GovDelivery logo

EPA ID# MO9890010524

DNR Contact: Don Dicks, 573-751-3553 or 800-361-4827
EPA Contact: Robert Aston, Jr., RG, 913-551-7392 or 800-223-0425
DOE Contact: David Caughey, 816-488-3449
GSA Contact: Kevin Phillips, 816-823-1220
Last Updated: April 8, 2013

  • Former Company Name: Allied Corp, Bendix/KC Div.; Allied-Signal Corp.; Bendix Plant; Honeywell FM&T; US DOE KC Plant.
  • Type of Facility: Permitted Hazardous Waste Storage and Disposal – closing.
  • Wastes of Concern: Volatile organic compounds and polychlorinated biphenyls, or PCBs.
  • Treatment and Disposal Methods: Land disposal.
  • Location of hard copies of hazardous waste permit application, Part I and Part II Permits, modification requests, reports, etc. and supporting documents:
Information icon

For More Information:

Current Activities

Permit Deliverables: DOE and GSA submitted to the department and EPA, several documents required to be submitted under their Missouri Hazardous Waste Management Facility Part I Permit Modifications, effective Aug. 24, 2012.

  • Revised Community Involvement Plan (CIP and Appendices): Approved with comments April 2013.
  • Description of Current Conditions Report (DCCR): Under review - The draft DCCR is available online on Honeywell's Kansas City Plant website.
  • Updated Long-Term Operation, Maintenance and Monitoring (LTOM&M) Plan: Under review.
  • Polychlorinated Biphenyl, or PCB, Fate and Transport Study Work Plan: Approved June 2013. The sampling has been partially completed.
  • Revised Sampling and Analysis Plan: Approved with conditions in March 2013.
  • Updated Spill Control/Emergency Plan: Under review.

Several of these documents are being made broadly available to the public due to the level of interest regarding activities at the complex. These documents are being made available solely for informational purposes. The department and EPA are not actively soliciting public comments on these documents. Please be aware that the department and EPA are currently reviewing several documents and the agency review and approval process is expected to take considerable time due to the size and scope of these documents.

The department recognizes that some of the electronic files are quite large, which may result in long download times for individuals with dial-up connections. While we would prefer individuals obtain these documents online, if you have any problems accessing these documents and are interested in obtaining an electronic copy through other means, please contact Don Dick at the Missouri Department of Natural Resources, Hazardous Waste Program, P.O. Box 176, Jefferson City, MO 65102-0176, by telephone at 573-751-3553 or 800-361-4827 or by email. Please be aware that standard copying charges will apply if a hard copy is requested.

Facility Description

The U.S. Department of Energy-Kansas City Plant is located on about 136 acres of the 300-acre Bannister Federal Complex, located at 2000 E. 95th St. in Kansas City, Missouri. The federal complex is approximately 13 miles south of downtown Kansas City, within the incorporated city limits. The federal complex is bordered on the north by Legacy Park, east by the Blue River and the Blue River Parkway, south by Indian Creek and Bannister Road and west by Troost Ave.

Before World War II, the area of the federal complex was mainly farm land. In 1942, the U.S. Navy built the main manufacturing building at the site. The Department of Defense also built a landfill on part of the property to be used as a disposal site for the Bannister Federal Complex. From 1943 to 1945, Pratt and Whitney Corp. built aircraft engines in the main manufacturing building for the U.S. Navy in support of World War II.  

In 1948, the main manufacturing building was declared excess to defense requirements and turned over to the War Assets Administration. The War Assets Administration used the building for a short time as a warehouse and housing for several private and governmental operations. In 1948, the building was transferred to the Department of the Navy, which leased part of the building to Westinghouse Electric Co. From 1948 until their lease was cancelled in 1961, Westinghouse built jet engines at in the main manufacturing building for the U.S. Navy in support of the Korean Conflict.

In 1949, Westinghouse subleased part of the main manufacturing building to Bendix Corp. Bendix was contracted by the Atomic Energy Commission to manufacture electrical, mechanical, plastic and other non-nuclear components of nuclear weapons. From 1984 to 1999, Bendix merged with Allied Corp., who merged with Signal Corp. and became Allied Signal Inc., who bought Honeywell Federal Manufacturing & Technologies LLC.

In 1964, the landfill was closed and the property was transferred to the General Services Administration. GSA manages government assets, including government-owned and leased buildings. GSA operated a warehouse in the western part of the building. The Atomic Energy Commission continued operating what is now known as the Kansas City Plant in their part of the building until the Commission was abolished in 1974. In 1975, the Energy Research and Development Administration was created and took custody and control of the Kansas City Plant in 1976. The U.S. Department of Energy (DOE) was created in 1977 and the Kansas City Plant was included in the new department. DOE continued operating the Kansas City Plant and took ownership of their part of the building. In 2000, DOE created the National Nuclear Security Administration, or NNSA, in part, to strengthen national security and reduce the global threat from weapons of mass destruction.

The Bannister Federal Complex is currently owned by two agencies: DOE/NNSA and GSA. The Kansas City Plant is owned by DOE/NNSA and operated by Honeywell Federal Manufacturing & Technologies LLC. GSA owns the remaining portions of the complex and leases space to other federal agencies; including the Internal Revenue Service, Federal Aviation Administration, or FAA, and U.S. Marine Corps.

The Kansas City Plant currently employs about 2,600 staff and continues to manufacture electrical, mechanical, plastic and other non-nuclear components of nuclear weapons. Acids, alkalines, solvents, acid and alkaline contaminated solid waste, solid debris waste, waste oil, wastewater treatment sludges and toxic metals are stored on site under generator storage requirements until they are either treated at the Kansas City Plant’s industrial wastewater pretreatment facility or shipped off-site to a permitted hazardous waste treatment, storage and disposal facility.  The Kansas City Plant currently has six hazardous waste container storage areas and three contingent areas. The Kansas City Plant also uses small amounts of radioactive materials in products and uses conventional, sealed industrial radioactive sources for instrument calibration, radiography and laboratory equipment. These processes occasionally produce mixed waste, which is stored in one area on-site until shipped off site.

On May 13, 2013, DOE/NNSA's Kansas City Field Office began the move to the new National Security Campus, located about eight miles south of the Bannister Federal Complex. DOE/NNSA plans to be completely vacated from the federal complex by 2014. About 130 people from Honeywell FM&T also made the move.

Post-Closure and Corrective Action Status

There are three closed hazardous waste management units located at the Kansas City Plant, two lagoons and an underground tank farm. DOE closed the north and south lagoons by removing the contaminated sediment, backfilling with uncontaminated soil and covering with a clay cap, topsoil and vegetation. The underground tank farm consisted of 28 tanks and associated underground piping and stored fuels, coolants and solvents. DOE closed the tank farm by removing all tanks, associated piping, concrete supports and fill to a depth of about 15 feet below ground surface. The area was then backfilled with uncontaminated soil and covered with a clay cap, topsoil and vegetation. The Missouri Department of Natural Resources accepted DOE’s closure report and certification for the hazardous waste management units; however, because of historical release of hazardous waste, the area is also required to go through a period of post-closure care. As part of the post-closure care, NNSA is required to monitor the groundwater and inspect and, if necessary, repair the clay caps.

As part of the corrective action process, all interim status and permitted hazardous waste treatment, storage and disposal facilities are also required to investigate and clean up hazardous waste and hazardous constituent releases at their facility resulting from present and past hazardous waste handling practices. There are two known historical releases of polychlorinated biphenyls, or PCBs, both from Department 26, which produced plastic in the southeast corner of the main manufacturing building. PCBs were used in transformers, other electrical equipment, hydraulic oil, caulking compounds and elastic sealant. In 1969, an expansion joint failed and released approximately 1,500 gallons of PCB oil to a gravel area. About 900 gallons of the PCB oil entered the storm sewer system and released to Indian Creek through the old 002 Outfall. Despite clean up efforts at the time of the spill, residual PCBs remained in the creek bottom sediments. Shortly after the spill, Indian Creek was rerouted and the PCB contamination was left in place alongside and underneath the box culvert. In 1971, about 1,100 gallons of PCBs were released to the ground outside Department 26, near a storm water drain. Some of the PCBs entered the storm sewer system and released to Indian Creek through the newly installed box culvert near the new 002 Outfall. This area of contamination, known as the 95th Terrace site, is located south of the main manufacturing building in the former Indian Creek channel. The 95th Terrace site is bordered to the south by Indian Creek and is partially located on property owned by the Missouri Department of Transportation.

PCBs were banned by EPA in 1979 and PCB replacement was not required in existing equipment. PCBs are common in cooling systems, transformers, capacitors, electrical equipment, oils, caulking compounds and elastic sealant. DOE replaced the PCB heat transfer piping and oil in 1986; however, materials made before the PCB ban, such as sealant and transformers, are still in use at the Kansas City Plant and other locations in the area.

Cleanup of the Kansas City Plant began in 1983, but most corrective action activity was initiated in 1989 with an EPA Consent Order. On June 23, 1989, DOE voluntarily entered into a 3008(h) Corrective Action Administrative Order on Consent with EPA, Docket No. VII-89-H-0026. The order initially listed 35 solid waste management units as possible release sites, including the two closed lagoons and underground tank farm. The order directed the investigation and corrective action activities at the facility until 1999, during which time eight more solid waste management units were identified. Releases from the underground tank farm, a trichloroethylene reclamation facility, a plating building and other industrial practices resulted in soil contamination and large groundwater plumes containing solvents and petroleum products.

On Oct. 6, 1999, the department and EPA issued two hazardous waste permits to DOE for the Kansas City Plant. The department issued a Missouri Hazardous Waste Management Facility Part I Permit and EPA issued a Hazardous and Solid Waste Amendments Part II Permit. These permits transferred the oversight responsibility and authority for the investigation and corrective action activities from EPA to the department. EPA terminated their Order on Dec. 30, 1999, and the corrective action process continued under Part I Permit.

Many of the solid waste management units on the DOE/NNSA portion of the federal complex were grouped together for further investigation and cleanup due to their close proximity to each other and the type of contamination. NNSA is currently performing post-closure, corrective action and long-term stewardship activities for the Kansas City Plant under Missouri’s EPA-authorized hazardous waste program, which is equivalent to the federal Resource Conservation and Recovery Act, or RCRA, with the department providing primary regulatory oversight. For enforcement and compliance history for the Kansas City Plant, please visit EPA's Enforcement & Compliance History Online database, or ECHO.  

NNSA is in the final remedy operating, maintenance and monitoring stage for all contaminated areas currently under their responsibility. The Kansas City Plant part of the federal complex is restricted to industrial use only and the groundwater cannot be used for any purpose. Groundwater is currently treated by an ultraviolet light-hydrogen peroxide system. Groundwater is collected from interceptor wells, footing tile drains and Outfall 002, treated and discharged to the local sewage treatment plant. As part of the approved final remedy for the 95th Terrace site, NNSA is required to inspect and maintain the box culvert under Bannister Road, the signs at the outfall and the protective cage over the concrete chute entering Indian Creek. NNSA is also required to sample surface water, sediment and fish tissue in Indian Creek and the Blue River for PCBs. Fish tissue was sampled for PCBs in 2005 and 2007, and is planned for 2013.  

GSA was performing environmental cleanup activities on their portion of the site under the Comprehensive Environmental Response, Compensation, and Liability Act, or CERCLA, with EPA providing regulatory oversight. Additional information about that cleanup effort is available on EPA's website. As of Aug. 24, 2012, the department and EPA modified DOE's permits to include the entire federal complex, including the property owned by GSA, under the permits and add GSA as a permittee. Additional information about the GSA-owned portion of the Bannister Federal Complex, including legacy environmental issues, is available on GSA's website.

The landfill, located on the GSA part of the federal complex, was closed in 1964. The U.S. Army Corps of Engineers is responsible for performing the environmental investigation and cleanup of the landfill under the Formerly Used Defenses Sites Program, with the department providing regulatory oversight. The presence of solvents has been confirmed in the groundwater in the vicinity of the landfill. The U.S. Army Corps of Engineers is continuing their investigation. Additional information about this cleanup effort is available on the department’s Federal Facilities website.

Regulatory Status

The Kansas City Plant operated the three hazardous waste management units (two lagoons and an underground tank farm) under the interim status portions of the federal and state hazardous waste laws, 40 CFR Part 265 and 10 CSR 25-7.265. When Congress passed the hazardous waste federal law in 1980, all existing facilities that treated, stored or disposed of hazardous waste in a manner that would necessitate a hazardous waste permit were required to get such a permit. Because of the large number of existing facilities, Congress set up requirements which allowed these facilities to operate temporarily under “interim status” until they received their permit. DOE decided not to continue the hazardous waste permitting process and to close the unit. DOE is subject to the permitting requirements of the Missouri Hazardous Waste Management Law and federal Hazardous and Solid Waste Amendments for post-closure care because hazardous waste remained in place after closure. DOE is also subject to corrective action because they completed closure after the effective date of the federal Hazardous and Solid Waste Amendments.

DOE is conducting post-closure and corrective action activities at the Kansas City Plant under two hazardous waste permits, one issued by the department and one issued by EPA, both effective Oct. 6, 1999.  The department issued the Missouri Hazardous Waste Management Facility Part I Permit. EPA issued the Hazardous and Solid Waste Amendments Part II Permit to cover regulatory requirements Missouri had either not yet adopted or adopted but not yet received EPA authorization. These permits require DOE to perform post-closure care for the three closed hazardous waste management units: the North Lagoon, South Lagoon and Underground Tank Farm, as well as operate, maintain and monitor all corrective action final remedies on the DOE part of the federal complex.

On Sept. 29, 2006, the department issued Part I department-initiated permit modifications to DOE, requiring the facility to implement the approved final remedy for the 95th Terrace site. On Aug. 24, 2012, the department and EPA issued Part I and Part II Class 3 Permit Modifications to DOE and GSA, requiring DOE and GSA to conduct further environmental investigation, monitoring, risk-assessment and cleanup at the federal complex under the modified permits. Both agencies were performing environmental investigation and cleanup activities on their respective portions of the federal complex, but under separate environmental laws. The permits were modified to include the entire federal complex, including the property owned by GSA, under the permits and add GSA as a permittee.

DOE submitted a permit application on April 7, 2009, for renewal of their existing hazardous waste permits. The facility's existing hazardous waste permits expired Oct. 6, 2009. State and federal regulations, 40 CFR 270.51, allow the existing hazardous waste permits to continue in effect until the department and EPA issue or deny new hazardous waste permits. The department is currently reviewing the application for completeness.