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 continued slab and basement assessment activities in the cellophane area.
Shaw received the final shipment of portland cement and completed the stabilization
process at the rifle range.
Shaw began and completed a round of well sampling in the EC building, Olin area and
along the ditches. Twenty wells were sampled including existing and new wells.
Shaw continued excavating hotspots in the Olin area. Excavated soil is being staged in
building 89.
Shaw cleared bldg 88 for demolition.
Shaw continued lead based paint sampling. A paint sample was also collected in building
55 for PCB’s.
Shaw began sampling crushed concrete and brick materials in the cellophane area.
DH Griffin (DARI) shipped four truckloads of asbestos to Charlotte Motor Speedway
Landfill totaling 35 tons.
DH Griffin shipped 23 loads of scrap metal weighing 333 tons to DH Griffins
Greensboro office for recycling.
DH Griffin sent off one load of hazardous materials(24.1 tons) and 3 loads of non-
hazardous materials (25.5tons).
DARI continued asbestos abatement in buildings 43,62.
DH Griffin continued demolition of buildings 34,35,46,48,50,53,56.
DH Griffin continued crushing operations in the cellophane area.
DH Griffin continued slab removal operations in the cellophane area.
DH Griffin continued perimeter dust monitoring.
DH Griffin began installing sedimentation basin #2 drainage piping.
Mountain Environmental continued to drain process lines, bulk oil and remove remaining
chemical containers.
DRV began discharging from the north clarifier into the ASB.
On-going activities in all area simultaneous as described above.
DARI ACM abatement crews will continue working in building 43,62.
DH Griffin demolition activities will continue in buildings cleared in phase I, the cellophane area buildings and building 70.
DH Griffin recycling contractors will continue removing recyclable supplies and equipment.
DH Griffin/ Shaw will continue slab removal and investigation in the cellophane area.
DH Griffin will continue installation of retention basins and the berm on the south end of the site.
DH Griffin and Mountain Environmental will continue to remove OHM materials,
including caustic tanks in building 70.
DH Griffin will perform perimeter dust monitoring.
Shaw will collect QC samples for lead paint and perimeter dust.
Shaw, DH Griffin and Mountain Environmental will continue the pre-demolition clearance process in phase I buildings.
Shaw will continue the slab investigation process in the cellophane area.
Shaw will analyze stabilized soil at the rifle range.
Shaw will collect groundwater samples from wells in the Olin area, EC bldg and around the east and south ditches.
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