5603_ROSCANS_1997

NC DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Solid Waste Management
Solid Waste Section
SOLID HASTE WINAGETENT FACILITY EVALUATION REPORT
Type of Facility,: Persit i' County
Name of Facility Location
Date of Last Evaluation
1. Permit Conditions Followed Yes No N/A
A. Specific Condition(s) Violated
11. Operational Requirements Followed Yes No
15A N-C. Admin. Code 13B Section
A_ Specific Violation(s) by saber and letter.
111. Other Violations of Rule or Law
IV. Evaluator's
V. Continuation Page Required _Yes _No Receiving Signature
Evaluation Date -Y Solid Waste Section
DEHNR 3793 (Part 1 White: Facility Part II Canary: Central Office Part III Pink: Regi mat Office)
Solid Waste Section (Review 7/94)

Waste Management Plan
for
Collins & Aikman Products Co.
Industrial Landfill
McDowell County
Old Fort, North Carolina
Permit No. 5603
June, 1997
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Introduction
This plan was prepared in accordance with North Carolina General Statute 130A-
309.09D(c) for the purpose of meeting our plant carpet waste disposal needs, and
protecting public health and the environment. The plan sections are arranged as
listed in the General Statute.
Through implementation of this comprehensive carpet waste management plan and
the plan updates that will follow every three years, Collins & Aikman will provide
for the management of carpet waste and its reduction for the next 10 years. Our
long range vision is for a waste management program that will provide disposal
capacity, encourage waste reduction at the plant, and increase waste recycling back
into the product.
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Section 1 - Facility Description
Collins & Aikinan owns a landfill in McDowell County approximately three miles
east of the town Old Fort on State Road 1240. The landfill is situated on property
consisting of approximately 85 acres. Access to the landfill is via a gated paved
drive that is locked during non -operating hours. The facility is non -seasonal,
operating year around six days a week except when our plant is closed for holidays
or vacation shutdown. An area map showing the landfill location is included in the
Appendix.
This is a monofill facility for the exclusive use of Collins & Aikman. Only waste
automotive carpet trimmings from our plant in the Town of Old Fort are accepted
here for disposal. There are no other materials or wastes disposed of at tivs landfill.
Collins & Aikman contracts with a private company to manage the landfill. This
company provides manpower, equipment and transportation services for the day-to-
day operation of the landfill. A Collins & Aikman staff associate is currently
registered to attend a Manager of Landfill Operations training and certification
course conducted by SWANA.
Section 2 - Waste Stream Evaluation
The waste stream consists of automotive carpet trimmings from carpet molding
operations. The carpets are constructed using a variety of mostly man made fibers
and backings as specified by our customers. The carpet waste generated by the
plant is separated by fiber content and type of backing. The materials that do not
currently have value as a fuel or are not suitable for recycling are baled for transport
to the landfill.
Section 3 - Waste Reduction Goal
It is Collins & Aikman's goal to reduce the amount of carpet waste being landfilled
by 40% from 1991 levels by the year 2001. Though product mix and business
cycles may impact progress, the company believes the goal to be achievable. The
bar graph included in the appendix depicts the progress of our efforts to reduce the
waste being landfilled.
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Section 4 - Management Options
The options for the management and reduction of carpet waste that are being
evaluated by Collins & Aikman include the following:
a. Waste Minimization - Continue efforts to reduce carpet blank size and
improve quality, resulting in a lower volume of trimmings.
b. Recycling - Continue developing systems and customer acceptance of
recycling material back into the product.
C. Conversion to Fuel - Where waste carpet is not recyclable but has
sufficient heat content (btu), the waste is to be used as fuel provided a
host boiler is available and the process is cost effective.
d. Landfilling - The option of last resort for the disposal of carpet waste
will be landfilling.
Section 5 - Waste Management Strate:?v
The long term goal of Collins & Aikman is to reduce the amount of carpet waste
being landfilled by 75% from 1991 levels by the year 2007. The company strategy
for achieving this goal will be to utilize a combination of the options listed in
Section 4. Emphasis will be placed on waste minimization and recycling.

Appendix
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Collins o Aikman Products Co.
McDowell County, Old Fort, NC
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Collins &
Aikman
ENVIRONMENTAL CREED
® We will operate our facilities in
compliance with all applicable laws and
regulations.
® We will instruct our employees about
their environmental responsibilities and our
commitment to sound environmental practices.
® We will minimize the volume of waste
through source reduction and recycling.
® We will address community concerns
which might arise in the course of our operations
and actively participate in the development of
responsible environmental laws and regulations.
® We will ensure that environmental
impact is an important consideration in all research
and development activities, purchasing and
marketing evaluations and shipping and
warehousing decisions.
Thomas E. Hannah
President and Chief Executive Officer

COLLINS & AIKMAN ENVIRONMENTAL POLICY
It is Collins & Aikman policy to operate all segments of our
business in full compliance with applicable environmental laws and
regulations. We will strive at all times to comply with both the spirit and
the letter of the law.
Our compliance strategy is based on team effort:
❑ Each facility is responsible for compliance with all environmental
regulations at that location. The plants are responsible for possessing and maintaining
necessary permits. They will inform Corporate Engineering of any plans for new
equipment, or changes in processes or chemical formulation which may require air,
water or waste permits.
After review by Corporate Environmental Engineering, all permit applications,
submission of plans, compliance reports and explanatory reports to regulatory agencies
will be signed by the plant manager or his designee.
❑ Corporate staff will provide technical assistance and advise the plants, but
the accountability for compliance will be at the plant level. Corporate staff will provide
technical, administrative and public relations support.
❑ Good communications keep the team going. Corporate Environmental
Engineering is to be kept aware of any situation which might have environment impact.
Issues which require immediate notification include:
a) When a spill occurs which might leave the plant site
b) Any emission which violates a statute and requires immediate reporting
c) When such an incident could result in future actions, such as permit
modification, fines or inquiries from others such as neighbors or the
news media.
❑ If there is any question concerning a potential environment impact,
Corporate Environmental Engineering should be contacted as soon as possible.
EMERGENCY CONTACTS
When engineering contacts must be made with State or Federal agencies,
the Environmental Engineering Department will do so if possible.
The Corporate Director of Public Relations will work closely with plant
management and engineering staff, providing communications expertise and
relieving plant management of the burden of news media contact wherever possible.
The unavailability of the above does nol relieve the affected facility of its
responsibilities in the given areas.

NC DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Solid waste Narugerent
Solid waste Section
SOLID WASTE MAIME)ENT FACILITY EVALUATION REPORT
Type of Facility. Permit f Canty.
Name of Facility- Location
Date of Last Evaluation
I. Permit Conditions Followed Yes No N/A
A_ Specific Condition(s) Violated
11. Operaticnal Requirer is Followed Yes No
15A N.C. /(bin. Code 13B Section
A. Specific Violation(s) by ember and letter.
III. Other Violatiors of Rule or Law
IV. Evaluator's C�ts
Y. Continstion Page Required! Yes _No Receiving Signature_ JL
Evaluation Date Solid Waste Section
DENNR 3793 (Part 1 White: Facility Part 11 Canary: Central office Part Ill Pink: Regional Office)
Solid waste Section (Review 7/94)

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Collins & Aikman_
Collins & Aikman Products Co.
701 McCullough Drive
P.O. Box 32665
Charlotte, NC 28232
[phone]
December 18, 1997
Mr. Dexter Matthews
Department of Environment,
Health and Natural Resources
Division of Waste Management
Solid Waste Section
P.O. Box 27687
Raleigh, North Carolina 27611-7687
Re: Collins & Aikman Industrial Lanrlfrll
McDowell County
Permit No. S6-03
Dear Mr. Matthews:
This letter responds to the Division's September 18, 1996 letter requesting additional information
regarding future development of our landfill. To address the specifics of your request we enclose
the following documents:
Site Development Plan, Sheet 1 of 3
Phase 3 Closure Plan, Sheets 2 and 3 of 3
Water Quality Monitoring Plan with May 1997 analytical results
We expect the current Phase 3 operations will meet our waste disposal needs for the next five
years or through December 31, 2003. The attached construction plans depict the development of
Phase 3 which is an intermediate step to the full development of the current working area. Phase
4 (not shown) is intended for operations after January 2003 and will overlay existing Phase 3 and
previous Phase 2. The maximum elevation of Phase 4 will be determined by how we control
stormwater runoff, but is planned to be approximately 1,550 feet. We will apply for a permit
amendment prior to implementing Phase 4 activities.
We employed the services of S&ME, Inc. to prepare a water quality monitoring plan for the
landfill site. This plan dated May 8, 1997 follows the recommendations of the Solid Waste
Section and is incorporated into the attached Water Quality Monitoring Report as Appendix III.
One new upgradient well and two new downgradient wells were installed, developed and sampled
in May of this year.. The analytical results, reported June 2, 1997 are presented in Appendix IV of
the report. "
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The report shows that there were no volatile organic compounds detected and no metals detected
above 15A NCAC 2L standards in the monitoring wells. Trace amounts of barium, cobalt, zinc,
and vanadium were detected in two surface water samples. These were also found in trace
amounts in the upgradient well. In the light of these findings, Collins & Aikman proposes that
sampling be conducted semi-annually and sampling parameters be limited to these four metals
with no testing for organics.
Should you have any questions or need additional information please call me at [phone].
Sincerely,
Collins & Aikman Products Co.
David N LiVttle
Corporate Engineering
DNL/sr
cc: J. Davis - Old Fort
G. Mackin - SSC
G. Miller - Albemarle
C. Moore - SSC
Enclosures (2)
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