Former Facility Name
McDonnell Douglas Corp.
Last Updated
Facility Physical Address

McDonnell Douglas Boulevard, North Lindbergh Boulevard, Banshee Road
Hazelwood, MO 63042-4207
United States

County
St. Louis
EPA ID
MOD000818963
MoDNR Contact Name
Michael Koestner
MoDNR Contact Phone
MoDNR Contact toll free number:
MoDNR Contact Email
Facility Contact(s)
Company
The Boeing Company
Facility Contact Name
Arthur Lenox
Facility Contact Phone Number

Permanent Hard Copy Location(s)

Location of hard copies of regulatory mechanism(s) and any modifications, reports and other supporting documents.

Missouri Department of Natural Resources, Elm Street Conference Center, Jefferson City, MO 65102 (Submit a Sunshine Law Request to review or obtain copies of the department's files.)

No EPA Hardcopy Location.

Overview

Background/ History

The Boeing Company (Boeing) operated an aerospace manufacturing facility at the location known as Tract I, which was previously operated by the McDonnell Douglas Corporation, located on James S. McDonnell Douglas Boulevard, North Lindbergh Boulevard, and Banshee Road in Hazelwood. Tract 1 occupies approximately 209 acres, with an additional 23 acres of leased property, next to the St. Louis Lambert International Airport (Airport). From 1941 to 1997, the McDonnell Douglas Corporation manufactured transport aircraft, aircraft components, space systems/missiles and combat aircraft. These processes included aluminum, titanium, composite structure and other airframe materials fabrication, chemical processing, degreasing, painting, fueling of vehicles, aircraft assembly and flight testing.

A variety of hazardous wastes were produced as part of the manufacturing operations. The McDonnell Douglas Corporation stored the waste in three hazardous waste container storage areas until it could be shipped to a hazardous waste disposal facility. The storage areas were permitted under two hazardous waste permits, one issued by the Missouri Department of Natural Resources, and one issued by the Environmental Protection Agency (EPA), originally issued in 1984, and reissued in 1997 and 2017. The EPA decided not to reissue its permit in 2017. The department issued the Missouri Hazardous Waste Management Facility Part I Permit. EPA issued the Hazardous and Solid Waste Amendments Part II Permit. The McDonnell Douglas Corporation also distilled spent solvents under a Resource Recovery Certification, issued by the department.

In May 2023, Boeing notified the department that it intended to resume operations on the Airport property, starting with the redevelopment of the buildings the Airport has not leased since the property was purchased from Boeing in 2005. Boeing intends to resume the manufacture and testing of aerospace components and aircraft at the facility. Pre-redevelopment investigations are underway, with construction activities to begin in late 2024.

Cleanup Summary

The McDonnell Douglas Corporation was acquired by Boeing in August 1997. Boeing has since stopped storing hazardous waste at the facility. In 2001, Boeing sold part of Tract 1 to GKN Aerospace, who uses the site for developing and manufacturing aircraft structures, components and assemblies. In 2005, Boeing sold most of the remaining Tract 1 to the Airport, who uses part of the site as a runway protection zone and has leased other portions of the site to tenants. Boeing closed all the hazardous waste storage units. The department accepted closure certifications for most of the units in 1993, 1995, 2001, and 2003. The remaining units were referred to corrective action and are currently being addressed.

Boeing conducted corrective action activities under the same two hazardous waste permits the facility operated under until 2017. In 2017, the EPA did not reissue their permit. Boeing continues to conduct corrective action under the department’s permit. According to applicable state and federal hazardous waste laws and regulations, all hazardous waste treatment, storage and disposal facilities are required to investigate and clean up releases of hazardous waste and hazardous constituents to the environment at their facility resulting from present and past hazardous waste handling practices. Investigations concluded that soil and groundwater at Tract 1 are contaminated with volatile organic compounds, polynuclear aromatic hydrocarbons, polychlorinated biphenyls, metals and total petroleum hydrocarbons. The contamination is limited to within the bounds of the permitted facility. In 2006, contaminated soils were removed from five of the nine identified contaminated areas that exceeded risk levels.

Boeing has implemented the final remedy in accordance with their Corrective Measures Implementation Work Plan, approved January 2019, and associated Quality Assurance Project Plan, revised June 2022. The approved final remedy also includes property activity and use limitations in the form of enforceable environmental covenants. The GKN Aerospace and Boeing environmental covenants were executed by the department and the property owners in September 2018. The St. Louis Lambert International Airport Environmental Covenant was executed by the department and the Airport in October 2020.

Starting in 2023, Boeing began investigating and addressing previously unknown hexavalent chromium releases to soil and groundwater from the industrial sewer lines throughout the facility which receives wastewater from Boeing facilities at and near the facility. Interim measures have been implemented on a portion of the industrial sewer line to treat the contamination in place the potential of contaminated groundwater. The section of industrial sewer has been repaired and no longer releases to the environment.

Operations

The Boeing Company’s (Boeing’s) Tract I facility is located on about 232 acres, in total, on James S. McDonnell Douglas Blvd, N. Lindbergh Blvd, and Banshee Road in Hazelwood. In 1941, The McDonnell Douglas Corporation began operating an aerospace manufacturing facility at the site. In 1997, the McDonnell Douglas Corporation (McDonnell Douglas) merged with the Boeing Company (Boeing), transferring all of Tract I to the Boeing Company. In 2001, 87.88 acres of Tract I was sold to GKN Aerospace (GKN), the lease for 23 acres of land from the Airport to Boeing ended in 2004, and in 2005, 75.99 acres were sold to the St. Louis Lambert International Airport (Airport). Boeing currently retains 45.54 acres.

During operations by the McDonnell Douglas Corporation, 48 distinct hazardous waste streams were produced as part of facility operations. These streams included emulsified cutting oils, waste jet fuels, paint solids, solvents and paint wastes, wastewater treatment sludges and acidic and caustic wastes. McDonnell Douglas recovered spent methyl ethyl ketone, methyl isobutyl ketone and perchloroethylene through two distillation units located in building 48. These solvents were used to clean spray paint guns, lines and equipment. Waste still bottoms were collected in drums and transported to a permitted hazardous waste disposal facility.

McDonnell Douglas stored hazardous waste in several accumulation areas located on the facility property and in three hazardous waste storage areas. Area 1, the scrap dock shelter, was divided into two sections by a 6-inch-high curb. Drums containing acids, alkalis and unwashed empty drums were stored in one section and paint sludges, oils, solvents and sulfide-bearing waste was stored in the other. Area 2, the cyanide and sulfide-bearing storage area, was first used in 1977 to store cyanide and sulfide compounds. Waste storage in this area ended in 1989 due to water seepage into the shelter after heavy rains and snowmelt. Area 2 was replaced with a fully enclosed, prefabricated storage building. Area 3, the explosive waste storage area, contained explosive waste from military aircraft and small amounts of black and smokeless powder. The building had concrete walls and floor. The use of the unit ended in 1985 and closed in 1993.
In 1970, McDonnell Douglas began operating an industrial wastewater treatment plant, which consists of several in-ground, open-top sludge settling and equalization tanks. Rinse water from chemical process operations was pumped to the sludge settling tanks via an industrial sewer line. Boeing continues to ship filter cake byproducts from the industrial wastewater treatment process to a permitted hazardous waste disposal facility as a listed hazardous waste within 90 days.

In August 1997, after being acquired by Boeing, all hazardous waste storage units were either closed or referred to corrective action. GKN continues to operate on its 87.88 acres of land. The Airport leases land from its 75.99 acres of property. A number of buildings were demolished after its purchase in 2005 that were within the runway protection zone. Boeing continues to operate the wastewater treatment plant.

In 2023, Boeing signed a lease with the Airport to build a new manufacturing plant on the Airport property. The proposed new buildings will be used for U.S. defense-related aircraft production and testing.

In May 2024, Boeing purchased the facility from GKN. GKN is now known as Aerospace Composites Center (ACC).

In 2025, Boeing began redeveloping the southern portion of the property leased from the Airport. Construction on the site is expected to begin sometime in 2026.

Closure & Cleanup

The McDonnell Douglas Corporation (McDonnell Douglas) closed the original cyanide and sulfide-bearing waste storage area in 1989. The department accepted the clean closure certification for this unit in November 1993.

In 1994, Science Applications International Corporation, on behalf of the EPA, performed a Resource Conservation and Recovery Act (RCRA) Facility Assessment for the site. The assessment was conducted to identify and gather information on actual and potential releases of hazardous waste and hazardous constituents to the environment. The 1995 RCRA Facility Assessment Report identified 32 solid waste management units that were recommended for additional investigation.

Four of the solid waste management units identified in the assessment required stabilizing interim measures. An interim measure is an action taken to temporarily control the contamination source or the path the contamination could take from the source to humans, animals or the environment, such as air, soil, water and food. The Boeing Company (Boeing) performed the following interim measures in October and November 1997:

  • Cleaned and removed the waste oil tank in Building 5
  • Cleaned the sumps and placed an asphalt lift over the paint booth satellite accumulation drum areas located outside the northwest side of Building 2
  • Cleaned and sealed cracks in the concrete floor of the “less-than-90-day” storage area in Building 40
  • Removed the leaking power transformer and impacted gravel and soil outside the northeast corner of Building 6

In response to the RCRA Facility Assessment, Boeing performed a RCRA Facility Investigation to define the horizontal and vertical extent of any contamination. The investigation was conducted in a phased approach, dividing the site into nine areas based on the results of the previous assessments, investigations, location of solid waste management units and interim measures. On behalf of Boeing, MACTEC Engineering and Consulting Incorporated submitted a RCRA Facility Investigation Report to the department and EPA in June 1998, with revisions in December 2004. The sample results showed soil and groundwater in Tract 1 contaminated with volatile organic compounds, polycyclic aromatic hydrocarbons, polychlorinated biphenyls (PCBs), metals and total petroleum hydrocarbons. The contamination is limited to the permitted facility. The contamination at the site also does not cross Banshee Road, which splits the site into northern and southern areas of contamination.

The RCRA Facility Assessment, RCRA Facility Investigation and later investigations identified the following potential sources of contaminant release: 68 underground storage tanks, three fuel distillation sites, a power plant, the industrial wastewater treatment plant, 32 solid waste management units and multiple drum storage areas. It was determined that 44 groundwater monitoring wells would be sampled twice a year until a long-term groundwater monitoring plan was put into place.

While conducting the facility assessment and investigation, McDonnell Douglas, and later Boeing, closed the remaining hazardous waste storage units at the facility. Boeing closed both the scrap dock shelter and new cyanide and sulfide-bearing waste storage area in 2001. The new cyanide and sulfide-bearing waste storage area was “clean closed.” Groundwater samples collected during the closure of the scrap dock shelter showed contamination above screening levels; however, it was determined the contaminated groundwater was from a nearby area of concern. The department accepted closure certifications for both units in November 2001, with the provision that institutional controls prohibiting groundwater use be put into place for the scrap dock shelter, as part of the final remedy. The department accepted closure certifications for most of the other units in 1993, 1995, 2001 and 2003. The remaining units are being addressed under corrective action.

At the department’s request, Boeing performed a risk assessment of the contaminated areas to determine if they exceeded risk levels and to address remaining elements necessary to adequately characterize the site. The risk assessment subdivided the nine areas of the site into 23 subareas, each characterized by similarities in factors that affect human health under current and reasonable future land use conditions. The risk assessment generally followed the Missouri Risk-Based Corrective Action (MRBCA) process. On behalf of Boeing, the RAM Group submitted a Risk Based Corrective Action Report to the department and EPA in September 2004, with revisions in 2009. The report concluded the cumulative risks were below the department and EPA target risk levels for 14 out of the 23 sub-areas. In the nine sub-areas that exceeded cumulative risks, the exceedances were for non-residential workers and construction workers. Of the nine subareas, five were determined to need interim measures implemented. Contaminated soils were removed from the five subareas in May and June 2006, which included the perchloroethylene (PCE) transfer area outside Building 51, former jet fuel underground storage tank farm immediately west of Building 41, 1000-gallon diesel underground storage tank next to Building 2, trash contactor located at the northwest corner of Building 220 and scrap metal recycling dock. Interim measures included removing the impacted soil and transporting it to a permitted hazardous waste disposal facility. The excavated areas were then backfilled with gravel.

As part of the EPA’s independent review of the Risk Assessment Report, the EPA asked Tetra Tech to perform a risk assessment of selected areas using the EPA Risk Assessment Guidance for Superfund (RAGS) process. The intent was to compare the results obtained from the MRBCA and RAGS risk assessment approaches. Tetra Tech submitted a Risk Assessment Report to the department and EPA in March 2008. The report concluded that the two risk assessment approaches generally resulted in similar risk management decisions. The Tetra Tech report identified two additional subareas that exceeded risk levels.

At the department’s request, Boeing performed a Corrective Measures Study to identify and evaluate possible remedial alternatives for the remaining soil and groundwater contamination. On behalf of Boeing, the RAM Group submitted the final Corrective Measures Study Report to the department and EPA in February 2012, with revisions in November 2012, July 2013, and July 2014. The report included Boeing’s preferred final remedy along with other remedial alternatives. The department selected the best remedy from the Corrective Measures Study Report, given site-specific considerations for each solid waste management unit and area of concern. The department prepared a Statement of Basis that summarizes the remedial alternatives and the department’s basis of support for the proposed final remedy. The department incorporated the proposed final remedy into Boeing’s draft hazardous waste permit during the permit renewal. The public was invited to review and comment on the proposed remedy and draft permit during a 45-day public comment period. On Nov. 15, 2017, the department, in coordination with EPA, approved the proposed final remedy and issued the final permit. The approved final remedy included property activity and use limitations in the form of enforceable environmental covenants. These covenants are clauses listed in the chain-of-title for the affected properties, which notifies in perpetuity, any potential purchaser of the environmental conditions of the properties. The environmental covenants were recorded in 2018 for Boeing and GKN. The Airport’s covenant was recorded in 2020.

Starting in 2023, Boeing began investigating and addressing previously unknown hexavalent chromium releases to soil and groundwater from the industrial sewer lines throughout the facility which receives wastewater from Boeing facilities at and near the facility. Interim measures have been implemented on a portion of the industrial sewer line to treat the contamination in place the potential of contaminated groundwater. The section of industrial sewer has been repaired and no longer releases to the environment.
Currently, with the approved groundwater monitoring program and the approved sampling and analysis plan, 34 monitoring wells are sampled annually and 17 are sampled once every three years.

Oversight

When the U.S. Environmental Protection Agency (EPA) implemented the federal hazardous waste laws under the Resource Conservation and Recovery Act (RCRA) in 1980, all existing facilities that treated, stored or disposed hazardous waste in a way that would require a hazardous waste permit were required to notify EPA and apply for the permit or close those operations. Because of the large number of existing facilities, Congress set up requirements under 40 C.F.R. Part 265, that allowed these facilities to operate temporarily under “interim status” until it received its permit.

The McDonnell Douglas Company submitted a RCRA Part A Permit Application on Nov. 17, 1980, and a RCRA Part B Permit Application on Oct. 6, 1982. The McDonnell Douglas Corporation received notice that interim status was granted on Dec. 27, 1980. On June 22, 1984, the department issued its Missouri Hazardous Waste Management Facility Part I Permit (permit) followed by the EPA on June 28, 1984, with their Hazardous and Solid Waste Amendments Part II Permit, ending the interim status period. These permits transferred the regulatory oversight responsibility and authority for the investigation and corrective action activities from EPA to the department, under Missouri’s RCRA-equivalent hazardous waste program.

The Boeing Company (Boeing), as the Permittee, is currently performing long-term monitoring and maintenance activities and conducting corrective action investigations and remediation activities at the facility property under the department re-issued Missouri Hazardous Waste Management Facility Part I Permit, effective November 15, 2017. The Part I Permit was originally issued with an EPA-issued Hazardous and Solid Waste Amendments Part II Permit in June 1984, and reissued in 1997. The EPA decided not to reissue the Part II Permit in 2017, since EPA had no site-specific conditions for the facility, beyond those contained in the Part I Permit, and Missouri is fully authorized for all permitting, post-closure, corrective action and RAP activities at the facility.

The permit requires Boeing to continue performing long-term monitoring and maintenance of the closed solid waste management units and areas of concern, and to conduct corrective action investigations and remediation activities. The permit also requires corrective action in the event there is a new release of hazardous waste to the environment, or if the contaminated groundwater poses a threat due to further migration. The approved final remedy for soil and groundwater contamination at Tract I was added to the permits on Nov. 15, 2017, during the permit re-issuance.

The existing Part I Permit expires Nov. 15, 2027.

Documents

Listed below are the currently effective regulatory mechanism(s) and any modifications, institutional controls and any supporting documents regarding this property that the department currently has available in electronic form. The department realizes some of the electronic files can be quite large, which may result in long download times for individuals with slow internet connections. If you have any problems accessing these documents, please contact the department’s Waste Management Program by telephone at 573-751-5401 or 800-361-4827, or by email at wmp@dnr.mo.gov.

You can review printed copies of all regulatory agreements, reports and other supporting documents at the department’s Elm Street Conference Center in Jefferson City, Missouri. To review or obtain copies of the department’s files, please submit an Open Records/ Sunshine Law Request.

Regulatory Agreement