There were nights in the autumn of 2005 when Larry Burgan says he slept with a loaded AK-47 assault rifle next to his bed. He suspected his phone was tapped; he feared that someone might torch his house. The reason for his wariness: A 12-pound bundle of documents released to him by the Illinois Emergency Management Agency, and the explosive contents therein.

The documents, which Burgan obtained under the state’s freedom of information law, outlined the extent of radioactive contamination at Burgan’s former workplace, Spectrulite Consortium Inc., in Madison, Ill. The plant was one of hundreds of low-priority radioactive sites nationwide identified by the federal government’s Formerly Utilized Sites Remedial Action Program in the 1990s.

Not only did Burgan’s cache of government records confirm that workers were exposed, it also raised new and troubling questions about the risks posed to residents of an adjacent neighborhood in Venice, Ill., over the past 50 years.

“For decades radioactive dust was falling on me and my coworkers everyday,” says Burgan, a 50-year-old disabled steelworker. “Millions of pounds of uranium were processed through my machine and no one ever told me — never told us. We deserve justice; justice not just for the employees, but the residents, too.”

The problems at Spectrulite began the year before Burgan was born, when the foundry was owned by Dow Chemical Co. Dow processed uranium at the plant between 1957 and 1961 under a subcontract with St. Louis-based Mallinckrodt Chemical Co., which was working for the U.S. Atomic Energy Commission (AEC). Dow’s work caused radioactive debris to accumulate on overhead girders — where it was ignored for decades.

In 2000, when the U.S. Army Corps of Engineers oversaw a radioactive cleanup at the Spectrulite plant, a spokesman for the agency assured employees and the public that the radiation levels inside the plant were low and there was no reason for concern. But in less than a year Burgan’s health began to decline. He says the first hint was when he noticed shortness of breath after climbing stairs. Then he developed a pain in his right foot. His hair began to fall out. Over the next year, his condition improved temporarily and then worsened. He started experiencing severe joint pain throughout his body. His doctor’s visits became more frequent and he was having difficulty doing his job. Eventually, he became bedridden and unable to walk. A severe rash covered his entire body.

“I was covered with scabs — large ones and small ones,” Burgan later wrote in his personal journal. “They would crack and bleed. . . . It was a nightmare.”

Burgan’s nightmare was far from over. His union, United Steelworkers Local 4804, was forced to go out on strike when the company demanded wage and benefit cuts in the new contract.

“Just like that my job was over,” he recalls. “I got sick and they got rid of me.” Unpaid bills piled up. The union stepped in and covered his mortgage payments during the 11-month strike. But despite the help, Burgan ultimately had to declare bankruptcy and go on disability.

Burgan’s nadir came one afternoon as he hobbled to the bathroom with the help of his wife. Passing by a mirror, he stopped to look at his reflection. “I didn’t recognize myself,” he later wrote.

After months of excruciating pain, his condition began to gradually improve. As he recuperated, Burgan pondered the cause of his illness. One of his coworkers suggested that chronic exposure to the radiation at work may have been responsible.

Once he was able to walk again, Burgan drove to a friend’s house who owns a computer. It didn’t take long for him to find a possible link between his health problems and his occupation. His online research led Burgan to an Army Corps Web site devoted to the cleanup of the Spectrulite plant. His friend printed out several illustrations related to the Corps remediation work there. One of the images was an overhead view of the plant. The spot directly over Burgan’s old work space was represented in glowing red, indicating the highest level of contamination in the factory.

Burgan later wrote down his reaction to this discovery in his journal: “My mouth opened in disbelief. My eyes watered up. One single tear fell and landed on the picture, staining it.”

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A photograph from 1993 depicts Burgan as a young man. He is smiling for the camera, cigar in hand, seated in a chair, with his feet propped up on the 50-ton extrusion press that he helped operate.

The day the snapshot was taken he was hamming it up. Burgan doesn’t smoke. The cigar was a prop. He had asked a coworker to take the picture so he could show his wife what a cushy job he had. The then-35-year-old steelworker viewed his job at Spectrulite as relatively easy. Burgan’s union wages and benefits afforded him and his family a middle-class life, and the opportunity to live the American dream. There was plenty of overtime available, too. Fellow employees even called him “Lucky Larry” because Burgan had a knack for finding money at work.

But Burgan was unknowingly paying a price that can’t be calculated in dollars and cents. The photograph shows that his work station was near Beam Z, the most radioactive hotspot in the foundry, 13.6 times above the safe guideline limits. Burgan and hundreds of his fellow steelworkers were not told they were working in a radioactively contaminated work place until 2000 even though their employer and the federal government were both aware of the dangers in 1989 — when he started working at the plant.

The Department of Energy conducted the first radiological testing at the facility in March 1989, which showed elevated levels of Uranium-238 and Thorium-232. A story published in the St. Louis Post-Dispatch the previous month had spurred the government to do the testing. The story was based on the earlier research of Kay Drey. In 1979, the St. Louis environmental activist had interviewed a terminally-ill truck driver who had delivered uranium ingots from Mallinckrodt Chemical in North St. Louis to the Dow plant in Madison. The truck driver attributed his lung cancer to his occupational exposure to radiation in the late 1950s and early 1960s.

The Madison plant had assembled tanks during World War II. Six years after the war, the federal government sold the facility to Dow. In 1957, Dow was licensed by the AEC to process fuel rods for nuclear reactors under the subcontract with Mallinckrodt. The uranium processing continued for four years. During that time, radioactive dust escaped as the uranium was heated up and forced through the extrusion press.

But uranium wasn’t the only radioactive material discovered by the Energy Department in 1989. Government records obtained by Burgan also show elevated levels of thorium present in the overhead girders. The records also show that by the summer of 1960, the plant had imported 80 tons of thorium pellets from Canada. Thorium was used in the making of lightweight alloys for military and aerospace applications, another job that Dow did at its Madison plant.

As work continued, the nuclear waste mounted. Dow’s original disposal plan called for the waste to be incinerated. But the burning couldn’t keep up with the increased volume of waste that was being generated. So between 1960 and 1973, Dow dumped millions of pounds of sludge containing 4 to 8 percent thorium behind the plant in a vacant lot that is adjacent to neighborhood residences. This level is several times over the current safety standards. Company guidelines also permitted up to 50 pounds of thorium sludge per month to be poured directly down the sewer. The radioactive contamination could also have been released into the environment by the plant’s several 20-foot diameter exhaust fans.

But Burgan suspects that some of the elevated levels of Thorium-232 detected overhead may have been of more recent origin. In 1992, Spectrulite leased out one of its presses to Martin Marietta, Burgan says. Employees of that firm were brought in to oversee the operation, which occurred for eight days over a two-month period. When Burgan asked what type of metal was being processed, he was only told that it was a “special alloy.” It didn’t dawn on him until much later that the method that Martin Marietta used was similar to the way Dow processed uranium in the same press decades earlier.

“It all started making sense after all the documents were in front of me,” says Burgan.

Armed with the government records, Burgan began his efforts to gain compensation for himself and his fellow workers. His campaign has included countless calls to state and federal regulators, members of the Illinois congressional delegation and the media. Burgan has testified before the federal Advisory Board on Radiation and Workers Health twice, and he also persuaded five of his former co-workers to submit affidavits to substantiate their potential exposure. As a result, former Spectrulite workers who worked at the plant as recently as 1999 are now eligible for inclusion in the Energy Employees Illness Compensation Program. The program provides $150,000 to workers or their surviving family members. To qualify, workers must show that they contracted one or more of the 24 types of cancer that are officially recognized as being associated with radiation exposure.

Proving the hazard was a laborious task. The potential health risks posed by chronic exposure, says Burgan, were repeatedly downplayed by both his employer and the federal regulators. At a company safety meeting in February 2000, for instance, Burgan says a manager told workers that the planned radiation cleanup at the plant was “just a way of the government trying to waste money.” On another occasion, Burgan says he was told by a company foreman that the radiation would only be harmful to those who were allergic to it. Around the same time, the project manager for Corps of Engineers told the Post-Dispatch, “Someone would have to eat 250 pounds of the contaminated material to create a health risk.”

Despite the Corps official’s dismissive comment, the agency ultimately concluded that the safe level of exposure for cleanup workers at the site would be two to four hours per year. Burgan estimates his exposure over 12 years at 25,000 hours.

In February 2000, the Illinois Department of Nuclear Safety contested the Corps’ cleanup plan as insufficient. In its comments, the state agency stated: “The Corps has not demonstrated that the proposed scope of removal is protective of public health . . . [and] has inadequately assessed the dose to the first critical group (workers) and has entirely ignored the second critical group (residents).”

Burgan’s sights are now set on helping the former residents and those who still live near the plant. For the past few months, he has been meeting weekly with former Spectrulite workers and residents at the Venice City Hall. An organizing committee of concerned citizens is now moving forward with plans to request an in-depth health study of the community by the federal Agency for Toxic Substance and Disease Registry. Among the primary concerns of the committee are health risks to children at a nearby elementary school.

Calvin Ratliff, a former Spectrulite worker who lived near the facility from 1950 to 1993, has conducted an informal survey of a two-block stretch of Meredocia Avenue near the plant. By his count, there were 44 cases of cancer or lung disease among longtime residents, many of whom are now deceased. A larger sampling of longtime neighbors tallied 68 cases of cancer or lung disease in the neighborhood.

Having worked there himself, Ratliff is aware of the different parts of the plant operations and the potential for emissions to escape into the outside environment. His concerns are close to home.

“I lost my father at 54 from a brain tumor and my sister has thyroid cancer,” he says. “I never thought anymore about it until the [Spectrulite] workers brought their claims.” Ratliff adds that he and his sister both have sarcoidosis, a debilitating, chronic disease that commonly causes inflammation of the lungs and other organs, and in some cases can be deadly.

The former resident and plant worker says he has uncovered evidence that a private environmental cleanup company removed 90,000 cubic yards of aluminum slag and contaminated soil from the vacant lot behind the plant in the fall of 1992. The contaminants included Thorium-230 and Thorium-232, as well as PCBs. More than a thousand railcars of waste were excavated and removed from the site, according to the information in Ratliff’s possession. Neither he nor Burgan are sure of who contracted the company to remove the waste. The other unanswered question is whether the cleanup removed all the contaminated soil.

The plant at Weaver and College streets operates today as Magnesium Elektron of North America, a non-union company and a subsidiary of Luxfur Group of Great Britain. After going bankrupt in 2003, Spectrulite’s owners sold the company, but continue to hold a stake in the operation and the property itself. The plant no longer processes radioactive materials, but it continues to process toxic heavy metals that are used to make lightweight alloys for military use.

Both Burgan and his wife survive on a monthly Social Security disability income of slightly over the poverty level. He attributes other serious illnesses, infant mortality and birth defects in his family to secondary exposure to radiation from the radioactive dust that he brought home on his work clothes. The possibility of this haunts his every waking moment.

“My wife is ill from transference, bringing my dusty clothes home everyday,” he says. “All my grandchildren passed away. I’m living on $31 a month over the poverty line, without me or my wife able to work. I have to stand in the food lines at Salvation Army. I’ve been doing this for years. It’s not because of choice or because I’m lazy. It’s because I was put here by people who poisoned me.” — C.D. Stelzer (cdstelzer@gmail.com)

C.D. Stelzer is a veteran investigative journalist based in St. Louis and senior writer forFOCUS/Midwest.