Aga Rayburn Coalbrookdale Draft Phase 1a Site Condition Report and Phase 2 Site Investigation (PPC) 28 August 2003 Entec UK Limited Report for Aga Rayburn Keith Lewis Engineering Manager Wellington Road Coalbrookdale Coalbrookdale TF8 7DX Draft Phase 1a Site Condition Report and Phase 2 Site Investigation (PPC) Main Contributors Rachel Johnson Louise Burden 28 August 2003 David Scott Entec UK Limited Issued by ………………………………………………………… Louise Burden Approved by ………………………………………………………… Ian Evans Entec UK Limited 160-162 Abbey Foregate Shrewsbury Shropshire SY2 6BZ England Tel: +44 (0) 1743 342000 Fax: +44 (0) 1743 342010 h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc Certificate No. FS 13881 In accordance with an environmentally responsible approach, this document is printed on recycled paper produced from 100% post-consumer waste or TCF (totally chlorine free) paper i Executive Summary To be completed after client approval. In accordance with the Pollution Prevention Control (PPC) Regulations the Coalbrookdale Foundry site, (the site), owned and operated by Aga Rayburn is obliged to apply for a permit to operate a Part A1 installation for the smelting of iron. The permit application requires the provision of a Phase 1a site condition report describing the condition of the site. This is to enable an initial condition of the site to be assessed and to create a baseline reference against which later determinations can be made as to whether or not deterioration of the site has taken place through the operations covered by the IPPC permit. The Phase 1a non-intrusive investigation incorporates the gathering of all available information from public domain sources, data searches, and a site reconnaissance. The site is located approximately 4 km southwest of Telford Town Centre, near Ironbridge, Shropshire. It is bounded to the north and south by Ironbridge Industrial Museums; to the west by a railway embankment, to the east by the Wellington Road. Historical information shows that various industrial works have been present on the site since the 1500s. A foundry works has been present on the site since at least 1709 when the site was taken over by the Coalbrookdale Company. Various activities associated with the casting of ferrous metals have been carried out across the site. A landfill for foundry sand, slag and ferrous scrap metal was present in the south of the site during the late 80s. The installation area is underlain by Made Ground comprising mainly foundry sand. The thickness is likely to be greatest in the south of the site. Lyde Brook, a tributary of the River Severn, is present on the western side of the site and is culverted for most of the length of the site. The installation area is serviced by an effluent and surface water drainage system. The surface water drainage system discharges to the Lyde Brook while the effluent from site amenities is discharged to mains sewer. At depth the site is underlain by a non aquifer (Wenlock Shales). Perched groundwater is likely to be present within foundry sand or underlying natural alluvial deposits beneath the site. The main process areas within the installation boundary are located on hardstanding. These impermeable surfaces reduce shallow groundwater movement by limiting rainfall infiltration. Oil and diesel is stored within a bunded area in the south of the site. There is visual evidence that containment measures have been breached (hydrocarbon ponding and staining). In general the condition of the installation is considered to be reasonable although general housekeeping could be improved, particularly in external areas. Improved pollution prevention measures are required in the south of the site where there is visual evidence of fuel spillages. The condition of the drainage system is unknown and there is the potential for contaminants to enter the shallow ground and groundwater through cracks or discontinuities. Potential contamination resulting from activities within the installation have been identified from anecdotal and visual evidence and may have impacted on shallow soil and groundwater. h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc 28 August 2003 ii Groundwater and soil quality data for the installation area is lacking. Therefore to confirm the site condition, intrusive works in the form of a Phase 2 (in accordance with current PPC guidance) will be necessary. h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc 28 August 2003 iii Contents 1. Introduction 1 1.1 Terms of Reference 1 1.2 Background 1 1.3 Scope of Work 1 1.4 Information Sources 2 1.5 Site Reconnaissance 2 1.6 Intrusive Investigation 3 2. Summary of Findings 5 2.1 Site Description 5 2.2 Site Layout 5 2.2.1 Overall Site 5 2.2.2 Installation Application Area 6 2.3 Building Functions 7 2.4 Adjacent Land Use 9 2.5 Environmental Setting 9 2.5.1 Geology 9 2.5.2 Hydrogeology 10 2.5.3 Hydrology and Drainage 10 2.5.4 Site Sensitivity 11 2.6 Site History 11 2.6.1 Summary of Site Development 12 2.6.2 Historical Information 13 2.7 Previous Site Investigations 13 2.7.1 Geotechnical Developments, Geotechnical Investigation, November 1995 13 2.8 Regulatory Authority Records 14 2.8.1 Integrated Pollution Controls 14 2.8.2 Discharge Consents 14 2.8.3 Pollution Incidents to Controlled Waters 14 2.8.4 Water Abstractions 14 2.8.5 Waste Disposal 14 2.8.6 Hazardous Substances 15 2.8.7 Registered Radioactive Substances 15 h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc 28 August 2003 iv 2.9 Site Visit and Information Collection 15 2.9.1 Installation Zones 15 2.10 General Activities 17 2.10.1 Materials Storage and Movement 17 2.10.2 Process Areas 18 2.10.3 Waste and By- Product Management 19 2.10.4 Ancillary Processes 19 2.10.5 Raw Materials and Site Chemicals 20 2.10.6 Environmental Management 20 2.10.7 Visual Evidence 20 2.11 Proposed Operations 20 2.12 Assessment of Chemicals of Concern 21 3. Intrusive Investigation 23 3.1 Introduction 23 3.2 Soil Sampling 24 3.2.1 Window Samples 24 3.2.2 Chain of Custody 25 3.3 Laboratory Testing 25 3.3.1 Chemical Testing 25 4. Ground Conditions 27 4.1 Strata Encountered 27 4.1.1 Made Ground 27 4.1.2 Natural Ground 27 4.2 Groundwater 27 5. Contamination Assessment 29 5.1 Soils 29 5.1.1 Made Ground 29 5.1.2 Natural Ground 31 5.1.3 Summary of Soil Contamination 32 5.2 Groundwater Chemistry 33 5.2.1 Metals 33 5.2.2 Inorganics 33 5.2.3 Organics 33 5.2.4 Summary of Groundwater Contamination 33 5.3 Leachate Analysis 33 h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc 28 August 2003 v 5.3.1 Toxic Metals 33 5.3.2 Phytotoxic Metals 34 5.3.3 Inorganics 34 5.3.4 Organics 34 5.3.5 Summary of Leachate Analysis 34 6. Conceptual Model 35 6.1 Initial Conceptual Site Model (CSM) 35 6.2 Conceptual Ground Model 35 6.3 Summary of Contamination Sources and Chemicals of Concern (COC) 35 6.3.1 All Areas 36 6.3.2 Area A 36 6.3.3 Area B 36 6.3.4 Area D 36 6.3.5 Pathways 36 6.3.6 Receptors 37 7. Conclusions 39 7.1 Summary of Current Site Condition 39 Table 2.1 Building Register - Aga Rayburn Coalbrookdale 7 Table 2.2 COCs Associated with Historical Activities 21 Table 2.3 COCs Associated with Current Site Activities 22 Table 3.1 Exploratory Hole Targets 23 Table 5.1 Range, Mean and Standard Deviation of Concentrations of Contaminants Detected in the Made Ground 29 Table 6.1 Contamination Sources and Chemicals of Concern 36 Figure 2.1 Site Location After Page 22 Figure 2.2 Site Plan After Page 22 Figure 2.3 Drainage Plan After Page 22 Figure 2.4 Observations Made During Walkover After Page 22 Figure 3.1 Exploratory Locations After Page 26 Figure 6.1 Conceptual Cross Sections After Page 38 Appendix A Completed Entec Questionnaire Appendix B Site Photographs Appendix C BGS Boreholes Appendix D Extracts and Drawings from Coalbrookdale Watercourse Project Appendix E Historical Maps Appendix F Extracts from Geotechnical Investigation Appendix G Envirocheck Report Appendix H List of Chemicals Used Appendix I Utilities Information Appendix J Borehole and Window Sample Records Appendix K Certificate of Analyses h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc 28 August 2003 vi h:\projects\cl-240\10499 aga rayburn phase 1a\docs\rr082i1.doc 28 August 2003 1 1. Introduction 1.1 Terms of Reference Entec was commissioned by Aga Rayburn to undertake a Phase 1a site condition assessment and Phase 2 intrusive investigation. The Phase 1a and 2 work has been completed in support of the permit application to operate a Part 1A installation at the site in accordance with the Pollution Prevention and Control (PPC) Regulations. The findings of the Phase 1a site condition assessment were previously published by Entec in April 2003 (ref 10499 rr025i1). This report combines the findings of both the Phase 1a and 2 investigations as a stand-alone report which supersedes the Phase 1a report. 1.2 Background The PPC Regulations provide that a permit application must include ‘a site report’. This must describe the condition of the site of the installation with regard to substances in, on or under the land which may constitute a pollution risk. This site report is intended to set out the ‘initial’ baseline condition at the site including any contamination present prior to the operation of the installation and to allow a reference point for comparison with the condition of the site at cessation of operations.