1302 Cabarrus County Type3 Permit_DIN20419_20131127.pdf

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Compost Application November 2013
TABLE OF CONTENTS
1.0 GENERAL PROVISIONS ................................................................................................1 1.1 Project Description.................................................................................................. 1
1.2 Site Requirements ................................................................................................... 2
2.0 FACILITY DESIGN ..........................................................................................................4 2.1 Site Development .................................................................................................... 4
3.0 DESIGN REPORT.............................................................................................................6 3.1 Design Capacity ...................................................................................................... 6
3.2 Material Processing ................................................................................................. 6
3.3 Temperature Monitoring ......................................................................................... 9 3.4 Temperature Control And Aeration ........................................................................ 9 3.5 Service Area .......................................................................................................... 10
3.6 Equipment Requirements ...................................................................................... 10
4.0 CONTAINMENT AND ENVIRONMENTAL CONTROL SYSTEM .......................12
4.1 Groundwater Considerations ................................................................................ 12 4.2 Surface Water Considerations ............................................................................... 12 4.3 Controlling Nuisances And Vectors ..................................................................... 13
5.0 AGROMATTERS CABARRUS ORGANICS RECLAMATION FACILITY
GENERAL OPERATION AND MAINTENANCE .....................................................14
5.1 Plan And Permit Requirements ............................................................................. 14 5.2 Facility Personnel.................................................................................................. 14
5.3 Hours Of Operation............................................................................................... 14
5.4 Drop-Off Area ....................................................................................................... 15
5.5 Aerated Static Pile Process ................................................................................... 15
5.6 Adverse Weather Conditions ................................................................................ 16 5.7 Flow Diagram ....................................................................................................... 16
5.8 Daily Closing Procedures ..................................................................................... 16
5.9 Contingency Plan .................................................................................................. 16
5.10 Facility Maintenance ............................................................................................. 17
6.0 FACILITY OPERATION ...............................................................................................19 6.1 Training Of Facility Personnel.............................................................................. 19
6.2 Entrance ................................................................................................................ 19
6.3 Access And Security ............................................................................................. 19
6.4 Signs ...................................................................................................................... 20
6.5 Waste Acceptance ................................................................................................. 20 6.6 Dust, Litter, Odors, And Vectors .......................................................................... 21
6.7 Monitoring And Testing ....................................................................................... 21
6.8 Reporting............................................................................................................... 22
6.9 Quality Assurance ................................................................................................. 23
7.0 PRODUCT MARKETING AND DISTRIBUTION .....................................................24

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Compost Application November 2013
Table of Contents (continued)

Facility Flow Diagram ...................................................................................................................25

APPENDICES

Attachment A - Proposed Compost Site Aerial
Attachment B - Compost Facility Site Plans, C201 and C202
Attachment C - Soil Testing Results
Attachment D - Zoning Consistency Letter Attachment E - Fire Department Service Letter
Attachment F – Phase 1 and 2 Compost System Construction Plans
Attachment G – ACT Operation and Maintenance Agreement
Attachment H – Compressor and Pump Operation and Maintenance Manuals
Attachment I – Cabarrus County – Agromatters Compost Agreement Attachment J – WSACC Leachate Acceptance Letter

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1.0 GENERAL PROVISIONS

1.1 PROJECT DESCRIPTION

This Application for a Large Type 3 Composting Facility permit for the Agromatters Cabarrus
Organics Reclamation Facility is being submitted by Civil & Environmental Consultants, Inc. on
behalf of Agromatters, LLC. This application meets the composting facility design parameters
and design drawing requirements found in Section .1400 of 15A NCAC 13B of the North
Carolina Department of Environment and Natural Resources (NCDENR) Solid Waste
Management Rules. This application package includes information regarding the site design,
construction and operation.

Project Title: Agromatters Cabarrus Organics Reclamation Facility Property Owner: Cabarrus County Solid Waste
P.O. Box 707
Concord, NC [phone]
Property Owner Representative: Mr. Kevin Grant, County Sustainability Manager
Consulting Engineer: Civil & Environmental Consultants, Inc.
1900 Center Park Drive
Suite A Charlotte, NC 28217
Consulting Engineer’s Scott L. Brown, P.E.
Representative:
Proposed Site Operator: Agromatters, LLC 4441 Irish Potato Road
Concord, NC 28025 [phone]

Operator’s Representative: Mr. Ron Gilkerson, President

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The Agromatters Cabarrus Organics Reclamation Facility is located at the Cabarrus County
Solid Waste Landfill (1302-CDLF-2006) at 4441 Irish Potato Road, in Concord, NC. The
Facility has been permitted as a large Type 1 facility with NC Permit #1302. The facility will
expand current operations and a Type 3 composting permit is being sought. The Type 3
composting facility will be located as shown on the Compost Site Aerial in Attachment A and
Compost Facility Site Plans in Attachment B. The existing facility will be expanded to
approximately 14 acres at the existing Cabarrus County Solid Waste Landfill site and continue to
be operated by Agromatters, LLC. The composting of Type 3 wastes will occur under roof in a
constructed facility utilizing aerated static pile composting technology. The project will be
constructed in two phases. The first phase will include the construction of a covered dumping
pad and a covered four (4) bay composting system. The second phase will include the
construction of a larger compost facility building containing fourteen (14) separate bays. The
Type 3 compost facility buildings will be constructed adjacent to the Type 1 composting area
and include a covered concrete dumping pad and mixing area. Access to the site is provided via
Irish Potato Road. The property is owned by Cabarrus County. The proposed compost facility
will be operated by Agromatters, LLC. Mr. Ron Gilkerson, President (Telephone (980) 721-
3088) will be responsible for daily operations. An agreement for the operation of the facility at
the Cabarrus County Landfill property is included in Attachment I.

1.2 SITE REQUIREMENTS

The Type 3 composting facility will not be located over a closed-out disposal facility. The
composting facility is located in an existing wooded area. This can be confirmed by viewing the
Compost Site Aerial in Attachment A and Compost Facility Site Plans in Attachment B. The
surrounding area consists of woods, vegetation and existing landfill operations. Existing ground
surface elevations of the proposed composting area range from 735 to 760 feet, mean sea level
(MSL). Based on monitoring well readings, a groundwater separation of approximately 44 feet
is provided in the area of the Type 3 composting structures. The property north, east and south
of the composting area is owned by Cabarrus County. Property to the west of the compost area
is private property, but separated from the compost area by a utility easement. The applicable

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buffer requirements are met (see Site Development section 2.1 below) where the composting
facility is surrounded by others.

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2.0 FACILITY DESIGN

2.1 SITE DEVELOPMENT

The site is located within flood zone X per FEMA Map Panel 3710564300J (November 5, 2008),
which is outside of the 100 year flood plain. The proposed design will not result in washout of
solid waste such as to pose a hazard to human life, wildlife, land or water resources. The
composting facility will be located, as required, a minimum of one hundred (100) feet from any
property boundary delineating parcels of land not owned by Cabarrus County. A five hundred
(500) foot minimum buffer between compost areas and residences or dwellings not owned or
occupied by the permittee will be maintained at all times. A one hundred (100) foot buffer will
be maintained between all wells and the compost area, except for monitoring wells. A fifty (50)
foot buffer zone will be maintained between the composting area and perennial streams/rivers.
A twenty-five (25) foot minimum buffer will be maintained between compost areas and swales
or berms to allow for adequate access of firefighting equipment. See Compost Site Aerial in
Attachment A and Compost Facility Site Plans in Attachment B for site buffer measurements.

The composting facility shall be located in accordance with 15A NCAC 2B .0200, Classification
and Water Quality Standards Applicable to Surface Waters in North Carolina. The site will not
cause a discharge of materials or fill materials into waters of the State that would be in violation
of Section(s) 404, and 402 of the Clean water Act, or in violation of the requirements of the
National Pollutant Discharge Elimination System (NPDES). The site will not cause non-point
source pollution of waters of the state that violates assigned water quality standards. The Type 3
composting activities will occur under roof in constructed bays to prevent stormwater contact
with raw and process materials. Additionally the dumping pad and mixing area for Type 3
feedstock materials will be constructed of curbed concrete and covered. A leachate collection
system will be utilized to contain liquid run-off from the compost bins, dumping pad and mixing
areas. The leachate will be recirculated into the composting process. If the leachate tanks must
be emptied, the liquid waste will be transferred via tanker to a wastewater treatment facility
operated by the Water and Sewer Authority of Cabarrus County (WSACC). WSACC has

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provided a letter confirming the acceptance of leachate, and this has been included in Attachment
J.

The site shall not contravene groundwater standards as established under 15A NCAC 2L. The
portion of the site designated for active composting will have a soil texture finer than loamy
sand, and a depth to the seasonal high water table shall be maintained of at least twenty-four (24)
inches, (Type 3 facility). Based on monitoring well readings, a groundwater separation of
approximately 44 feet is provided in the area of the Type 3 composting structures.
(measurements taken and provided by Cabarrus County for MW-A on May 8, 2013). The Type
3 composting activities, dumping pad and mixing area will all be constructed under roof on a
concrete floor with trench drains and a leachate collection system to prevent impacts to the
groundwater.

The proposed compost facility is located on the existing Cabarrus County Landfill site. The 317
acre landfill site was recently rezoned to designation AO-CU. The compost facility is an
approved conditional use under this zoning designation. Cabarrus County zoning department has
provided a letter that states the compost facility is an acceptable use for the property. A copy of
this letter can be found in Attachment D.

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3.0 DESIGN REPORT

3.1 DESIGN CAPACITY

The design capacity of the Type 3 facilities is approximately 13,550 tons per year. The capacity
of the facility was determined using the following process and equipment specifications:
Phase 1
Volume of four (4) composting bays: 218 CY
Volume of Type 3 materials: 131 CY (60% Type 3 material)
Retention time for each bay: 14 days Cycles per year: 26
Phase 1 annual volume: 3,401 CY
Phase 1 annual tonnage: 2,550 tons*

Phase 2
Volume of fourteen (14) composting bays: 940 CY
Volume of Type 3 materials: 564 CY (60% Type 3 material)
Retention time for each bay: 14 days
Cycles per year: 26 Phase 2 annual volume: 14,664 CY
Phase 2 annual tonnage: 11,000 tons*

* assumes Type 3 ground feedstock bulk density is 1,500 lbs/CY
Phase 1 and 2 Total 13,550 tons/year

3.2 MATERIAL PROCESSING

Incoming Type 3 feedstock material will be dumped onto the covered concrete dumping pad. If
necessary, the incoming feedstock will be ground on the dumping pad. Type 1 material such as
leaves, grass clippings or ground land-clearing debris may be incorporated into the feedstock
either on the dumping pad or in the compost bays. The Type 3 composting operations will occur
under roof in “bays” utilizing aerated static pile technology. It is intended that each bay operate
as a separate management unit.

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The composting process requires the proper ratio of nitrogen-rich feedstock sources such as food
wastes and carbon-rich material such as ground wood waste or sawdust. The appropriate
feedstocks will be layered into the bays so as to provide the correct ratio of carbon to nitrogen.
A layer of ground wood waste or sawdust may be placed as a final layer on top of the material in
the bin to act as a bio-filter and to keep odors to a minimum. If necessary, leachate or another
moisture source will be added to the top of the material.

The bays are equipped with forced air technology to assist in the composting process. The air
distribution system, located in the bottom of each bay, will be activated during the loading of the
bay and the composting process. The air flow to each bay can be controlled separately to
maintain the correct microbial activity in each bay.

Detailed operations are illustrated on the flow diagram on Page 25 of this report.

Compost (grass clippings and loose leaves)

Grass clippings generated by Cabarrus County and contiguous counties will be received and
charged a tipping fee, unless other agreements are made. All material shall be transported
through the scales for weight determination. The material will then be transported to the drop-off
area for unloading. The grass clippings and leaves will be added to the Type 3 feedstocks in the
compost bays or if necessary, segregated into Type 1 compost windrows. Product mixing may
include some soil and mulch fines to enhance nutrification. The compost produced will be either
offered to the public or distributors for resale. It is anticipated that the time for production of
compost from leaves and grass clippings will be approximately 6 months in the Type 1 compost
windrows. Production time will vary depending on ambient air temperature, moisture and the
ratio of leaves to grass in the incoming material.
Land-clearing debris (tree limbs, tree stumps, etc.)
Land-clearing debris will be transported in bulk loads and weighed at the scale house. Land-
clearing debris generated from on site clearing activities will not be weighed. The material will
then be transported to the drop-off area for unloading. The debris will be routed to temporary
stockpiles in the reprocessing areas. This processed debris material will also be stored in

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windrows for proper management. The material will be scheduled for grinding quarterly or when
storage capacity reaches 3,000 cubic yards. A grinder will be utilized to produce mulch from the
material. The mulch products will then be added to the Type 3 feedstocks in the compost bays or
be placed in the windrows for storage. All windrow mulch products will be power screened for
fines separation and topsoil generation. The mulch produced may be used on-site to supplement
erosion control measures. As with the compost produced, the mulch material may be offered to
residents or distributers for resale.

Soil from land-clearing debris

Topsoil from root balls of stumps will be removed prior to grinding and stockpiled separately.
The fines from mulch screening will be mixed with the topsoil removed from the root balls, and
power screened to refine the product type. The material will then be windrowed for storage. This
material will be used to provide daily cover for the operating landfill cell, or utilized onsite.

Type 3 materials feedstock

Pre-consumer and post-consumer food processing waste and source separated food wastes,
agricultural waste including manures, meats, source-separated paper or other source specialty
wastes, which are relatively low in physical contaminants but may be high in pathogens from
Cabarrus County and contiguous Counties may be accepted at the facility. The material will be
accepted in bulk loads and weighed at the scale-house. After weighing, the material will be
placed on the covered dump pad. If necessary, the material will be ground on the dumping pad
and/or combined with Type 1 material feedstock. After grinding and/or mixing, the material will
be transported by loader into the Phase 1 and/or Phase 2 compost buildings and placed in a static
aerated pile bay for composting. Additional Type 1 material, partially composted or composted
material may be added to the bay. Collected leachate and/or water may be added to the bay to
add moisture. Aerobic conditions will be maintained during the compost process. The
temperature of the material will be maintained in accordance with NC solid waste guidelines,
which are discussed in detail in the following sections. It is anticipated that the material will
remain in the bay for 14 days. After 14 days, the composted material may be moved to another

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bay in the buildings to mature feedstock material or may be moved to a stock pile on the site.
The compost produced will be either offered to the public or distributors for resale.

3.3 TEMPERATURE MONITORING

The Type 3 composting operations will occur in bins utilizing aerated static pile technology.
Each active compost bin will be monitored for temperature once daily. Temperature probes will
be placed into each compost bay to document and measure temperature generations. The
recorded temperature will be used to ensure that the temperature in the pile be maintained above
104 degrees F (40 degrees Celsius) for 14 days or longer and the average temperature for that
time shall be higher than 133 degrees F (45 degrees Celsius). In addition, temperatures in the
bay shall be maintained at 131 degrees F (55 degrees Celsius) for at least three days. Should the
recorded temperature fall below the 131º F temperature specified, pathogen testing will be
performed to ensure pathogen levels are in the required range.

Each composting bay will be monitored with a compost thermometer, which has a 36-inch probe
to ensure that all areas inside the bay can be measured. Each probe will be monitored for a period
of approximately five minutes, or until the temperature reading has stabilized. Each monitoring
event will be recorded on a monitoring chart. The probe will be verified twice daily at the same
location for temperature recordation. If necessary, the material may be turned inside the bay or a
bulking agent may be added to the compost to bring the temperature up to the required 131º F for
three days.

3.4 TEMPERATURE CONTROL AND AERATION

The bays are equipped with forced air technology to assist in the composting process. The air
distribution system, located in the bottom of each bay, will be activated during the loading of the
bay and the composting process. The air flow to each bay can be controlled separately to
maintain the correct microbial activity in each bay. If temperatures fall below 131º F, air flow
can be increased to the bay to increase the microbial activity and pile temperature.

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In addition to increasing aeration, adding wood chips as a bulking agent will increase
biodegradation. The material may also be turned inside the bay to increase activity. If aeration or
the addition of a bulking agent or turning does not bring temperatures to the desired range,
ammonium nitrate or nutrient rich leachate may be added to improve biodegradation.

3.5 SERVICE AREA

The Agromatters Cabarrus Organics Reclamation Facility will serve Cabarrus County and
contiguous counties.

3.6 EQUIPMENT REQUIREMENTS

The facility will be operated with equipment capable of windrow turning, loading, grinding,
shredding and screening of the incoming waste stream, intermediate product and cured compost.
It is anticipated that following heavy equipment will be utilized for the Type 3 compost facility:

Mid-size Wheel Loader
Windrow Turner
Track Hoe
Tractor
Trommel Screen
Skid Steer Loader

This equipment may be moved off-site for periodic maintenance or replacement. Equipment
make and model is subject to change as replacement becomes necessary. At a minimum,
adequate equipment will be available to ensure facility operation in accordance with this
application and NC Solid Waste Regulations.

The heavy equipment will be supplemented by additional equipment used by the landfill owner
(Cabarrus County) to maintain and operate the existing landfill to maintain the existing haul
roads, control dust and other common landfill operations.

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Additional mechanical equipment is required for the operation of the static pile aerated bays
within the Phase 1 and Phase 2 compost buildings. Forced air compressors will be used to
maintain aerobic conditions within the piles. Each of the four (4) bays in Phase 1 will be
equipped with a Gast (or equivalent) ¾ hp, 220 V, single phase blower. Each of the fourteen
(14) bays constructed in Phase 2 will be equipped with a Gast (or equivalent) 1 hp, 220 V, single
phase blower. Each blower can be individually controlled to adjust airflow through a PVC
distribution system in concrete trenches in the floor of each compost bay.

The leachate collection system for Phase 1 includes one 2,000 gallon underground concrete
leachate collection tank. The leachate will be collected by drains in the dumping pad area and in
the floor of each composting bay. The leachate tank will be equipped with one 1.5 scfm @ 2
psig air compressor to aerate the leachate with one air diffuser (24” long, 2” diameter fine bubble
diffuser constructed of EPDM) in the bottom of the tank. The leachate tank will be equipped
with a ½ hp, 10 gpm @ 50’ TDH 2” solids handling submersible pump that will be used to pump
the leachate via PVC pipe back to a single hose bib located in the Phase 1 building. The hose bib
will be used to recirculate leachate back to the compost bays as needed.

The leachate collection system for Phase 2 includes four 2,500 gallon underground concrete
leachate collection tanks. The leachate will be collected through drains located in the floor in
each composting bay. Each of the four leachate tanks will be equipped with one 2.5 scfm @ 2
psig air compressor to aerate the leachate with one air diffuser (24” long, 2” diameter fine bubble
diffuser constructed of EPDM) in the bottom of each tank. Each leachate tank will be equipped
with a ½ hp, 10 gpm @ 50’ TDH 2” solids handling submersible pump that will be used to pump
the leachate via PVC pipe back to hose bibs located in the Phase 2 building. The hose bibs will
be used to recirculate leachate back to the compost bays as needed.

The Phase 1 and Phase 2 systems have been designed by Advanced Composting Technologies
(ACT). Detailed engineered construction plans for the pad, buildings, aeration systems and
leachate collection systems have been included with this application and can be found in
Appendix E.

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4.0 CONTAINMENT AND ENVIRONMENTAL CONTROL SYSTEM

4.1 GROUNDWATER CONSIDERATIONS

A minimum of twenty-four (24) inches will be maintained to the seasonal high water table.
Based on monitoring well readings, a groundwater separation of approximately 44 feet is
provided in the area of the Type 3 composting structures. (measurements taken and provided by
Cabarrus County for MW-A on May 8, 2013). In addition, the covered dumping pad and
compost building floors utilized for the Type 3 feedstock processing will be constructed of
concrete to ensure separation of material from bare ground. The covered dumping pad and
compost buildings will be constructed with trench drains and a leachate collection system and
storage tanks to prevent leachate run-off outside of the covered areas. The collected leachate
will be recirculated back into the aerated piles as needed to maintain moisture levels in the pile.
If the leachate tanks must be emptied, the liquid waste will be transferred via tanker to a
wastewater treatment facility operated by the Water and Sewer Authority of Cabarrus County
(WSACC). WSACC has provided a letter confirming the acceptance of leachate, and this has
been included in Attachment J.

4.2 SURFACE WATER CONSIDERATIONS

The dumping pad and static aerated pile operations of the Type 3 compost facility will be
operated under roof, on concrete to prevent commingling of feedstock and compost leachate with
stormwater. The covered dumping pad and compost buildings will be constructed with trench
drains and a leachate collection system with storage tanks to prevent leachate run-off outside of
the covered areas. The collected leachate will be recirculated back into the aerated piles as
needed to maintain moisture levels in the pile. If required, the leachate tanks will be periodically
pumped out, and the leachate transported to an accepting municipal wastewater treatment plant.
The site will be graded to divert stormwater away from the operational area and buildings. Site
stormwater will be routed towards a sediment control basin equipped with a surface skimmer.
The site will not cause a discharge of materials or fill materials into waters or wetlands of the
state that is in violation of Section 404 of the Clean Water Act. The site will not cause a

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discharge of pollutants into waters of the state that is in violation of the requirements of the
NPDES under 402 of the Clean Water Act.

4.3 CONTROLLING NUISANCES AND VECTORS

Potential nuisances affecting the area surrounding the composting facility include odor, dust,
fires, blowing litter, sedimentation, and vectors. Potential vectors include rodents, birds, and
other scavengers.

A water truck will be used to control dust emissions on haul roads, the loading and unloading
area and in the processing area. This equipment will be used on an as-needed basis.

Open burning is not permitted. In the event of a fire in the debris, the burning materials will be
covered with a soil cover if the fire is deemed manageable. If the fire is determined to be
unmanageable for landfill personnel, the Rimer Volunteer Fire Department will be notified.
Fences will be used to control blowing litter. Routine inspection and policing of the facility will
be conducted to ensure that litter will not pose a nuisance or hazard.

Odors and vectors are not expected to be problematic. The dumping pad will be cleared at the
end of each workday. Any excess material will be placed in a compost bay and covered with
ground wood material.

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5.0 AGROMATTERS CABARRUS ORGANICS RECLAMATION FACILITY
GENERAL OPERATION AND MAINTENANCE

5.1 PLAN AND PERMIT REQUIREMENTS

All construction documents and plans of the permit shall be followed. A copy of the plans,
permits, and operational reports shall be maintained at the office at all times. In addition, copies
of the equipment manufacturer performance data and maintenance manuals will be maintained at
the office. The office is located in the scalehouse at the entrance to the landfill site.

5.2 FACILITY PERSONNEL

Proposed Site Operator: Agromatters, LLC 4441 Irish Potato Road
Concord, NC 28025 [phone]

Operator’s Representative: Mr. Ron Gilkerson, President The site will be adequately staffed as required to operate and maintain the facility as described in
this application.

5.3 HOURS OF OPERATION

The Agromatters Cabarrus Organics Reclamation Facility will maintain operating hours between
8:00 AM and 5:00 PM Monday through Friday. The facility will be closed on the following
holidays:

New Year’s Day Labor Day Memorial Day Thanksgiving Day Independence Day Christmas Day

A sign or signs identifying the owner, operator, telephone number, NCDENR permit number,
types of waste accepted and the landfill operating hours will be posted at the entrance to the
landfill.

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5.4 DROP-OFF AREA

Incoming Type 2 and 3 feedstocks will be weighed at the scale-house at the entrance to the
landfill site and delivered to the covered, concrete dumping pad. If necessary, grinding of the
incoming material or mixing with carbon-rich material will take place on the dumping pad. The
dumping pad will be sized to allow for the dumping of a truck simultaneously with grinding and
mixing operations with both activities occurring under roof. Incoming Type 1 material will
continue to be placed in the Type 1 compost area, and segregated per the Type 1 composting
permit (NC Solid Waste permit #1302).
Waste will be inspected before and after dumping onto the pad. Waste that does not meet the
criteria for the acceptable materials shall be disposed of in an on-site waste container for future
disposal at a permitted solid waste landfill. Large loads of unacceptable materials will be turned
away prior to dumping for disposal at a permitted solid waste facility. The dumping pad will be
cleared at the end of each operating day.

5.5 AERATED STATIC PILE PROCESS

The Type 3 composting operations will occur under roof in “bays” utilizing aerated static pile
technology. It is intended that each bay operate as a separate management unit. After grinding
and/or mixing, the material will be transported by loader into the Phase 1 and/or Phase 2
compost buildings and placed in a static aerated pile bay for composting. Additional Type 1
material, partially composted or composted material may be added to the bay. Collected leachate
and/or water may be added to the bay to add moisture. Aerobic conditions will be maintained
during the compost process. Material will be placed in each bay and monitored for temperature
as discussed in the Material Processing Section 3.0. Each bay is serviced by an individual air
compressor and air distribution system to ensure aeration throughout the composting process.
The material will remain in the compost bays for a minimum of 14 days.

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5.6 ADVERSE WEATHER CONDITIONS

Processing, loading, and storage of mulch and compost are done regardless of the weather
conditions. The Type 3 composting activities occur under roof, and are not affected by
inclement weather.

The drop-off area is covered concrete and the entrance is by an all-weather roadway. The
roadways shall be kept clear during periods of snowfall. Grinding and screening may be stopped
during periods of high winds, should dust become an issue. Dust shall be controlled on the
roadways as described in Section 6.6.

5.7 FLOW DIAGRAM

Please refer to the attached Flow Diagram on Page 25 of this report.

5.8 DAILY CLOSING PROCEDURES

At the end of each business day, the composting facility will be inspected to ensure the
mechanical equipment, including the aeration compressors, is in good operating condition. All
remaining Type 3 materials will be placed in a bay inside the compost buildings. The dumping
pad and grinding area will be cleared of materials. A layer of ground wood material will be
placed in the bays as required to cover any Type 3 material feedstock. The gates at the entrance
to the landfill will be secured each night by landfill personnel.

5.9 CONTINGENCY PLAN

Should an instance of on-site equipment failure or temporary shutdown of the facility occur, all
incoming loads of Type 1 material (limited to yard and garden waste, land clearing debris,
silvicultural waste and unpainted, untreated wood waste) shall be stockpiled at the drop-off area.
If the Type 1 material stockpile has reached capacity, the material will be turned away for
disposal at a permitted solid waste facility. During a shutdown, no incoming loads of Type 3

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materials in excess of the storage capacity of the bays will be accepted. Additional Type 3
materials in excess of this capacity will be turned away for disposal at a permitted solid waste
facility.

On-site, no open burning of material is permitted. Should accidental fires occur, equipment and
stockpiled soil shall be provided to control them. Any occurrence of fire at the facility shall be
reported to the NCDENR Division of Waste Management within 24 hours, and written
notification shall be submitted by the Operations Manager within 15 days.

Should a fire occur at the facility, the local fire department (Rimer Volunteer Fire Department)
shall be notified. Loads that are hot shall be removed immediately and placed away from the
facility and the fire department shall be notified. Compost bays that are hot shall be emptied and
spread out to a thickness of 12” on the ground. Said loads shall be sprayed down with water
until the fire and/or combustion is extinguished. The load shall then be reloaded for disposal in
the landfill. The Rimer Volunteer Fire Department is aware of this proposed facility. Should a
fire occur they have agreed to respond to the site. A letter indicating this has been included in
Attachment E.

5.10 FACILITY MAINTENANCE

All heavy equipment required for the compost facility will be maintained by the operator in
accordance with the manufacturers’ recommendations. Cabarrus County landfill equipment,
which may be utilized to maintain haul roads, control dust, and provide other landfill functions
will continue to be maintained by Cabarrus County as part of the county solid waste program.

Each compost bay will be inspected between compost cycles when it is empty, prior to filling
with new feedstock material. The distribution pipes, concrete floor and trenches, aeration holes,
leachate drains and collection system will be inspected at this time. The air pressure within the
bay will be checked to ensure that it is in the acceptable operating range of 5 - 30 Inches of
Water Column before refilling. The site will keep on hand one extra air Gast (or equivalent) ¾
hp, 220 V, single phase blower for quick replacement of a faulty blower if necessary.

-18- 131-242 Agromatters Cabarrus Compost Application
November 2013

The leachate tank liquid level, submersible pumps and air compressors will be checked daily.
Should a malfunctioning of the leachate tank pump occur, the tank leachate will be pumped as
needed and transported to a permitted wastewater treatment plant. Building and structure
inspection will occur weekly and maintenance will be performed as needed. Concrete floors,
curbs, or gravel areas will be repaired as necessary to assure proper operation and
integrity. Roofed structures will be inspected weekly for structural integrity and leaks and
repaired as necessary.

The air compressors and pumps will require routine maintenance. Agromatters, LLC. has
entered into an agreement with Advanced Compost Technologies (ACT) for the Operation and
Maintenance of the facility’s air compressors and distribution system and the leachate collection
and pumping system. ACT will provide the routine and scheduled maintenance as well as non-
scheduled service due to equipment failure. A copy of this agreement can be found in Appendix
G. As a reference Operation and maintenance manuals for the air compressors and submersible
leachate pumps have been included in Appendix H.

-19- 131-242 Agromatters Cabarrus Compost Application
November 2013
6.0 FACILITY OPERATION

6.1 TRAINING OF FACILITY PERSONNEL

The proposed compost site manager (Agromatters, LLC) and site operation staff are properly
trained to execute important tasks such as the following:

1. Monitoring of incoming wastes.
2. Identification of unauthorized wastes.
3. Accurate recording of accepted wastes.
4. Operation and maintenance of forced aeration equipment.
5. Temperature monitoring during composting process.
6. Safe equipment operation.
The compost site manager will be Mr. Ron Gilkerson, President of Agromatters, LLC. The
assistant manager will be Mr. Tyler Gilkerson.

6.2 ENTRANCE

The existing entrance and haul roads for the Cabarrus County Landfill will be used to access the
Agromatters Cabarrus Organics Reclamation Facility.

6.3 ACCESS AND SECURITY

The site has controlled access with the use of entrance gates. The entrance gates allow entry to
the currently operating landfill located to the east of the composting facility. The same entrance
will be used for access to the composting facility, and will remain gated. Access to the
composting facility is restricted to the entrance gate only. The currently operating landfill (with
fencing and wooded buffer) prevents un-authorized access to the compost area. Access roads are
all-weather construction and will be maintained in good condition.

-20- 131-242 Agromatters Cabarrus Compost Application
November 2013
A scalehouse is located at the entrance with an attendant present during operational hours. The
attendant is responsible for evaluating loads to assure compliance with operation requirements
and to direct the loads to the appropriate location on site—landfill or composting facility. In
addition, signs are posted to direct loads to the appropriate area.

Dust is controlled on access roads through the use of a water truck. Signs are posted indicating
that liquid, hazardous, and municipal wastes are prohibited.

6.4 SIGNS

Existing signs are provided at the existing site entrance and show the contact name, telephone
number, permit number, and the facility operating hours. Information on waste acceptance
procedures and wastes that cannot be accepted is also provided. Traffic signs will be provided as
needed to direct customers and to promote orderly traffic flow to and from the disposal areas.

6.5 WASTE ACCEPTANCE

The Agromatters Cabarrus Organics Reclamation Facility will accept Type 1, 2 and 3 materials
as defined in Section .1402(f)(1)-(3) The following waste will be accepted:
1. Grass clippings, loose leaves, etc.
2. Tree limbs, stumps, etc.
3. Soil from land clearing debris.
4. Pre- and post-consumer food processing waste including meat.
5. Agricultural waste including manures.
6. Paper, un-painted and untreated wood waste
7. Other source separated specialty waste low in physical contaminants but may have a high level of pathogens or nutrients.

-21- 131-242 Agromatters Cabarrus Compost Application
November 2013
6.6 DUST, LITTER, ODORS, AND VECTORS

Dust, litter, odors, and vectors are discussed in Section 4.2. Dust generated by composting
operation will be controlled or reduced by:

1. Application of water by using a water truck.
2. Regular removal of mud and dirt from the paved roads.
3. Vegetating of graded site areas as soon as practical.

Blowing litter will be reduced or controlled by:
1. Limiting the size of the active working area.
2. Utilization of litter fences.
3. Policing of the area.

Odors and vectors are not expected to be problematic.

If environmental problems associated with the composting facility are detected and confirmed by
NCDENR, Agromatters, LLC. will submit to NCDENR for review and approval a corrective
action plan and a schedule of compliance for implementing the plan.

6.7 MONITORING AND TESTING

Each active compost bin will be monitored for temperature once daily using a 36” temperature
probe. Temperature probes will be placed into each compost bay to document and measure
temperature generations. The recorded temperature will be used to ensure that the temperature in
the pile be maintained above 104 degrees F (40 degrees Celsius) for 14 days or longer and the
average temperature for that time shall be higher than 133 degrees F (45 degrees Celsius). In
addition, temperatures in the bay shall be maintained at 131 degrees F (55 degrees Celsius) for at
least three days. Should the recorded temperature fall below the 131º F temperature specified,
pathogen testing will be performed to ensure pathogen levels are in the required range.

-22- 131-242 Agromatters Cabarrus Compost Application
November 2013
Compost will be sampled for metals, foreign matter and pathogens every 20,000 tons of compost
produced or every six months, whichever comes first. The compost will not be applied to the
land, sold or given away if the concentration of any metal exceeds the concentration in 40 CFR
503.13(b)(3) [See Table 1 below], unless the concentration of all metals are less than the values
in 40 CFR 503.13(b)(1) and records are maintained to show compliance with the cumulative and
annual metal levels in 40 CFR 503.13(b)(2) and (4).

As the compost will be marketed and distributed as Grade A, the final product will be composed
of less than 6% by weight man-made inerts. In no case shall the man-made inerts be larger than
1” in diameter. The compost will be sampled for pathogens using the methods described in Rule
.1400 Appendix B.

The site manager will record and maintain records for a minimum of five years. Records shall be
available for inspection by Division personnel during normal business hours and shall be sent to
the Division upon request. The records will include at a minimum those items listed in Rule
.1408(c).

6.8 REPORTING

An annual report detailing the facility operations will be submitted for the period June 30th to
July 1st will be submitted prior to August 1st of each year. The report will contain at a minimum
the information those items listed in Rule .1408(d). Yearly tonnage for the facility will be
reported back to the municipality from where the waste was received to be used in that
municipality’s annual recycling reporting.

Prior to the distribution or marketing of any compost material, the site manager will submit
results from the analytical testing described above to NCDENR Division of Waste Management
Solid Waste Section. Based on an approval from the Solid Waste Section, the compost material
may be marketed and distributed.

-23- 131-242 Agromatters Cabarrus Compost Application
November 2013
6.9 QUALITY ASSURANCE

Facility personnel will inspect each load of compost feedstock prior to and after dumping to
exclude prohibited materials from the feedstock prior to composting. Accurate and regular
record keeping during the process will ensure proper temperature, moisture and microbial
activity. Each bay will be inspected daily for odors or other signs of inadequate processing.

Finished compost quality assurance will be based upon the testing outlined in the previous
sections. The compost will be marketed as Grade A compost, so particular attention will be paid
to pathogen reduction through the monitoring of temperature during the static aerated pile
process. The product will be screened prior to distribution to remove man-made inerts and other
large particles.

The compost facility will participate in the US Composting Council’s Seal of Testing Assurance
Program (USCC STA). The program includes product testing, labeling and information
disclosure in accordance with the Test Methods for the Examination and Composting Manual
(TMECC), jointly produced by the USDA and the USCC. The seal is an accepted standard
measure of quality for the compost industry and will be an integrated part of the facilities quality
assurance and marketing program.

-24- 131-242 Agromatters Cabarrus Compost Application
November 2013
7.0 PRODUCT MARKETING AND DISTRIBUTION

The finished compost will be distributed to municipalities within Cabarrus County and
contiguous counties and other parties. The finished compost produced will conform to Grade A
standard in accordance with Rule .1407(d)(1) and have unrestricted, unlimited marketing and
distribution. Product labeling and information in accordance with the USCC STA program will
be provided with the distribution of the finished compost. Per the attached agreement with
Cabarrus County (Attachment I), Agromatters will supply Cabarrus County with 5% of the total
monthly compost produced or not less than 1,500 CY per year. Compost in excess of what can
be marketed, can be land applied to enhance vegetation on the landfill site.

-25- 131-242 Agromatters Cabarrus Compost Application
November 2013

Flow Diagram

Station 1 – Covered Dumping Pad

Station 2 – Grinding and
Mixing on
Covered Dumping Pad

Station 3 – Aerated Static Pile
Compost Bays in
Buildings

Station 4 - Finished Compost into Stockpile or Windrow

Station 5 – Final Screening, Final
Oversize Material (>1/2”) Product
Returned to Station 3 Distribution

______________________________________________________________________________

ATTACHMENT A PROPOSED COMPOST SITE AERIAL ______________________________________________________________________________

ATTACHMENT B
COMPOST FACILITY SITE PLANS, C201, C202
______________________________________________________________________________

NORTH CAROLINA
BOARD OF EXAMINERS
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ATTACHMENT C

SOIL TESTING RESULTS
______________________________________________________________________________

ATTACHMENT D
ZONING CONSISTENCY LETTER
______________________________________________________________________________

ATTACHMENT E

FIRE DEPARTMENT SERVICE LETTER
______________________________________________________________________________

ATTACHMENT F
PHASE 1 AND 2 COMPOST SYSTEM CONSTRUCTION PLANS
______________________________________________________________________________

ATTACHMENT G

ACT OPERATION AND MAINTENANCE AGREEMENT
______________________________________________________________________________

P.O. Box 2440 Candler, N.C., 28715 phone [phone]

October 25, 2013
Ron Gilkerson
Agromatters, LLC
11743 Trails End Lane
Huntersville, NC 28078

SUBJECT: Maintenance Agreement

Dear Ron,

Thank you for choosing Advanced Composting’s Forced Aeration technology for your food
waste composting requirements. We take great pride in the quality of our systems and know
that with proper care, it will serve your needs for many years to come. One of the key
components to long-term reliability and performance is regular system maintenance.
Therefore, ACT has three maintenance agreement options from which you can choose.

These contract offers help ensure that your compost facility and its equipment is maintained
in accordance with our and the manufacturer’s recommendations and is not a guarantee
against breakdowns. At the end of our one year warranty period, we recommend continuing
our preventative maintenance, service and repair through one of the following three options:
1) An Annual Preventive Maintenance Agreement
2) A Semi-Annual Maintenance Agreement
3) A Fixed-Rate Plus Materials Agreement

Each option is detailed on the following pages. Our goal is to provide the option that best
suits your needs today and tomorrow. After each visit you will be provided with a detailed
service report explaining the work that was performed and making any future
recommendations.

These agreements cover only the services listed on pages 2 and 3. If additional repairs are
required, you will be notified and your approval obtained before commencing any repairs.

We value our customers and hope that this added service will strengthen our relationship. If
you are interested in being part of either agreement please contact me at [phone] or
email me at [e-mail] or mail the selected option into our office at
the address at the top of this letter.

Best Regards,

Keith Warren
ACT President

P.O. Box 2440 Candler, N.C., 28715 phone [phone]

Option 1: Annual Preventive Maintenance:
Cost: $750.00/year

The scope of services provided: (all labor and material costs are included unless otherwise
indicated)

• Contact Owner’s Representative to schedule an appropriate time and date for an
Annual Preventative Maintenance and Service visit.
• Change compressor filter and housing - Remove old filter housing and replace with
newly reconditioned housing and new filter cartridge.
• Take electrical readings (voltage & amperage); analyze and log on the service ticket.
• Om the capacitor for strong compressor starts. Replace if low.
• If we do find that your compressor is having issues, we will remove and have it rebuilt
and leave you running in the mean time with our service compressor. Note: most
rebuilds if caught early enough are $100 - $150. Whereas, if not caught early
enough- bearings and motor wiring and windings could be damaged and you could
be looking at $800 - $1,000 to replace (cost of replacing the compressor is the
owner’s expense). Compressors have a one year warranty under this agreement.
• Remove leachate pump and clean and check for efficiency.
• Check the pressure in each bin and recommend any needed repairs.
• Power wash doors and adjust hinges.
• Flush leachate drain lines with leachate for optimum performance.
• Leachate compressor - clean filter and around the unit.
• Provide a detailed service report.
• This agreement covers multiple trips if required to complete the service items listed.

Terms: Upon completion of work
Warranty: Parts & Labor warranted for workmanship and defects for a
period of 90 days.

P.O. Box 2440 Candler, N.C., 28715 phone [phone]

Option 2: Semi-Annual Preventive Maintenance
Cost: $950.00/year

The scope of services provided. (All labor and material costs are included unless otherwise
indicated)
All of the Annual service items are included, specifically:
• Contact Owner’s Representative to schedule appropriate times and dates for two
Preventative Maintenance and Service visits per year.
• Change compressor filter and housing - Remove old filter housing and replace with
newly reconditioned housing and new filter cartridge.
• Take electrical readings (voltage & amperage); analyze and log on the service ticket.
• Om the capacitor for strong compressor starts. Replace if low.
• If we do find that your compressor is having issues, we will remove and have it rebuilt
and leave you running in the interim with our service compressor. Note: most
rebuilds if caught early enough are $100 - $150. Whereas, if not caught early
enough- bearings and motor wiring and windings could be damaged with costs of
$800 - $1,000 (cost of replacing the compressor is the owner’s expense).
Compressors have a two year warranty under this agreement.
• Remove leachate pump and clean and check for efficiency.
• Check the pressure in each bin and recommend any needed repairs.
• Power wash doors and adjust hinges.
• Flush leachate drain lines with leachate for optimum performance.
• Leachate compressor - clean filter and around the unit.
• Provide a detailed service report.
• This agreement covers multiple trips if required to complete the service items listed.
Plus:
• Touch up galvanizing on the door.
• Mix the leachate tank and pump empty into a new mix bin and refill with fresh water.

Terms: Upon completion of work
Warranty: Parts & Labor warranted for workmanship and defects for a
period of 90 days.

ATTACHMENT H
COMPRESSOR AND PUMP OPERATION AND MAINTENANCE MANUALS
______________________________________________________________________________
GAST LUBRICATED 23 SERIES ROTARYVANEVACUUMPUMPS&COMPRESSORSOPERATION&MAINTENANCE MANUAL
Thank you for purchasing this Gast product.It is manufactured to the highest standardsusingqualitymaterials.Please follow all recommended maintenance,operationalandsafetyinstructionsandyouwillreceiveyearsoftroublefreeservice.
www.gastmfg.comISO9001 & 14001 CERTIFIED
•Operate at 32ºF -104ºF (0ºC -40ºC).•Protect unit from dirt &moisture.•Protect all surrounding items from hot exhaust air.This exhaust air can become very hot.•Product is not a consumer product and is forcommercialapplicationsonly.
•Do not pump flammable or explosive gases or use
in an atmosphere that contains such gases.
•Corrosive gases and particulate material willdamageunit.Water vapor,oil-based contaminantsorotherliquidsmustbefilteredout.•Consult your Gast Distributor/Representativebeforeusingathighaltitudes.•Use Gast #AD220 or a detergent SAE#10 automotiveengineoilforlubricating.
PART NO.70-325 (Rev.G)
WARNING
PLEASE READ THIS MANUAL COMPLETELY BEFORE INSTALLING AND USINGTHISAIRPUMP.SAVE THIS MANUAL FOR FUTURE REFERENCE ANDKEEPINTHEVICINITYOFTHEAIRPUMP.
Product Use Criteria:
70-325 Rev G.qxd:70-325 Rev D.qxd 2/11/11 2:29 PM Page 1
INSTALLATION
Disconnect electrical power at the circuit breaker
or fuse box before installing this product.
Install this product where it will not come into
contact with water or other liquids.
Install this product where it will be weather
protected.
Electrically ground this product.
Failure to follow these instructions can result in
death, fire or electrical shock.
WARNING
Electrical Shock Hazard
WARNING
DANGER
Your safety and the safety of others
is extremely important.
We have provided many important safety messages
in this manual and on your product. Always read
and obey all safety messages.
This is the safety alert symbol. This symbol
alerts you to hazards that can kill or hurt you and
others. The safety alert symbol and the words
“DANGER” and “WARNING” will precede all safety
messages. These words mean:
You will be killed or seriously injured if you don’t
follow instructions.
You can be killed or seriously injured if you don’t
follow instructions.
All safety messages will identify the hazard, tell you
how to reduce the chance of injury, and tell you
what can happen if the safety instructions are not
followed.
2
Correct installation is your responsibility.Make sure youhavetheproperinstallationconditionsandthatinstallationclearancesdonotblockairflow.Properguardsshouldbeinstalledtopreventcontactwithmoveablepartsofthispump.Do Not lift the unit by thefanshroud.Blocking air flow over the product in any way can causetheproducttooverheat.MountingPositionthe mounting the product to a stable,rigidoperatingsurfaceandusingshockmountswillreducenoiseandvibration.
PlumbingToprevent air flow restriction,use pipe and fittings that arethesamesizeorlargerthanthethreadedportsofthepump.The ports are marked "IN"and "OUT".If the distance isgreat,use lines with a larger diameter than the connections.Give lines a uniform slope,place drain cock at low point,and avoid extra elbows.For ease of servicing,use a unionorhosewithclampsnearthepump(a hose helps eliminatenoiseandvibration).If a vacuum/pressure supply tank isused,slope the line towards tank,provide a drain at thebottom,and place a check valve between the tank andpumpsothepumpwillnotrunbackwardswhenturned off.
AccessoriesIntakeandexhaust filters are external to the pump and willprovideadequatefiltrationformostapplications.Checkfiltersperiodicallyandreplacewhennecessary.Consult aGastRepresentativeforadditionalfilterrecommendations.Install relief valves and gauges at the inlet or outlet,or both,to monitor performance.Check valves may be required topreventbackstreamingthroughthepump.
Motor ControlItisyourresponsibility to contact a qualifiedelectriciantoassurethattheelectricalinstallation isadequateandinconformancewithallnationalandlocalcodesandordinances.Determine the correct overload setting required toprotectthemotor(see motor starter manufacturerʼsrecommendations).Select fuses,motor protectiveswitchesorthermalprotectiveswitchestoprovideprotection.Fuses act as short circuit protection for themotor,not as protection against overload.Incoming linefuseshelptowithstandthemotorʼs starting current.Motor starters with thermal magnetic overload or circuitbreakersprotectmotorfromoverloadorreducedvoltageconditions.The wiring diagram supplied with the product providesrequiredelectricalinformation.Check that powersourceiscorrecttoproperlyoperatethedual-voltagemotors.
Grounded Plug Grounding Pin
Grounded Outlet120-volt grounded connectorsshown.220/240-volt groundedconnectorswilldifferinshape.
DIAGRAM A
Electrical Connection
70-325 Rev G.qxd:70-325 Rev D.qxd 2/11/11 2:29 PM Page 2
MAINTENANCE
Disconnect electrical power supply cord before
performing maintenance on this product.
If product is hard wired into system, disconnect
electrical power at the circuit breaker or fuse box
before performing maintenance on this product.
Failure to follow these instructions can result in
death, fire or electrical shock.
Electrical Shock Hazard
WARNING
Start UpIfpumpis extemely cold,let it warm up to roomtemperaturebeforestarting.If motor fails to start orslowsdownsignificantlyunderload,shut off anddisconnectfrompowersupply.Check that the voltageiscorrectformotorandthatmotoristurningintheproperdirection.Turning in the wrong direction willdrasticallyreducevanelife.Vane life will be drasticallyreducedifmotorisnotoperatingproperly.Vanes canbreakorbedamagedifmotor/pump runs in the wrongdirection.
OPERATION WARNING
Injury Hazard
Air stream from product may contain solid or liquidmaterialthatcanresultineyeorskindamage.
Wear hearing protection.Sound level from productmayexceed85db(A).Failure to follow these instructions can result in eyeinjuryorotherseriousinjury.
Pump only clean dry air.Do not pump flammable or explosive gases or useinanatmospherethatcontainssuchgases.
Install proper safety guards as needed.Pumps withglassjarsneedsafetyguardstoprotectagainstbreakingglass.Use only recommended air handling parts acceptableforpressurenotlessthan70psi.Keep fingers and objects away from openings androtatingparts.When provided,motor terminal covers must be inplaceforsafeoperation.Check that coupling guard and shroud are in placebeforeoperating.Product surfaces may become hot during operating,allow product surfaces to cool before handling.Do not direct air stream at body.Air stream fromproductmaycontainsolidorliquidmaterialthatcanresultineyeorskindamage,wear proper eyeprotection.
Do not spray flammable or combustible liquid.
3
Check with a qualified electrician or serviceman if thegroundinginstructionsarenotcompletelyunderstood,or if you are not sure whether the product is properlygrounded.Do not modify the plug provided.If it will notfittheoutlet,have the proper outlet installed by aqualifiedelectrician.Model that is permanently wired:This product must be connected to a grounded,metallic,permanent wiring system,or an equipmentgroundingterminalorleadontheproduct.Power supply wiring must conform to all required safetycodesandbeinstalledbyaqualifiedperson.Checkthatsupplyvoltageagreeswiththatlistedonproductnameplate.Extension cords:Use only a 3-wire extension cord that has a 3-bladegroundingplug.Connect extension cord plug to amatching3-slot receptacle.Do not use an adapter.Make sure your extension cord is in good condition.Check that the gage wire of the extension cord is thecorrectsizewiretocarrythecurrentthisproductwilldraw.
Minimum gage for extension cordsAmpsVoltsLengthofcordinfeet120v2550100150200 250 300 400 500240v5010020030040050060080010000-2 18 18 18 16 16 14 14 12 122-3 18 18 16 14 14 12 12 10 103-4 18 18 16 14 12 12 10 10 84-5 18 18 14 12 12 10 10 885-6 18 16 14 12 10 10 8886-8 18 16 12 10 10 86668-10 18 14 12 10 8866410-12 16 14 10 88664412-14 16 12 10 86664214-16 16 12 10 86644216-18 14 12 886442218-20 14 12 8664422
It is your responsibility to operate this product atrecommendedpressuresorvacuumdutiesandroomambienttemperatures.Do Not start against a vacuumorpressureload.
In the event of an electrical short circuit,groundingreducestheriskofelectricshockbyprovidinganescapewirefortheelectriccurrent.This product maybeequippedwithapowersupplycordhavingagroundingwirewithanappropriategroundingplug.The plug must be plugged into an outlet that is properlyinstalledandgroundedinaccordancewithalllocalcodesandordinances.
Model with a power supply cord:This product must be grounded.For either 120-volt or220/240-volt circuits connect power supply cordgroundingplugtoamatchinggroundedoutlet.Do notuseanadapter.(See DIAGRAM A)
70-325 Rev G.qxd:70-325 Rev D.qxd 2/11/11 2:29 PM Page 3
SHUTDOWN PROCEDURES
It is your responsibility to follow proper shutdownprocedurestopreventproductdamage.
4
It is your responsibility to:•Regularly inspect and make necessary repairs toproductinordertomaintainproperoperation.•Make sure that pressure and vacuum is releasedfromproductbeforestartingmaintenance.
FlushingFlushingthis product to remove excessive dirt,foreignparticles,moisture or oil that occurs in the operatingenvironmentwillhelptomaintainpropervaneperformance.If your pump is not getting the vacuum orpressurelevelexpected,flushing is required.Vanes willstickwhendirtyandmaycausepumptobenoisyorinefficient.Use only Gast recommended Flushing Solvent or othernon-petroleum based flushing solvent.Do Not usekeroseneorANYothercombustiblesolventtoflushproduct.
Check that all external accessories such as relief valvesandgaugesareattachedtocoverandarenotdamagedbeforere-operating product.
1.Disconnect electrical power supply.2.Release all pressure and vacuum from pump.3.Remove all accessories at the inlet and exhaustports.4.Remove filter.5.Start product.Place towel over exhaust port tocleanupsolvent.If using liquid solvent,pourseveraltablespoonsdirectlyintoinletport.If usingGastrecommendedFlushingSolvent,spray solventfor5-10 seconds into inlet port.6.Block the inlet port and draw a deep vacuum for15-20 seconds.Release the vacuum.7.Listen for changes in the sound of the motor.Ifmotorsoundssmooth,go to next step.If motordoesnotsoundlikeitisrunningsmoothly,repeatsteps5and6untilyoucanhearadifferenceintheoperatingsoundofthepump.8.Start the pump and let it run for 1 minute,then turnpumpoff.9.Replace all accessories at the inlet and exhaustports.10.Replace filter before resuming operation.
Check intake and exhaust filters after first 500 hours ofoperation.Clean filters and determine how frequentlyfiltersshouldbecheckedduringfutureoperation.Thisoneprocedurewillhelptoassuretheproduct’sperformanceandservicelife.Clean filters when necessary by removing and washinginasolventorsoapandwater.After cleaning,dry withcompressedairtomakesureallmoistureisremovedbeforereplacingfilters.
Failure to do so may result in premature pump failure.The Gast Manufacturing lubricated Vacuum Pumps andCompressorsareconstructedofferrousmetalsoraluminumwhicharesubjecttorustandcorrosionwhenpumpingcondensablevaporssuchaswater.Follow thestepsbelowtoassurecorrectstorageandshutdownbetweenoperatingperiods1.Disconnect plumbing.2.Operate product for at least 5 minutes withoutplumbing.3.Cover inlet port (vacuum side)and run pump for 1-3minutes.Shut the pump down under vacuum.4.This unit requires lubrication.Refill oil reservoir toproperlevelbeforestorage.5.Be sure to plug open ports so dirt and othercontaminantsdonotentertheunit.It is now readyforshutdown.
Air stream from product may contain solid or liquidmaterialthatcanresultineyeorskindamage.Flush this product in a well ventilated area.Do Not use kerosene or other combustible solventstoflushthisproduct.
WARNING
Injury HazardWeareyeprotectionwhenflushing this product.
Failure to follow these instructions can result ineyeinjuryorotherseriousinjury.
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5
Disposal (Please note current regulations)Parts of the rotary vane pumps and compressors,shafts,iron or aluminum castings,plastic or glasspartsorbearings,may be recycled as scrapmaterials.
PUMP DISASSEMBLY1.Remove the End Plate bolts.
DO NOT at any time remove the rotor or loosen
any of the electric motor thru-bolts.2.Remove End Plate and check for scoring on EndPlate,Rotor,and Body.Surfaces should besmooth.If severe scoring is visible contact anAuthorizedServiceFacility.3.Remove vanes.4.Clean all surfaces with Gast recommendedFlushingsolventanddrywell.
PUMP RE-ASSEMBLY5.Apply a light coat of Gast recommended Oilpart#AD220,(an equivalent 10 wt.high detergentoilcanalsobeused)to the vanes.6.Re-install vanes,noting the proper direction ofthebevelededge(Refer to exploded view).7.Install End Plate and tighten End Plate Bolts.8.Install new cover gasket on Filter/Muffler Assem-bly and Lubricator.9.Before putting the pump into service,ensurethatanyexternalaccessorieshavenotbeendamaged.If the pump fails to produce proper vacuum or pressure,or is excessively noisy,turn off and return unit to anAuthorizedServiceFacility.
Gast will NOT guarantee field-rebuilt productperformance.For performance guarantee,the productmustbereturnedtoaGastAuthorizedServiceFacility.Service Kit contents vary.Most contain vanes,gasketsoilerwickandfilterelements.
SERVICE KIT INSTALLATION
Disconnect electrical power supply cord before
installing Service Kit.
If product is hard wired into system, disconnect
electrical power at the circuit breaker or fuse box
before installing Service Kit.
Disconnect air supply and vent all air lines to
release pressure or vacuum.
Failure to follow these instructions can result in
death, fire or electrical shock.
WARNING
Electrical Shock Hazard
Do Not attempt to remove the rotor.It is held in placebyLoctiteandcanonlybeservicedbyaGastAuthorizedServiceFacility.
We have Gast Certified Service
Centers throughout the world.
For the most up-to-date listing,
contact one of our sales offices
below:
GastGroup Limited,UnitedKingdomUnit11,The I O CentreNashRoadRedditch,B98 7ASUnitedKingdomph:[phone]Fax:[phone]www.gastmfg.com
Gasts Manufacturing,Inc.2300 S.Highway M139BentonHarbor,MI 49022Ph:269/926-6171FAX:[phone]www.gastmfg.com
Gast Hong KongRoom6,9/F.New Commerce Centre19OnSumSt.,ShatinN.T.Hong KongPh:(852)2690 1066Fax:[phone]www.gasthk.com
70-325 Rev G.qxd:70-325 Rev D.qxd 2/11/11 2:29 PM Page 5
Lubrication
Series 0323 and 0523:These models use a siphon oiler.Thelubricationrateisdeterminedbythetemperature,the operating vacuum orpressure,and the siphon jar oil level.Keepthesiphonjarfilledtothelineshownonthejar.Either unscrew the jar or fill through thespring-loaded cap.
All Models:The oil wick should be folded in half,with thetwoendssubmergedintheoilatthebottomoftheJar,and the folded center inserted intotheconnectorapproximately3/8"past the twobreatherholesintheconnector(but nottouchingthefeedholeleadingtothepump).Both the breather holes and the feed holemustbeunrestricted.
EXPLODED PRODUCT VIEW,PARTS &ORDERING INFORMATION
0323/0523 SERIES
REF DESCRIPTION QTY 0323-V3 0523-V3
NO.
1 BODY 1 AK503 AK505
2 ∆VANE 4 AK731 AK731
3 SHROUD 1 AK502 AK502
4 END PLATE 1 AK516B AK516B
5 SIPHON OILER 1 AA930A AA930A
6 ∆COVER GASKET 1 AA932 AA932
7 ∆WICK 1 AA934 AA934
8 JAR 1 AA935A AA935A
9 FILTER ELEMENT ASSM.1 B343B B343B
10 ∆FILTER FELT 4 B344A B344A
11 INTAKE FILTER ASSM.1 V400G V400G
12 ∆COVER GASKET 2 B62A B62A
13 MUFFLER ASSEMBLY 1 V425K V425K
14 JAR 2 AA125A AA125A
15 FOOT SUPPORT ASSM.1 AC136 AC136
***SERVICE KIT 1 K485 K485
6 ∆Parts included in repair kit
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EXPLODED PRODUCT VIEW,PARTS &ORDERING INFORMATION
Lubrication
Series 0823 and 1023:These models use a constant level oiler.Thelubricationrateisdeterminedbythetemperature,the vacuum or pressure at which the pump isoperating,and the siphon jar oil level(determined by the vertical position of the tube inthejar).The lower end of the tube should be 1/4"fromthebottomoftheoiljarfornormallubrication.Torepositionthetube,loosen the locknut and adjustthesleeveupordown.Lock the new positionwiththelocknut.For faster lubrication,raise thereservoirtubeawayfromthebottomoftheoiljar.For slower lubrication,lower the reservoir tubetowardthebottomofthejar.To replenish the oil,pull the reservoir upward outoftheadjustingsleeveandturnitover.Add oilthroughthetube.When the upper reservoir isfilled,replace it through the adjusting sleeve andfirmlyseatitagainstthetopofthesleeve.
All Models:The oil wick should be folded in half,with the twoendssubmergedintheoilatthebottomoftheJar,and the folded center inserted into theconnectorapproximately3/8"past the twobreatherholesintheconnector(but not touchingthefeedholeleadingtothepump).Both thebreatherholesandthefeedholemustbeunrestricted.
REF DESCRIPTION QTY 0823-V2 1023-V2NO.1 BODY 1 AK517 AK5182∆VANE 4 AK741 AK7413SHROUD1AK511AK5114ENDPLATE1AK515BAK515B5INTAKEFILTERASSEMBLY1AB599AB5996∆COVER GASKET 2 AA405 AA4057FILTERELEMENTASSEMBLY1AC433AC4338∆CARTRIDGE 2 AC393 AC39310EXHAUSTMUFFLERASSEMBLY1AB599CAB599C11MUFFLERELEMENTASSEMBLY1AC434AC43412CONSTANTLEVELOILER1AD125KAD125K13OILRESERVOIR1AD117AD11714JAR2AA805AA80515JAR1AA935AAA935A16WICK1AA934AA934***SERVICE KIT 1 K486 K486
0823/1023 SERIES
7∆Parts included in repair kit
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Gast finished products, when properly installed and operated under normal conditions of use, are warranted by Gast to
be free from defects in material and workmanship for a period of twelve (12) months from the date of purchase from
Gast or an authorized Gast Representative or Distributor. In order to obtain performance under this warranty, the buyer
must promptly (in no event later than thirty (30) days after discovery of the defect) give written notice of the defect to
Gast Manufacturing Incorporated, PO Box 97, Benton Harbor Michigan USA 49023-0097 or an authorized Service
Center (unless specifically agreed upon in writing signed by both parties or specified in writing as part of a Gast OEM
Quotation). Buyer is responsible for freight charges both to and from Gast in all cases.
This warranty does not apply to electric motors, electrical controls, and gasoline engines not supplied by Gast. Gast’s
warranties also do not extend to any goods or parts which have been subjected to misuse, lack of maintenance,
neglect,damage by accident or transit damage.
THIS EXPRESS WARRANTY EXCLUDES ALL OTHER WARRANTIES OR REPRESENTATIONS EXPRESSED OR
IMPLIED BY ANY LITERATURE, DATA, OR PERSON. GAST’S MAXIMUM LIABILITY UNDER THIS EXCLUSIVE
REMEDY SHALL NEVER EXCEED THE COST OF THE SUBJECT PRODUCT AND GAST RESERVES THE RIGHT,
AT ITS SOLE DISCRETION, TO REFUND THE PURCHASE PRICE IN LIEU OF REPAIR OR REPLACEMENT.
GAST WILL NOT BE RESPONSIBLE OR LIABLE FOR INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND,
however arising, including but not limited to those for use of any products, loss of time, inconvenience, lost profit, labor
charges, or other incidental or consequential damages with respect to persons, business, or property, whether as a
result of breach of warranty, negligence or otherwise. Notwithstanding any other provision of this warranty, BUYER’S
REMEDY AGAINST GAST FOR GOODS SUPPLIED OR FOR NON-DELIVERED GOODS OR FAILURE TO FURNISH
GOODS, WHETHER OR NOT BASED ON NEGLIGENCE, STRICT LIABILITY OR BREACH OF EXPRESS OR
IMPLIED WARRANTY IS LIMITED SOLELY, AT GAST’S OPTION, TO REPLACEMENT OF OR CURE OF SUCH
NONCONFORMING OR NON-DELIVERED GOODS OR RETURN OF THE PURCHASE PRICE FOR SUCH GOODS
AND IN NO EVENT SHALL EXCEED THE PRICE OR CHARGE FOR SUCH GOODS. GAST EXPRESSLY DISCLAIMS
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE OR PURPOSE WITH RESPECT
TO THE GOODS SOLD.THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTIONS SET
FORTH IN THIS WARRANTY, notwithstanding any knowledge of Gast regarding the use or uses intended to be made
of goods, proposed changes or additions to goods, or any assistance or suggestions that may have been made by Gast
personnel.
Unauthorized extensions of warranties by the customer shall remain the customer’s responsibility.
CUSTOMER IS RESPONSIBLE FOR DETERMINING THE SUITABILITY OF GAST PRODUCTS FOR CUSTOMER’S
USE OR RESALE,OR FOR INCORPORATING THEM INTO OBJECTS OR APPLICATIONS WHICH CUSTOMER
DESIGNS, ASSEMBLES, CONSTRUCTS OR MANUFACTURES.
This warranty can be modified only by authorized Gast personnel by signing a specific, written description of any
modifications.
8
TROUBLESHOOTING CHART
Low High Pump Motor Reason and remedyVacuumPressureVacuumPressureOverheatOverloadforproblem.••At pump ••Filter dirty.Clean or replace.•At pump ••Muffler dirty.Clean or replace.•At pump ••Vacuum line collapsed.Repair or replace.••••Relief valve set too high.Inspect and adjust.••Relief valve set too low.Inspect and adjust.••At pump At pump ••Plugged vacuum/pressure line.Inspect and repair.••Vanes sticking.Clean or replace.••Vanes worn.Replace.••Shaft seal worn.Replace.•• ••Dust or offset powder in pump.Inspect and clean.•• •Motor not wired correctly.Check wiring diagram and line voltage.••••Running at too high an RPM.Check wiring diagram and line voltage.
www.gastmfg.comISO9001&14001 CERTIFIED
WARRANTY
-269-926-6171
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ATTACHMENT I
CABARRUS COUNTY – AGROMATTERS COMPOST AGREEMENT
______________________________________________________________________________

ATTACHMENT J
WSACC LEACHATE ACCEPTANCE LETTER
______________________________________________________________________________