The families of the 16 victims killed in the devastating blast at a Tennessee explosives plant have been notified.

No one has been found alive in the search and investigators are working through the scene metre by metre, Humphreys County Sheriff Chris Davis said.

Earlier, officials thought 18 people were missing because their vehicles and personal items were at the facility, but they were later able to locate two people off-site, officials said.

“We’re moving to recovery,” Davis said with emotion during a news conference one day after the blast, his voice trailing off at times.

“At this time, we have recovered no survivors.”

“As we get into this, we find it even more devastating than what we thought initially,” he added.

Early on Friday, the thundering blast at Accurate Energetic Systems reverberated across a tight-knit community, razing an entire building on the plant’s sprawling campus.

The recovery effort was being made “more volatile” with the presence of ordnance at the site, and investigators were working with the FBI to use cell phone technology to figure out what happened at the time of the explosion, Davis said.

Investigators were also using DNA to try to identify the remains of victims.

Melissa Dawn Stanford, a 53-year-old production supervisor at the plant, is believed to have died, her niece, Brittany Kirouac, told CNN in a statement.

The Tennessee Bureau of Investigation informed Kirouac they don’t believe her aunt could have survived, she said.

“To say our family is devastated is to put it lightly. We are honestly at a loss for words and grief is not linear. In the past 24 hours I have seen: anger, sadness, bargaining, denial, and acceptance,” Kirouac said.

“Not only from our family, but from the families who surrounded us waiting to hear news about their loved ones,” she continued.

“At this time, we are just hoping to bring her home to say goodbye.”

Kirouac asked for prayers as her family, like so many others, attempts to “navigate these coming days, weeks, and months”.

Davis said more than 300 people had searched “almost every square inch” of the plant.

The Bureau of Alcohol, Tobacco, Firearms and Explosives’ elite National Response Team, which provides a range of specialists who investigate bombings and wildfires, is part of the complicated recovery operation.

“I never want to give up hope. Hope’s always been my heart, but I don’t want to give false hope either,” Davis said.

“We need our communities to come together and understand that we’ve lost a lot of people. This don’t only affect those families, it runs deeper … this could be people that you grew up with,” Davis said, noting one victim was a childhood friend of his.

The explosion occurred during an early shift at Accurate Energetic Systems, a manufacturer of military and demolition explosives that employs scores of local residents.

“Prayers are needed … our hearts are broken for the families and for the loved ones that lost their lives,” Wendall Stinson, the manufacturer’s CEO, said alongside officials Friday.

The blast triggered a series of smaller explosions, officials said, and the cause is still under investigation.

Officials will be on site today detonating explosives because “chemicals are more unstable” than previously thought, according to a source familiar with the investigation.

The source added the timing of these controlled explosions is unknown but will be audible to people in the area, noting the point is to ensure the area is safe.

Investigators are also pulling employment records, according to the source.

Here’s what we know as the investigation continues:

The explosion happened around 7.45am local time, waking residents for miles around.

“I thought the house had collapsed with me inside of it,” Gentry Stover told The Associated Press, explaining how he was jolted awake.

It took him only moments to piece what happened together.

“I live very close to Accurate (Energetic Systems), and I realised about 30 seconds after I woke up that it had to have been that.”

Officials said the explosion was felt as far as 24km, but Cody Warren, who lives more than 32km from the plant, told CNN the noise woke him and at first he thought lightning had struck his house.

“I went outside and could still hear the ring of the sound off in the distance. I thought maybe it was an earthquake or a meteor explosion,” Warren told CNN.

Closer to the plant, charred debris and mangled vehicles were spread across a vast area.

Davis called it “the most devastating scene that I’ve seen in my career”.

Residents who find debris are being asked to call their local sheriff “so trained personnel can respond safely”.

Officials are requesting everyone to avoid the area near the plant while emergency teams do their job.

It’s unclear how many people were inside the plant when the explosion happened, Hickman County Mayor Jim Bates said.

“It’s going to be an investigation that’s probably going to go on for days,” Bates said.

The ATF and Hickman and Humphreys counties’ sheriff’s offices will co-lead the investigation, which will also include the FBI, the officials said.

In a statement on Friday evening, AES called the explosion a “tragic accident” and said, “Our thoughts and prayers are with the families, coworkers, and community members affected by this incident.”

Investigators using phonerecords to help determine who was at the plant

As of Friday evening, authorities were still working to contact some of the next-of-kin of employees who were believed to have been inside the building at the time of the explosion, a law enforcement source told CNN.

As part of the ongoing effort to determine which company employees may have been among the victims, the source said authorities are now also conducting analysis of records from nearby cell phone towers.

The sophisticated process involves comparing the cell phone numbers of employees with local cell phone tower registration records to help pinpoint the geographical location of a device at the time of the explosion.

Davis noted people in the community were undergoing a “gauntlet of emotions” as many awaited word of loved ones.

“I understand that some families get mad. I understand that some people get upset. … We’re doing the very best we can to take care of this,” Davis said.

‘A well-loved company in the area’

Accurate Energetic Systems makes “various high explosive compositions and specialty products” for the US military and industrial markets, according to the company’s Facebook page.

The AES plant employs around 80 people, the Hickman County mayor said.

The facility is spread across 1300 acres in a rural, wooded area off Interstate 40, roughly 100km west of Nashville near the border of Hickman and Humphreys Counties, officials said.

The relatively remote area where the plant is located is typically patrolled by smaller law enforcement departments, so other agencies have volunteered resources for support, a source told CNN.

The site consists of five production buildings and “a quality lab for product evaluation and analysis,” according to a company profile from the nongovernmental Association of the United States Army, which lists AES as a sponsor.

Last month, the Department of Defence awarded AES a nearly $US120 million ($183 million) contract “for the procurement of TNT.”

Tennessee state Senator Kerry Roberts told CNN the company is a beloved employer for many, with workers often seen at community events sporting baseball caps with the company’s logo.

“It is a well-loved company in the area,” Roberts said.

“This is going to have a devastating impact on quite a few families.”

Plant’s history includes previous deadly blast

The plant has suffered deadly accidents in the past and faced federal fines related to workplace safety practices, according to media reports and federal data.

In April 2014, an explosion at the facility killed one worker and injured four others, CNN affiliate WSMV reported.

The blast, in the back of a building used for shotgun ammunition, caused severe damage.

At the time, authorities said several companies operated on the property, and the explosion happened in an area run by Rio Ammunition.

Tennessee OSHA said Saturday the 2014 incident involved a different company, American Sporting Supplies, which was leasing a building at the site at that time.

American Sporting Supplies no longer operates there, and Accurate Energetic Systems was not connected to the 2014 incident, according to Tennessee OSHA.

Years later, the Occupational Safety and Health Administration fined the company $US7200, after a 2019 inspection found violations related to personal protective equipment, employee exposure to contaminants and inadequate safety training, among other citations.

The company contested the findings, OSHA records show, and eventually reached a formal settlement.

Details about the inspection and its conclusion are limited, and it’s unclear if the plant has faced more recent health or safety reviews.

Records show the company has reported 46 work-related injuries since 2016, the earliest year on record.

No workplace deaths were reported during this period.

In 2024, the most recent year for which data is available, the company reported five injuries and one illness.

In 2021, a former employee sued the company, alleging wrongful termination after being blamed for a fire that broke out at the facility the previous year.

The company disputed the claim, and the case was dropped after mediation.

The Tennessee explosion is a stark reminder of the long history of deadly workplace accidents in small-town America.

That history includes the 1947 Texas City disaster, when a ship carrying ammonium nitrate exploded and killed nearly 600 people, and the 2013 fertiliser plant explosion in West, Texas, which killed 15 people.

A wave of high-profile industrial accidents in the 1960s prompted legislative action, leading to the OSHA’s creation, signed into law by President Richard Nixon.

A tight-knit community in mourning

A small crowd gathered for a vigil on Friday evening at a nearby park, holding candles as they prayed for the missing and their families, joining voices to sing Amazing Grace, the AP reported.

The Humphreys County sheriff said the incident struck close to home, placing a heavy strain on the tight-knit community.

“There are three families that’s involved in this that I’m very close to. When you have small counties like this, we know each other … we love each other,” Davis said.

Three individuals with “minor injuries” were treated at TriStar medical facilities in Dickson, according to a TriStar Health spokesperson.

Two were discharged, while one remained under observation in an emergency room as of late Friday, the spokesperson said.

Among those hurting Saturday was Janie Brown, who sought comfort at a prayer vigil at a chapel in McEwen, Tennessee.

She said she knew and worked with some victims and their families.

“It’s going to be a sad, sad day in our community for a while,” she lamented, urging people to “give us time to heal and pray for us”.

The focus now should be on the families, not on how the tragedy occurred, she said.

“The time is not to worry about why it happened, it’s to worry about who it happened to, the families,” said Brown, adding the victims “were loved by their families and by their communities … Everybody knew them.”