{"id":39116,"date":"2023-09-21T22:58:33","date_gmt":"2023-09-21T22:58:33","guid":{"rendered":"https:\/\/one.sightlinemg.com\/airforcetimes\/uncategorized\/2023\/09\/21\/inside-the-delicate-art-of-maintaining-americas-aging-nuclear-weapons\/"},"modified":"2026-08-07T21:19:11","modified_gmt":"2026-08-07T21:19:11","slug":"inside-the-delicate-art-of-maintaining-americas-aging-nuclear-weapons","status":"publish","type":"post","link":"https:\/\/one.sightlinemg.com\/airforcetimes\/news\/your-air-force\/2023\/09\/21\/inside-the-delicate-art-of-maintaining-americas-aging-nuclear-weapons\/","title":{"rendered":"Inside the delicate art of maintaining America\u2019s aging nuclear weapons"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">KANSAS CITY NATIONAL SECURITY CAMPUS, Mo. \u2014 In an ultra-sterile room at a secure factory in Kansas City, U.S. government technicians refurbish the nation\u2019s nuclear warheads. The job is exacting: Each warhead has thousands of springs, gears and copper contacts that must work in conjunction to set off a nuclear explosion.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Eight hundred miles (about 1,300 kilometers) away in New Mexico, workers in a steel-walled vault have an equally delicate task. Wearing&nbsp;<a href=\"https:\/\/apnews.com\/article\/1f5cdd0caea5ac013c77168e89268f01\" target=\"_blank\">radiation monitors<\/a>, safety goggles and seven layers of gloves, they practice shaping new warhead plutonium cores \u2014 by hand.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">And at nuclear weapons bases across the country, troops as young as 17 keep 50-year-old warheads working until replacements are ready. A hairline scratch on a warhead\u2019s polished black cone could send the bomb off course.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The Associated Press was granted rare access to&nbsp;<a href=\"https:\/\/apnews.com\/article\/nuclear-weapons-missile-military-overhaul-f7ac8939a3bd3e6455b144f0cb5da528\" target=\"_blank\">key parts of the highly classified nuclear supply chain<\/a>&nbsp;and got to watch technicians and engineers tackle the difficult job of maintaining an aging nuclear arsenal. Those workers are about to get a lot busier. The U.S. will spend more than $750 billion over the next 10 years replacing almost every component of its nuclear defenses, including new stealth bombers, submarines and ground-based intercontinental ballistic missiles in the country\u2019s most ambitious nuclear weapons effort since the Manhattan Project.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">It\u2019s been almost eight decades since a nuclear weapon has been fired in war. But military leaders warn that such peace may not last. They say the U.S. has entered an&nbsp;<a href=\"https:\/\/apnews.com\/article\/nuclear-test-ban-treaty-weapons-ratifications-b355af60ae029ebc046398f23a5a0715\" target=\"_blank\">uneasy era of global threats<\/a>&nbsp;that includes a nuclear weapons buildup by&nbsp;<a href=\"https:\/\/www.militarytimes.com\/flashpoints\/china\/\" target=\"_blank\">China<\/a>&nbsp;and Russia\u2019s repeat threats to use a nuclear bomb in Ukraine. They say that America\u2019s aged weapons need to be replaced to ensure they work.<\/p>\n\n\n\t<aside class=\"smg-interstitial-link wp-block-smg-interstitial-link\">\n\t\t<a href=\"https:\/\/one.sightlinemg.com\/airforcetimes\/news\/your-air-force\/2023\/09\/20\/this-is-what-its-like-to-maintain-the-us-nuclear-arsenal\/\" class=\"smg-interstitial-link__inner\">\n\t\t\t\t\t\t\t<div class=\"smg-interstitial-link__media\">\n\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"300\" height=\"200\" src=\"https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251782045085.jpg_a01dc6.jpg?w=300\" class=\"smg-interstitial-link__image wp-post-image\" alt=\"\" \/>\t\t\t\t<\/div>\n\t\t\t\t\t\t<div class=\"smg-interstitial-link__content\">\n\t\t\t\t<span class=\"smg-interstitial-link__kicker\">Related<\/span>\n\t\t\t\t<h3 class=\"smg-interstitial-link__title\">This is what it\u2019s like to maintain the US nuclear arsenal<\/h3>\n\t\t\t\t\t\t\t\t\t<p class=\"smg-interstitial-link__excerpt\">The jobs are exacting and often require a deft touch. That\u2019s because many of the maintenance tasks must be performed by hand.<\/p>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/a>\n\t<\/aside>\n\t\n\n\n<p class=\"wp-block-paragraph\">\u201cWhat we want to do is preserve our way of life without fighting major wars,\u201d said Marvin Adams, director of weapons programs for the Department of Energy. \u201cNothing in our toolbox really works to deter aggressors unless we have that foundation of the nuclear deterrent.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">By treaty the U.S. maintains 1,550 active nuclear warheads, and the government plans to modernize them all. At the same time, technicians, scientists and military missile crews must ensure the older weapons keep running until the new ones are installed.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The project is so ambitious that watchdogs warn that the government may not meet its goals. The program has also drawn criticism from non-proliferation advocates and experts who say the current arsenal, though timeworn, is sufficient to meet U.S. needs. Upgrading it will also be expensive, they say.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cThey are going to have extreme difficulty meeting these deadlines,\u201d said Daryl Kimball, executive director of the Arms Control Association, a non-partisan group focused on nuclear and conventional weapons control. \u201cAnd the costs are going to go up.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">He cautioned that the sweeping upgrades could also have the undesired effect of pushing Russia and China to improve and expand their arsenals.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Where it begins<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The core of every nuclear warhead is a hollow, globe-shaped plutonium pit made by engineers at the&nbsp;<a href=\"https:\/\/apnews.com\/article\/science-politics-los-alamos-labor-859d8e0cc088f84b149068bd57e64133\" target=\"_blank\">Energy Department\u2019s lab in Los Alamos<\/a>, New Mexico, birthplace of the atom bomb. Many of the current pits in use come from the 1970s and 80s. That can be problematic, because there\u2019s a lot about plutonium\u2019s aging process that scientists still don\u2019t understand.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"3061\" height=\"2041\" src=\"\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg\" alt=\"In this image provided by Los Alamos National Laboratory, Bob Webster, deputy director of weapons at Los Alamos speaks on June 23, 2023, at Los Alamos National Laboratory, in New Mexico.\" class=\"wp-image-71773\" srcset=\"https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg 3061w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg?resize=300,200 300w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg?resize=768,512 768w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg?resize=1024,683 1024w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg?resize=1536,1024 1536w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781984510.jpg.jpg?resize=2048,1366 2048w\" sizes=\"auto, (max-width: 3061px) 100vw, 3061px\" \/><figcaption class=\"wp-element-caption\">In this image provided by Los Alamos National Laboratory, Bob Webster, deputy director of weapons at Los Alamos speaks on June 23, 2023, at Los Alamos National Laboratory, in New Mexico. (Los Alamos National Laboratory via AP)<\/figcaption><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">The key radioactive atom in the plutonium pit has a half life of 24,000 years, which is the amount of time it would take roughly half of the radioactive atoms present to decay. That would suggest the weapons should be viable for years to come. But the plutonium decay is still enough to cause concern that it could affect how a pit explodes.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">President George H.W. Bush signed an order in the 1990s banning underground nuclear tests, and the U.S. has not detonated pits to update data on their degradation since. When the last tests were performed, they provided data on pits that were at most about two decades old. That generation of pits is now pushing past 50.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Bob Webster, deputy director of weapons at Los Alamos, said scientists have relied on computer models to determine how well such old pits might work, but \u201ceverything we\u2019re doing is extrapolating,\u201d he said.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">That uncertainty has pushed the department to restart pit production. The U.S. no longer produces man-made plutonium. Instead, old plutonium is essentially refurbished into new pits.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This task takes place inside PF-4, a highly classified building at Los Alamos that\u2019s surrounded by layers of armed guards, heavy steel doors and radiation monitors. Inside, workers handle the plutonium inside steel glove boxes, which allow them to clean and process the plutonium without being exposed to deadly radiation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">In the final production steps, a lone employee in the vault takes the almost-completed pit into both of her gloved hands and shapes it into its final form.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cThings have to fit a certain way, and everything is by touch, by feel,\u201d said the Los Alamos employee, who the AP has agreed not to name because she is one of only a handful of people in the U.S., and the only female, who performs this sensitive task.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">For about the last 10 years technicians have been practicing on \u201ctest\u201d pits that aren\u2019t ready for the stockpile. The U.S. is planning to fully recycle its first weapon-ready pit next year \u2014 and quickly increase annual production to as many as 80 new pits.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The painstaking and hazardous work has led a government watchdog to express doubts about whether the U.S. government can meet that goal.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cThe United States has not regularly manufactured plutonium pits since 1989,\u201d the Government Accountability Office noted in a January 2023 report, adding that the Energy Department\u2019s National Nuclear Security Administration has provided \u201climited assurance that it would be able to produce sufficient numbers of pits.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Webster has been at Los Alamos since Ronald Reagan was president. He could have retired years ago, but has remained to shepherd the first new plutonium pits through to production. The lab is starting to feel a bit like it did in the 1980s, during the Cold War, he said. Los Alamos scientists are having intense discussions about weapon design \u2014 how much each can weigh, its explosive punch, how far it must travel.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cWe need our nation to be back making pits,\u201d Webster said. \u201cWe just have to be able to do that.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The warhead and the wristwatch<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Completed pits are protected and detonated by an outer warhead layer that is built at the Energy Department\u2019s Kansas City National Security Campus. Inside that three-story windowless factory, workers restore and test those warhead parts, work that&nbsp;<a href=\"https:\/\/www.gao.gov\/assets\/gao-23-104661.pdf\" target=\"_blank\">a government watchdog<\/a>&nbsp;said required \u201ca great deal of precision manufacturing to exacting specifications.\u201d<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"3200\" height=\"2133\" src=\"\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg\" alt=\"In this photo provided by Kansas City National Security Campus, an employee works on a mechanical wristwatch at the National Nuclear Security Administration's Kansas City facility in Kansas City, Mo., May 23, 2023.\" class=\"wp-image-71783\" srcset=\"https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg 3200w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg?resize=300,200 300w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg?resize=768,512 768w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg?resize=1024,683 1024w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg?resize=1536,1024 1536w, https:\/\/one.sightlinemg.com\/wp-content\/uploads\/2026\/08\/AP23251781990859.jpg.jpg?resize=2048,1365 2048w\" sizes=\"auto, (max-width: 3200px) 100vw, 3200px\" \/><figcaption class=\"wp-element-caption\">In this photo provided by Kansas City National Security Campus, an employee works on a mechanical wristwatch at the National Nuclear Security Administration&#8217;s Kansas City facility in Kansas City, Mo., May 23, 2023. (Kansas City National Security Campus via AP)<\/figcaption><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">There are thousands of tiny parts inside each warhead, so steady hands are key. That\u2019s why technicians go through a skills assessment that includes disassembling and assembling a mechanical wristwatch.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cEverything is done under a microscope with tweezers,\u201d said Molly Hadfield, a spokeswoman for the Kansas City plant. \u201cAnd it\u2019s pass (or) fail. Either the watch works or it doesn\u2019t work.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This factory would be busy even if an overhaul wasn\u2019t underway. All warheads have regular maintenance requirements. Their plastics age, and metal gears and wiring are weakened by the years and by exposure to radiation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The factory is also working on warheads for&nbsp;<a href=\"https:\/\/www.defensenews.com\/air\/2023\/09\/14\/b-21-ground-tests-proceed-as-bombers-first-flight-deadline-approaches\/\" target=\"_blank\">the B-21 Raider<\/a>, a futuristic stealth bomber, while also supporting the Sentinel, a new intercontinental ballistic missile and on warheads for a new class of submarines.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cThere\u2019s a huge modernization effort going on,\u201d said Eric Wollerman, who manages the Kansas City complex for the Department of Energy through its federal contract with Honeywell. \u201cIf you\u2019re going to update the delivery systems, you would also then update the warheads in the missiles and the bombs that are with them.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">To meet the demand for both maintenance and modernization, the facilities have gone on a hiring spree. The Kansas City plant has 6,700 employees, a 40% jump since 2018, with plans to add several hundred more. The Los Alamos lab has added more than 4,000 employees in that same time frame.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Old missiles, young troops<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">The U.S. nuclear arsenal reveals its age each time troops fix a missile. That can occur as often as twice a week, but only if the equally old tools, or the truck carrying the tools, or the truck needed to transport the missile itself isn\u2019t also broken down, which is often.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">That is why Airman 1st Class Jonathan Marrs was dragging a second 225-pound (102-kilogram) aluminum tow behind him toward a concrete silo in the midst of vast Montana farmland on a recent hot afternoon.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Marrs, 21, and other airmen used a tow and wrenches the size of human femurs to dislodge silo Bravo-9\u2032s 110-ton blast door. Underneath its cement and steel cover was a 70,000-pound (31,750-kilogram) nuclear missile; the missile\u2019s warhead tip needed to be lifted out and trucked to base for work.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Except the blast door wouldn\u2019t budge. The first 225-pound (102-kilogram) tow, or mule, as the troops call it, couldn\u2019t generate the power needed to pull back the door.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">After attaching a second mule, Marrs and the other airman succeeded in pulling the door free, releasing scores of mice.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The maintainers next unfastened the warhead from the missile and placed it in a specialized truck. It\u2019s then escorted by Air Force security forces back to a heavily guarded hangar at&nbsp;<a href=\"https:\/\/www.airforcetimes.com\/news\/your-air-force\/2023\/08\/08\/carcinogens-found-at-montana-nuclear-missile-sites-amid-cancer-reports\/\" target=\"_blank\">Montana\u2019s Malmstrom Air Force Base<\/a>.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Marrs and the other young airmen \u2014 known as maintainers \u2014 are closely monitored as they handle nuclear weapons, U.S. Air Force officials said.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cIf I under-inflate a basketball at the gym, no one will care,\u201d said Chief Master Sgt. Andrew Zahm, the maintenance group senior enlisted leader at F.E. Warren Air Force Base. \u201cIf I did something with one of these weapons, the president would know about it in 45 minutes.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The workload is already a challenge for these troops, and there aren\u2019t many easy ways to relieve it.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">While the private-sector managed Los Alamos and Kansas City plants have hired personnel to meet the rising workload, the military has struggled to fill jobs and retain experienced technicians. Instead, the military must do more with fewer maintainers, and for much less money than those troops could make as government contractors.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">\u201cOnce you start showing a staff sergeant the $80,000\u2033 they could make in the private sector, they are going to take it, Zahm said.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Zahm is a rarity. While many have retired or left for private industry, he\u2019s remained to keep serving the military\u2019s nuclear mission. With the U.S. so close to its first new weapon, he\u2019s driven by a desire to see it through. \u201cIn 21 years I\u2019ve never seen a new thing,\u201d Zahm said. \u201cI want to see the new stuff.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><i>Copp reported from Los Alamos National Laboratory, New Mexico; the Kansas City National Security Campus, Missouri; Malmstrom Air Force Base, Montana and F.E. Warren Air Force Base, Wyoming.<\/i><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><i>The Associated Press receives support for nuclear security coverage from&nbsp;<\/i><a href=\"https:\/\/www.carnegie.org\/\"><i>the Carnegie Corporation of New York<\/i><\/a><i>&nbsp;and&nbsp;<\/i><a href=\"https:\/\/outrider.org\/\"><i>Outrider Foundation<\/i><\/a><i>. The AP is solely responsible for all content. Del Wilber is the Washington investigations editor for the AP.<\/i><\/p>\n","protected":false},"excerpt":{"rendered":"<p>The AP was granted access inside military nuclear missile bases and other facilities to report on how they are adjusting to meet the increasing workload.<\/p>\n","protected":false},"author":7,"featured_media":71764,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_yoast_wpseo_meta-robots-noindex":"","_yoast_wpseo_meta-robots-nofollow":"","_yoast_wpseo_canonical":"","_acf":"","_yoast_wpseo_primary_category":67,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","_smg_distribution_targets":{"2":{"categories":["your-military","news"],"primary_category":"your-military"}}},"categories":[101,23,16,26,67],"tags":[],"coauthors":[3350],"class_list":["post-39116","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-daily-news-roundup","category-disaster","category-news","category-newsletters","category-your-air-force"],"acf":{"subheadline":"","legacy_arc_id":"D3LTF7KD45H3BG3B63SIJDZTTM","arc_canonical_url":"\/news\/your-air-force\/2023\/09\/21\/inside-the-delicate-art-of-maintaining-americas-aging-nuclear-weapons\/","remove_feature_photo":false,"is_sponsored":false,"subtype":"","redirect_url":"","disable_inline_ads":false,"native_logo_pretext":"Presented By:"},"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.0 (Yoast SEO v28.1) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Inside the delicate art of maintaining America\u2019s aging nuclear weapons - Air Force TImes<\/title>\n<meta name=\"description\" content=\"The AP was granted access inside military nuclear missile bases and other facilities to report on how they are adjusting to meet the increasing workload.\" \/>\n<meta name=\"robots\" content=\"noindex, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Inside the delicate art of maintaining America\u2019s aging nuclear weapons\" \/>\n<meta property=\"og:description\" content=\"The AP was granted access inside military nuclear missile bases and other facilities to report on how they are adjusting to meet the increasing workload.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/one.sightlinemg.com\/airforcetimes\/news\/your-air-force\/2023\/09\/21\/inside-the-delicate-art-of-maintaining-americas-aging-nuclear-weapons\/\" \/>\n<meta property=\"og:site_name\" content=\"Air Force TImes\" \/>\n<meta property=\"article:published_time\" content=\"2023-09-21T22:58:33+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2026-08-07T21:19:11+00:00\" \/>\n<meta name=\"author\" content=\"Tara Copp, AP\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Tara Copp, AP\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"10 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\n\t    \"@context\": \"https:\\\/\\\/schema.org\",\n\t    \"@graph\": [\n\t        {\n\t            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