NCG020072_COMPLETE FILE - HISTORICAL_20100423

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STORMWATER DIVISION CODING SHEET
NCG PERMITS
PERMIT NO.
IV U& D,-9 0 0 _a
DOC TYPE
C'� HISTORICAL FILE
❑ MONITORING REPORTS
DOC DATE
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YYYYMMDD

NCDENR
North Carolina Department of Environment and Natural Resources -
Division of Water Qualify
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Governor Director Secretary
A pri 123, 2010
Mr. Brian Pfohl
Carolina Sunrock, LLC
200 Horizon Drive, Suite 100
Raleigh, NC 27615
Subject: NPDES General Permit NCG020000
Certificate of Coverage NCG020072
Carolina Sunrock, LLC.
Formerly Rea Contracting, I.I.C.
Granville County
Dear Mr. Pfolil:
Division personnel have reviewed and approved your request to transfer coverage under the General
Permit, received on June 16, 2009.
Please find enclosed the revised Certificate of Coverage. The terms and conditions'contained in
the General Permit remain unchanged and in full effect. "]'his revised Certificate of Coverage is issued
under the requirements of North Carolina Generai Statutes 143-215.1 and the Memorandum of
Agreement between North Carolina and the U.S. Environmental Protection Agency.
If you have any questions, please contact the Stornnvater Permitting Unit at [phone].
Sincerely,
Coleen 1-1. Sullins
cc: DWQ Central Files
Mooresville Regional Office
Stormwater Permitting Unit
Wetlands and Stormwater Branch
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet, www.ncwaterquality.org
One
North Carolina
Aahlrally
An Equal Opportunity 1 Affirmative Action Employer

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG020000
CERTIFICATE OF COVERAGE No. NCG020072
SI'ORMWA`I ER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and the Fedcral Water Pollution Control Act, as amended,
Carolina Sunrock, LLC
is hereby authorized to discharge stomilwater from a facility located at
Butner Quarry
100 Sunrock Drive
Butner
Granville County
to receiving waters designated as a UT to the Neuse River, a class WS-IV, NSW, CA river, in the Neuse
Basin in accordance with the effluent limitations, monitoring requirements, and other conditions set forth
in Parts 1, II, III, IV, V and VI of General Permit No. NCG020000 as attached.
"]'his certificate of coverage shall become effective April 23, 2010.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day April 23, 20I0.
Coleen 1-1. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Michael F. Fasley, Governor
William G. Ross Jr„ Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Qualify
February 7, 2005
Bryan Pfohl
Carolina Sunrock LLC
PO Box 25
Butner. NC 27509
Subject: NPDES Stormwater Permit Coverage Renewal
Butner Concrete
COC Number NCG020072
Granville County
Dear Permittee:
In response to your renewal application for continued coverage under general permit NCG020000 the Division of Water
Quality (DWQ) is forwarding herewith the reissued stormwater general permit. Please review the new permit to familiarize
yourself with the changes in the reissued permit. The general permit authorizes discharges of stormwater and some types of
wastewater. You must meet the provisions of the permit for the types of discharges present at your facility. This permit is
reissued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between the state of North Carolina and the U.S. Environmental Protection Agency, dated December 6, 1983,
The following information is included with your permit package:
• A new Certificate of Coverage
A copy of General Stormwater Permit NCG020000
• A copy of a Technical Bulletin for the general permit
• Five copies of Discharge Monitoring Report (DMR) Forms - wastewater and stormwater
Five copies of Qualitative Monitoring Report Form
Your coverage under this general permit is not transferable except after notice to DWQ. The Division may require modification
or revocation and reissuance of the Certificate of Coverage. This permit does not affect the legal requirements to obtain other
permits which may be required by DENR or relieve the permittee from responsibility for compliance with any other applicable
federal, state, or local law, rule, standard, ordinance, order, judgment, or decree.
If you have any questions regarding this permit package please contact Aisha Lau of the Central Office Stormwater Permitting
Unit at [phone], ext.578.
Sincerely.
ice/'. yt.ell
for Alan W. Klimek, P.E.
cc: Central Files
Stormwater & General Permits Unit Files
Raleigh Regional Office
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617
Intemet. h2o.enr.state.nc.uslsulstormwater.html 512 N. Salisbury St. Raleigh, NC 27604
One
NorthCarolina
Naturally
Phone [phone] Customer Service
FAX [phone]
An Equal Opportunity/Affirmative Action Employer- 50% Recycled110% Post Consumer Paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG020000
CERTIFICATE OF COVERAGE No. NCG020072
STORMWATER AND PROCESS WASTEWATER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and
the Federal Water Pollution Control Act, as amended,
Carolina Sunrock LLC
is hereby authorized to discharge stormwater and to operate treatment systems and discharges associated
with mine dewatering wastewater and process wastewater from a facility located at
Butner Concrete
1001 W B St
Butner
Granville County
to receiving waters designated as a UT of the Neuse River, a class WSIV-NSW-CA stream in the Neuse
River Basin in accordance with the effluent limitations, monitoring requirements, and other conditions set
forth in Parts I, II, III, IV, V, and VI of General Permit No. NCG020000 as attached.
This certificate of coverage shall become effective February 7, 2005,
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day February 7, 2005
%/�
for Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

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Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
December 3, 2008
CERTIFIED MAIL 7006 0810 0002 6049 7338
RETURN RECEIPT REQUESTED
Mr. Tony Sample
Compliance Manager
Carolina Sunrock Corporation
200 Horizon Dr., Suite 100
Raleigh, NC 27615
Subject: Request for Representative Outfall Status
Sunrock Butner Quarry
Stormwater Permit NCG020072
Butner, NC
Granville County
Dear Mr. Sample:
Coleen N. Sullins, Director
Division of Water Quality
On July 2, 2008 Raleigh Regional Office (RRO).rcpresentatives Myrl Nisely and Danny Smith
observed the mine site with you to evaluate adherence to the Sunrock mine stomiwater permit
NCG020072. Several deficiencies in carrying out permit requirements were noted in a NOV
letter dated 7/10/08. During that inspection the possibility of Representative Outfall Status was
discussed: You soon submitted a written request to RRO with an annotated aerial photo.
The Representative Outfall Status request identified:
1) OutfalI 7 to represent outfalls 3,4,5,6 and 8,
2) Outfall 9 serving industrial activity in the vicinity of the Vehicle Maintenance Shop,
3) - Outfall 10 serving Pit Dewatering and
4) Outfall 1 serving a combination of Ready Mix Concrete, Asphalt, and the Fines Pond.
(Note: it was explained that Outfall 2 has been eliminated.)
The RRO conducted follow-up inspections on 6/26 and 8/12/08 to observe conditions and better
understand the request. Based upon several site visits, the absence of historic monitoring data,
the failure to maintain'control measures, sediment observed in surface waters, sediment observed
in riparian/ streamside areas (pursuant to 15A NCAC 2B .0233) and your site descriptions the
following representative outfall locations are approved:
Outfall 1 — Sampling is required at the frequency and for the parameters set forth in the permit.
Outfall 2 , Sampling is required at the frequency and for the parameters set forth in the permit.
[Note: you have explained that this outfall no longer discharges; if that is the case you
do not have sample this location. However, our observations are different. If this
outfall discharges you are required to sample it and conduct qualitative monitoring. For
TRW
Raleigh Regional office 1628 Mail service Center hone 919 791-4200 `JCUE�`;IR
A ( ) Customer Service
Water Quality Section Raleigh, NC 27699-1628 facsimile t919i 788-7159 1-g77_F71_F7AJR

Sunrock Butner Request for Representative Outfall Status, December 2008
Page 2 of
clarification purposes, if this outfall is discharging and monitoring does not occur, this
will be considered a violation of your permit]
Outfall 3 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit. This outfall (4) may be used as a representative outfall location for outfall #
3 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry, Revised dated 8-
11-08" [RRO received date stamp September 9, 2008] '
Outfall 6 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit. This outfall (6) may be used as a representative outfall location for outfalls
# 5, 6 and 7 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry,
Revised dated 8-11-08" [RRO received'date stamp September 9, 2008].
Outfall 8 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit.
Outfall 9 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit'
Outfall 10 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Qualitative; Monitoring
Sampling is required at all ten outfalls at the frequency and for the parameters set forth
in the permit. - This kind of monitoring does not receive representative outfall status. The
observation forms are to be made available during inspections.
Because topography, changes in a dynamic mine situation, the above approval.of the
representative outfall maybe revisited/re-opened by either Division of Water Quality or Carolina
Sunrock Corporation. Further, if Carolina Sunrock Corporation wishes to revisit or make future
requests for. representative outfalls, status is subject to changes or revocation from time to time.
Also, if new outfalls are created or if outfall locations are changed, sampling is required.
As stated in.the Notice of Violation 7/10/08, there has been a failure to carry out Qualitative and
Quantitative monitoring -of these locations as required by Part III Sections B and C.
In addition to monitoring, NCG020000 permit includes the following conditions (please review
permit,. for other permit conditions not listed below).
Implementation of stormwater BMPs must ensure contaminants do. not enter surface waters
via stormwater.
e Stormwater BMPS are required to be maintained for land disturbing process areas and areas
that are outside process areas (access roads, areas being prepared for mining, equipment storage
areas etc).
e Stormwater BMPs are required to be inspected at least once every seven -calendar days and
within 24 hours after any storm event that results in a discharge.
e BMPs are to be Operated and Maintained so they are cleaned out when the sediment'storage
capacity has been reduced by 50%.
e Visible sediment is not allowed to leave the property.

Sunrock Butner Request for Representative Outfall Status, December 2008 Page 3 of 3
If sedimentation has occurred, records with a brief explanation as to the measure taken to
prevent future releases and to remove sediment need to be available.
As already noted, there have been failures in the past for Sunrock Butner Quarry to carry out and
comply with permit conditions as set forth in NCG020000. It is the intention of this office to
conduct another inspection in the near future. If violations are continuing, enforcement
proceeding.as appropriate may be recommended. Please note that violations are subject to a
civil penalty assessment of up to $25,000.00 per day for each violation.
If you have comments or questions about this letter, or want to further review any details with
our office, please contact Myrl Nisely or me at 919-791-4200.
cc: SWP/RRO Files
Central Files
Sincerely,
1��/Jrl l
Dann Y Smifh
Surface Water Protection Supervisor
Raleigh Regional Office
V-�
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Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
December 3, 2008
CERTIFIED MAIL 7006 0810 0002 6049 7208
RETURN RECEIPT REQUESTED
Mr. Tony Sample
Compliance Manager
Carolina Sunrock Corporation
200 Horizon Dr., Suite 100
Raleigh, NC 27615
Subject: Request for Representative Outfall Status
Sunrock Butner Quarry
Stormwater Permit NCG020072
Butner, NC
Granville County
Dear Mr. Sample:
Coleen H. Sullins, Director
Division of Water Quality
On July 2, 2008 Raleigh Regional Office (RRO) representatives Myrl Nisely and Danny Smith
observed the mine site with you to evaluate adherence to the Sunrock mine stormwater pernlit
NCG020072. Several deficiencies in carrying out permit requirements were noted in a NOV
letter dated 7/10/08. During that inspection the possibility of Representative Outfall Status was
discussed. You soon submitted a written request to RRO with an annotated aerial photo.
The Representative Outfall Status request identified:
1) Outfall 7 to represent outfal Is 3,4,5,E and 8,
2) Outfall 9 serving industrial activity in the vicinity of the Vehicle Maintenance Shop,
3) Outfall 10 serving Pit Dewatering and
4) Outfall 1 serving a combination of Ready Mix Concrete, Asphalt, and the Fines Pond.
(Note: it was explained that Outfall 2 has been eliminated.)
The RRO conducted follow-up inspections on 6/26 and 8/12/08 to observe conditions and better
understand the request. Based upon several site visits, the absence of historic monitoring data,
the failure to maintain control measures, sediment observed in surface waters, sediment observed
in riparian/ streamside areas (pursuant to 15A NCAC 2B .0233) and your site descriptions the
following representative outfall locations are approved:
Outfal I 1 — Sampling is required at the frequency and for the parameters set forth in the permit.
Outfall 2 — Sampling is required at the frequency and for the parameters set forth in the permit.
[Note: you have explained that this outfall no longer discharges; if that is the case you
do not have sample this location. However, our observations are different. If this
outfall discharges you are required to sample it and conduct qualitative monitoring. For
Raleigh Regional Offce 1628 Mail Service Center phone [phone] Customer Service
Water Quality Section Raleigh, NC 27699-1628 facsimife [phone] 1-877-623-6748
NCDOUR

Sunrock Butner Request for Representative Outfall Status, December 2008 Page 2 of 3
clarification purposes, if this outfall is discharging and monitoring does not occur, this
will be considered a violation of your permit]
Outfall 4 - Sampling is required at this location at the frequency and for the parameters set
forth in the permit. This outfall may be used as a representative outfall location for
outfalls # 3 and #4 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry,
Revised dated 8-11-08" [RRO received date stamp September 9, 20081 (wording change
from earlier version)
Outfall 6 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit. This outfall may be used as a representative outfall location for outfalls # 5,
6 and 7 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry, Revised
dated 8-11-08" [RRO received date stamp September 9, 2008].
Outfall 8 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit.
Outfall 9 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Outfall'10 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Qualitative Monitorin
Sampling is required at all ten outfalls at the frequency and for the parameters set forth
in the permit. This kind of monitoring does not receive representative outfall status. The
observation forms are to be made available during inspections.
Because topography changes in a dynamic mine situation, the above approval of the
representative outfall may be revisited/re-opened by either Division of Water Quality or,Carolina
Sunrock Corporation. Further, if Carolina Sunrock Corporation wishes to revisit or make future
requests for representative outfalls, status is subject to changes or revocation from time to'time.
Also, if new outfalls are created or if outfall locations are changed, sampling is required.
As stated in the Notice of Violation 7/10/08, there has been a failure to carry out Qualitative and
Quantitative monitoring of these locations as required by Part III Sections B and C.
In addition to monitoring, NCG020000 permit includes the following conditions (please review
permit, for other permit conditions not listed below).
• Implementation of stormwater BMPs must ensure contaminants do not enter surface waters
via stormwater.
• Stormwater BMPS are required to be maintained for land disturbing process areas and areas
that are outside process areas (access roads, areas being prepared for mining, equipment storage
areas etc).
• Stormwater BMPs are required to be inspected at least once every seven -calendar days and
within 24 hours after any storm event that results in a discharge.
• BMPs are to be Operated and Maintained so they are cleaned out when the sediment storage
capacity has been reduced by 50%.
0 Visible sediment is not allowed to leave the property.

Sunrock Butner Request for Representative Outfall Status, December 2008
Page 3 of 3
If sedimentation has occurred, records with a brief explanation as to the measure taken to
prevent future releases and to remove sediment need to be available.
As already noted, there have been failures in the past for Sunrock Butner Quarry to carry out and
comply with permit conditions as set forth in NCG020000. It is the intention oFthis office to
conduct another inspection in the near future. If violations are continuing, enforcement
proceeding as appropriate may be recommended. Please note that violations are subject to a
civil penalty assessment of up to $25,000.00 per day for each violation.
If you have comments or questions about this letter, or want to Further reviey.}with
our office, please contact Myrl Nisely or me at 919-791-4200. Vol
Sincerely, ,A
r, )�
Danny Smith G
Surface Water Protection Supervisor
Raleigh Regional Office
cc: SWP/RRO Files
Central Files
Bethany Georgoulias, SWPU
UM
rN
S� U N

�- • ""' o�oF w A rFRQG
� Y
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
December 3, 2008
CERTIFIED MAIL 7006 0810 0002 6049 7208
RETURN RECEIPT REQUESTED
Mr. Tony Sample
Compliance Manager
Carolina Sunrock Corporation
200 Horizon Dr., Suite 100
Raleigh, NC 27615
Subject: Request for Representative Outfall Status
Sunrock Butner Quarry
Storinwater Permit NCG020072
Butner, NC
Granville County
Dear Mr. Sample:
Coleen H. Sullins, Director
Division of Water Quality
,&Jc- . 4-,of + h i3 t MS
(-2.�/CA3 = �
On ,luly 2, 2008 Raleigh Regional Off ice (RRO) representatives Myrl Nisely and Danny Smith
observed the mine site with you to evaluate adherence to the Sunrock mine stormwater permit
NCG020072, Several deficiencies in carrying out permit requirements were noted in a NOV
letter dated 7/10/08. During that inspection the possibility of Representative Outfall Status was
discussed. You soon submitted a written request to RRO with an annotated aerial photo.
The Representative Outfall Status request identified:
1) Outfall 7 to represent outfal is 3,4,5,6 and 8,
2) Outfall 9 serving industrial activity in the vicinity of the Vehicle Maintenance Shop,
3) Outfall 10 serving Pit Dewatering and
4) Oulfflll I serving a combination of'Ready Mix Concrete, Asphalt, and the Fines Pond.
(Note: it was explained that Outfall 2 has been eliminated.)
The RRO conducted follow-up inspections on 6/26 and 8/12/08 to observe conditions and better
understand the request. Based upon several site visits, the absence of historic monitoring data,
the failure to maintain control measures, sediment observed in surface waters, sediment observed
in riparian/ streamside areas (pursuant to 15A NCAC 213 .0233) and your site descriptions the
following representative outfall locations are approved:
Outfall i — Sampling is required at the frequency and for the parameters set forth in the permit.
Outfall 2 — Sampling is required at the frequency and for the parameters set forth in the permit.
[Note: you have explained that this outfall no longer discharges; if that is the case you
do not have sample this location. However, our observations are different. It. this
outfall discharges you are required to sample it and conduct qualitative monitoring. For
Raleigh Regional Office 1628 Mail Service Center phone [phone]
Water Quality Section Raleigh, NC 27699.1628 facsimile [phone]
Customer Service
1-877-623-6748
HCUENR

Sunrock Butner Requcst for Representative Outiall Status, December 2008 Page 2 of 3 '
clarification purposes, if this outfall is discharging and monitoring does not occur, this
will be considered a violation of your permit]
Outfall 4 - Sampling is required at this location at the frequency and for the parameters set
forth in the permit. This outfall may be used as a representative outfall location for
outfalls # 3 and #4 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry,
Revised dated 8-11-08" IRRO received date stamp September 9, 20081 (ivording change
from earlier version)
Outfall 6 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit. This outfall may be used as a representative outfall location for outfalls # 5,
6 and 7 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry, Revised
dated 8-1 1-08" [RRO received date stamp September 9, 2008].
Outfall 8 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit.
Outfal1 9 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Outfall 10 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Qualitative Monitoring
Sampling is required at all ten outfalls at the frequency and for the parameters set forth
in the permit. This kind of monitoring does not receive representative outfall status. The
observation forms are to be made available during inspections.
Because topography changes in a dynamic mine situation, the above approval of the
representative outfall may be revisited/re-opened by either Division of Water Quality or Carolina
Sunrock Corporation. Further, if Carolina Sunrock Corporation wishes to revisit or make future
requests for representative outfalls, status is subject to changes or revocation from time to time.
Also, if new outfalls are created or if outfall locations are changed, sampling is required.
As stated in the Notice of Violation 7/10/08, there has been a failure to carry out Qualitative and
Quantitative monitoring ofthese locations as required by Part III Sections B and C.
In addition to monitoring, NCG020000 permit includes the following conditions (please review
permit, for other permit conditions not listed below).
• Implementation of stormwater BMPs must ensure contaminants do not enter surface waters
via stormwater.
• Stormwater BMPS are required to be maintained for land disturbing process areas and areas
that are outside process areas (access roads, areas being prepared for mining, equipment storage
areas etc).
• Stormwater BMPs are required to be inspected at least once every seven -calendar days and
within 24 hours after any storm event that results in a discharge.
BMPs are to be Operated and Maintained so they are cleaned out when the sediment storage
capacity has been reduced by 50%.
Visible sediment is not allowed to leave the property.

SUIVOCk Butner Request for Represcmative 011tfall Status, December 2008 Page 3 of 3
0 if sedimentation has occurred, records with a brief explanation as to the measure taken to
prevent future releases and to remove sediment need to be available.
As already noted, there have been failures in the past for Sunrock Butner Quarry to carry out and
comply with permit conditions as set forth in NCG020000. It is the intention of this office to
conduct another inspection in the near future. If violations are continuing, enforcement
proceeding as appropriate may be recommended. Please note that violations are subject to a
civil penalty assessment of up to $25,000.00 per day for each violation.
If you have comments or questions about this letter, or want to further review any details with
our office, please contact Myr] Nisely or me at 919-791-4200.
Sincerely,
Danny Smith
Surface Water Protection Supervisor
Raleigh Regional Office
cc: SWPIRRO Files
Central Files
Bethany Georgoulias, SWPU

le,
o� w a r�RQ�
A 40
>_ z 3Qa
❑ Y 0
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
December 3, 2008 -
CERTIFIED MAIL- 7006 0810 0002 6049 7338 '(•N"
RETURN RECEIPT REQUESTED S�
Mr. Tony Sample
Compliance Manager
Carolina Sunrock Corporation
200 Horizon Dr., Suite 100
Raleigh, NC 27615
Subject: Request for Representative Outfall Status
Sunrock Butner Quarry
Stormwater Permit NCG020072
Butner, NC
Granville County
Dear Mr. Sample:
Coleen H. Sullins, Director
Division of Water Quality
On July 2, 2008 Raleigh Regional Office (RRO) representatives Myrl Nisely and Danny Smith
observed the mine site with you to evaluate adherence to the Sunrock mine stormwater permit
NCG020072. Several deficiencies in carrying out permit requirements were noted in a NOV
letter dated 7/10/08. During that inspection the possibility of Representative Outfall Status was
discussed. You soon submitted a written request to RRO with an annotated aerial photo.
The Representative Outfall Status request identified:
1) Outfall 7 to represent outfalls 3,4,5,6 and 8,
2) Outfall 9 serving industrial activity in the vicinity of the Vehicle Maintenance Shop,
3) Outfall 10 serving Pit Dewatering and
4) Outfall 1 serving a combination of Ready Mix Concrete, Asphalt, and the Fines Pond.
(Note: it was explained that Outfall 2 has been eliminated.)
The RRO conducted follow-up inspections on 6/26 and 8/12/08 to observe conditions and better
understand the request. Based upon several site visits, the absence of historic monitoring data,
the failure to maintain control measures, sediment observed in surface waters, sediment observed
in riparian/ streamside areas (pursuant to 15A NCAC 213 .0233) and your site descriptions the
following representative outfall locations are approved:
Outfall 1 — Sampling is required at the frequency and for the parameters set forth in the permit.
Outfall 2 — Sampling is required at the frequency and for the parameters set forth in the permit.
[Note: you have explained that this outfall no longer discharges; if that is the case you
do not have sample this location. However, our observations are different. if this
outfall discharges you are required to sample it and conduct qualitative monitoring. For
Raleigh Regional Office
Water Quality Section
1628 Mail Service Center
Raleigh, NC 27699-1628
phone [phone]
facsimile [phone]
Customer Service
I-R77-F7%R7AA
MW
'4 UDE`;

:s
Sunrock Butner Request for Representative Outfall Status, December 2008 Page 2 of 3
clarification purposes, if this outfall is discharging and monitoring does not occur, this
will be considered a violation of your permit]
Outfall - ampling is required at this location at the frequency and for the parameters set forth
in the permit. This outfall (4) may be used as a representative outfall location for outfall #
3 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry, Revised dated 8-
11-68" [RRO received date stamp September 9, 20081
OutfalI 6 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit. This outfall (6) may be used as a representative outfall location for outfalls
# 5, 6 and 7 as depicted on the "Site Map, Carolina Sunrock, LLC, Butner Quarry,
Revised dated 8-11-08" [RRO received date stamp September 9, 2008].
Outfall 8 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit.
Outfall 9 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Outfall 10 - Sampling is required at this location at the frequency and for the parameters set forth
in the permit
Qualitative Monitoring
Sampling is required at all ten outfalls at the frequency and for the parameters set forth
in the permit. This kind of monitoring does not receive representative outfall status. The
observation forms are to be made available during inspections.
Because topography changes in a dynamic mine situation, the above approval of the
representative outfall may be revisited/re-opened by either Division of Water Quality or Carolina
Sunrock Corporation. Further, if Carolina Sunrock Corporation wishes to revisit or make future
requests for representative outfalls, status is subject to changes or revocation from time to time.
Also, if new outfalls are created or if outfall locations are changed, sampling is required.
As stated in the Notice of Violation 7/10/08, there has been a failure to carry out Qualitative and
Quantitative monitoring'of these locations as required by Part III Sections B and C.
In addition to monitoring, NCG020000 permit includes the following conditions (please review
permit, for other permit conditions not listed below).
• Implementation of stormwater BMPs must ensure contaminants do, not enter surface waters
via stormwater.
• Stormwater BMPS are required to be maintained for land disturbing process areas and areas
that are outside process areas (access roads, areas being prepared for mining, equipment storage
areas etc).
0 Stormwater BMPs are required to be inspected at least once every seven -calendar days and
within 24 hours after any storm event that results in a discharge.
• BMPs are to be Operated and Maintained so they are cleaned out when the sediment storage
capacity has been reduced by 50%.
0 Visible sediment is not allowed to leave the property.

FV Sunrock Butner Request for Representative Outfail Status, December 2008 Page 3 of 3
• If sedimentation has occurred, records with a brief explanation as to the measure taken to
prevent future releases and to remove sediment need to be available.
As already noted, there have been failures in the past for Sunrock Butner Quarry to carry out and
comply with permit conditions as set forth in NCG020000. It is the intention of this office to
conduct another inspection in the near future. If violations are continuing, enforcement
proceeding as appropriate may be recommended. Please note that violations are subject to a
civil penalty assessment of up to $25,000.00 per day for each violation.
If you have comments or questions about this letter, or want to further review any details with
our office, please contact Myrl Nisely or me at 919-791-4200.
S'ncerely, /" �
t
Dann Sm/
Y
Surface Water Protection Supervisor
Raleigh Regional Office
cc: SWP/RRO Files
Central Files
bf�a61r y rljc.n►me + +

�� fy
ASUNROCK w ob ;nt y ` k
CAROLINA SUNROCK LLC �`+ `�u Tony Sample, CPESC
�n/]� Compliance Manager
��''JJ Horizon Drive Suite 100
Raleigh, NC 27615
August 27, 2008`° .�'
fir?,
Ms. Sarah Young qb
North Carolina Division of Water Quality
1617 Mail Service Center pp� (;
Raleigh, NC 27669-1617 r`a
r�1 71 I 71
RE: Stormwater Permit No . 140225, 20072 20438, 160161, 14032 .160138, 40251, 20722
Carolina Sunrock LLC
Dear Ms. Young:
Carolina Sunrock LLC has relocated its corporate office to the following address. The phone numbers will change as well.
Please make the appropriate address changes for the permits listed above.
Carolina Sunrock LLC
200 Horizon Drive, Suite 100
Raleigh, NC 27615
Phone: [phone]
Fax: [phone]
Please contact the undersigned at 747-6336, if you require further information or have questions on this.
Please contact us if you need further information or if this does not meet your requirements.
Sincerely,
Carolina Sunrock, LLC
�e mple, C.P.E,S.C.
Compliance Manager
[e-mail]
Phone: [phone]
Fax: [phone]
www.thesunrockgroup.com

ASUNROCK 0
CAROLINA SUNROCK LLC
August 11, 2008
Mr, Danny Smith
Surface Water Protection Supervisor
Raleigh Regional Office, NCDENR
3800 Barrett Drive
Raleigh, NC 27609
Re: Permit No, NCG020072
Butner Quarry
Carolina Sunrock LLC
Raleigh, North Carolina, Granville County
Dear Mr. Smith:
Tony Sample, CPESC
Compliance Manager
PO Box 25 Butner, NC 27509
This letter is to request representative outfali status for the outlet number 7indicated on the attached map as representing
numbers 3 through 8 and the new measures to be installed in the expansion area east of the creek. This represents run-off
from the areas stripped or in the process of being stripped for mine expansion. The recommended locations for the
monitoring location for the vehicle maintenance area and for the pit dewatering area are also identified on the map. The
location of the Concrete Plant sampling point is also located and identified on the map. The pipe at the fines disposal area
has been welded shut and the water diverted to the outlet used for the discharge of the concrete storm water (cutlet 1). The
laftong of the sampling points are identified on the map as well.
Please contact us if you need further information or if this does not meet your requirements.
Sincerely,
Carolina Sunrock LLC
�amp.E.S.C.
Compliance Manager
tsample@thesunrockgreup, corn
Phone: 919.575,4502
Fax; 919.575,4510
www.ihasmn rockgrov p.com

4tate of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Bill Holman, Secretary
Kerr T. Stevens, Director
December 17, 1999
JOHN KUHNE
CAROLINA SUNROCK CORPORATION
P O BOX 25
BUTNER, NC 27509
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT ANO NATURAL RESOURCES
Subject: Reissue - NPDES Stormwater Permit
Carolina Sunrock Corporation
COC Number NCG020072
Granville County
Dear Permittee:
In response to your renewal application for continued coverage under general permit NCG020000, the Division of
Water Quality (DWQ) is forwarding herewith the reissued stormwater general permit. This permit is reissued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between the state of North Carolina and the U.S. Environmental Protection Agency, dated December 6, 1983.
The following information is included with your permit package:
* A copy of general stormwater permit NCG020000
* Five copies of the Analytical Monitoring form and five copies of the Qualitative Monitoring form
* A copy of a Technical Bulletin on this permit which outlines permit components and
addresses frequently asked questions
* A Certificate of Coverage for your facility
* DWQ fee schedule
Your coverage under this general permit is not transferable except after notice to DWQ. The Division may require
modification or revocation and reissuance of the Certificate of Coverage. This permit does not affect the legal
requirements to obtain other permits which may be required by DENR or relieve the permittee from responsibility
for compliance with any other applicable federal, state, or local law rule, standard, ordinance, order, judgment, or
decree.
Please note that in 1998 Senate Bill 1366 established changes to the permit fee structure for DWQ permits effective
January 1, 1999. This change requires that you pay an annual fee to assure continued coverage under this permit.
You will be invoiced for this fee beginning next year. A copy of the current fee schedule is included with this letter.
If you have any questions regarding this permit package please contact Tony Evans of the Central Office Stormwater
and General Permits Unit at [phone]. ext. 584
Sincerely,
for Kerr T. Stevens
Director, Division of Water Quality
cc: Central Files
Raleigh Regional Office
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

STATE OF NORTH CAROLINA
DEPARTMENT CF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG020000
CERTIFICATE OF COVERAGE No. NCG020072
STORMWATER AND PROCESS WASTEWATER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the
Federal Water Pollution Control Act, as amended,
CAROLINA SUNROCK CORPORATION
is hereby authorized to discharge stormwater and to operate or continue operation of treatment systems and
discharges associated with mine dewatering and process wastewater from a facility located at
CAROLINA SUNROCK CORPORATION
1001 WEST B STREET
BUTNER
GRANVILLE COUNTY
to receiving waters designated as a UT of the Neuse River in the Neuse River Basin in accordance with the effluent
limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, IV, V, and VI of General
Permit No. NCG020000 as attached.
This certificate of coverage shall become effective December 17, 1999.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day December 17, 1999.
bf a.'Aev
for Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
James B. Hunt, Jr., Governor A. Preston Howard, Jr., P. E.
Jonathan B. Howes, Jr., Secretary Director
April 23, 1993
Dick Hoffman
1001 West B Street
Butner, NC 27509
Subject: General Permit No. NCG020000
Carolina Sunrock Corp. - Butner Quarry
COC NCG020072
Granville County
Dear Mr Hoffman:
In accordance with your application for discharge permit received on October 29, 1992, we are
forwarding herewith the subject certificate of coverage to discharge under the subject state - NPDES general
permit. Issuance of this certificate of coverage supercedes the individual NPDES permit No. NC0061549.
This permit is issued pursuant to the requirements of North Carolina General Statute 143-215 .1 and the
Memorandum of Agreement between North Carolina and the US Environmental Protection agency dated
December 6, 1983.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual permit
application. Unless such demand is made, this certificate of coverage shall be final and binding.
Please take notice that this certificate of coverage is not transferable except after notice to the Division
of Environmental Management. The Division of Environmental Management may require modification or
revocation and reissuance of the certificate of coverage.
This permit does not affect the legal requirements to obtain other permits which may be required by the
Division of Environmental Management or permits required by the Division of Land Resources, Coastal Area
Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Ms. Susan Robson at telephone number
9191733-5083.
cc
Sincerely,
Original Si �� y
Coleen K Sullins
A. Preston Howard, Jr.
Director
Raleigh Regional Office
Pollution Prevention Pays
P.Q. Box 29535, Raleigh, North Carolina 27626.0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

f
;f
GENERAL PERMITS
COPIES OF PERMITS ARE TO BE SENT
TO THE FOLLOWING:
� SIGNED ORGINAL TO APPLICANT **
7SIGNED COPY TO CENTRAL FILES
TCOPY TO REGIONAL OFFICE
COPY TO P&E FILE
_COPY TO COMPLIANCE
_COPY TO WAKE COUNTY
_COPY TO MECKLENBURG COUNTY
COPY TO TRAINING & CERT. **
**ATTACH COPY OF GENERAL PERMIT

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
M-N-t4m.116yalli ! ;: �rII II
STORMWATER, MINE DEWATERING, AND/OR OVERFLOW FROM
PROCESS WATER RECYCLE SYSTEMS DISCHARGES
In compliance with the provision of North Carolina General Statute 143-215.I, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the
Federal Water Pollution Control Act, as amended,
Carolina Sunrock Corporation
is hereby authorized to continue operation of a treatment system for mine dewatering and a closed loop recycle
system with the discharge treated wastewater from a facility located at
Butner Quarry
on West "B" Street
Town of Butner
Granville County
to receiving waters designated as an unnamed tributary to Cedar Creek in the Neuse River Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, I1I
and IV of General Permit No. NCG020000 as attached.
This certificate of coverage shall become effective April 23, 1993
This Certificate of Coverage shall remain in effect for the'duration of the General Permit.
Signed this day April 23, 1993
Original Signed BY
Coleen H. Sullins
A. Preston Howard, Jr., P.E., Director
Division of Environmental Management
By Authority of the Environmental Management Commission

1Q-Wqo
V�'f\A SN ' n ! -5A ' -1 E1 11 eA a+ _0
I

a
State of North Carolina
Department of Environment, Health, and Natural Resources
Division of Environmental Management
Non -Discharge Permit Application
(THIS FORM MAYBE PHOTOCOPIED FOR USE AS AN ORIGINAL)
RECYCLE FACILITIES
I. GENERAL INFORMATION:
1. Applicant (corporation, individual, or other): Carolina Sunrock Corporation
2. Print Owners or Signing Official's Name and Title (the person who is legally
responsible for the facility and its compliance) Lou i e M. Walters , Jr
General Manager
3. Mailing Address: P • 0. Box 25, 1001 West B Street
City: Butner
State: N • C • Zip. 27509-0025
Telephone No.: g( 19 ) 5 7 5 - 45 0 2
4. Project Name' (subdivision, facility, or establishment name - should be consistent with
project name on plans/specs., letters of flow acceptance, Operational Agreements, etc.):
Butner Quarry - Washwater_Recycle System _
5. Application Date:Dec . 7, 1992 6. Fee Submitted: $ 4 0 0 . 00
7. County where project is located: Granville
8. Latitude: 360 07' 01" ; Longitude 780 46' 18" of recycle facility location
II. PERMIT INFORMATION:
1. Permit No. (will be completed by DEM):
2. Specify whether project is: new; renewal *;••" `� X �tm6dificati8nFV-
* If renewal, complete only sections I, II, III, & appl'icant' signatures
(on pg.6). Submit only pgs. 1, 2, 6 (original and 3 copies A"each). ngi�neer
signature not required for renewal. �1,A ,lg
3. If this application is being submitted as a result of a renewal or modif cat grj�'q an
existing permit, list the existing permit number W90002831 and issue dateFeb . 27 1990
4. Specify whether the applicant is public or X private.
FORM: RFAC 4191 Page 1 of 7

RECYCLE FACILITIES
PAGE 2 (4/91)
III. INFORMATION ON WASTEWATER:
1. Nature of Wastewater: % Domestic; % Commercial;
100 % Industrial; % Other waste (specify):
2. Please provide a one or two word description specifying the origin of the wastewater,
such as school, subdivision, hospital, commercial, industrial, apartments, etc.:
Stone Washwater
K�
Volume of recycle water generated by this project: 1, 9 20 , 000
gallons per day
4. Explanation of how.recycle water volume was determined- 2000 GPM X
60 Min/Nr X 1Hr Max/Operating Day
5. Brief project description: Modification of Quarry
Washwate.r Recycle System
IV. DESIGN INFORMATION
1. Provide a brief listing of the components of the recycle facilities, including dimensions,
capacities, and detention times of tanks, pumping facilities, high water alarms, filters,
ponds, lagoons, etc.: See A t t a r h P rl R e q, R c t-
0a
3
Name of closest downslope surface waters: cedar Creek
-Classification of closest downslope surface waters: B-NSW
(as established
by the Environmental Management Commission & specified on page 4 of this
application).
4. If a power failure at the facility could impact waters classified as WS, SA, B, or
SB, describe which of the measures are being implemented to prevent such impact, as
required in 15A NCAC 2H .0200: No Impact Possible - _
Gravity System
5. The facilities must conform to the following buffers (and all other applicable buffers):
a) 400 feet between a lagoon and any residence under separate ownership;
b) 100feet between a surface sand filter and any residence under separate ownership;
c) 100 feet between recycle facilities and a water supply source;
d) 50 feet between the recycle facilities and property lines;
•
•
s
2of7

r�
U
•
•
RECYCLE FACILITIES
PAGE- 3 (4/91)
6. If any of the buffers specified in no. 5 above are not being met, please explain how the
proposed buffers will provide equal or better protection of the Waters of the State with
no increased potential for nuisance conditions: A I l Buffers Met
7. Are any components of the recycle facility located within the 100-year flood plain?
yes; X no. If yes, briefly describe the protective measures being taken to protect
against flooding.
THIS APPLICATION PACKAGE WILL NOT BE ACCEPTED BY THE
DIVISION OF ENVIRONMENTAL MANAGEMENT UNLESS ALL OF
THE APPLICABLE ITEMS ARE INCLUDED WITH THE SUBMITTAL
Required Items
a. One original and three copies of the completed and appropriately executed application form.
b. The appropriate permit processing fee, in accordance with 15A NCAC 2H .0205(c)(5).
C. Five sets of detailed plans and specifications signed and sealed by a North Carolina
Professional Engineer. The plans must include a general location map, a site map which
indicates where any borings or hand auger samples were taken, along with buffers,
structures, and property lines. Each sheet of the plans and the first page of the specifications
must be signed and sealed.
d_ For industrial wastewater, a complete chemical analysis of the typical wastewater
must -be provided. The analysis may include, but shall not be limited to, Total .Organic
Carbon, BOD, COD, Chlorides, Phosphorus, Nitrates, Phenol, Total Trihalomethanes,
TCLP analysis, Total Halogenated Compounds, Total Coliforms, and Total Dissolved
Solids.
e. If lagoons are a part of the facilities and the recycle water is industrial, provide a
hydrogeologic description of the subsurface to a depth of 20 feet or bedrock, whichever is
less. The number of borings shall be sufficient to define the following for the area
underlying each major soil type at the site: significant changes in lithology, the vertical
permeability of the unsaturated zone, the hydraulic conductivity of the saturated zone, and
the depth of the mean seasonal high water table.
f. Five copies of all reports, evaluations, agreements, supporting calculations, etc.,,Jmu tAb'A�
submitted as a part of the specifications which are signed and sealed, by a Nor�h�arolina
Professional Engineer. Although certain portions of this required s0ffiiital must b06
developed by other professionals, inclusion of these materials under the signature and`'seal
of a North Carolina Professional Engineer signifies that he has reviewed tlilspatenal and _J
has judged it to be consistent with his proposed design. �• �'p` 0!
g. Five copies of the existing permit if a renewal or a modification. G
3 o f 7

RECYCLE FACILITIES
PAGE 4 (4/91)
TO: REGIONAL WATER QUALITY SUPERVISOR •
Please provide me with the classification of the surface waters identified in number 5
below and on the attached map segment:
Nameofsurfacewaters: Cedar Creek- Tributary of Neuse Rivar-Bakin
Classification (as established by the Environmental Management Commission): B-NSW
Proposed Classification, if applicable:
Signature of regional office personnel: from NPDES Permi r Date:
# NC 0061549
INSTRUCTIONS TO ENGINEER
In order to determine whether provisions for dual or standby power may be required for the
subject facility, the classification of the closest downslope surface waters (the surface waters that
any overflow from the facility would flow toward) must be determined. You are required to
submit this form, with items I through 10 completed,•to the appropriate Division of Environmental
Management Regional Water Quality Supervisor (see attached listing). At a minimum, you must
include an 8.5" by I I" copy of the portion of a 7.5 minute USGS Topographic Map which shows
the subject surface waters. You must identify the location of the facility and the closest downslope
surface waters (waters for which you are requesting the classification) on the submitted map copy.
The application may not be submitted until this form is completed and included with the submittal.
1. Applicant (corporation, individual, or other ):Carolina Sunrock Corporation •
2. Name and Complete Address of Engineering Firm: Carolina Sunrock Corporation
P. 0. Box 25, 1001 West B Street
City: Butner State: N. C • Zip: 27509-0025
Telephone No. 919 - 5 75 - 45 0 2
3. Project Name: Butner Quarry - Washwater Recycle System
4. Storage Facility Volume: 2,946,488 gallons
5. Name of closest downslope surface waters: Cedar Creek
6. County(s) where project and surface waters are located: Granville
7. Map name and date: Northeast Durham Quadrangle- - 1973 1987
8. North Carolina Professional Engineer's Registration No. `r s z o
9. Print Name of Engineer L c, u , e M. W R l � e ar`s I (J-Y
10. Seal and Signature (specify date):
•1� � V %j /i llf
d.�
4 of 7
Jim,.t�t�`'
U

® DIVISION OF ENVIRONMENTAL MANAGEMENT REGIONAL OFFICES (4/91)
Asheville Regional WQ Super.
Washington Regional WQ Super.
Raleigh Regional WQ Super,
59 Woodrin Place
P O Box 1507
3800 Barrett Dr., Suite 101
Asheville, NC 28802
Washington, NC 27889
Raleigh, NC 27609
704/251-6208
919/946-6481
919f733-2314
Avery Macon
Beaufort Jones
Chatham Nash
Btmcombe Madison
Bertie Lenoir
Durham Northampton
Burke McDowell
Camden Martin
Edgecombe Orange
Caldwell Mitchell
Chowan Pamlico
Franklin Person
Cherokee Polk
Craven Pasquotank
Granville Vance
Clay Rutherford
Currituck Perquintans
Halifax Wake
Graham Swain
Dare Pitt
Johnston Warren
Haywood Transylvania
Gates Tyrell
Lee Wilson
Henderson Yaney
Greene Washington
Jackson
Hertford Wayne
Hyde
Fayetteville Regional WQ Super.
Mooresville Regional WQ Super.
Wilmington Region. WQ Super.
Wachovia Building, Suite 714
919 North Main Street
127 Cardinal Drive Extension
Fayetteville, NC 28301
Mooresville, NC 28115
Wilmington, NC 28405-3845
919/486-1541
704/663-1699
919/395-3900
Anson Moore
Alexander Mecklenburg
Brunswick New Hanover
Bladen Robeson
Cabamis Rowan
Carteret Onslow
Ctunberland Richmond
Catawba Stanly
Columbus Pender
Harnett Sampson
Gaston Union
Duplin
Hoke Scotland
h-edell Cleveland
Montgomery
Lincoln
Winston-Salem Regional WQ Super.
8025 North Point Boulevard, Suite 100
Winston-Salem, NC 27106
9191761-2351
Alamance Rockingham
Alleghany Randolph
Ashe Stokes
Caswell Surry
Davidson Watauga
Davie Wilkes
Forsyth Yadkin
Guilford
•
5of7

RECYCLE FACILITIES
PAGE 6 (4/91)
Name and Complete Address of Engineering Firm: Carolina Sunrock Corporation
P. 0. Box 25, 1001 West B Street
City: Butner
Telephone No. 919-575-4502
Professional Engineer's Certification:
S tate:
N. C
1, L o L" e /" I. Sr , attest that this application for
Zip: 27509-0025
Co—eG"--�-+U-% has been reviewed by me and is accurate
and complete to the best of my knowledge_ I further attest that to the best of my knowledge the
proposed design has been prepared in accordance with the applicable regulations. Although certain
portions of this submittal package may have been developed by other professionals, inclusion of
these materials under my signature and seal signifies that I have reviewed this material and have
judged it to be consistent with the proposed design.
North Carolina Professional Engineer's Registration No. 7 -5 z U
Print Name of Engineer
51 `tyt111 t7 ),r !.
CHKG
Seal.and Signature (specify date):
7520
c,
!!lf +71111 i�1titi�`
Applicant's Certification:
I, L o,,, e. /` l- wa li-c--s �9�- , attest that this application for C—
SvL.%v-ac.IC ce,-0owa7�o"l
has been reviewed by the and is accurate and complete to the best of my knowledge. I understand
that if all required parts of this application are not completed and that if all required supporting
information and attachments are not included, this application package will be returned as
incomplete.
Signature Date / z 7��
THE COMPLETED APPLICATION PACKAGE, INCLUDING ALL SUPPORTING
INFORMATION AND MATERIALS, SHOULD BE SENT TO THE FOLLOWING ADDRESS:
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
•
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
512 NORTH SALISBURY STREET
RALEIGH, NORTH CAROLINA 27626-0535 •
TELEPHONE NUMBER: 919/733-5083
6of7

RECYCLE FACILITIES
PAGE- 7 (4/91)
PERMIT APPLICATION PROCESSING FEES
(effective October 1, 1990)
CATEGORY NEW APPLICATIONS RENEWALS WITHOUT
MODIFICATIONS MODIFICATIONS
> 1,000,000 GPD
Industrial $400 $300
Domestic/Cooling Water $400 $300
10,001 - 1,000,000 GPD
Industrial $400 $250
Domestic/Cooling Water $400 $250
1,001 - 10,000 GPD
Industrial $400 $200
Domestic/Cooling Water $400 $200
< or = 1,000 GPD and
Single Family Dwelling $240 $120
Sludge < or = 300 Acres $400 $250
Sludge > 300 Acres $400 $250
Sewer Extensions
(nondelegated) $400 0
Sewer Extensions
(delegated) $200 0
Closed -Loop Recycle
or Evaporative $400 $200
NOTE: The Fees for Soil Remediation Projects are the same as for Sludges.
Under the Sewer Extension Fee, "delegated to municipalities" applies
only to those 'governmental jurisdictions that have specific delegation
review authority, as granted by the Division of Environmental
Management.
7 of 7

•
REQUEST TO MODIFY THE
WASHWATER RECYCLE SYSTEM
AT
CAROLINA SUNROCK CORPORATION
BUTNER QUARRY
GRANVILLE COUNTY
NORTH CAROLINA
PERMIT NO. WQ0002831
DECEMBER 7, 1992
Prepared by:
R. F. Hoffman
Checked by:
Louie M. Walters, Jr. PE
't51f41llllfl
C
� 0'
7520 l
Vd 1

•
INTRODUCTION
This request is to modify the Washwater Recycle System
at Carolina Sunrock Corporation's Butner Quarry. The
existing system was permitted and constructed in 1985. The
new system will perform the same function as the existing but
allow for increased plant production with lower maintenance
costs. The new system will be located adjacent to the
existing system (see attached drawing 92-221). There will be
no change in distances to down slope water ways.
DESIGN INFORMATION
The new system will be comprised of 4 settling ponds and
1 finish, gathering pond (see drawings 92-221 & 92-222). The
return water from the stone processing plant will be
conducted by 18" Corrugated Metal Pipe (CMP) to a concrete
flow diverter box. There will be a diverter box at the head
end of each settling pond. The diverter box will send the
return water to the pond at the diverter box or on to the
next diverter box and pond. Only one settling pond will be
used at a time. The water will enter the settling pond and
slow down because of the pond size. The water will be
retained in the settling pond, depending upon the flow rate
and pond condition, between 1.3 to 11 hours. This amount of
® time and with the use of the NALCO coagulant, will allow the
rock fines to settle out and the water to clarify. The water
will flow out the settling pond over an adjustable weir into
the finish, gathering pond. This finish pond will retain the
water for another 3 to 6 hours. The pond dimensions,
capacities and detention times are attached.
The water will be pumped back into the stone processing
plant by 2 - Crane Deming, figure 5062 pumps with 40 Hp
electric motors. The pumps are rated at 600 GPM at 182 ft.
of head each. The water supply line from the pumping station
to the stone processing plant will be 6" and 811 diameter
schedule 40 pipe. The new supply line will connect into the
existing water system near the base of the wash screen.
The processing plant will not change. The existing wash
screens, supply / return piping and sand dewaterer will
remain.
No high water alarms will be required since the system
is designed to operate on gravity. All water is treated by
the time it passes through the settling ponds. The finish
pond collects the treated water as a safety measure. Anv
discharges due to rain fall runoff will be sent throu+
PAGE 1 of 11

0
•
the settling ponds as normal flow, then through the finish
pond. If the finish pond then becomes over full, the excess
flow from this pond returns to the old quarry through a 24"
CMP drain. The old quarry provides for a further detention
time and settling of any remaining rock fines in the process
water. Both the settling ponds and the old quarry contain a
volume greater than the required 10 year, 24 hour storm event
as required by current regulations. All make up water for
the washwater system is pumped up from the old quarry.
No back up electric system will be required since the
system is gravity operated. The water pumps are used only to
supply water to the processing plant and the water is gravity
returned.
CONSTRUCTION
The settling ponds will be built upon undisturbed earth
and fill. Since the washwater system is handling only
processed rock fines, no ground water contamination is
possible. The bed rock under lying the settling ponds is a
Diabase Traprock of massive structure. There are very few
joints and seams. The existing quarry has very little inflow
of ground water. The water that is pumped from the quarry is
mostly storm run off. With the Diabase under the ponds, no
ground water in flow is expected from the ponds.
The ponds sides will be constructed of materials
borrowed from the site. All fills will be compacted to 95%
of maximum Proctor density. The bottoms and sides will then
be lined with compacted ABC to form an impermeable layer.
The overflow weirs will be constructed of concrete and wood.
Any areas where there is a possibility of erosion will be
either concrete lined or treated with erosion control stone.
The water freeboard and elevations will be maintained as
shown on the attached drawings. The weir flow design is
attached.
The ponds numbered 1, 2, & 5 will be constructed first.
The existing ponds will then be drained into the new settling
ponds no. 1 & 2 and the new system placed into operation.
The old ponds will then be backfilled and reclaimed for stone
storage and stockpiling. Ponds no. 3 & 4 will then be
constructed as shown on the drawings.
PAGE 2 of 11

0
C7
C,
OPERATION
The settling ponds no. 1 through 4 will be operated one
at a time. The return water from the stone processing plant
will be gravity fed into one pond and the rock fines allowed
to settle out. The treated water will then flow over the
weir at the end of the settling pond into the finish pond.
When the pond in operation fills to 3/4 full of rock tines,
the return water will be diverted to the next pond. The
first pond will then be allowed to settle further. A
portable pump will then be used to empty the excess water
from the first pond into the operating pond. As the first
pond continues to settle and the rock fines begin to dry, the
rock fines will be removed by mechanical means and trucked to
a storage area on the site. The rock fines when dried will
then be either sold for use as fill or used on site for
construction projects around the quarry.
The rock fines from the ponds do not contain any
hazardous wastes. These fines are an extremely pulverized
version of the Diabase Traprock being mined on the site for
use in roads, buildings, and industrial processes.
As each pond is in operation, another pond will be
prepared for use in the next cycle. This cycling will
continue between the four settling ponds.
The NALCO 9152 coagulant will continue being used to
help the rock fines to settle out. The relocated ponds,
being larger in capacity, should require a lower application
rate of the coagulant due to the longer detention time.
PAGE 3 of 11

•
•
•
CALCULATIONS
Storm water holding Capacity:
Design for a 10 year, 24 hour storm event:
Drainage area: 5.03 Ac. digitized
10 yr, 24 hr storm: 5.5"
Total Volume:
fig. 8.03j *
5.03 Ac (43,560 SF/Ac) (5.5" / 12"/FT)
= 100,424 CF Storm Runoff
Ponds 1 through 5 Design Storm Volume: (see
attached
sheet)
148,697 CF > 100,424 CF
Piping Head losses:
Suction: 15' max. elev. diff.
friction: 40'
10'
Equivalent length of pipe: 50'
(501) x (6.2) = 3.1'
100'
Pump Discharge:
OK
pipe 6110
900 ell
(friction loss
for 6110 pipe
at 1000 gpm
= 6.2 ft.
100t)
friction: 10' pipe 6"
4' 6" valve
39' 6" check valve
10' 900 ell
Equivalent length of pipe: 63'
6f 3') x (6.2) = 3.9'
100'
* Note: All figures and tables refer to the North Carolina
Erosion and Sediment Control Planning and Control Manual A
PAGE 4 of 11

LJ
0
•
Line to plant:
Static head: 80'
friction:
400' pipe 8"
12' 900 ell
Equivalent length of pipe: 412,
(friction loss
4( 12') x (6.0) = 24.72' for 8110 pipe
100, at 2000 gpm
use = 25' = 6.0 ft.
Total Dynamic Head:
15' + 3.1' + 3.9' + 80' + 25' = 127'
From attached pump chart:
At 127 ft. head:
appox: 840 gpm for each pump.
Gravity return line sizing:
Use corragated metal pipe:
Q = 2000 GPM max.
= 4.46 Cf. / Sec,
use = 4.5 CFS
n = 0.024 for Mannings formula
Use Mannings Nomograph:
try s = 0.001 = 24"
try s = 0.005 = 19"
try s = 0.010 = 16"
use 18" 0 at 0.01 slope OK
PAGE 5 of 11
100 t
M
cvoa 1 f05

0 0 0
SETTLING
SETTLING
SETTLING
SETTLING
TIME
TIME
TIME
TIME
WATER FLOW
WATER FLOW
EMPTY
114 FULL
112 FULL
314 FULL
SQ. FEET:
ACRES:
VOLUMES:
GPM
CFM
HRS:
HRS:
HRS:
HRS:
AREA NO.
1
SETTLING
POND
AREA AT TOP OF BERMS:
13,0G0.00
0.298
89,560.00
CF.
2,500,G0
334.22
4.47
3.35
2.23
1.12
STORM HOLDING
WATER SURFACE AREA:
11,776.00
0,270
3,317.04
CY,
2,000.00
267.3a
5.58
4.19
2.79
1.40
VOLUME: 24,776.00 CF.
BOTTOM AREA:
6,136.00
0.141
669,908.80
GALS.
1,500.00
200.53
7.44
5.58
3.72
1.86
DEPTH:
10.00
(FT.)
11000.00
133.69
11.17
8.37
5.58
2.79
AVG. WATER AREA:
8,956.00
0.206
AREA NO.
2
SETTLING
POND
AREA AT TOP OF BERMS:
13,000-GO
0.298
89,560.00
CF.
2,500.00
334.22
4.47
3.35
2.23
1.12
STORM HOLDING
WATER SURFACE AREA:
11,776.00
0.270
3,317.04
CY.
21000.00
267.38
5.58
4,19
2.79
1.40
VOLUME: 24,776.00 CF.
BOTTOM AREA:
6,136.00
0.141
669,908.80
GALS.
1,500.00
200.53
7.44
5.58
3.72
1.86
DEPTH:
10.00
(FT.)
1,000.00
133.69
11.17
8.37
5.58
2.79
AVG. WATER AREA:
a,956.00
0.206
AREA NO,
- 3
SETTLING
POND
AREA AT TOP OF BERMS:
12,460.00
0.286
85,635.00
CF.
2,500.00
334.22
4.27
3.20
2.14
1.07
STORM HOLDING
n
WATER SURFACE AREA:
11,278.00
0,259
3,171.67
CY.
2,000.00
267.39
5.34
4.00
2.67
1.33
VOLUME: 23,738-00 CF.
r
BOTTOM AREA:
5,849.00
0.134
640,549.80
GALS.
1,500.00
200.53
7.12
5,34
3.56
1.78
DEPTH:
10.00
(FT.1
1,000,00
133.69
10.68
8.01
5.34
2.67
AVG, WATER AREA:
8,563.50
0.197
AREA NO,
4
SETTLING
POND
AREA AT TOP OF BERMS:
12,015.00
0.276
82,465.00
CF.
2,500.00
334.22
4.11
3.0a
2.06
1.03
STORM HOLDING
WATER SURFACE AREA:
10,870.00
0.250
3,054.26
CY.
2,000.00
267.38
5.14
3.86
2.57
1.29
VOLUME: 22,885.00 CF.
BOTTOM AREA:
5,623.00
0.129
616,838.20
GALS.
1,500.00
200.53
6.85
5.14
3.43
1.71
DEPTH:
10.00
iFT.)
1,000.00
133.69
10.28
7.71
5.14
2.57
AVG. WATER AREA:
8,246.50
0,189
AREAaq�
5
COLLECTING POND
AREA AT TO.t}QF 0ERMS:
19,974.00
0.459
52,712.00
CF.
2,500.00
334.22
2.63
1.97
1.31
0.66
STORM HOLDING
W06ING WATER SURFA6K:
10,530.00
0.242
1,952.30
CY.
2,000.00
267.38
3.29
2.46
1.64
0.82
VOLUME: 52,522.00 CF.
B�'TOM�AREA:
2,648.00
0.061
394,285.76
GALS.
1,500.00
200.53
4.38
3.29
2.19
1.10
8.00
(FT.1
1,000.00
133.69
6.57
4.93
3.29
1.64
AVG, Wd KING K#ER AREA:
6,589.00
0.151
OVER FLOW
TOTAL STORM
HOLDING
VOLUME: 148,697.00 CF.
OVERFOW SURFA E AREA:
15,731.00
0.361 HOLDING VOLUME:
NOTE: 2500
GPM. FLOW RATE
IS FOR REFERENCE
ONLY.
AVG. VER FLU AREA.
13,130.50
0.301
52,522.00
CF.
1,945.26
CY.
392,864.56
GALS.

ul
OPERATING
RANGE:
{
•
WEIR FLOW RATES
h
Hd
L
Cw
Q
inches
FEET
FEET
CPS
GPM
3.000
10.0
45.0
3.2185
1.8.104
8125.14
2.875
10.0
45.0
3.2181
16.982
7621.66
2.750
10.0
45.0
3.2177
15.885
7129.11
2.625
10.0
45.0
3.2173
14.812
6647.74
2.500
10.0
45.0
3.2168
13.765
6177.80
2.375
10.0
45.0
3.2164
12.744
5719.56
2.250
10.0
45.0
3.2160
11.750
5273.32
2.125
10.0
45.0
3.2156
10.783
4839.41
2.000
10.0
45.0
3.2152
9.844
4418.17
1.875
10.0
45.0
3.2148
8.935
4009.99
1.750
10.0
45.0
3.2143
8.055
3615.28
1.625
10.0
45.0
3.2139
7.207
3234.51
1.500
10.0
45.0
3.2135
6.391
2868.20
1.375
10.0
45.0
3.2131
5.608
2516.92
1.250
10.0
45.0
3.2127
4.860
2181.34
1.125
10.0
45.0
3.2122
4.149
1862.22
1.000
10.0
45.0
3.2118
3.477
1560.44
0.875
10.0
45.0
3.2114
2.845
1277.03
0.750
10.0
45.0
3.2110
2.258
1013.27
0.625
10.0
45.0
3.2106
1.717
770.72
0.500
10.0
45.0
3.2102
1.229
551.41
0.375
10.0
45.0
3.2097
0.798
358.11
0.250
10.0
45.0
3.2093
0.434
194.90
0.125
10.0
45.0
3.2089
0.154
68.90
h= WATER DEPTH OVER WEIR
Hd= WATER DEPTH AT WEIR
L= LENGTH OF WEIR
Cw= CALCULATED FACTOR
Q= WATER FLOW IN CUBIC FEET PER SECOND
GPM= WATER FLOW IN GALLONS PER MINUTE
Pg 7 of I I

1,500 2,400
O.Oa4 0, 5 0.4
2,000
0.005 0.3
1.000 1,500
$00 0.006 0.6 0.2
0.007
600 1,000 o.008 0.7
500 800 0.009 0.1
400 0.01 0.8 0.08
600
30-0 500 0.9 0.06
0.05
400 1.0
- a.oa
200 20
300 0.02 0.03
C� v
15 °'
200 �� 0.02
v
100 a 0.03 " 0. 0 O
7
80 10 -5 1'5 J 0.01
100 9 .a M 0.008
60 a
0
50 80 96 8 0 0.10 0.05 0.006rtt, �� p• Q C)84 7 [ 0.08 0.005
>, 40 60 72 6 v � 0.05 0/ 0.004
R � O. W w
30 50 0 60 5 T. DIO'>Lq 0.05 0.003
-0,
04 0.
a 40 v 54 4 - p '�.
N
0 20 0 c 48 4 b a 0,1 _ 0.002
�a '42
L _C� C O
o Cu 33,3_ 5 3 001
20 Qj
�o
10 a o 27 11 n 0.0008 a a. T� \j
V
8 C ±; 24/ ` e 0 006 0' Z 0.0006
10 ai 61 21 4 C 0.0005
6 °°/ �/� `° 0.0004
5 8 u/ 0.0003
y+ o
4 6 �u 5
0.4 0.0002
C 3 -o
4 12 0.5
6
2 3 10 0.6 0.0001
g 0.7 0.00008
2 4 9 7
0.00006
1.0 6 1.0 8 0.00005
0.00004
0.8 a 9 0.00003
0.6 1.0 °.-'
0.5 0.8 4 c 10 0.00002
v
0.4 0.6 a' 2
0.3 0 5 0.00001
0.4 3 0.000008
0.2 0.3 15 0.000006
4 ��05
0,131 0.2 5 18 000004
Alignment chart for energy loss in pipes, for Manning's formula. FILES
Note: Use chart for flow computations, hl,,=S GEN�RPL
Figure 3-29a Nomograph for solution of Manning's formula.

L) 7'
NORTHEAST DURHAM QUADRANGLE
NORTH CAROLINA 4A
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SUPPLY LINE
GRAVITY RETURN LINE
SETTLING POND FLOW
WASH SCREEN
SAND DEWATERER
6" PVC RETURN LINES
6' PIPE 18' CMP RETURN LINE
1
_ --- SPRAY BARS ` r \ `PONDS
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