USAE performs cradle-to-grave environmental remediation using best practices and innovative technologies to support safe execution and quality results at current and former military sites contaminated with munitions and explosives. Our experience with performing building demolition and remediation, contaminant sampling and testing, and addressing regulatory compliance is demonstrated by our projects at the former Sunflower Army Ammunition Plant (SFAAP), KS.

The former SFAAP encompasses over 9,060 acres and operated from 1943 to 1992. In 1943, the SFAAP commenced smokeless powder and propellant production for small weaponry, cannons, and rockets. The installation also manufactured and regenerated nitric and sulfuric acids and ammunitions proving. The Sevenson-USAE JV completed two large projects at the former SFAAP for the removal and decontamination of explosive-contaminated sewer lines.

The two projects included extensive chemical sampling and analysis, as the contaminants of concern included dioxin, nitrocellulose, nitroglycerine, nitroguanidine, TNT explosive residues, ammonia, nitrates, 2,4-dinitrotoluene, asbestos-containing material (ACM), semi-volatile organic compounds, volatile organic compounds, Total Petroleum Hydrocarbons, lead, arsenic, and elemental mercury. The combined projects had eight Solid Waste Management Units and two Areas of Concern.

• Removed and thermally decontaminated 171,765 LF of MEC-contaminated piping 
• Excavated > 338,000 tons of contaminated soil containing dioxin and ACM from a variety of on-site locations
• Prepared and implemented a USACE-approved Mercury Remediation Plan and removed >4,400 lb. of mercury-contaminated material
• Removed >614,364 SF of concrete building foundations across the SFAAP
• Crews completed 532,104 safe workhours without a lost-time incident.

During inspection of piping ranging from 12 to 60 inches in diameter for explosive residue, a UXO technician visually inspected each pipe before removal. Since some pipes were too small for personnel to safely USAE implemented innovative technology through the use of a remote-controlled robotic sewer inspection camera system to streamline inspections. This innovative camera system saved over $300K and enhanced safety by minimizing human exposure to hazardous conditions while increasing operational production.

Working closely with regulators, including the Kansas Department of Environmental Quality, EPA Region 7, and USACE Kansas City, the JV mitigated potential schedule delays due to COVID-related site shutdowns, extreme weather, and unauthorized site visitors. These projects demonstrate successful environmental remediation with extensive investigation and cleanup of comingled MEC and HTRW.

USAE received “Very Good” ratings for Quality and Cost Control. Comments included: “Safety Officer does a great job from the morning safety meeting to the daily safety oversight.  Innovative use of the robot as a pipe pre-survey to them safe and allow them to access and expose more length of pipe for excavation/burning at any given time.” 

“The contractor MEC QC team completed the contract with no deficiencies, enabling the Army to declare the sites MEC safe with confidence. The contractor continued to produce detailed and informative daily QC reports and periodic updates of MEC progress via CAD drawings for the Army, making governmental MEC removal substantiation for certification clear.”