In the immediate aftermath, news coverage included speculation about fermentation that produced too much pressure inside the tank. Some blamed anarchists for setting off a bomb. “Explosion Theory Favored by Expert,” reported the Boston Evening Globe. The trial that ensued lasted for years and gathered input from thousands of expert witnesses, producing 20,000 pages of conflicting testimony.
Ultimately, U.S. Industrial Alcohol, the company that owned the tank, was found liable, even as many questions remained about what had actually happened.
Steel Tank Structure Was Flawed
More recent investigations suggest several fundamental problems with the structure of the tank. Designed to hold 2.5 million gallons of liquid, it measured 50 feet tall and 90 feet in diameter. But its steel walls, which ranged from 0.67 inches at the bottom to 0.31 inches at the top, were too thin to support the weight of a full tank of molasses, found a 2014 analysis by Ronald Mayville, a senior structural engineer in the Massachusetts consulting firm of Simpson, Gumpertz & Heger.
Flawed rivet design was another problem, according to Mayville’s analysis, and stresses were too high on the rivet holes, where cracks first formed. Although molasses had been poured into the container 29 times, only four of those refills were to near capacity. The fourth top-off happened two days before the disaster when a ship arrived from Puerto Rico carrying 2.3 million gallons of molasses. At that point, the tank held enough molasses to fill 3.5 Olympic-sized swimming pools.
Both the inadequate thickness and rivet issues were signs of negligence, and structural engineers knew better at the time, says Rossow. But the tank had been built quickly in the winter of 1915 to meet rising demand for industrial alcohol, which could be distilled from molasses and sold to weapons companies, who used it to make dynamite and other explosives for use during World War I.
And instead of inspecting the tank and filling it with water first to test it for flaws, USIA ignored all warning signs, including groaning noises every time it was filled. There were also obvious cracks. Before the tank blew, children would bring cups to fill with sweet molasses that dripped out of it.
“When a laborer brought actual shards of steel from the tank’s walls into the treasurer’s office as evidence of the potential danger,” Rossow wrote in a 2015 analysis, “he replied, ‘I don’t know what you want me to do. The tank still stands.’”
What engineers didn’t know at the time, Rossow says, was that the steel had been mixed with too little manganese. That gave it a high transition temperature, making the metal brittle when it cooled below 59°F. The air temperature on the day of the disaster was about 40°F. Its brittleness might have been a final straw.
“There were a lot of culprits,” Rossow says. A similar flaw, he adds, befell some of the early Liberty ships built by the U.S. during World War II.