NC0083780_Complete File - Historical_20171231 (2)

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ENGINE AND ENVII
NIA L tl)WILTING
Mr. Jay Lucas
NCDEHNR
P.O, Box 29535
Raleigh
NC 27626-0535,
N.C. DI PT. OF
ENVIRONMENT, IIF'.,',,:."•-'t
& NATURAL iE,::tiit^
NOV 2 4 1993
DIVISION Of ENYIROWMAL itAtAGEMENT
MOORESVILLE REGIONAL OTRCE
3680 LAKEVIEW DRIVE
PFAFFTOVriN, N.(. 27040 U.S.A.
PHONE: [phone]
FAX: [phone]
November 21, 1993.
Application No, NC0083801 Newton Facility, American Concrete Products, Inc.
Application No. N 0083' 80, Hick F ility, rican Concrete ucts, Inc,
Dear Mr. Lucas:
I am writing to advise you of some decisions taken recently in respect to the referenced
NPDES permit applications.
During a recent review of process and storm water discharges at the Hickory and Newton
facilities conducted with Mr, Michael Parker of the Mooresville Regional Office it was
agreed that a more appropriate course of action would be to separate the process and
storm water discharges and recycle the process water so that the discharge will be
eliminated. Conceptual plans for the engineering work to accomplish this were reviewed
with Mr. Parker on November 17th and it was agreed that these were appropriate to
accomplish the desired objective.
The proposed solution is to separate process and storm water by constructing a series of
berms to deflect storm water around those areas where process water is discharged, and to
construct retention and recycling systems for the process water, which will then be reused
in the concrete manufacturing process. In this way all discharges of process water to the
surface waters will be eliminated. Consequently the requirement to obtain NPDES permits
for the discharge of process water will be voided,
As you will note from Application No. NC0083780, the Hickory facility already operates
a recycle system that is permitted under Permit No. WQ0004266, therefore only the
Newton facility will require a new recycling system.
We respectfully request that you:
1. Void the NPDES permit application for the Hickory facility and refund the
application fee to the undersigned.

- 2. Void the NPDES permit application for the Newton facility and credit the
- application fee towards our application for a recycle facility. The permit application is
currently being prepared and will be forwarded to you in due course. • .
•
I trust that you will agree that this is a preferable course of action for American Concrete
Products, Inc. since it will entirely eliminate process water discharges from the two plants.
- If you have any 'questions or connnents concerning this letter please contact the
undersigned.
Yours sincerely,
Dr. David P. Boden.
•
•
•
cc. ' Mr. Michael Parker, NCDEHNR Mooresville Regional Q ice.
Mr. Andy Stankwytch, American Concrete Products, Inc.
•

ENTAL CtlttSUITIN
Mr. Michael Parker
NCDEHNR
919 North Main Street
Mooresville
North Carolina 28115,
Dear Mr, Parker:
3680 LAKEVIEW DRIVE
PFAFFTOWN, N.C. 21040 U.S.A.
PHONE: [phone]
FAX: [phone]
November 9, 1993
I am writing to outline in concept form our plans for the separation of process water and
storm water at,the Hickofylind Newton plants of American Concrete Products, Inc. At
both of these plants there is some mixing of process and storm water which, on occasion
results in discharges to the local surface waters. The discharge of storm water will be
regulated by the General Permit for our industry group and we were in the process of
making an application for a permit to discharge process water from both plants
(Application Nos. NC0083801 and NC0083780). At the recent meeting with Mr. Andy
Stankwytch you requested that we draw up plans to separate storm water from process
water and recycle the process water so that process water permits would not be required.
We agreed to study this and, following our investigation, we believe that your suggestion
is feasible. We, therefore, would like you to review the following conceptual plans. If
these meet with your approval we will proceed to draw up full engineering plans.
1. Hickory:
Please see attached concept sketch.
There are three sources of process water at the site. These are:
the concrete manufacturing plant
- the truck bowl cleaning operation
- the concrete reclamation facility.
Water from these sources is collected in a retention pond for recycling.
The topography of the plant is such that storm water flows through the concrete
manufacturing plant and also across the plant yard into the retention ponds. During
periods of heavy rain, this storm water causes the retention ponds to overflow resulting in
discharges of mixed storm water and process water to Lyle Creek.

Our plan is to construct berms around the concrete manufacturing plant and the concrete
reclamation plant to divert the storm water away from the sources of process water. Truck
washing will be conducted inside the berm that surrounds the retention pond so that all
run-off from this operation will be trapped in the ponds. Process water from the concrete
plant will be prevented from coming into contact,with storm water by being captured by
.the berm and directed to an underground drain that will convey it to the retention pond. In
•this way all process water will be collected in the retention pond, from which it will be
recycled into the concrete manufacturing process. Storm water from the plant yard will be
diverted around the retention pond by a second system of berms and will be channeled
directly into the feeder to Lyle Creek. •
In this way the mixing of storm and process waters will be eliminated, storm water will be
directed into the Lyle Creek feeder and process water will be recycled into the concrete
- plant. • - _ - -
The storm water will be regulated by the General Industry NPDES Storm Water Permit
and, since there will be no discharge of process water, a NPDES Process Water Permit
should not be required. -
2. Newton
Please see attached concept sketches.
There are two sources of process water at the site. These are:
- the concrete manufacturing plant
- the truck bowl cleaning operation.
Water from the concrete plant flows through a concreted channel into a retention system
for clarification arid, ffrom,there into McLin Creek. Water from the truck bowl cleaning
operation is collected in a retention pond where the solids are allowed to settle before they
- are pumped out and stored on the site for future use as landfill.
The topography of the site'is"such that during heavy rain storm water flows into the
concreted channel where it is mixed with the process water and is subsequently discharged -
into McLin Creek. Storm water also flows into the truck wash retention pond which
causes it to overflow into the creek. • - •
•

Truck cleaning to remove residual concrete will be discontinued at this site and will be -
transferred to the Hickory facility. This will eliminate one of the sources of process water.
-A berm will be constructed along the concreted channel to divert storm water run -off -from
the plant yard away from the process water. A new -retention pond system will be : -
constructed alongside the existing process water drain to trap and clarify process water for
,recycling into the concrete manufacturing process. This will be achieved by increasing the
height of the concrete retaining wall along the existing drain and excavating new
settlement ponds parallel to the drain. We estimate that the new retention system will be
approximately 15 feet wide' by 25 feet long.. It will be composed of two chambers, the =
primary chamber being 10 feet long and 6 feet deep, and the secondary chamber being 15
feet long and decreasing in depth from 6 feet to ground level. Water from the secondary
chamber will be pumped to the concrete plant for re -use.
We believe that these changes will effectively separate process water and storm water. All
storm water will be discharged into McLin Creek while all process water will be recycled.
•
The storm water discharge will be regulated by the General Industry NPDES Storm Water
Permit and, since there will be no discharge of process water, a NPDES Process Water
Permit should not be required.
We would like to meet with you to review these concepts to ensure that they satisfy your .
requirements. If you approve them, we will proceed to prepare full engineering plans.
I would like to assure you that American Concrete Products, Inc. wishes to work with you
in a timely manner to resolve this situation. -
Yours jncerely,
Dr. David P. Boden
•

HICKORY PLANT

NEWTON PLANT
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RETENTION
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RET4NTION POND
NEW BERM
TRUCK RAMP
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STORM WATER
FLOW ROUTES
CONCRETE
PLANT
OFFICE
STREET

NEW RETENTION POND -- NEWTON PLANT
•
•
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14" RCP
PLAN ELEVATION
A.
15'
EXISTING CONCRETE DRAIN
10'
END ELEVATION
15'
15'
SEAL EXISTING
.411E- WALL BUILT
UP 3'
EXISTING
CONCRETE
DRAIN

NEW RETENTION POND -- NEWTON PLANT

5083.
Enclosu
State of North Carolina
Department of Environment,
Health ant Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
November 29, 1993
Mr. David P. Boden
American Concrete Produc
P. O. Box 835
Statesville, NC 28687
11993
Subject: NPDES Pennit Application Return
NC0083780
American Concrete Prod. - Hickory
Catawba County
Dear Mr. Boden:
On November 24, 1993 the Division of Environmental Management received your
request for return of application number NC0083780 for your Hickory facility. The subject
application is enclosed and the $400.00 fee will be returned under a separate cover,
If in the future, you determine that you wish to have a discharge, you roust first
apply for and receive a new NPDES permit. Discharging without a valid NPDES permit wil
subject the discharger to a civil penalty of up to $10,000 per day.
If you have any question regarding this matter please contact Jay Lucas at (919) 733-
cc: TOM. lle Regional ftc
Pe it File
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
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