United States Environmental Protection Agency
Region IV
POLLUTION REPORT

Subject: 

The Ecusta Mill is a former flax pulping and paper manufacturing facility that was built in 1939 and was operational until 2002.  Cellophane production also occurred at the facility for approximately 30 years.  In addition, the following activities have occurred at the Site:  chlorine production operations using Sorenson mercury cells (electro-chemical building); caustic storage; water and wastewater treatment; and printing.  EPA's Removal Program and the North Carolina Department of Environment and Natural Resources (NC DENR) first responded when the plant was closed down in 2002.  Of primary concern were potential releases from an interruption of power to the basement sumps under the production buildings.  The EPA Environmental Response Team conducted sampling of the concrete floor, the sub-floor, and soils under the electro-chemical building and sediments in on-site ditches.  This sampling confirmed the presence of mercury in the sub-floor structures to 16 feet below ground surface (580 mg/kg) and the floor drains (260 mg/kg) of the electro-chemical building, in the indoor air and in the overland drainage ditches which had received historic discharge from the building.

    An Expanded Site Inspection (ESI) was conducted by EPA Region 4, Science and Ecosystem Support Division and the State in March, 2004.  The ESI focused on two main areas of concern, the electro-chemical building and the Aeration and Sedimentation Basin (ASB) area.  Mercury was detected in soils adjacent to the electro-chemical building, in sediments in the on-site drainage ditches and in sediments of the Davison River immediately adjacent to the manufacturing area. The ESI also confirmed soils and sediments in other areas of the site are contaminated with mercury and dioxin.   Groundwater sampling has confirmed low-levels of mercury in groundwater near the electro-chemical building, low levels of carbon disulfide and 1,1-Dichloroethane near the cellophane plant, and a high pH reading (pH 12.17) in the area of a previous caustic spill.

    The total Site is approximately 527 acres in a mixed-use residential/industrial area.  The manufacturing facility is approximately 213 acres. The ASB has a surface area of approximately 75 acres and was used for wastewater treatment.  The ASB also receives storm water from approximately one-third of the site, including those areas historically most actively involved in paper production.  The following industrial solid waste landfills are located at the Site:  the Island landfill, the new ash landfill; the old ash and sludge landfills which are unlined industrial landfills which do not have permit numbers issued.  The previous site owner is in the process of closing all landfills in compliance with State permit requirements.

    A small arms firing range has been historically operated on the Site south of the main manufacturing operations on a largely undeveloped parcel of land near the confluence of the Davidson and French Broad Rivers.  Lead impacted soil has been document from the historic firing range.

    Renova Partners, a Brownfields redevelopment company purchased the property in January 2008.  Renova formed a subsidiary company Davidson River Village, LLC (DRV) who is conducting complete demolition of all on-site structures prior to site redevelopment.  D.H. Griffin was retained by DRV to conduct the demolitiion.  

  DRV is conducting the Removal Activities at the site under an AOC with EPA.  They have hired Shaw Environmental as the lead environmental contractor. Removal Activities include a Time Critical Removal Action and 2 Non-Time Critical Removal Actions.  

Shaw continuing sampling crushed concrete/brick debris.

Shaw continuing the building clearance process. Building 11 was cleared for demolition.

DH Griffin shipping loads of scrap metal to DH Griffins Greensboro office for recycling.

DH Griffin continue shipping lead impacted brick to Republic landfill.

DH Griffin continue demolition of buildings 11,62.

DH Griffin continue crushing operations in the north end of the site.

DH Griffin continue demolition of building slabs 38,87.

DH Griffin continue removing utilities behind building 62.

DH Griffin continue perimeter dust monitoring.

Kessel Engineer continue oversight of the geotechnical operations for fill being placed
in reservoirs 47 and 54.

Kessel Engineering completing collection of geotechnical boring samples.

Mountain Environmental continue removing weak liquor from building 56 chests and
transferring to the clarifier.

DRV continue discharging from the north clarifier into the ASB.

Shaw continue slab assessment activities in building slabs 68,88.

Shaw finishing collecting environmental samples from Kessel Engineering geotechnical
borings. Four boring locations had arsenic levels above RG’s. Three borings also had PID
readings above 5ppm. Samples from these three locations were sent to the laboratory
VOC and PAH analysis.

Shaw collecting samples from crush material for lead analysis.

DH Griffin alerted Shaw to area below reservoir 38 with strong organic odors. PID
readings were noted in excess of 50 ppm. Samples were collected and sent to the
laboratory for VOC’s and PAH’s. Results indicated that soil in the area of concern is
below RG’s.

Shaw and DH Griffin will continue the building clearance process.

Shaw will survey the coal yard capacity for use as a potential fill area for arsenic soils.

DH Griffin demolition activities will continue in buildings cleared.

DH Griffin will continue loading out scrap, C&D debris, asbestos, non-hazardous
materials and recyclable product.

DH Griffin will continue removing utilities less than 4 ft below ground level.

DH Griffin/ Shaw will continue slab removal and investigation process.

DH Griffin and Mountain Environmental will continue to remove and or transfer OHM
materials.

DH Griffin will continue T & D of lead impacted brick.

Shaw will continue collecting samples for crushed debris.

Kessel Engineering will continue to provide oversight for backfill operations as needed.

Shaw will continue site wide sub slab analysis and documentation.

State/federal regulators will continue to investigate arsenic soil background levels.

Shaw will install additional wells near the caustic area and begin pump and slug testing.

Jennifer asked about the EC building demo plan. Mike explained he hadn’t decided how
to handle the trenches and he was willing to send her the draft report sans the trench
section. Also Shaw is pulling together the estimates of cement totals for disposal. They
discussed the issues for a bit and Jennifer told Mike to go ahead and finish gathering
everything before he sends the report to her.

Jennifer asked about the building 27 pit. Ron has the TCRA request in hand, just needs
to review and send to Jennifer. He will copy Jim and Harry also. Paul also explained that
the drawing of the pit showed a drain on the north side but they found a drain on the
south side. They will evaluate the situation as the pit is pulled up.

DH Griffin shipped 42 loads of scrap metal weighing 662 tons to DH Griffins Greensboro office for recycling.

DH Griffin continued shipping lead impacted brick to Republic landfill, 17 loads weighing 280 tons were shipped.

Mountain Environmental continued removing weak liquor from building 56 chests and transferring to the clarifier. Approximately 24 loads have been removed totaling 72,000
gallons of weak liquor. Approximately 18,000 gallons remain.