WQ0006847_Final Permit_19920918

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor A. Preston Howard, Jr., P.E.-
William W. Cobey, Jr., Secretary Acting Director
September 18, 1992
Mr. Steve Chappell
Martin Marietta Aggregates, Buchanan Quarry
Post Office Box 30013
Raleigh, North Carolina 27622
Subject: Permit No. WQ0006847
Martin Marietta Aggregates
Buchanan Quarry
Wastewater Recycle System
Guilford County
Dear Mr. Chappell:
In accordance with your application received August 5, 1992, we are forwarding herewith Permit
No. WQ0006847 dated September 18, 1992, to Martin Marietta Aggregates Buchanan Quarry for the
construction and operation of the subject cleanstone washing operation recycle system.
This permit shall be effective from the date of issuance until August 31, 1997, and shall be subject
to the conditions and limitations as specified therein. Please pay particular attention to the monitoring
requirements in this permit. Failure to establish an adequate system for collecting and maintaining the
required operational information will result in future compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have
the right to request an adjudicatory hearing upon written request within 30 days following receipt of this
permit. This request must be in the form of a written petition, conforming to Chapter 150B of North
Carolina General Statutes, and filed with the Office of Administrative Hearings, F.O. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
Regional Offices
Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem
704/251-6208 919/486-1541 704/663-1699 919/571-4700 919/946-6481 919/395-3900 919/896-7007
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Mr. John S at 9191733-5083.
cc: Guilford County Health Department
Winston-Salem Regional Office
Training and Certification Unit
Facilities Assessment Unit

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina
as amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Martin Marietta Aggregates, Buchanan Quarry
Guilford County
10714-r1i�
construction and operation of a 576,000 GPD closed loop stone wash water wastewater recycle system
consisting of two 70 foot by 300 foot by 10 feet deep settling cell lagoons with piping arrangements for
series or parallel operation, a 3.2 million gallon supply pond with a smaller influent pond (18 inch piping
flow from settling ponds), a 1,000 GPM pump station with 8 inch force main to supply the Plant, and all
associated piping, valves, controls and appurtenances to serve Martin Marietta Aggregate's Buchanan
Quarry cleanstone washing operation with no discharge of wastes to the surface waters, pursuant to the
application received August 5, 1992, and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment, Health and Natural
Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until August 31, 1997, and shall be subject
to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans, specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a nacre change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.

5. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with this permit, the approved plans and
specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box
29535, Raleigh, NC 27626-0535.
6. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as
may be required by this Division, such as the construction of additional or replacement
wastewater treatment or disposal facilities.
7. The Winston-Salem Regional Office, telephone number 9191896-7007 shall be notified at
least forty-eight (48) hours in advance of operation of the installed facilities so that an in-
place inspection can be made. Such notification to the regional supervisor shall be made
during the normal office hours from 8:00 am. until 5:00 p.m. on Monday through Friday,
excluding State Holidays.
8. The sludge generated from these treatment facilities must be disposed of in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
9. The issuance of this pernnit shall not relieve the Permittee of the responsibility for damages
to surface or groundwaters resulting from the operation of this facility.
10. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the lagoons, ponds, and cells shall not be less than two feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle facilities to prevent
malfunctions and deterioration, operator errors and discharges which may cause or lead to
the release of wastes to the environment, a threat to human health, or a nuisance. The
Permittee shall keep an inspection log or summary including at least the date and time of
inspection, observations made, and any maintenance, repairs, or corrective actions taken
by the Permittee. This log of inspections shall be maintained by the Perrnittee for a period
of three years from the date of the inspection and shall be made available upon request to
the Division of Environmental Management or other permitting authority.
16. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the recycle system at any reasonable time for the purpose
of determining compliance with this permit; may inspect or copy any records that must be
kept under the terms and conditions of this permit; or may obtain samples of groundwater,
surface water, or leachate.
17. The annual administering and compliance fee must be paid by the Permittee within thirty
(30) days after being billed by the Division. Failure to pay the fee accordingly may cause
the Division to initiate action to revoke this permit as specified by 15 NCAC 2H .0205
(c)(4).
2

18. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6A to 143-215.6C.
19. The issuance of this permit does not preclude the Permittee from complying with any and
all statutes, rules, regulations, or ordinances which may be imposed by other government
agencies (local, state, and federal) which have jurisdiction.
20. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
21. Noncompliance Notification:
The Permittee shall report by telephone to the Winston-Salem Regional Office, telephone
number 9191896-7007 as soon as possible, but in no case more than 24 hours or on the
next working day following the occurrence or first knowledge of the occurrence of any of
the following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such
as the dumping of the contents of a basin or tank; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures
of pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-
pass directly to receiving waters without treatment of all or any portion of the
influent to such station or facility.
d. Any time that self-monitoring information indicates that the facility is not in
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 days following first knowledge of the occurrence. This report must outline
the actions taken or proposed to be taken to ensure that the problem does not recur.
22. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202. Once
the facility is classified, the Permittee must submit a letter to the Certification Commission
which designates the operator in responsible charge within thirty days after the wastewater
treatment facilities are 50% complete.
23. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Commission will review the adequacy of the
facilities described therein, and if warranted, will extend the permit for such period of time
and under such conditions and limitations as it may deem appropriate.
3

Permit isst%d this�the 18th day of September, 1992
AL MANAGEMENT COMMISSION
V �-v- '
A. Preston How r., ,Acting Director
Division of Enviro anacgtent
By Authority of the Environmental Management Commission
Permit No. WQ0006847

Permit No. WQ0006847
September 18, 1.992
Engineer's Certification
1, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project,far the
Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of the approved plans and specifications.
Signature
Date
R
Registration No.

M,
It's,
Jill! 14 1II
4

{ RATING SCALE FOR LASSIFICATION OF FACILITIES
Name of Plant: VY14ZTIN—CY]„�2tETrA , ��C.�tANoN uarcrt
Owner or Contact Person: VM(ta S. W I L -
Mailing Address:sviire ��tn•1('�lctlt+�' �i l0
aunty: QuA l- RR Telephone: `7 I
NPDES Permit Na. NC©Q -7-7Q-TC Nondisc. Per. No. 4j Q s4_
IsslleDate: 11_— "7 —A 9 Expiration Date:
Existing FaRiiliity ts New Facility, V.P carA& 76�
Rated By: k�CL"Date. $ LOO Z. 0 -
Reviewed (Train. & Cert.) eg. Office
Reviewed (Train. & Cert.) Central Office
ORC_ _UAAV a -ij Grade
Plant Class: (circle one)
it III IV Total Points
ITEM POINTS (5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage
(1) Industrial Pretreatment Units and/or (i)Aeration - High Purity Oxygen System ..... 20
Industrial Pretreatment Program Diffused Air System ........... 10
(see definition No. 33) 4 Mechanical Air System (fixed,
(2) DESIGN FLOW OF PLANT IN GPD floating or rotor) .. . ......... .
(not applicable to nonconiaminated cooling waters, sludge Separate Sludge edge Reaeration ..... 3 3
handling facilities for water purification plants, totally (ii) Trickling Filter
dosed cycle systems (def. No. 11), and facilities High Rate ..................
consisting only of Item (4) (d) or Items (a) (d) and (11) (d))
0 -- 20,000 .......................... 1 Standard Rale ............... 5
5
Packed Tower . .. _ .. 5
20.001 -- 50,ODD.......................... 2 (iii) Biological Aerated Filter or Aerated
50,001 — 100,000. 3 sioiogical Filter ...................... 10
100,001 -• 250,000 .......................... 4 (iv) Aeraled lagoons ............ _ ........ . 10
250.001 -- 500,000._._ ......................
500.001 --1,000,000 ..........................(v) (v) Rotating Biological Contactors . 10
1,000,001 —2,000.000 ....................... 1
......
2,000,001 (and up) - rate. 1 point additional for each (vi) Sand Filters -
200,000 gpd capacity up to a intern,itlent biological ..... 2
maximumo 30 /� recirculating biological .. _ .. 3
Design Flow (gpd) S'� 600 Lr1�9 011+W1Sc (vu Stabilization Lagoons ................... r
(3) PRELIMINARY UNITS (see definition no!32) , ,(viii)CIarilier .............................. 5
(a) Bar Screens ................................ 1 (Ix) Single stage system for combined
or carbonaceous removal of BOD and
(b) Mechanical Screens, Static Screens or nitrogenous removal by nitrification
Comminuting Devices ........... ............. 2 (see dei. No. 12) (Points for this Item
(c) Grit Removal ............................... 1 have to be in addition to items (5) (a)
or
n through (5) (a) (vru) ................. a
(d) Mechanical or Aerated Grit Removal ........... 2 (x) Nutrient additions to enhance SOD
(e) Flow Measuring Device ....................... 1 removal ... ........ ... ......... 5
or (xi) Biological Culture ("Super Bugs') addition
(Fj Instrumented Flow Measurement .............. 2 1 to enhance organic compound removal ..... 5
(g) Preaeration ............................ . ... 2 (b) Nitrogenous Stage
(i) Aeration - High Purity Oxygen System ..... 20
(h) influent Flow -Equalization ................... 2 Diffused Air System ........... 10
(i) Grease or Oil Separators - Gravity .......... 2 Mechanical Air System (fixed,
Mechanical .......... 3 floating, or rotor) ...... ... _ .. B
Dissolved Air Flotation. 6 Separate Sludge Reaeration ..... 3
@ Prechlorinatlon .............................. 5 (ii) Trickling Filter -
High Rate . 7
(4) PRIMARY TREATMENT UNITS Standard Rale ............ 5
(a) Septic Tank (see definition no. 43) .............. 2 Packed Tower............ 5
(b) Imhoff Tank .................................. 5 (Iii) Biological Aerated Filter or Aerated
(c) Primary Clarifiers .. ........ .... 5 Biological Filter ......................... 10
(d) Seilling Ponds or Settling Tanks for Inorganic (iv) Polaling Biological Contactors ............ 10
Non-toxic Materials {sludge handling facilities (v) Sand Filter -
for water purification plants, sand, gravel, intermittent biological ........ 2
stone, and other mining operations except recirculating biological ........ 3
recreational activities such as gem or gold to�'N (vi) Clarifier....... ............... 5

(� T�fiyIARY fDFt J►DVANCEDTFiEAT11ENTt1NiT
(10) 4D EMICAL ADDITION SYSTEM (S) (See defuution No. 9)
(a) Aetivalddt carbon regeneration .................. 5
(not applicable to chemical additions rated as item
withou.
with carbon regeneraf+on .................... 1 S
(9) ). (5) (a) ((6) (e), (6) (b), (7) (b), (e),
Powdered or Granular Activated Carbon feed -
(f;i) (aa), (4) (b), Off {9) (C) 5 Points each: List:
without carbon regeneration ................. 5
. 5
5
with carbon regeneration ..... ............. 1 5
(c) Air StrrPPlng ............................. 5
.... 5
(d) Denitrification Process (separate process)..... 10
(e)
(t 1) IrtIS) Holding 5 IWTS
Foam Separation ..............................�.• 5
(t3(a)
Ponds.
Halting Ponds, Holding~Tanks or Settling Ponds
(g) IonExchainge... •... ....................... 5
lot Organic or Toxic Materials including wastes
(h) UvW Application of Treated Effluent
from mining operations containing nitrogen andlor
(see definiyon no. 22b) (not applicable for
phosphorous compounds in amounts significantly
X". gravel, stone and other similar mWng
greater than is common for domestic wastewater _ _.„.. 4
operations)
(b) Effluent Flow Equalization (not applicable to storage
(7 on agrrarRurafly managed ales (See def.
basins which are inherent in land application systems). 2
No. 4) .................................... 10
(c) Stage Discharge (not applicable to storage basins
(ii) by high rale infiltration on non-agriculturally
managed sites (includes rotary distributors
inherent in land application systems».._.._.....»... __ ......
(d) turps 3
and similar fixed nozzle systems) ........... 4
(e) Stand-By Power Supply
(tri) by subsurface disposal (includes low pressure
(r) Thermal Pollution Control Device._ _ . 3
pipe systems and gravity systems except at
plants consisting of septic tank and nitrifica-
lion fines only) ............................. 4
TOTAL POINTS
{� Mkmscreens.................................. 5
(t) Phosphorus Removal by Biological Processes .
CLASSIFICATION ”
(See def. No. 2S) ............................ 20
(k) Polishing Ponds - without aeration ....... 2
Class 1--------------------- --- 5 - 25 Points dc—
with aeration .......... S
Class 11. 26- 50 Points
{i} Post Aeration cascade .............. 0
Class lll _ „ 51- 65 Points
diffused or me6anical ... 5
Class IV. 68- Up Points
(m) Reverse Osmosis ............................... 5
(n) Sand or Mixed-Media Filters - low rate ........... 2
Facilities having a rating of one through tour points, inclusive,
high rate .......... 5
do not require a certified operator. Classification of all other
(o) Treatment processes for removal of metal or
facilities requires a comparable grade operator in responsible
cyanide .................................... 15
charge.
(p) Treatment processes for removal of toxic
materials other than metal a cyanide ......... 15
Facilities having an activated sludge process will be assigned
a minimum classification of Class Il.
SLUDGE TREATMENT
Facilities having treatment processes for the removal of metal
(a) Sludge Digestion Tank -Heated...............
10 or cyanide will be assigned a minimum classification of Class 11.
Aerobic...............
5
Unhealed.............
3 Facilities having treatment processes for the biological removal
5
(b) Sludge Stabilization (chemical or thermal} .......
of phosphorus will be assigned a minimum classification of Class
(c) Sludge Drying Beds - Grady... .. ........
2 III.
Vacuum Assisted .......
5
(d)Sludge Eluldation .........• • •............ . • • • '
S In-plant processes and related control equipment which are an
(e) Sludge Conditioner (chemical or thermal) ........
5 integral part of industrial production shall not be considered waste
(f) Sludge Thickener (gravity) ......................
5 treatment. Likewise, discharges of wastewater from residences
(g) Dissolved Air Flotation Unit
having a design flow of 1,000 gpd or less, shall not be subject to
(not applicable to a unit rales as (3) (ij .........
ft rating.
(h) Sludge Gas Uli ization (including gas storage) ....
2
(i) Sludge Holding Tank - Aerated................
5 ADQITI.QNALMM
Non-aerated .... ... .
2
67 Sludge incinerator - (not including activated
carbon regeneration) ...
10 '
(k) Vacuum Filter. Centrifuge or Filler Press or other
similar dewatering devices ....................
10
(8) SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons.........................................2Ot.iIY1��
,r
(b) Land Application (surface and subsurface)
(see definition 223)
m y �11Q �� t �n�(�, �Ll�iPtlirll�
-where the facility holds the land app. permit ...
10
-by contracting to a land application operator who
S�pmk ov\
holds the land application permit ... ........
. 2
-land application of sludge by a contractor who does
not hold the permit for the wastewater treatment
faciiily where the sludge is generaled .........
10
(c) Landfilled (burial) .............................
5
(0) D1StNIFECTiON
(a) Chlorination .............................
5
(b) DecNorinalion ........................
5
(c) Ozone ..............................
5
(d) Radiation ..........................
5