38° N 19' 46" N | 104° N 21' 21" W

Pueblo Chemical Agent-Destruction Pilot, Colorado, USA Overview

Scope of Work EPC, commissioning, performance testing, startup, operation, and closing
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Safe, environmentally sound destruction of chemical weapons

The Pueblo Chemical Agent-Destruction Pilot Plant (PCAPP) is a state-of-the-art facility built to safely and efficiently destroy the chemical weapons stockpile currently in storage at the U.S. Army Pueblo Chemical Depot near Pueblo, Colorado.

The Bechtel Pueblo Team, which includes Bechtel, URS, Battelle Memorial Institute, and Parsons Infrastructure and Technology, won the competition in 2002 to design, build, test, operate, and ultimately close PCAPP after destroying the stockpile. 

Inside the Project

Unlike other demilitarization facilities, this one dismantles munitions using a first-of-a-kind robotic process.

2,611

Tons of mustard agent in artillery projectiles and mortar rounds stored at the U.S. Army Pueblo Chemical Depot that will be safely destroyed. After the chemical weapons have been eliminated, the plant will be closed in an environmentally responsible manner.

For more info

Visit the Pueblo Chemical Agent-Destruction Pilot Plant website.

Expected to be operational in 2015

The construction phase of the Pueblo Chemical Agent-Destruction Pilot Plant was completed in 2013. During construction, craft workers hired from the Colorado Building & Construction Trades Council, installed more than $200 million worth of underground utilities, redundant electrical and control systems, titanium piping and storage systems, and specialized first-of-a-kind equipment.

PCAPP is currently in the systemization phase of the chemical weapons destruction process, a period during which more than 300 associated subsystems, spread over an 85-acre site, are tested to make sure they work and function together properly. The facility is expected to go operational in 2015.


How it works: a five-step process

The Department of Defense’s Assembled Chemical Weapons Alternatives program worked together with the community to select a safe technology—neutralization followed by bio treatment—to destroy the chemical weapons stored at the Pueblo Chemical Depot. 

The five steps:

  1. Robotic equipment removes explosives from the weapon.
  2. The system remotely accesses the weapon’s interior and washes out the mustard agent with water under high pressure.
  3. Next the facility neutralizes mustard agent with caustic solution and hot water. The byproduct is hydrolysate.
  4. Microbes treat the hydrolysate, breaking it down into brine. The brine is separated and the water recycled. Staff ship the resulting salt cakes for disposal at a permitted facility.
  5. After heating metal parts to 1,000 degrees Fahrenheit (nearly 538 degrees Celsius) for 15 minutes, crews send them out for recycling.

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Why it matters

Neutralizing and disposing of World War II- and Cold War-era chemical weapons will help create a safer tomorrow.

Bechtel team honored

The Bechtel Pueblo Team has earned a number of honors, including exceptional achievement, or Star level, in the U.S. Occupational Safety and Health Administration’s Voluntary Protection Program. This program recognizes U.S. worksites that have exemplary records and demonstrate commitment to workplace safety and health.

Safely destroying the legacy of 20th-century chemical weapons production

Though never used by the United States, chemical weapons were stockpiled by the Army at a number of bases during and after World War II. In 1985, Congress decided to turn the aging weapons into a harmless part of history. Bechtel is now building two chemical demilitarization projects at U.S. military sites—the Pueblo Chemical Agent-Destruction Pilot Plant in Pueblo, Colorado, and the Blue Grass Chemical Agent-Destruction Pilot Plant in Richmond, Kentucky.

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