NCGNE1407_Application_20200611

MM
Division of Energy, Mineral and Land Resources
Land Quality Section
National Pollutant Discharge Elimination System
NO EXPOSURE CERTIFICATION for Exclusion
Environmental Quality NCGNE0000
FOR AGENCY USE ONLY
Date Received
Year
Month
Day
Certificate of Coverage
NCGNE
National Pollutant Discharge Elimination System application for exclusion from a Stormwater Permit based
on NO EXPOSURE:
Submission of this No Exposure Certification constitutes notification that your facility does not require a
permit for stormwater discharges associated with industrial activity in the State of North Carolina because
it qualifies for a no exposure exclusion. A condition of no exposure at an industrial facility means all
industrial materials and activities are protected by a storm resistant shelter (with some exceptions) to
prevent exposure to rain, snow, snowmelt, and/or runoff.
For permitted facilities in North Carolina, DEMLR must approve your application for No
Exposure Certification before this exclusion is effective. Until you are issued a No
Exposure Certification and your NPDES permit is rescinded, your facility must continue
to abide by the terms and conditions of the current permit.
Industrial materials or activities include, but are not limited to: material handling equipment or activities,
industrial machinery, raw materials, intermediate products, by-products, final products, or waste products.
Material handling activities include the storage, loading and unloading, transportation, or conveyance of
any raw material, intermediate product, final product or waste product. A storm resistant shelter is not
required for the following industrial materials and activities: drums, barrels, tanks, and similar containers
that are tightly sealed, provided those containers are not deteriorated and do not leak. "Sealed" means
banded or otherwise secured and with locked or non -operational taps or valves; adequately maintained
vehicles used in material handling; and final products, other than products that would be mobilized in
stormwater discharges (e.g., rock salt).
A No Exposure Certification must be provided for each facility qualifying for the no exposure exclusion. In
addition, the exclusion from NPDES permitting is available on a facility -wide basis only —not for individual
outfalls. If any industrial activities or materials are, or will be, exposed to precipitation, the facility is not
eligible for the no exposure exclusion. By signing and submitting this No Exposure Certification form, you
certify that a condition of no exposure exists at this facility or site and are obligated to comply with the
terms and conditions of 40 CFR 122.26(g).
If approved, your conditional No Exposure Exclusion has no expiration date
BUT MUST BE self re -certified at least annually.
Please look for information about re -certification under the No Exposure section on this page:
https://deg. nc.gov/about/divisions/energy-mineral-land-resources/energy-mineral-land-perm its/stormwater-
perm its/npdes-industrial-sw
For questions, please contact the DEMLR Regional Office for your area. (See page 6)
(Please print or type)
1) Mailing address of owner/operator (address to which all certification correspondence will be mailed):
Name Oerlikon Additive Manufacturing
Contact
Street Address
City
Telephone No.
Alfred Reid, Head of Operations
12021 Vanstory Drive
Huntersville
980 213-7223
Page 1 of 7
State NO ZIP Code 28078
Fax:
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NCGNE0000 No Exposure Certification
2) Location of facility producing discharge:
Facility Name
Oerlikon Additive Manufacturing
Facility Contact
Alfred Reid, Head of Operations
Street Address
12021 VanstoryDrive
City
Huntersville
County
Mecklenburg
Telephone No.
980 213-7223
3) Physical location information:
State NO ZIP Code 28078
Fax:
Please provide a narrative description of how to get to the facility (use street names, state road numbers, and
distance and direction from a roadway intersection). Head NW on WT Harris Blvd off of 1-485, make a right onto Mt. Holly-Huntersville Rd. (0.6 mi),
Turn left to stay on Mt. Holly Huntersville Rd. (1.0 mi), Turn left onto Reese Blvd. (1.7 mi), Turn left onto Vanstory Dr (0.3 mi), in 0.3 mi the facility is on your left
(A copy of a map with the facility clearly located on it should be included with the certification application.)
4) Is the facility located on Native American Lands? 0Yes ENO
5) Is this a Federal facility? ❑ Yes 10 No
6) Latitude 35°23'26.6"N Longitude 80'51'38.9"W (deg., min., seconds)
7) This NPDES No Exposure Exclusion application applies to which of the following:
New or Proposed Facility
a Existing
Date operation is to begin
Date operation began September2018
E3 Renewal of existing No Exposure Certification Certification No.: NCGNE
8) Was this facility or site ever covered under an NPDES Stormwater Permit? El Yes 0 No
If yes, what is the NPDES Permit Number?
9) Standard Industrial Classification:
Provide the 4-digit Standard Industrial Classification Code (SIC Code) that describes the primary industrial
activity at this facility
SIC Code: 3 4 9 9
10) Provide a brief description of the types of industrial activities and products produced at this facility:
Please see attached description.
11) Does this facility have any Non -Discharge permits (ex: recycle permits)?
0 No
Yes
If yes, list the permit numbers for all current Non -Discharge permits for this facility:
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R
NCGNE0000 No Exposure Certification
Exposure Checklists (12. - 14.)
12) Are any of the following materials or activities exposed to precipitation, now or in the foreseeable
future? (Please check either "Yes" or "No.") If you answer "Yes" to any of these items, you are not
eligible for the no exposure exclusion.
a. Using, storing, or cleaning industrial machinery or equipment, and areas where 0 Yes O No 0 N/A
residuals from using, storing or cleaning industrial machinery or equipment
remain and are exposed to stormwater
b. Materials or residuals on the ground or in stormwater inlets from spills/leaks
❑ Yes
13 No
0 N/A
c. Materials or products from past industrial activity
❑ Yes
p No
❑ N/A
d. Material handling equipment (except adequately maintained vehicles)
❑ Yes
5 No
0 N/A
e. Materials or products during loading/unloading or transporting activities
0 Yes
EI No
❑ N/A
f. Materials or products stored outdoors (except final products intended for outside ❑ Yes 0 No 0 N/A
use [e.g., new cars] where exposure to stormwater does not result in the
discharge of pollutants)
g. Materials contained in open, deteriorated or leaking storage drums, barrels, ❑ Yes p No ❑ N/A
tanks, and similar containers
h. Materials or products handled/stored on roads or railways owned or maintained 0 Yes [] No ❑ N/A
by the discharger
i. Waste material (except waste in covered, non -leaking containers [e.g., 0 Yes El No 13 N/A
dumpsters])
j. Application or disposal of process wastewater (unless otherwise permitted) O Yes 13 No 0 N/A
k. Particulate matter or visible deposits of residuals from roof stacks and/or vents ❑ Yes p No I] N/A
not otherwise regulated (i.e., under an air quality control permit) and evident in the
stormwater outflow
I. Empty containers that previously contained materials that are not properly stored 0 Yes p No p N/A
(i.e., not closed and stored upside down to prevent precipitation accumulation)
m. For any exterior ASTs, as well as drums, barrels, tanks, and similar containers 0 Yes 0 No 0 N/A
stored outside, has the facility had any releases in the past three (3) years?
13) Above Ground Storage Tanks (ASTs): If you answer "No" to any of the following items, you are not
eligible for the no exposure exclusion.
a. Are exterior ASTs or piping free of rust, damaged or weathered coating, pits, or EI Yes 0 No 0 N/A
deterioration, or evidence of leaks?
b. Is secondary containment provided for all exterior ASTs? If so, is it free of any 11 Yes ❑ No ❑ N/A
cracks, holes, or evidence of leaks, and are drain valves maintained locked
shut?
14) Secondary Containment: If you answer "No" to any of the following items, you are not eligible for the
no exposure exclusion.
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NCGNE0000 No Exposure Certification
a. Is secondary containment provided for single above ground storage containers 0 Yes ❑ No O N/A
(including drums, barrels, etc.) with a capacity of more than 660-gallons?
b. Is secondary containment provided for above ground storage containers stored El Yes ❑ No ❑ N/A
in close proximity to each other with a combined capacity of more than 1,320-
gallons?
c. Is secondary containment provided for Title III Section 313 Superfund p Yes ❑ No I!] N/A
Amendments and Reauthorization Act (SARA) water priority chemicals*?
d. Is secondary containment provided for hazardous substances** designated in p Yes Q No 0 N/A
40 CFR §116?
e. Are release valves on all secondary containment structures locked? ❑ Yes 0 No p N/A
15) Hazardous Waste:
a. Is this facility a Hazardous Waste Treatment, Storage, or Disposal Facility? El Yes a No ❑ N/A
b. Is this facility a Small Quantity Generator (less than 1000 kg. of hazardous El Yes ❑ No ❑ N/A
waste generated per month) of hazardous waste?
c. Is this facility a Large Quantity Generator (1000 kg. or more of hazardous waste O Yes O No p N/A
generated per month) of hazardous waste?
If you answered yes to questions b. or c., please provide the following information:
Type(s) of
waste: Metal Powder/Water/Mineral Oil Mixture
How is material stored: 55-gallon drums
Where is material stored: Designated hazardous waste accumulation area
How many disposal shipments per year:
Name of transport / disposal
vendor: Heritage Environmental Services
Vendor address: 550B Gulf Dr, Charlotte, NC 28208
Footnotes to Questions 14) c. & d.
*Note that amounts below the 660-gallon (single) and 1,320-gallon (combined) bulk storage minimums require
secondary containment. However, some exceptions may be made for de minimis amounts of certain substances,
and/or other qualifiers, as described in the exemptions from reporting requirements of Title III SARA 313 in 40 CFR
§372.38.
**Note that amounts below the 660-gallon (single) and 1,320-gallon (combined) bulk storage minimums require
secondary containment. However, some exceptions may be made for amounts less than the Reportable
Quantities of the hazardous substances listed in 40 CFR §117.3.
16) Other information: If you answer "Yes" to any of the following items, you might not be eligible for the
no exposure exclusion. A more in-depth evaluation of the site circumstances may be required.
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NCGNE0000 No Exposure Certification
a. Does your facility store used, recycled, or otherwise reclaimed pallets outside? p Yes 13 No B N/A
b. Does your facility have coal piles on site?
p Yes ❑ No 0 N/A
c. Does your facility store other fuel sources outside in piles, such as wood chips,
p Yes ❑ No 8 N/A
sawdust, etc.?
d. Does your facility have air emissions associated with its industrial activity (e.g.,
❑ Yes ID No ❑ N/A
degreasing operations, plating, painting and metal finishing)? If so, describe the
Industrial activity: Trace dust/particulates only
e. If you answered yes to d., are those emissions permitted by an Air Quality
p Yes 0 No ❑ N/A
Permit? Please specify:
f. Please list any other environmental program permits (federal, state, etc.) not
specified earlier in this application (such as Hazardous Waste Permits, etc.):
Permit: NCR000173104 Program: RCRA
Permit: Program:
Permit: Program:
Permit: Program:
Permit: Program:
Permit: Program:
Permit: Program:
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NCGNE0000 No Exposure Certification
17) Certification:
I certify under penalty of law that I have read and understand the eligibility requirements for claiming a condition of "no
exposure" and obtaining an exclusion from NPDES stormwater permitting.
I certify under penalty of law that there are no discharges of stormwater contaminated by exposure to industrial activities or
materials from the industrial facility or site identified in this document (except as allowed under 40 CFR 122.26(g)(2)).
I understand that I am obligated to maintain no exposure conditions and complete a Self -Recertification form at least once
each year, and if requested, provide this certification to the operator of the local municipal separate storm sewer system
(MS4) into which the facility discharges (where applicable). I understand that I must allow the North Carolina Division of
Energy, Mineral, and Land Resources, or MS4 operator where the discharge is into the local MS4, to perform inspections
to confirm the condition of no exposure and to make such inspection reports publicly available upon request. I understand I
must keep a copy of annual re -certifications on file at the facility.
In the event that the site no longer qualifies for a No Exposure Exclusion, I understand that I must obtain coverage under
an NPDES permit prior to any point source discharge of stormwater from the facility. Additionally, I certify under penalty of
law that this document and all attachments were prepared under my direction or supervision in accordance with a system
designed to assure that qualified personnel properly gathered and evaluated the information submitted. Based on my
inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the
information, the information submitted is to the best of my knowledge and belief true, accurate and complete. I am aware
that there are significant penalties for submitting false information, including the possibility of fine and imprisonment for
knowing violations.
I certify that I am familiar with the information contained in this application and that to the best of my knowledge and belief
such information is true, complete, and accurate.
(Signature of Applicant)
lb
(Date Signed) /
Please note: This application for the No Exposure Exclusion is subject to approval by the NCDEQ
Regional Office prior to issuance. The Regional Office may inspect your facility for compliance
with no exposure conditions prior to that approval. The Regional Office may also inspect your
facility at any time in the future for compliance with the No Exposure Exclusion.
North Carolina General Statute 143-215.6 B(i) provides that:
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan, or other
document filed or required to be maintained under this Article or a rule implementing this Article; or who knowingly makes a false
statement of a material fact in a rulemaking proceeding or contested case under this Article; or who falsifies, tampers with, or knowingly
renders inaccurate any recording or monitoring device or method required to be operated or maintained under this Article or rules of the
[Environmental Management] Commission implementing this Article shall be guilty of a Class 2 misdemeanor which may include a fine
not to exceed ten thousand dollars ($10,000).
There is currently no fee for a No Exposure Exclusion.
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NCGNE0000 No Exposure Certification
Final Checklist
This application should include the following items:
❑ This completed application and all supporting documentation.
❑ A map with the location of the facility clearly marked.
❑ If the site currently has an NPDES Stormwater Permit, be sure to indicate the permit number in Question 8.
Mail the entire package to:
DEMLR - Stormwater Program
Dept. of Environmental Quality
1612 Mail Service Center
Raleigh, North Carolina 27699-1612
Note
The submission of this document does not guarantee the issuance of a No Exposure Exclusion.
For questions, please contact the DEMLR Regional Office for your area.
DEMLR Regional Office Contdut Irrfurrnaliun:
Asheville Office ......
[phone]
Fayetteville Office ...
[phone]
Mooresville Office ...
[phone]
Raleigh Office ........
[phone]
Washington Office ...
[phone]
Wilmington Office ...
[phone]
Winston-Salem ......
[phone]
Central Office .........
[phone]
Page 7 of 7
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QQ
BRIEF DESCRIPTION OF OPERATIONS
Oerlikon AM in Huntersville is housed within a 125,000 square foot facility on a 40.24 acre site. The front offices,
meeting and training rooms are in the front 25,000 square feet of the facility, while the back 100,000 square feet
houses an additive manufacturing area, powder storage rooms, a powder analysis laboratory, a powder blending
room, a metallurgy & microscopy laboratory, a finished part processing area, a quality analysis room, a shipping &
receiving area, a maintenance area and a waste & recycling area.
The additive manufacturing area, storage rooms and labs are maintained to "aerospace" clean conditions. They all
have static dissipate epoxy floors. And the temperature and humidity are controlled for manufacturing optimization (70
degrees Fahrenheit +/- 2 degrees; 40% relative humidity +/- 10%).
To successfully build a part in an additive manufacturing printer, there are four essential elements that must be
present throughout the build process. These elements are metal alloy powder (henceforth referred to as "powder"),
inert gas, compressed air and electricity. If there is a lack of any one of these elements, the build will fail. A part build
ranges from a couple of hours, to a couple of days, to a couple of weeks. The longest build to date has taken 23
days. Should there be a lack of any element during the course of the build, the part will fail to print properly and the
build will have to be restarted on a clean build plate.
The size of the part is limited to the size of the build plate and it can be no higher than about 75% of the longest side
of the plate. For example, a 12 inch square build plate can build a part no higher than 9 inches, whereas a 14 inch
build plate (our largest plate) can build a part no higher than 10 inches. However, the length of the part is limited by
the angular dimensions of the build zone (i.e., no more than 17 inches on the largest build plate).
The leftover powder is collected and reused after sieving out imperfect -sized particulate from the powder. The
imperfect particulate is collected and disposed through a licensed hazardous waste hauler. Powder can potentially be
reused until it is totally consumed.
Newly received powder is segregated and stored in either reactive or non -reactive powder storage rooms. Reactive
powders (aluminum and titanium), are called such because they are a combustible solid under the right conditions.
Non -reactive powders (mostly iron with elements of nickel, cobalt or chromium depending on the alloy) do not have
the same propensity to burn.
Samples of the received powder are analyzed in the powder analysis lab to determine that the chemical composition
meets the alloy specifications. Small amounts (i.e., one gram) of powder are consumed in analyzers to do this. Once
the powder passes the tests, it is released for use in the additive manufacturing process.
Powders are blended in alloy specific blenders to prevent cross -contamination. The sealed blenders heat the powder
to about 300 degrees Fahrenheit by a recirculating heated oil system in an inert gas (i.e., argon or nitrogen)
atmosphere. The powder is then sieved to screen out improperly -sized particles. The powder can then be loaded into
the printers either manually or automatically from powder containers.
Samples from the part build are examined in the metallurgy & microscopy lab. Samples are prepared using abrasive
pads and water. They are etched typically with hydrochloric acid, but some are etched with nitric acid and a small
number of samples are etched using acetic acid. The spent acid is collected and disposed through a licensed
hazardous waste hauler.
Leftover powder, still in the built part, is removed inside a powder collection cabinet in water and/or with an ultrasonic
cleaning bath that uses Simple Green in the water. The collection of bath water and powder is disposed through a
licensed hazardous waste hauler.
The part can then be stress -relieved or heat -treated either on the build plate or by itself. We have a heat treat vacuum
furnace with an argon quench cycle (if required) and a hot isostatic press (aka, HIP — which also uses argon gas).
Page 1 of 2

BRIEF DESCRIPTION OF OPERATIONS
Oerlikon AM in Huntersville is housed within a 125,000 square foot facility on a 40.24 acre site. The front offices,
meeting and training rooms are in the front 25,000 square feet of the facility, while the back 100,000 square feet
houses an additive manufacturing area, powder storage rooms, a powder analysis laboratory, a powder blending
room, a metallurgy & microscopy laboratory, a finished part processing area, a quality analysis room, a shipping &
receiving area, a maintenance area and a waste & recycling area.
The additive manufacturing area, storage rooms and labs are maintained to "aerospace" clean conditions. They all
have static dissipate epoxy floors. And the temperature and humidity are controlled for manufacturing optimization (70
degrees Fahrenheit +/- 2 degrees; 40% relative humidity +/- 10%).
To successfully build a part in an additive manufacturing printer, there are four essential elements that must be
present throughout the build process. These elements are metal alloy powder (henceforth referred to as "powder"),
inert gas, compressed air and electricity. If there is a lack of any one of these elements, the build will fail. A part build
ranges from a couple of hours, to a couple of days, to a couple of weeks. The longest build to date has taken 23
days. Should there be a lack of any element during the course of the build, the part will fail to print properly and the
build will have to be restarted on a clean build plate.
The size of the part is limited to the size of the build plate and it can be no higher than about 75% of the longest side
of the plate. For example, a 12 inch square build plate can build a part no higher than 9 inches, whereas a 14 inch
build plate (our largest plate) can build a part no higher than 10 inches. However, the length of the part is limited by
the angular dimensions of the build zone (i.e., no more than 17 inches on the largest build plate).
The leftover powder is collected and reused after sieving out imperfect -sized particulate from the powder. The
imperfect particulate is collected and disposed through a licensed hazardous waste hauler. Powder can potentially be
reused until it is totally consumed.
Newly received powder is segregated and stored in either reactive or non -reactive powder storage rooms. Reactive
powders (aluminum and titanium), are called such because they are a combustible solid under the right conditions.
Non -reactive powders (mostly iron with elements of nickel, cobalt or chromium depending on the alloy) do not have
the same propensity to burn.
Samples of the received powder are analyzed in the powder analysis lab to determine that the chemical composition
meets the alloy specifications. Small amounts (i.e., one gram) of powder are consumed in analyzers to do this. Once
the powder passes the tests, it is released for use in the additive manufacturing process.
Powders are blended in alloy specific blenders to prevent cross -contamination. The sealed blenders heat the powder
to about 300 degrees Fahrenheit by a recirculating heated oil system in an inert gas (i.e., argon or nitrogen)
atmosphere. The powder is then sieved to screen out improperly -sized particles. The powder can then be loaded into
the printers either manually or automatically from powder containers.
Samples from the part build are examined in the metallurgy & microscopy lab. Samples are prepared using abrasive
pads and water. They are etched typically with hydrochloric acid, but some are etched with nitric acid and a small
number of samples are etched using acetic acid. The spent acid is collected and disposed through a licensed
hazardous waste hauler.
Leftover powder, still in the built part, is removed inside a powder collection cabinet in water and/or with an ultrasonic
cleaning bath that uses Simple Green in the water. The collection of bath water and powder is disposed through a
licensed hazardous waste hauler.
The part can then be stress -relieved or heat -treated either on the build plate or by itself. We have a heat treat vacuum
furnace with an argon quench cycle (if required) and a hot isostatic press (aka, HIP —which also uses argon gas).
Page 1 of 2

am
Parts are removed from build plates with either a band saw or a wire EDM (electrostatic discharge machine — utilizes
deionized water). The residual metal and wire are collected and sold to a recycler.
Parts are finished by removing build supports by hand and then rough areas are smoothed out by hand or belt
sanding. Debris from the parts is collected and sold to a recycler. Additional finishing is done in grit blasting cabinets
or a rotary tumbler. The water and soap from the rotary tumbler is collected and disposed through a licensed
hazardous waste hauler.
The parts and used build plates can be machined on a CNC (computer numerical control) machine that consumes
metalworking fluid. The metal chips are collected and sold to a recycler.
The Quality Room measures parts and refinished build plates to determine if they meet specifications. Finished parts
are measured using a CMM (computerized measurement machine) or a GOM (geometric optical measurement)
machine along with hand measurement devices (i.e. calipers). Build plates are measured for flatness on a granite
truing table.
Approved parts are packaged and shipped in cardboard or wooden boxes from the Shipping Dock.
Waste material is segregated in the waste and recycling area. Metal sludge and contaminated water (i.e., aluminum,
titanium, mixed metals, etc.) is disposed through a licensed hazardous waste hauler. Wooden pallets are collected in
a dumpster as is cardboard. General waste also has its own dumpster.
Page 2 of 2

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REFERENCE SCALE IN FEET
1. U.S.G.S. 7.5' TOPOGRAPHIC MAP, CORNELIUS QUADRANGLE, 0 2000 4000
NC DATED: 2019•
Z1201A I
OERLIKON AM US, INC
Z A
2 VANSTORY DRIVE
Civil & Environmental Consultants, Inc. HUNTERSVILLE, NORTH CAROLINA 28078
3701 Arco Corporate Drive • Suite 400 • Charlotte, NG 28273
Ph: 980.237.0373 • Fax: [phone] SITE LOCATION MAP
www.cecinc.com
DRAWN BY: JKS I CHECKED BY: DRAFT APPROVED BY: DRAFT I FIGURE NO.:
DATE: FEBRUARY 20201 DWG SCALE: 1 "=2,000' PROJECT NO: 196-717