all ten lines were in
pounds of Composition B per month, and its total wartime output reached
levels until July 1945, when nine of its ten explosives lines were de-
November 1, 1945, the HSAAP was designated a "standby" facility, and two
weeks later, the Tennessee Eastman Corporation turned the installation over
KOREAN WAR
In April 1949, the HSAAP was removed from standby status and reactivated as
manufacturing line. But as the Korean War got underway, most of the
Construction
During the 1950s, the HSAAP witnessed the construction of approximately one
dozen new buildings that closely conformed to the utilitarian-industrial
architectural style employed during World War II. Plant A received two
were constructed between Plant A and B for the transport of acetic acid and
acetic anhydride, thus eliminating the previous use of tank cars over the
Technology
Although most of the HSAAP *s production lines for SDK and Composition B
were modified during rehabilitation for the Korean War, the basic
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minute amounts during the manufacture of RDX by the Bachmann method, and it
was first isolated and identified by Bachmann during his experimental work
on RDX in 1941-1942. Although HMX was found highly suitable for plastic
World War II, and only a pilot production run of 25,000 pounds was
attempted at the HSAAP before V-J Day. In 1952, however, the HSAAP once
batch operation at Production Line 4 that was quite similar to the general
Bachmann method used for RDX manufacture. When the D building for HMX
bottleneck at the installation during the 1940s, the HSAAP also was
equipped with two new conventional Nitric-Acid Concentrating Plants
(Buildings b-303-C, b-303-D) in 1951 and 1954, a new Ammonium Oxidation
VIETNAM WAR
Although the HSAAP remained in operation after the Korean War, production
did not resume until the Vietnam buildup of the mid-1960s. During
1965-1966, the government appropriated about $40 million to modernize the
Production Lines 9 and 10, which had not seen use since World War II. By
December 1968, all ten lines were in service, with a combined monthly
production of about 33 million pounds of Composition B, which nearly
equalled the World-War-II record. With the conclusion of the Vietnam War
Construction
During the 1960s and early 1970s, the HSAAP witnessed the construction of
Technology
Although the HSAAP did not incorporate any radical new procedures for
0
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four in Building a-334 in 1966. The installation of the maggie units was
to less than a million pounds per month, this decline in production was
explosives using RDX and HMX. Between 1974 and 1983, the HSAAP also
produced about one-quarter of a million pounds of HMX per month for the
44
Navy's Trident Program.
Construction
With the conclusion of the Vietnam War, the Department of Defense initiated
a ten-year modernization program for its munitions facilities, including
the HSAAP. This program entailed the replacement of outmoded structures
with permanent modern facilities, and the implementation of pollution-
the modernization program of the 1970s, the HSAAP still strongly reflects
its World-War-II origin. As of 1983, the installation contains
approximately 465 buildings, and more than three-quarters of these
45
structures date from the original construction period.
Technology
During the 1970s, most of the technological developments at the HSAAP were
geared to bringing the installation into compliance with federal clean air
the steam plants (Buildings a-8, b-200), and the erection of a new Ammonium
Oxidation Plant (Building b-337) with "an extra large absorption tower to
46
reduce nitrogen oxide fumes to acceptable standards."
NOTES
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22. "Making Acetic Anhydride from Petroleum Ethyl Alcohol," Oil ways, 14
(June 1948), 3. Although this article describes the Tennessee Eastman
plant in Kingsport, the same technology was used at the HSAAP. The
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23. Lipscomb, pp. 93-98; "Making Acetic Anhydride for Petroleum Ethyl
Alcohol," 3.
24. Building a-6 also contained an azeotropic still. The thermal cracking
of glacial acetic acid in Buildings a-7 and a-20 was never 100%
efficient, and residual amounts of acetic acid were carried over into
the ketene-and-water-vapor mixture. The dilute acid was separated
from the ketene by condensing trains in Buildings a-7 and a-20, and
piped into the azeotropic still in Building a-6, where it was
processed into glacial acetic acid. This concentrated acid was then
piped back to Buildings a-7 and a-20, where it was used to scrub the
ketene.
25. "Producer gas ... is made by blowing air or a mixture of air and
steam through an incandescent fuel bed. The oxygen of the air
combines with the carbon in the fuel bed to produce carbon monoxide
and some carbon dioxide, while the steam in the entering blast
combines with the carbon. . . to produce carbon monoxide and hydrogen.
The nitrogen of the air passes through the fuel bed unchanged and
appears in the final product .... Producer gas from bituminous coal
contains several percent of methane and some additional hydrogen, as
well as tar vapors, all derived from the volatile matter of the coal";
from Basis W. Waring and John F. Foster, eds., Economics of Fuel Gas
from Coal (New York: McGraw-Hill Book Company, Inc., 1950), pp. 13, 4.
Easy and cheap to manufacture, producer gas saw widespread industrial
use in the United States during the period between the two world wars,
especially in areas that were not supplied with natural gas. The
system at the HSAAP was designed by the Semet-Solvey Engineering
Corporation of New York, a prominent firm in the synthetic-gas
equipment field. The HSAAP gas plant was an atmospheric system
consisting of twelve fixed-bed producer units equipped with overhead
coal feeds. Steam and air were mixed in a saturation column and then
fed, in an up-draft arrangment, through the coal bed of each producer.
The resulting gas was taken off under vacuum at the top of the
producers and sprayed with water to remove pitch and other impurities.
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33. Bearden, p. 9.
35. This passage is from Holston Army Ammunition Plant (n. pi.: Holston
Defense Corporation, n.d), pp. 11-18. Although the description
primarily applies to RDX and Composition B production as of 1983, it
also covers the essential features of the World-War-II operation.
This judgement is based upon information provided by Jerry Blair,
Holston Defense Corporation Superintendent of HMX Products, during an
on-site interview, April 12, 1983, and upon "equipment layout" plans
for the various production buildings in "Industrial Facilities
Inventory," Plant B, Part III, Section 1, n.p. The spent-acid
solution removed from the RDX slurry in the E Buildings consisted of
nitric acid, acetic acid, and residual amounts of RDX. This solution
was pumped to a row of structures (Buildings b-B-1, B-3, B-5, B-7,
B-9) bordering the west end of the manufacturing area. There the
nitric acid was neutralized with caustic, the RDX residue recovered
and pumped back to the E Buildings, and the acetic acid distilled to
60% strength and shipped to Plant A for processing into glacial
acetic.
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Holston Army Ammunition Plant
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planned for the initial construction period, using "a copper pipe line
for return of Acetic Acid to Area A from Area B and a steel pipe line
for pumping Acetic Anhydride from Area A to Area B. [ But] at that
time it was impossible to get the necessary copper so arrangments were
made to do this work utilizing Acid tank cars, and a railroad was
built between the plants"; see Carter, Appendix IV-62.
39. The initial discovery of HMX is noted in Bachmann and Sheehan, 1844.
The pilot production of the material at the HSAAP during World War II
is discussed in Carter, p. 47, Appendix IV-42, 43. On HMX production
during the 1950's, see "Holston Army Ammunition Plant Historical
Monograph," pp. 2. 19; Pridemore, p. 6.
42. Holston Army Ammunition Plant Real Property Inventory; the Steam Plant
Addition is described in Pridemore, "Holston Army Ammunition Plant,
Unit History, Annual Supplement-CY 1968," unpublished report prepared
by HSAAP, p. 4, in HSAAP Administrative Archives.
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Chapter 3
PRESERVATION RECOMMENDATIONS
BACKGROUND
program is to:
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Revised Guidelines for Rehabilitating Historic Buildings and
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properties:
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deteriorating.
HABS/HAER Documentation Level IV has been completed for all Category III
they are not endangered. Category III historic properties that are
and page 55, note 25) was built in 1943 as an integral part of the
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bituminous coal and steam into a synthetic gas. The gas is piped to
fuel cracking furnaces in Buildings 7 and 20 for use in acetic-
anhydride production.
in active industrial use. After this peak period, producer gas waned
the HSAAP had "one of the few gas producer facilities in operation in
for properties less than fifty years old. The Producer-Gas Plant
HSAAP.
its preservation.
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M1-M10)
of the Holston River in Plant B, they are organized into ten nearly
demolished after a fire in 1957, and Building G10, which was doubled
mass-production operation. During World War II, the HSAAP was (and it
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HAER No. TN-10
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Atlantic, [which was] acknowledged by both the United Nations and the
Axis alike as the most important single phase of the war." The large
paved the way for the invasion of the European continent and for the
13
final destruction of the Japanese war effort."
Because of their pivotal role in the Allied war effort, the 116
which was partially demolished and vacated after a fire in 1957, all
NOTES
11. Marcella Sherfy and W. Ray Luce, "How to Evaluate and Nominate
Potential National Register Properties that Have Achieved
Significance within the Last 50 Years" (Washington, D.C.: U.S.
Department of the Interior, Heritage Conservation and Recreation
Service, 1979).
12. Buford Rowland and William B. Boyd, U.S. Navy Bureau of Ordnance
in World War II (Bureau of Ordnance, Department of the Navy,
n.d.), p. 206.
82^
Holston Army Ammunition Plant
HAER No. TN-10
Page 6 I
BIBLIOGRAPHY
Published Sources
Bachman, W. E. and John C. Sheehan. "A New Method of Preparing the High
Explosive RDX." Journal of the American Chemical
Society, 71 (May 1949), 1842-1845. The first published description of
the Bachmann method.
Burton, R.C. "The Origin of Holston Army Ammunition Plant." Speech before
the Rotary Club of Kingsport Term., Sept. 10, 1975. Kingsport: n.
pub,, 1975. Palmer Room, Kingsport Public Library. Excellent
discussion of the development of the Woolwich and Bachmann methods for
RDX production by General Superintendent of Production of the HSAAP
during World War II.
far
Holston Army Ammunition Plant
HAER No. TN-10
Page %l
Higham, Robin, ed. A Guide to the Study and Use of Military History.
Hatnden, Conn.: Archon Books, 1975.
Hoy, Suellen M- and Michael C. Robinson, eds. Public Works History in the
United States. Nashville: American Association for State and Local
History, 1982.
"It's a Long Way fran a Pasture to Ammo Plant." Kingsport News. November
14, 1969. Provides information on prior land use of HSAAP site.
Jessup, John E. and Robert W. Coakley. A Guide to the Study and Use of
Military History. Washington, D.C.: U. S. Government Printing
Office, 1979.
M
Holston Army Ammumcion jriam.
HAER No. TN-10
Page $&
Sherfy, Marcella and W. Ray Luce. "How to Evaluate and Nominate Potential
National Register Properties that Have Achieved Significance within
the Last 50 Years." Washington, D.C.: U. S. Department of the
Interior, Heritage Conservation and Recreation Services, 1979.
Unpublished Sources
Voight, William Jr. "The Ordnance Organization in World War II" Report
prepared for the Ordnance Department, 1945- On microfiche, AMCCOM
Historical Office, Rock Island Arsenal. Provides brief historical
sketches of all government-owned, contractor-operated munitions plants
during World War II.