NCG140325_COMPLETE FILE - HISTORICAL_20150317

STORMWATER DIVISION CODING SHEET
NCG PERMITS
PERMIT NO.
DOC TYPE
�SHISTORICALFILE
❑ MONITORING REPORTS
DOC DATE
❑
YYYYMMDD

NCDENR
North Carolina Department of Environment and Natural Resources
Pat McCrory
Governor
Mr. Patrick Boone
McDowell Concrete Supply, LLC
P.O. Box 1147
Marion, NC 28752
Dear Mr. Boone:
March 17, 2015
RECEIVED
MAR. 17 2015
CENTRAL FILES
DWR SECTION
Donald R. van der Vaart
Secretary
RECEIVED
MAR 17 4o;a
CENTRAL, FILES
DWR SECTION
Subject. NPDES Stormwater Permit NCG140325
McDowell Concrete Supply, LLC
Formerly McDowell Cement Products, Inc
McDowell County
Division personnel received your request to revise your stormwater permit to accurately reflect
your new company and/or facility name.
Please find enclosed the revised Certificate of Coverage. The terms and conditions contained in
the General Permit remain unchanged and in full effect. This revised Certificate of Coverage is
issued under the requirements of North Carolina General Statutes 143-215.1 and the
Memorandum of Agreement between North Carolina and the U.S. Environmental Protection
Agency.
If you have any questions or need further information, please contact the Stormwater Permitting
Program at [phone].
Sincerely,
for -Tracy E. Da ' , P.E., CPM, Director
Division of Energy, Mineral and Land Resources
cc: Asheville Regional Office
Stormwater Permitting Program Files
Central Files
Division of Energy, Mineral, and Land Resources
Energy Section - Geological Survey Section • Land Quality Section
1612 Mail Service Center, Raleigh, North Carolina 27699-1612 - 919-707-92001 PAX: 919-715-8801
512 North Salisbury Street, Raleigh, North Carolina 27604 • Internet: htt:11 ortal.ncdenr.or Iweblirl
An Equal Opportunity 1 Affirmative Action Employer — 50% Recycled 110% Post Consumer Paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF ENERGY, MINERAL, AND LAND RESOURCES
GENERAL PERMIT NO. NCG140000
CERTIFICATE OF COVERAGE No. NCG140325
STORMWATER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
McDowell Concrete Supply, LLC
is hereby authorized to operate approved wastewater treatment system(s) and discharge
stormwater and/or wastewater, as approved in the original permit/application or subsequent
permit modification, from a facility located at:
101 South Garden Street
Marion
McDowell County
to receiving waters designated as an unnamed tributary to Youngs Fork, a class C water, in the
Catawba River Basin in accordance with the effluent limitations, monitoring requirements, and
other conditions set forth in accordance in Parts I, II, III, and IV of General Permit No.
NCG140000 as attached.
This certificate of coverage shall become effective March 17, 2015.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day March 17, 2015.
for Tracy E. Davis, P.E., Director
Division of Energy, Mineral, and Land Resources
By the Authority of the Environmental Management Commission

��7
` - r ; � Division of Energy, Mineral & Land Resources
r Land Quality Section/Stormwater Permitting
NCI.VLPiPDEn�NR National Pollutant Discharge Elimination System
NORM CAR- T-ENT OF
r_-ei+ -N41. ,R£]OL1n PERMIT NAME/OWNERSHIP CHANGE FORM
FOR AGENCY USE ONLY
Date Received
Year
Month
Day
I. Please enter the permit number for which the change is requested.
NPDES Permit (or) Certificate of Coverage -
N G S O N C G 1 1 1 4 1 0 1 3 2 5
It. Permit status prior to requested change.
a. Permit issued to (company name): McDowell Cement Products, Inc
b. Person legally responsible for permit: Robert H Boone
!�
/ I �� t First MI Last
r ` President
Title
P.O.Box 1147
Permit Holder Mailing Address
Marion NC 28752
City State Zip
[phone]„ [phone]
E'hone Fax
c. Facility name (discharge): McDowell Cement Products
d. Facility address: 101 South Garden STreet
Address
Marion NC 28752
City State Zip
c. Facility contact person: Pat Boone [phone]
First / MI 1 Last Phone
III. Please provide the following for the requested change (revised permit).
a. Request for change is a result of: ® Change in ownership of the facility
® Name change of the facility or owner
If other please explain:
b. Permit issued to (company name):
c. Person legally responsible for permit:
RECEIVED
JAN 2 3 2015
DENR-LAND QUALITY
STORMWATER PERMITTING
d. Facility name (discharge):
e. Facility address:
f. Facility contact person:
McDowell Concrete Supply, LLC
Patrick
Bootle
First
M1 Last
Member 1 Owner
Title
P.O. Box 1 147
Permit Holder Mailing Address
Marion
NC 28752
City
State Zip
[phone]
Phone
E-mail Address
Mcdowell
Concrete Supply, LLC
101 South Garden Street
Address
Marion
NC 28752
City
State Zip
Patrick
Boone
First
Ml Fast
[phone]
Phone
E-mail Address
IV. Permit contact information (if different from the person legally responsible for the permit)
Revised Jan. 27, 2014

NPDES PERMIT NAME/OWNERSHIP CHANGE FORM
Page 2 of 2
Permit contact:
Patrick Boone
First M I Last
Member / Owner
"Title
101 South Garden Street
Mailing Address
Marion NC 28752
City State Zip
[phone]
Phone E-mail Address
V. Will the permitted facility continue to conduct the same industrial activities conducted prior
to this ownership or name change?
® Yes
❑ No (please explain)
VI. Required Items: THIS APPLICATION WILL BE RETURNED UNPROCESSED IF ITEMS
ARE INCOMPLETE OR MISSING:
❑ This completed application is required for both name change and/or ownership change
requests.
❑ Legal documentation of the transfer of ownership (such as relevant pages of a contract deed,
or a bill of sale) is required for an ownership change request. Articles of incorporation are
not sufficient for an ownership change.
The certifications below must be completed and signed by both the permit holder prior to the change, and
the new applicant in the case of an ownership change request. For a name change request, the signed
Applicant's Certification is sufficient.
PERMITTEE CERTIFICATION (Permit holder prior to ownership change):
I, Robert H Boone, attest that this application for a name/ownership change has been reviewed and is
accurate and complete to the best of my knowledge. I understand that if all required parts of this
application are not completed and that if all required supporting information is not included, this application
package will be returned as incomplete.
94t, t /�/ / // z 11-5
Signature Date
APPLICANT CERTIFICATION
I, Patrick Boone, attest that this application for a name/ownership change has been reviewed and is accurate
and complete to the best of my knowledge. I understand that if all required parts of this application are not
completed and that if all required supporting information is not included, this application package will be
returned as ncom ete.
Signature Date
PLEASE SEND THE COMPLETE APPLICATION PACKAGE TO:
Division of Energy, Mineral and Land Resources
Stormwater Permitting Program
1612 Mail Service Center
Raleigh, North Carolina 27699-1612
Revised Jan. 27, 2014

wAr�RQ�
0
O 'C
June 2, 2008
Pat Boone
McDowell Cement Products Inc
PO Box 1147
Marion NC 28752
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
SUBJECT: NPDES Stormwater Permit Compliance Inspection
McDowell Cement Products Inc
Permit No: NCG140325
McDowell County
Dear Mr. Boone:
Coleen H. Sullins, Director
Division of Water Quality
This letter is in follow-up to the NPDES Stormwater Permit Compliance Inspection conducted on May 19,
2008. The facility's constructed waste treatment unit was found to be in compliance with the issued
Authorization to Construct.
Enclosed is a copy of the Compliance Inspection Report, which contains additional observations and
comments for your reference. The facility is responsible to make sure that the waste treatment unit operates
such that no water discharges onto adjacent ground or into the adjacent creek. If the treatment unit
discharges additional measures will likely be required to bring the facility into compliance.
Copies of the NCG 140000 permit, monitoring form and technical bulletin are included in this
correspondence for your reference. The facility must come into compliance with all conditions of this
permit. A stormwater pollution prevention plan must be developed and implemented, and monitoring must
be conducted in accordance with permit conditions.
Please contact me at [phone] or starr.silvis(i)nemail.net, if I can be of any further assistance.
Sincerely,
Starr Silvis, P.E.
Environmental Engineer
Enclosure
cc: Mr. Ken Pickle, Stormwater Permitting Unit
Central Files
Asheville Files
No Carolina
Nawrally
North Carolina Division of water Quality 2090 U.S. Highway 70 Swannanoa, NC 28778 Phone [phone] Customer Service
Internet: www,,ncwalorquality.org FAX [phone]
An Equal OpportunitylA(frmative Action Employer— 50% Recydedl10% Post Consumer Paper
G:IWPDATAIDEMN1QWcdowelRStormwater Redi-Mix NCG14WcDowell Cement ProductslCEI 05-08.doc

4S �
Compliance Inspection Report
Permit: NCG140325 Effective: 08/01/04 Expiration: 07/31/09 Owner: McDowell Cement Products Inc
SOC: Effective: Expiration: Facility: McDowell Cement Products Inc
County: McDowell S Garden St
Region: Asheville
Marion NC 28752
Contact Person: Pat Boone Title: Phone: [phone]
Directions to Facility:
System Classifications:
Primary ORC: Certification: Phone:
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Inspection Date: 05/1912008 Entry Time: 09:00 AM Exit Time: 09A5 AM
Primary Inspector: Starr Silvis Phone: [phone]
Secondary Inspector(s):
Reason for Inspection: Fallow -up Inspection Type: Compliance Evaluation
Permit Inspection Type: Ready Mix Concrete StormwaterNVastewater Discharge
COC
Facility Status: ■ Compliant ❑ Not Compliant
Question Areas:
Other
(See attachment summary)
Page: 1

Permit: NCG140325 Owner - Facility: McDowell Cement Products Inc
Inspection Date: 05/19/2008 Inspection Type: Compliance Evaluation Reason for VisIt: Follow-up
Inspection Summary:
The facility has closed the trench and moved truck washing operations as instructed. The weirs have been cut down 6
inches so that the unit can operate without discharging. Mr. Boone was instructed to operate the system such that the unit
does not overflow or discharge. He was informed that should the unit discharge we will need to reevaluate the unit and
the operation and may require pH treatment.
The facility now needs to come into compliance with all other permit conditions, including; developing and implementing a
stormwater pollution prevention plan, conducting monitoring, etc.
Other
Comment:
Yes No NA NE
Page: 2

Permit: NCG140325
SOC:
County: McDowell
Region: Asheville
Compliance Inspection Report
Effective: 08/01/04 Expiration: 07/31/09 Owner: McDowell Cement Products Inc
Effective: Expiration: Facility: McDowell Cement Products Inc
S Garden St
Contact Person: Pat Boone
Directions to Facility:
System Classifications:
Primary ORC:
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Inspection Date: 06/14/2008
Primary Inspector: Starr Silvis
Secondary Inspector(s):
Title:
Entry Time: 12:35 PM
Marion INC 28752
Phone: [phone]
Certification
Exit Time: 01:27 PM
Phone:
Phone: [phone]
Reason for Inspection: Follow-up Inspection Type: Compliance Evaluation
Permit Inspection Type: Ready Mix Concrete 5tormwater/Wastewater Discharge
COC
Facility Status: ■ Compliant 0 Not Compliant
Question Areas:
0 Other
(See attachment summary)
Page: 1

Permit: NCG140325 owner • Facility: McDowell Cement Products Inc
Inspection Date: 05114/2008 inspection Type: Compliance Evaluation Reason for Visit: Follow-up
Inspection Summary:
The inspection was to review the constructed wastewater treatment system for compliance with the issued Authorization
to Construct. The construction was not in accordance with the approved plans. At the time of the inspection there was a
trench that had been dug which increased the contributing area significantly. The trench was not on the approved plans.
Mr. Pat Boone was instructed to fill the trench and to limit the contributing area to that which was on the approved plans.
Truck washing activities were taking place in an area not shown on the approved plans. Mr. Boone was instructed to
move truck washing activites to the constructed truck wash pad.
At the time of the inspection the treatment facility was discharging onto the ground. Upon further investigation it was
determined that the design for the treatment facility was not correct. There was no provision in the design for the required
foot of freeboard. In order for the unit to funtion properly the water level must be maintained such that it is topping the
weirs between the chambers. However, at the level where the weirs are being topped, the unit begins to overflow onto
the adjacent ground. The problem lies in the fact that there is no freeboard designed into the sytem. After conversations
between the inspector and Mr. Ken Pickle of the stormwater permitting unit in Raleigh it was determined that the best
course of action at this time was to have Mr. Boone cut out 6 inches of the weirs so that the unit can operate without
discharging.
Other
Comment:
Yes No NA NF
Page: 2

TRIGON I KLE[NFELDER, INC.
3500 Gateway Centre Blvd., Suite 200 • Morrisville, North Carolina 27560 • P 919.755,501 1 •
LETTER OF TRANSMITTAL
TO: Mr. Ken Pickle - Environmental Engineer II
NCDENR — Division of Water Quality
Stormwater Permitting Unit
1617 Mail Services Center
Raleigh, NC 27699-1617
WE ARE SENDING YOU THE FOLLOWING ITEMS:
DATE: May 8, 2008 '
RE: Engineer's Certification —
McDowell Cement Facility
❑ Attached ❑ Under separate cover via:
v / /13
GsyL��f ,$coal � ffll%/�EM2i/
COPIES
DESCRIPTION
I
Signed and Sealed Engineer's Certification Form
THESE ITEMS ARE TRANSMITTED AS CHECKED BELOW:
Q For Your Approval Q For Your Files For Responsible Official Signature (where noted) ❑ For Fonvardingto NCDENR
REMARKS:
Mr. Pickle,
Please find attached the engineer's certification form associated with a recent stormwater permit application for
the installation of a wash water recycle system at the McDowell Cement facility in Marion, North Carolina. Mr.
G. Stephen "Steve" Lineback of Trigon's Greensboro office prepared the design plans and provided the site
inspections and subsequent certification that the proposed stormwater conveyance systems were installed as
designed. Please review this form and assuming it meets your approval, reply to Mr. Todd Phillips of Trigon via
mail or e-mail with your authorization to proceed operation of the newly permitted stormwater conveyances at
the referenced facility. McDowell Cement also requests that NCDENR issue a new copy of their stormwater
permit and certificate of coverage to Mr. Phillips. If you have any questions or concerns, please feel free to
contact Mr. Phillips at your convenience (contact information below).
Transmitted By:
Todd R. Phillips — Noject Manager
Trigon I Kleinfelder, Inc.
3500 Gateway Centre Blvd., Suite 200
Morrisville, NC 27560
Phone: 919,755.501 1 ext. 103
Fax: 919,755,1414
e-mail: [e-mail]

Mr. Robert Boone
Page 3 of 3
November 7, 2007
Engineer's Certification
as a dui istered Professional Engineer in the State
of North Carolina have to observed periodicaii weekly, full time) the construction of
the project,
Project Name
Location
for the Permittee, i hereby state that, to the best of my abilities, due care and diligence
was used In the observation of the construction and Installation of a truck wash water
recycle system, a transfer pump and piping, a truck wash pad, and 70' of 12" RCP
conveyance system for other wastewaters, such that the construction was observed to be
built within substantial compliance and intpn� of the approved plans and specifications,
Signature
Registration No. -ag. e3 v.
Date / . 01a08
FA
Mail this Certification to: Stormwater Permitting Unit
NC Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
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O�O� W A rFi94G Michael F. Easley, Governor
7 William G. Ross Jr., Secretary
r- North Carolina Department of Environment and Natural Resources
0 t Coleen H. Sullins, Director
Division of Water Quality
November 7, 2007
Mr. Robert H. Boone
McDowell Cement Products, Inc.
POB 1147
Marion, North Carolina 2752
Subject: Authorization to Construct
McDowell Cement - Marion plant
NCG140325
McDowell County
Dear Mr. Boone:
The Division of Water Quality (DWQ) received your request to construct stormwater and
wastewater controls at the subject facility on December 28, 2006, and again with revisions on
February 6, 2007, and on June 4, 2007 with further revisions, and on October 29, 2007. In
accordance with your request, you are authorized to construct the approved control facilities,
effective today.
Authorization is hereby granted for the construction and installation of 70' of 12" RCP, a truck
wash pad, a three -cell wash water recycle system, a recycle pump; and a recycle pump discharge
line back to the mix plant, all_ in accordance with the approved site drawing, equipment
specifications, and submitted design calculations.
You must notify DWQ's Asheville Regional Office supervisor, telephone number [phone], at
least 48 hours in advance of operation of the installed facilities so that regional office staff can
conduct an in -place inspection. prior to operation. Such notification to the regional supervisor shall
be made during the normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through
Friday, excluding state holidays.
Upon completion of construction and prior to operation of the authorized controls, you must
submit a certification from a professional engineer certifying that the controls have been
constructed and installed in accordance with the NPDES permit requirements in NCG140000, the
Certificate of Coverage NCG140325, this Authorization to Construct, and the approved site plan,
specifications, and calculations. Please mail the engineer's certification to DWQ Stormwater
Permitting Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617. Our
Authorization to Construct is subject to revocation unless the control facilities are constructed in
accordance with the approved site plan, specifications, and calculations.
You must maintain on file a copy of the approved site plan, specifications, and design calculations
for the life of the facility.
In the event that the controls fail to perform satisfactorily, including the creation of nuisance
conditions, you must take immediate corrective action, including those actions as may be required
by this Division, such as the construction of additional or replacement controls.
One
No;thCarolina
Naturally
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
Internet: www.newaterquality.org Location: 512 N. Salisbury St. Raleigh, NC 27604 Fax [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

Mr. Robert Boone
Page 2 of 3
November 7, 2007
Failure to abide by the requirements contained in this Authorization to Construct may subject the
Permittee to, an enforcementaction by DWQ, in accordance with North Carolina General Statute
143-215.6A to 143-215.6C.
This Authorization to Construct does not affect the legal requirements to obtain other permits or
authorizations that may be required by DWQ, or other federal, state, or local government
agencies.
Please contact Ken Pickle at [phone] x 584, with any comments or questions.
Sincerely,
r e Coleen H. Sullins
Enclosure: -Approved plans
cc: Todd Phillips, Trigon Engineering, 700 Blue Ridge Rd., Raleigh, NC 27606
DWQ Asheville Regional Office
DWQ Central Files, letter only
SPO file NCG140325

McDowell Cement
L rI `
C •` a
Subject: McDowell Cement
From: Starr Silvis <[e-mail]>
Date; Thu, 19 Jul 2007 13:15:01 -0400
To: Ken Pickle <Ken.Pickle@ncmaiLnet>
CC: [e-mail]
H i Ken,
1 am sending you the latest A to C request from McDowell Cement. Please note that the second request
stated that it would be returned if incomplete. I am also attaching electronic copies of the correspondence
from me to them to date. I will include in the mail package copies of the ARO file for McDowell Cement,
Please note that I sent the most recent add info letter April 2. We met on site on April I 1 to discuss the
deficiencies and possible remedies. At that time I said that if the submittal was complete I would do my
best to expedite the turn around time. I did not receive a submittal from them until June 4th.
Here are my list of concerns and comments about the current submittal;
1) The Volume calculations appear to be correct. 1 scaled off the delineated drainage areas and calculated
using the simple method - their number is slightly higher which is fine.
/ 2) The table on the last page shows average plant mix required to be 2,900 gallons. I would like to see
some documentation on how this number was derived. Le. how many batches per day, how much per
batch, i.e. finish the water balance.
3) the plans show the drainage areas delineated, but how does this work on the ground? They will need
curbs or other diversion structures, which 1 do not see detailed on the plans.
✓ 4) Also the bar runoff from one of the spray bars will be generated at the area labeled concrete mixing area
adjacent to the block building on the pad. how will the water be transported to the treatment system?
5) how will water be recycled? I do not see a pump or other mechanism proposed to drain the treatment
area after a rain event.
6) The elevation on the southwest corner of the truck washpad is such that water will runoff onto adjacent
areas. how will this be captured?
I may still be in the office when you receive these plans, don't hesitate to contact me with any questions. I
will also be available via e-mail - though my response time may be slow. This baby thing may take more
time and energy than I can predict at this point, not something I have any experience with :)
Thanks again for your help!
Starr Silvis, P.E. - [e-mail]
Environmental Engineer -_
North Carolina Dept_ of Environment and Natural Resources
Asheville Regional office
Division of Water Quality - Surface Water Protection Section
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Starr Silvis, P.E. <Starr.SilyiS ri,ncmail.net>
Environmental Engineer
NC DEER - Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
] of 2 7/20/2007 7:55 AM

[Fwd: McDowell Cement]
Subject: [Fwd: McDowell Cement]
From: Starr Silvis <Starr.Silvis a ncmail.net>
Date: Thu, 19 Jul 2007 12:38:43 -0400
To: Ken Pickle'<[e-mail]>
Starr Silvis, P.E. - [e-mail]
Environmental Engineer
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Subject: McDowell Cement
From: "Winegar, James" <[e-mail]>
Date: Fri, 22 Jun 2007 12:11:51 -0400
To: <[e-mail]>
I am the new project manager for McDowell Cement (Doug Johnson resigned last week) and am writing to
request an update on the status of the stormwater permit for their Marion facility.
Thanks,
James B. Winegar
Sr. Project Manager
Trigon Engineering Consultants, Inc.
3344 Hillsborough Street, Suite 200
Raleigh, NC 27607
Phone: [phone], Ext. 109
Fax: [phone]
Starr Silvis, P.E. <Starr.Silvis c ncmail.net>
Environmental Engineer
i
NC DENR - Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
McDowell Cement Content -Type: message/rfc822
Content -Encoding: 7bit
1 of 1 7/20/2007 7:55 AM

5J
ENGINEERING CONSULTANTS, INC.
www. frigoireng. com
P.O. Box 18846 • Zip 27419-8846 • 313 Gallimore Dairy Road • Greensboro, NC27409 . p 336.668.0093 • f 336.668.3868
May 31, 2007
Starr Silvis - Environmental Engineer
NCDENR
Asheville Regional Office
2090 U.S. Highway 70
Swannanoa, NC 28778
Subject: Additional Information Request
Authorization to Construct Application
Permit NCG 140325
McDowell Cement Products
McDowell County
Dear Ms. Silvis:
In response to your request for additional information dated 04/02/2007, we have enclosed three sets of
the revised plans and calculations. Our responses to your comments are not below.
Per your comments we have decided to reduce the area included in the treatment system to capture only
that area of the site that contains process water. We have provided for a truck washdown area as shown on
the plans, and have provided underground piping to provide flow for the spray from the spray bars at the
plant area to drain to the treatment basin. We have enclosed a revised water balance_tharshows=we will
recycle the entire 25 year storm from the treatment basin to the plant. This revision should take care of
your comments on the previously prepared plans, and should eliminate any discharge from the treatment t
system for storm water runoff from storms up to the 25 year storm.
If you have any further comments or questions, please contact us.
Sincerely,
k" z.M11 to-. _• � - _, _ _ ...P,I��»_
�
T GON`ENGG\ ENGINEERING CONSULTANTS, INC. �
PC: Doug Johnson
Pat Boone — McDowell Cement Products
Trigon Engineering Consultants, Inc.

11TRIGONIJ
ENGINEERING CONSULTANTS, INC.
www.trigoneng.com
P.O. Box 18846 * Zip 27419-8846 - 313 Gallimore Dairy Road * Greensboro, NG 27409 - p 336.668.0093 o f 336.668.3868
LETTER OF TRANSMITTAL
To: Starr Silvis -Environmental Engineer
NCDENR
Ashville Regional Office
2090 US Hwy 70
Swanna.noa, NC 28778
Date: 02/02/2007
Regular Mail
Express Mail
Federal Express X
Hand Carried
Other
COPIES PAGES 77�
;�:.:r'DESCRIPTiiIA 3 3 McDowell Cement Products Site Plan
3 1 4 1 Additional Information Request and Calculations
Comments:
Please contact Pat Jennings if you have any questions.
C rff
J -4 2007
UN
WATER QUALITY SECTION
ASHEVILLE REGIONAL OFFICE
Anthony O. Stolts, E.I.
11111aiik YL)ij {or OUr SUCCVFS.

SHEET LIST TABLE
TITLE
REVISION
05-30-07
N CONTROL PLAN
05-30-07
05-30-07
Dig ; Safely.
two workinna4Z3 44rt-
Kp
��fore You9N4o
l-800-632-4949
�. DLI
i
i WA'. C C r.ON
r A� 'CE
SITE PLAN
COVER SHEET
MCDOWELL CEMENT
PRODUCTS COMPANY
101 SOUTH GARDEN STREET
MARION TOWNSHIP
TOWN OF MARION
MCDOWELL COUNTY,
NORTH CAROLINA, 28752
HORZ. SCALE: NIA
VERT. SCALE: NIA
DESIGNED BY: PCJ
DRAWN BY: AOS
CHECKED BY: PGJ
DATE: 10-25-06
PROJECT NUMBER: 045-06-081
DRAWING

recu f,o
Date: May-07 KZ a...p dV*%(L
Project'. McDOWELL CEMENT
Project No.: 04506081
Location: Marion, NC
Designed by: PJ
SCS RUNOFF CURVE NUMBER COMPUTATION SHEET
BASIN
LAND USE
SOIL NAME 1
HYDROLOGIC GROUP
AREA
(ACRES)
AREA
(%)
CURVE NO.
(CN)
PRODUCT
CN X AREA
EXISTING
Concrete Pavement
VARIOUS SOILS 1 B
0.12
100.00%
98
98.0
Building 1
0.0
0.0
TOTALS
0.12
100.00%
98.0
NOTES: WEIGHTED CN W 98
from NCRS TR55

0
Date: May-07
z Project: McDOWELL CEMENT
Project No.: 04506081
Location: Marion, NC
TRIOON Designed by: PJ
STORM WATER TREATMENT DESIGN
Drainage Area = 0.12 acres see Drainage Area Map
Weighted RCN = 98
t,= 0.10 hrs
18 = 0.04 in.
Rainfall Depth (P):
(25yr. R.I.) = 6.7 in
Runoff:
(25 yr. R.I.) = 6.46 in.
V, = 2,878 cf
Unit Peak Discharge:
Peak Flow:
assumed minimum time of concentration TR55
la = 0.2S
where S = (1000/RCN) - 10
from NC Rainfall Maps 25 year- 1 day storm
R.O. = (P - 0.2S)2 / (P + 0.8S)
where S = (1000/RCN) - 10
Vr = R,O.(in.) * D.A.(acres) / (43,560 sf/acre * 12 in./ft.)
la/P = 0.01
(25 yr. R.I.) = 1010 csm/in. from NCRS TR55 - Exhibit 5-II
Weir Design:
Q25 = 1.3 cfs
H,,= 0.20ft
Cd = 3.0
L = 4.7 ft
Storage Volume:
Provide 3-Compartment Box
1 st Compartment
Length = 19.0 ft
Width = 18.0 ft
Depth = 4.5 ft
Volume =* 1,539 cf
2nd & 3rd Compartments
Length = 19.0 ft
Width = 14.0 ft
Depth = 4.5 ft
Volume =* 2,394 cf
Total Volume =* 3,933 cf
Q25 = P (in.) * Unit Peak Discharge (csm/in. R.O.) * D.A.(acres) / 640 acres/sm
H,f, = headwater depth over weir
broadcrested weir coefficient of discharge
L= Q/(Cd*H3r2)
minus 1-foot of freeboard to weir elevation
minus 1-foot of freeboard to weir elevation
Volume required = 2905 cf
volume not including 1-foot of freeboard over weir

Date: May-07
Project: McDOWELL CEMENT
Project No.: 04506081
Location: Marion, NC
iRIGON Designed by: PJ
STORM WATER TREATMENT DESIGN _
Design Elevations:
Bottom El. = 1359.25
Top of Sediment = 1359.50
Top of Require Storage = 1364.00
Top of Tank = 1365.00
assume 3-inch permanent sediment layer
at 4.5-foot depth
1-foot of freeboard

Date: May-07
Project: McDOWELL CEMENT
Project No.: 04506081
Location: Marion, NC
Designed by: PJ
SITE WATER BALANCE
LSource I (gallons) I (gallons) ITotal I E
Storm Water Runoff
2,878
2,878
Truck Wash
200
' 200
0
based on 8 trucks/day " 25 gallonsltruck
Drum Rinse
100
100
0
Spray Bar - Plant Loadou
50
- 50
0
based on 2 bars " 25 gallons/day/bar
Plant Mix Water
2,900
(2,900)
avers a plant mix required
Total Water Use 1 3,2281 3,250 -22

Re: [Fwd: McDowell Cement]
Subject: Re: [Fwd: McDowell Cement]
From: Starr Silvis <Starr. Silvis @ncmail. net>
Date: Mon, 16 Apr 2007 1 1:00:25 -0400
To: Ken Pickle <ken,[e-mail]>
Hi Ken,
1 did indeed go with the business as usual approach. DAQ has decided to suspend issuing their permit
until McDowell Cement gets their A to C from us. They have resubmitted in response to the 1 /25/2007
add -info letter, however that submittal was inadequate (showed discharge of 195,000 gallons of
wastewater). I just sent them a second add -info on 3/30. 1 think they now understand that their best bet
is to minimize the contributing area for wastewater. They plan to resubmit in the next two weeks.
I reviewed the file before the meeting and was chagrined to find that regional office staff had suggested
in October of 2005 that they collect all wastewater and stormwater in a central location for treatment. It
has taken a lot of time and hand holding to undo that damage. But I think we finally have gotten through
to them.
So for the time being, I think we are ok both with the permittee and DAQ.
Thanks for the follow up!
Starr
Ken Pickle wrote:
Starr,
I'm sorry we couldn't be much help on this question, yet. How did you address this with DAQ and
McDowell?
Did you go with the "business as usual" approach? Has McDowell responded to your 1 /25/07
add -info letter?
Ken
Starr Silvis wrote:
FYI
Starr Silvis - Starr. Silvis Pncmail.net
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel. [phone]
Fax: [phone]
1 of 3 4/16/2007 11:28 AM

Re: [Fwd: McDowell Cement]
w�
r"
Subject:
McDowell Cement
From:
Harold Brady <[e-mail]>
Date:
Fri, 30 Mar 2007 14:06:54 -0400
To:
Starr Silvis <Starr.S1lvisp,ncmai1.net>
To:
Starr Silvis <Starr.Silvispncmai1.net>
Starr:
Air Quality will not issue the air permit for McDowell Cement until the water treatment issue is
resolved with your Division. I am to draft a letter to notify the facility. I need to get with you
on Monday, if you're available, to help me get the verbiage consistent with yours. I'll also need
to get some information about applications, etc.
I plan to leave early, so I won't bother you today.
Thanks a lot.
Harold
Harold Brady - Harold. Brady(a ncmai1.net
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Air Quality
2090 US70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Starr Silvis - [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
2090 U.S. 70 Highway
Swannanoa, NC 28778
2 of 3 4/16/2007 11:28 AM

Mr. Patrick C. Jennings II
Trigon Engineering Consultants, Inc.
PO Box 18846
Greensboro, NC 27409
Dear Mr. Jennings:
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of water Quality
April 2, 2007
2D
€ FL. 1 0 20P
DENR - WA-TeR QUALI
id"tinnrlc ^ , . —a per Rmnrr'
Subject: Additional Information Request
Authorization to Construct application
Permit NCG140325
McDowell Cement Products
McDowell County
On December 28, 2006, the Division of Water Quality, Stormwater Permitting Unit received your
application for an authorization to construct treatment facilities at the subject site in Marion, North
Carolina. On January 25, 2007 additional information was requested. On February 6, 2007 the
additional information was received. North Carolina rules require DWQ to conduct an engineering
review of your request for an Authorization To Construct.
For a sufficient application, the information must demonstrate compliance of final discharge with permit
effluent limits (pH — 6-9 SU, Total Suspended Solids (TSS) — 30 mg/I, and Settleable Solids (SS) - 5
ml/1), or must demonstrate that the recycle system has sufficient capacity to contain runoff from a 25-
year, 24-hr rainfall event plus one foot of freeboard under design operating conditions (from the Notice
of Intent for stormwater and process water discharges associated with activities classified as Standard
Industrial Classification Code 3273 Ready Mixed Concrete), There are two potential options to satisfy
these conditions 1) demonstrate compliance of final discharge with permit effluent limits, or 2) design
the recycle system to contain (i.e, not discharge) runoff from a 25-yr, 24-hr rainfall event.
1) Demonstrate compliance of final discharge with permit effluent limits. -The most recent application
indicates that approximately 195,000 gallons of wastewater will be discharged into the on -site stream.
Calculations demonstrating compliance of final discharge with permit effluent limits must be provided in
order for DWQ to permit this discharge. The application states that the water will be treated for pH prior
to discharge. However, there is no evidence included in the application that indicates compliance with
total suspended solids limits (TSS). In order to permit this site as designed, you must to provide
calculations that support the assertion that the wastewater discharge will meet TSS limits.
2) Design the recycle system to contain and not discharge runoff from a 25-yr, 24-hr rainfall event.
The system could be redesigned to capture only that portion of the runoff from the property that
contains process wastewater. This would significantly reduce the volume of wastewater the facility has
to treat and/or contain. Many ready mix sites permitted to date have minimized the amount of
contributing area, therefore reducing total wastewater volume. These sites then entirely recycle the
wastewater into batches. This option eliminates the need to provide TSS calculations by eliminating
discharge of wastewater to the stream.
NorthCarolina
Alatrrra!!y
North Carolina Division of Water Quality, 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
lnternct: wmw,ncwvatergnalitv.orQ Location: 512'N. Salisbury St, Raleigh, NC 27604 Fax [phone]
An Equal OpponunitylAf#innative Action Employer — 50% Recycledl10% Post Consumer Paper

Mr. Patrick Jennings
Page 2 of 2
April 2, 2007
In summary if you choose to proceed with the design as submitted you are required to submit
calculations and sound engineering evidence that the discharge will meet permit effluent limits as
described above. If you choose to redesign the treatment facilities they must contain the entire 25-yr,
24-hr storm event, and provide for reuse of this water on the site so that the system is brought back to
initial conditions in a reasonable amount of time.
Please note that three copies of any re -submittal are required. Should your resubmittal fail to
demonstrate this requested evidence, entire application will be returned for revision.
Sincerely,
1`
Starr Silvis
Environmental Engineer
Asheville Regional Office
[phone]
cc: ARO
Pat Boone, McDowell Cement Products, PO Box 1147, Marion, NC 28752
',-,.-Ken Pickle,. SPU .files- -
DWQ Central Files

[Fwd: [Fred: [Fwd: [Fwd: Concrete Batch Water Spray]]]]
Subject: [Fwd: [Fwd: [Fwd: [Fwd: Concrete Batch Water Spray]]]]
From: Starr Silvis <[e-mail]>
Date: Thu, 29 Mar 2007 09:16:45 -0400
To: Ken Pickle <[e-mail]>
Starr Silvis -- Starr.Silvis@ncmail.
North Carolina Dept. of Environment
Asheville Regional Office
net
and Natural Resources
Division of Water Quality - Surface Water Protection Section
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Subject: [Fwd: [Fwd: {Fwd: Concrete Batch Water Spray]]]
From: Harold Brady <Harold.Brad y@nemail. net>
Date: Mon, 26 Mar 2007 08:45:57 -0400
To: Starr Silvis <[e-mail]>
OOPS!!
There are two of these spray systems at this facility now, so runoff will be 48 gallons per hour instead of
24.
Harold
Harold Brady - [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Air Quality
2090 US70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Subject: [Fwd: [Fwd: Concrete Batch Water Spray]]
From: Harold Brady <[e-mail]>
Date: Mon, 26 Mar 2007 08:35:14 -0400
To: Starr Silvis <[e-mail]>
Starr
I may have gotten things out of order here, but please bear with me.
1 of 4 4/16/2007 10:42 AM

[Fwd: [Fwd: [Fwd: [Fwd: Concrete Batch Water Spray]]]]
McDowell Cement in Marion has applied to install a water spray system to control cement particulate
emissions from the truck mix on their two truck mix operations. The design they supplied provides for 8
spray nozzles with a total volume rate of 24 gallons per hour (3 gallons per hour each) and it appears
that most if not all the water will go to run-off. (I have a sketch of the design if you wish to review it.)
In accordance with the attached email, the Division of Air Quality requests that DWQ supply an
"approval" letter (email) for the additional runoff generated by the water spray.
Any questions, let me know.
Thanks,
Harold (Office #202)
Harold Brady -- Harold. [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Air Quality
2090 US70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Subject: [Fwd: Concrete Batch Water Spray]
From: Patrick Ballard <Patrick. Ballard @ncmail. net>
Date: Wed, 21 Jun 2006 14:02:41 -0400
To: Melanie Pitrolo <[e-mail]>, Chris Scott <[e-mail]>, Harold
Brady <[e-mail]>
FYI
Patrick Ballard - [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office
Division of Air Quality
2090 U.S. 70 Highway
Swannanoa, NC 28778
Tel: [phone]
Fax: [phone]
Subject: Concrete Batch Water Spray
From: Tom McKinney <[e-mail]>
Date: Wed, 21 Jun 2006 12:29:26 -0400
To: "Sammy.Amerson" <[e-mail]>, "DENR.Permit_Coordinators.DAQ"
<[e-mail]>
2 of 4 4/16/2007 10:42 AM

[Fwd: [Fetid: [Fwd: [Fwd: Concrete Batch Water Spray]]]]
CC: Richard. Morris@ncmail. net, Donald vanderVaart <Donald,vanderVaart@ncmaiLnet>,
Steven. Vozzo@ncmaiLnet, Betty Gatano <Betty.Gatano@ncmaiLnet>, Gary. Saunders@ncmailnet,
Mark.Yoder@ncmailnet, Markus. ElIiott@ncmailnet, Jim.Moser@ncmaiLnet, Jay Evans
<Jay,[e-mail]>, Jim Roller <Jim.Rol ler@ncmailnet>, Christy. Richardson@ncmailnet,
Michael Pjetraj <Michael.Pjetraj@ncmaiLnet>, Fern. Paterson@ncmaiLnet, Robert. Hayden@ncmailnet,
Thom Allen <[e-mail]>, William Willets <Will]am.Willcts@ncmaiLnet>, Donnie
Redmond <Donme.Redmond@ncmaiLnet>, lloydpb <[e-mail]>, Ashley Featherstone
<Ashley. Featherstone@buncombecounty. org>, Donna Cavaliere <CAVALDS @co.meeklenburg.nc.us>,
liucs <[e-mail]>, Robert.Kennedy@ncmaiLnet
This is a quick update to the PWG minutes on the issue of concrete batch plants that
want to use "water spray" controls rather than filter systems. The "immediate" cases
include one facility in the Fayetteville region and one in the Asheville region. The
first step requires that the facility submit information about the control system and
water runoff to DENR Water Quality and request that a letter of "approval" be
forwarded from DWQ to DAQ. The second step is the DAQ review of the proposed control
device with respect to AQ issues. Gary Saunders will conduct a technical review for
each "water spray" application. (For the Fayetteville facility, he has already
deemed the system "equivalent" to a central dust collector system.) As we gradually
get more experience with these alternative control systems we will be able to develop
additional guidelines for both permits and compliance. Feel free to forward any
questions, comments, or suggestions.
Patrick Ballard <P atri ck. Ball ardgncmail.net>
ncmailnet>
NC DENR - Asheville Regional Office
Division of Air Quality
Harold Brady <Harold.Brady cr,ncmail.nct>
NC DENR - Asheville Regional Office
Division of Air Quality
Harold Brady <Harold.Brady@,ncmail.net>
NC DENR - Asheville Regional Office
Division of Air Quality
Starr Silvis <Starr,Silvisgncmail.net>
Environmental Engineer
NC DENR - Asheville Regional Office
Division of Water Quality - Surface Water Protection Section
--
Content-Type: message/rfc822
�[Fwd: [Fwd: [Fwd: Concrete Batch Water Spray]]1',! Content -Encoding: 7bit
Content -Type: message/rfc822
[Fwd: [Fwd: Concrete Batch Water Spray]]
Content -Encoding: 7bit
3 of4 4/16/2007 10:42 AM

McDowell Concrete status
rd
Subject: McDowell Concrete status
From: "Johnson, Doug" <[e-mail]>
Date: Thu, 29 Mar 2007 18: l 8:36 -0400
To: "Jennings, Pat" <[e-mail]>, "Winegar, James" <[e-mail]>, "Starr
Silvis" <[e-mail]>, <[e-mail]>, "Pat Boone at McDowell Cement"
<explode3 @charterinternet. com>
CC: <[e-mail]>, <expsupco@belIsouth. net>
All,
Thanks in advance for your participation in this effort. 1 would like to request that we all meet at the McDowell
Cement facility in Marion, NC to discuss the two options that I have spoken to Starr Silvas of NCDENR about
this afternoon for going forward with the Water Quality permitting. The McDowell site is located within the
Marion town limits, and is bisected by a stream. Meeting at the McDowell facility can be a benefit should
site -specific questions come up during our discussions.
First, Total Suspended Solids (TSS) calculations can be submitted as additional information to the current design
package. Second, the truck rinse water, drum rinse water, aggregate pile runoff, and spray bar water can be
separately collected to a smaller process water system, and the precipitation that does not directly impact and mix
in these designated areas can be discharged as stormwater runoff, presumably not requiring treatment.
I understand the TSS request for going forward with the current design, and I think I understand the option
discussed today; however I would like to have all heads together and get a consensus input going forward. We
need to get a permit in place so McDowell Cement can resume compliant operations. I think that is what we all
want as an end result.
I propose the following agenda for the meeting:
1.) Discuss Air Quality involvement
-process spray bar dust control
-application status
2.) McDowell process water
-define type, quantities, etc.
3.) Process water system design considerations
-current options agreement
-current design plans
-visual site review
-plans related to the most recent option
4.) Discuss NPDES Stormwater permitting
-Status of permit
-General permit applicable to McDowell
-permitting process overview
5) Follow-up discussion
-Consensus plan
-Action items
-Close
I of 2 8/24/2007 9:08 AM

McDowell Concrete status
f"
Please let me know what you think. The following dates have been proposed. Meeting time would be 1 i am to
accommodate Raleigh participation. Please pick 2 or 3 dates in your preferred order and I will coordinate and get
back to you:
April 4 ,5, 6 10, or 11
Please feel free to call or email me if none of these dates will suit you, or if you have other concerns or questions.
Thanks again. 1 look forward to hearing from you.
Doug
Douglas G. Johnson, PE
TRIGON ENGINEERING CONSULTANTS, INC.
3344 I-ffiborough Street, Suite 200
Raleigh, North Carolina 27607
919.861.7772 phone
919.861.7777 facsimile
919.219.6307 mobile
[e-mail]
2 of 2 8/24/2007 9:08 AM

t
ENGINEERING CONSULTANTS, INC. wiviv.trigoneug.corn
P.O, Box 18846 • Zip 27419-8846 • 313 Gallimore Dairy Road • Greensboro, NC27409 • p 336.668.0093 . f 336.668.3868
Starr Silvis - Environmental Engineer
NCDENR
Asheville -Regional -Off ice
2090 U.S. Highway 70
Swannanoa, NC 28778
Subject: Additional Information Request
Authorization to Construct Application
Permit NCG140325
McDowell Cement Products
McDowell County
Dear Ms. Silvis:
17 [:�"fps
In response to your request for additional information, we have enclosed three sets of the revised plans
and calculations. Our responses to your individual comments are not below:
1. Site map. The site map must show the outline of the drainage areas (storm sinter and process
water).
Storm water and process water are both captured into the treatment basins. Due to the site size
and configuration, it is not possible to segregate process water from storm water, so the
treatment basins are sized for both. Drainage limit is shown on the plan and in the computations.
2. Design calculations, design basis, and design details
a. The design calculations do not account for truck wash water input to the system. Please
provide the volume of water that will be contributed to the system due to truck washing.
We have provided a water balance showing the water input, water usage, and required
discharge from the system. This includes truck wash water.
b. The design calculation for the recycle system do not account for losses to the system.
There are no recycle rates or other losses to seater volume accounted for in the
calculations. Please provide calculations that include losses to the system.
We have provided a water balance showing the water input, water usage, and required
discharge from the system. This includes recycle rates, and other water usage.
c. In order for us to concur that the recycle system has adequate capacity to contain the 25-
yr, 24-hr storm we need further information. Specifically, should the system become full
how will it be emptied in a short period of time so that the system operates as assumed in
the initial conditions for design calculations?
Trigon Engineering Consultants, Inc. Page I

Ms. Starr Silvis - NCDEh'R February 1, 2007
McDowell Cement Products - Marion, North Carolina Trigon Project Number 04SO6081
We propose to pump the excess water to the outlet structure, and discharge through the
storm drain system over a period of one day. We would not discharge until the pH and '
TSS met the permit requirements.
d. The treatment system must be maintained such that sufficient capacity is present to
contain the 25-yr, 24-hr storm plus one foot of freeboard. The frequency of system clean
out should be revised to keep sufficient capacity in the system to contain the required
volume.
We have revised the cleaning sequence to clean the basin after every storm of 2-inches or
V.
greater-, This-should-maintain-the-capacity-e7�pec-iolly-with- foo"ffreeboard, to -meet
the design capacity.
e. Will aggregate piles be irrigated? If so the water that runs off the pile is then considered
process water and must be treated as such.
According to McDowell Cement Products, they do not irrigate stockpiles.
f. Please provide equations and calculations in the design calculations. The current version
provides only inputs and outputs, not the process by which the outputs are derived.
Equations have been provided with the design calculations to show how the outputs were
derived The inputs if not calculated are referenced in the calculations.
g. Based on my calculations the storage volume listed in the design calculation for the 3
compartments of the treatment system is based on a five-foot depth. The five-foot depth
is the depth at which flow will begin to crest the weir and will flow into the outfall
structure. We require that there be one foot of freeboard of storage capacity in the system
above the calculated required volume.
,' The storage volume was revised to provide 1 foot of freeboard.
h. The narrative states that a portable pump will be used to pump from the storm water
treatment facility into the clearwell. You may want to consider a passive system to
reduce the potential for maintenance problems.
Portable Pumps are used to allow the appropriate amount of water to be pumped to the
� cleantifell for reuse.
i. Will drums be washed out at the facility? A drum wash out area is not shown on the
plans. If drum wash out wilt not be conducted at the facility, where will it be conducted?
Drum wash out water must be treated as process water.
Drum washout area is now shown on the plans.
3. The current site map shows that runoff from the site will be piped directly to the creek with no
treatment. We strongly recommend the use of a settling basin at a minimum prior to discharge of
storm water into the creek.
Due to the size of the site and site topography, there is really no room to install a settling basin
prior to discharge from the site into the adjacent creek.
Trrgon Engineering Consultants, Inc. Page 2

Ms. Starr Silvis - NCDEA'R February 1, 2007
McDowell Cement Products - ,Marion, North Carolina Trigon Project Number 04506081
If you have any further comments, please contact us.
Sincerely,
G CONSULTANTS, INC.
M
ck C. nnings
ager roil Engineerft Services
PC: Doug Johnson
Pat Boone — McDowell Cement Products
Trigon Engineering Consultants, Inc. Page 3

Date: Feb-07
Project: McDOWELL CEMENT
Project No.: 04506081
Location: Marion, NC
Designed by: PJ
STORM WATER TREATMENT DESIGN
Drainage Area = 1.4 acres
Weighted RCN = 88
t, = 0.10 hrs
18 = 0.27 in.
Rainfall Depth (P):
(25yr. R.I.) = 6.7 in
Runoff:
(25 yr. R.I.) = 5.30 in
Vr = 26,369 cf
Unit Peak Discharge:
Peak Flow:
see Drainage Area Map
assumed minimum time of concentration TR55
1. = 0.2S
where S = (1000/RCN) - 10
from NC Rainfall Maps 25 year - 1 day storm
R.O. = (P - 0.2S)2 / (P + 0.8S)
where S = (1000/RCN) - 10
V,= R.O.(in.) * D.A.(acres) / (43,560 sf/acre * 12 in./ft.)
IJP = 0.04
(25 yr. R.I.) = 1010 csm/in. from NCRS TR55 - Exhibit 5-II
Weir Design:
Q25 = 11.5 cfs
Hr, = 0.75 ft
Cd = 3.0
L = 5.9 ft
Storage Volume:
Provide 3-Compartment Box
1 st Compartment
Length = 60.0 ft
Width = 29.5 ft
Depth = 4.5 ft
Volume =" 7,965 cf
2nd & 3rd Compartments
Length = 69.5 ft
Width = 29.5 ft
Depth = 4.5 ft
Volume =' 18,452 cf
Total Volume =" 26,417 cf
Q25 = P (in.) * Unit Peak Discharge (csm/in. R.O.) * D.A.(acres) / 640 acres/sm
H,, = headwater depth over weir
broadcrested weir coefficient of discharge
L= Q/(Cd*H')
minus 1-foot of freeboard to weir elevation
minus 1-foot of freeboard to weir elevation
Volume required = 26,369 cf
volume not including 1-foot of freeboard over weir
.tznvjCA R 800/J�
101
bye QQ` T
e
° & Q
Q � e
2fla42
a _
2

STORM WATER TREATMENT DESIGN
Design Elevations:
Bottom El. = 1359.25
Top of Sediment = 1359.50
Top of Require Storage = 1364.00
Weir El. = 1365.00
Design H.W. El. = 1365.75
Top Tank El. = 1366.00
Outlet Pipe Size:
Q25 = 11.5 cfs
Pipe Size = 24 in.
Pipe Invert Upstream = 1359.50
Inlet Control
H„/D = 1.0
H,H = 2.0
H, Elevation = 1361.50
Outlet Control
H = 0.3
H.G. Downstream = 1361.50
HN, Elevation = 1361.80
Date: Feb-07
Project: McDOWELL CEMENT
Project No.: 04506081
Location: Marion, NC
Designed by: PJ
assume 3-inch permanent sediment layer
at 4.5-foot depth
1-foot of freeboard
weir el. + headwater depth over weir
from FHWA HDS5
H /D " Pipe Size
from FHWA HDS5
Controls

Date: Feb-07
Project: McDOWELL CEMENT
Project No.: 04506081
Location: Marion. NC
Designed by: PJ
SITE WATER BALANCE
Source
Water IN
(gallons)
Water OUT
(gallons)
ITotal
Storm Water Runoff
197,240
197,240
Truck Wash
200
200
0
based on 8 trucks/day ` 25gallons/truck
Drum Rinse
100
100
0
Spray Bar - Plant Loadout
50
50
0
based on 2 bars " 25 gallons/day/bar
Plant Mix Water
2,500
2,500
average plant mix required
Total Water Use
197,5901
2,8501
194,7401 required discharge after 25 year storm

Date: Feb-07
Project: McDOWELL CEMENT
Project No.:
Location:
Designed by:
SCS RUNOFF CURVE NUMBER COMPUTATION SHEET
04506081
Marion, NC
Pi
BASIN
LAND USE
SOIL NAME 1
HYDROLOGIC GROUP
AREA
(ACRES)
AREA
(%)
CURVE NO.
(CN)
PRODUCT
CN X AREA
EXISTING
Industrial Site
VARIOUS SOILS 1 B
1.4
100.00%
88
88.0
Building 1
0.0
0.0
TOTALS
1 1.41100.00%1
1 88.0
NOTES: WEIGHTED
CN = 88
from NCRS TR55

Mr. Patrick C. Jennings II
Trigon Engineering Consultants, Inc.
PO Box 18846
Greensboro, NC 27409
Dear Mr, Jennings:
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
January 25, 2007 D L2Qr._11�LJ V 0
JAN 3 0 ?P0?
DENR - WATER OU
Subject; Additional Information PVYetlands&�
Authorization to Construct application
Permit NCG140325
McDowell Cement Products
McDowell County
On December 28, 2006, the Division of Water Quality, Stormwater Permitting Unit received your
application for an authorization to construct treatment facilities at the subject site in Marion, North
Carolina. North Carolina rules require DWQ to conduct an engineering review of your request for
an Authorization To Construct. Some portions of the submittal are unclear to us, and we are
requesting additional information in order to continue processing your application. Please submit
additional information addressing the items listed below.
1. Site map. The site map must show the outline of the drainage areas (stormwater and
process water).
2. Design calculations, design basis, and design details
a. The design calculations do not account for truck wash water input to the system.
Please provide the volume of water that will be contributed to the system due to
truck washing.
b. The design calculation for the recycle system do not account for losses to the
system. There are no recycle rates or other losses to water volume accounted for in
the calculations. Please provide calculations that include losses to the system.
c. In order for us to concur that the recycle system has adequate capacity to contain
the 25-yr, 24-hr storm we need further information. Specifically, should the system
become full how will it be emptied in a short period of time so that the system
operates as assumed in the initial conditions for design calculations?
d. The treatment system must be maintained such that sufficient capacity is present to
contain the 25-yr, 24-hr storm plus one foot of freeboard. The frequency of system
clean out should be revised to keep sufficient capacity in the system to contain the
required volume.
e. Will aggregate piles be irrigated? If so the water that runs off the pile is then
considered process water and must be treated as such.
f. Please provide equations and calculations in the design calculations. The current
version provides only inputs and outputs, not the process by which the outputs are
derived.
g. Based on my calculations the storage volume listed in the design calculation for the
compartments of the treatment system is based on a five-foot depth. The five-foot
depth is the depth at which flow will begin to crest the weir and will flow into the
NorthCarolina
��1�ntrrtnll�
North Carolina Division of Water Quality 1617 R9ail Service Crater RaleiEih_ NC 27699-1617 Phone [phone] Customer Service
Internet: Location: 512 N. Salishur• St. Raleigh, NC 27604 Fax [phone]
An Fqual Opportunity/Affirmativc Action Employer— 50°o Recvcled110% Post Consumer Paper

Mr. Patrick Jennings
Page 2 of 2
January 25, 2007
outfall structure. We require that there be one foot of freeboard of storage capacity
in the system above the calculated required volume.
h. The.narrative states that a portable pump will be used to pump from the stormwater
t reaf ib ht facility into the clearwell. You may want to consider a passive system to
reduce the potential for maintenance problems.
i. Will arum's be washed out at the facility? A drum wash out area is not shown on the
plans. `If drum wash out will not be conducted at the facility, where will it be
conducted? Drum wash out water must be treated as process water.
3'1'171he cd'rri2ht site map shows that runoff from the site will be piped directly to the creek with
no treatment. We strongly recommend the use of a settling basin at a minimum prior to
discharge of stormwater into the creek.
4. Finally, please note that we need three copies of any re -submittal.
Sincerely,
Starr Silvis
Environmental Engineer
Asheville Regional Office
[phone]
cc: ARO
Pat Boone, McDowell Cement Products, PO Box 1147, Marion, NC 28752
Ken Pickle, SPU files -
DWQ Central Files

��•s d ,% DEC 2 8 2006
DENR - WATER QUALITY
16 Wetlands 8 St
orrnwatu $ranch
ENGINEERING CONSULTANTS, INC. www.trigoneng.coin
P.O. Box 18846 • Zip 27419-8846 • 313 Gallimore Dairy Road • Greensboro, NC27409 p 336.668.0003 • f 336.668.3868
December 22, 2006
Mr. Ken Pickle
NCDENR
Stormwater Permitting Unit
512 N. Salisbury Street
Raleigh, NC 27604 .
Reference: McDowell Cement Products
Marion, NC
Dear Mr. Pickle:
Attached please find three (3) copies of the storm water treatment system plans for the McDowell
Cement Products concrete batch plant in Marion, NC. We have also included three (3) copies of the
stormzwater sizing calculations for the storm water treatment basin. The basin was designed to have a
volume equal to the 25 year storm water runoff volume for the area draining to the basin. The truck
washout area is included in that area and is also designated on the plans..
We have provided a clearwell to recycle the water in the treatment system to the concrete batch plant.
Water will be pumped as required from the last cell of the water treatment basin to the clearwell with,a
portable pump. We have specified a pump to pump from the clearwell to the batch plant water supply
tank (see plans). We have also shown a pH adjustment system to keep the pH in the last cell above the
NPDES level for discharge, in case all of the water generated cannot be used in the concrete batch
plant process, and needs to discharge from the site. The water discharging would have to be tested to
insure the TSS requirements of the NPDES permit are met with the proposed treatment basin. A
settlement enhancing chemical could be added if the treatment system does not perform as well as
expected.
Please review the plans, and let us know if you have any comments.
Sincerely,
CONSULTANTS, INC.
C. J
cc: l Pat Boone
v Doug Johr
Cement Products
Trigon Engineering Consultants, Inc.

SHEETUST TABLE
TITLE
REVISION
12-22-06
N CONTROL PLAN
12-22-06
1 2-22-06
Dig o Safely.'a
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S
b
n
c�a
C7
`
two Working
� a
c
1-800-632-4949
DEC 2 8 2.006
DENR • WATER QUALITY
Wetlands & Rtormwater Branrl-
SITE PLAN
COVER SHEET
MCDOWELL CEMENT
PRODUCTS COMPANY
101 SOUTH GARDEN STREET
MARION TOWNSHIP
TOWN OF MARION
MCDOWELL COUNTY,
NORTH CAROLINA, 28752
HORZ- SCALE: NIA
VERT. SCALE: NIA
DESIGNED BY: PCJ
DRAWN BY: AOS
CHECKED BY: PCJ
DATE: 'I I}25-06
PROJECT NUMBER: 045-"l
DRAWING

Date: Dec-06
Project: McDOWELL CEMENT
7CAI
Project No.: 04506081
Location: Marion, NC
'r IGO N Designed by: PJ
SCS RUNOFF CURVE NUMBER COMPUTATION SHEET
BASIN
LAND USE
SOIL NAME /
HYDROLOGIC GROUP
AREA
(ACRES)
AREA
(%)
CURVE NO.
(CN)
PRODUCT
CN X AREA
EXISTING
Industrial Site
VARIOUS SOILS I B
1.4
100.00%
88
88.0
Building 1
0.0
0.0
TOTALS
1.4
100.00%
88.0
NOTES: WEIGHTED
CN = 88
n
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Date: Dec-06
Project: McDOWELL CEMENT
Project No.: 04506031
Location: Marion, NC
Designed by: PJ
STORAGE BASIN DESIGN
IPRE-i]EVELOPMENT
Drainage Area = 1.4 acres
Weighted RCN = 88
t�= 0.10 hrs.
I, = 0.27 in.
Rainfall Depth (P):
(25yr. R.I.) = 6.7 in.
Runoff:
(25 yr. R.I.) = 5.30 in.
V,= 26,369 cf
Unit Peak Discharge:
I./P
(25 yr. R.I.) = 1010 csWin. 0.04
Peak Flow:
Q25 = 11.5 cfs
Weir Design:
HW= 0.75ft
Cd = 3.0 broadcrested weir coefficent of discharge
L = 5.9 R L= GI(Cd•H'n)
Storage Volume:
Provide 3-Compartment Box
Volume =• 8,408 cf 1st compartment
Volume =' 20,503 cf 2nd & 3rd compartments
Total Volume =• 28,910 cf
' volume not including 1-foot of freeboard over weir
Outlet Pipe Size:
Q25 = 11.5 cfs
Pipe Size = 24 in.
Pipe Invert Upstream = 1359.5
Inlet Control
H,10 = 1.0
H. Elevation = 1361.5
Outlet Control
H = 0.3
H.G. Downstream = 1361.5
H, Elevation = 1361.8 Controls
1R2UL;9UVv L9 o
DEC 2 8
►�ettllaNndds & Storrmwaee � .nnch

Re: Preliminary plans
Subject: Re: Preliminary plans
From: Ken Pickle <[e-mail]>
Date: Mon, 20 Nov 2006 07:48:51 -0500
To: "Johnson, Doug" <[e-mail]>
CC: [e-mail], [e-mail], "Jennings, Pat" <[e-mail]>,
"Stolts, Anthony" <[e-mail]>, [e-mail]
BCC: Bethany Georgoulias<[e-mail]>, aisha Lau <[e-mail]>
RE: ATC for McDowell Cement, NCG140235
Doug,
I can't review the email attachments. Please provide DWQ with full size drawings
stamped by a PE. Note that the calculations must establish either that you will meet
the permit limits for pH, TSS, and settleable solids; or, that there will be no
wastewater discharge in response to the 25-year storm (plus one foot of freeboard,
plus some way to bring the 25--year capacity back on line in a relatively short time
period.) I think we would need -to see construction details on the recycle system
configuration in order to conclude that the proposed construction complies with DWQ
requirements. Please contact Starr Silvis in the Asheville Regional Office for more
requirements on the elements of an adequate submittal.
Ken Pickle
[phone]x584
Stormwater Permitting Unit
Johnson, Doug wrote:
All,
Attached'please find the preliminary drawings and calculations for the proposed
stormwate.� management system at McDowell Cement in Marion, NC. I will thank you
ahead of time for expediting your review and providing feedback as soon as your
schedules allow. If you have design questions please call Pat Jennings of Trigon
at 336.668.0093. For other questions please call me at the number listed below.
Thanks,
Douglas G. Johnson, PE
Environmental Engineering Manager_
*TRIGON ENGINEERING CONSULTANTS, INC.*
700 Blue Ridge Road
Suite 101
Raleigh, North Carolina 27606
919-755.5011 phone
919.755.1414 facsimile
919.219.6307 mobile
[e-mail] <mailto:[e-mail]>
1 of 2 11/20/2006 7:54 AM

Mr. Pat Boone
McDowell Cement Product, Inc.
Post Office Box 1147
Marion, North Carolina 28752
Dear Mr. Boone:
/I f � /'. /��j 2'
Mic iF. Easlev, Governor
Lti7
V (
North Carolina Depar ent of Env
0
n
Z�} Di i
Ross Jr., Secretary
Natural Resources
t -, P.E. Director
ater Quality
October 18, 2005 7
cp
Subject: Construction of New Wastewater Treatment System
McDowell Cement Products
McDowell County
You expressed an interest in placing a new ready mix plant in the location of your present
wastewater/storm water settling basin and building a new wastewater treatment system. Such
a project seems doable.
To build a new wastewater treatment system you would need to submit three sets of plans and
specifications signed and sealed by a consulting engineer licensed to practice engineering in
this State. The plans will obviously detail the wastewater treatment system. Supporting design
calculations will address the stormwater volume, wastewater volume, plans for recycle of
treated wastewater and demonstrate compliance with final effluent limits. Before starting work,
strongly suggest that the consulting engineer you select have a conversation with Ms.
Bethany Georgoulias at 919-733-5083, Extension 529 to gain a clear understanding as to what
we need in the way of plans, specifications and supporting information. When submitting the
plans, you would need to submit a letter under your signature requesting authorization to
construct the new wastewater treatment system.
Given the topography of your property, I would think that you would want to consider bringing
all your stormwater and wastewater to one central location for treatment. You will obviously
want to exclude all stormwater coming onto your property from elsewhere or otherwise not
requiring treatment such as water from roof drains. You can reduce the volume of treated
wastewater/stormwater discharged by using treated water in the mix and for drum wash water.
You will notice that your General Permit No. NCG140000 relieves from self monitoring any
facility which routes all stormwater and process wastewater to a recycle system which
discharges only as a result of a 10 year-24 hour storm event.
You will also notice that NCG140000 contains self monitoring requirements for your industry.
Please take a look at these requirements and make sure that you take stormwater runoff
samples and analyze same. Sample results should be submitted to our Raleigh office and a
copy retained on site.
NorthCarokina
.1111f11r1111 f
North Carolina Division of Water Quality 2090 U.S. Highway 70 Swannanoa, NC 28778 Phone [phone] Customer Service
Internet: h2o.ennstate.nc.us FAX [phone]
An Equal Opportunity/Affirmative Action Employer — 50% Recycled110% Post Consumer Paper

Attached you wrillJind a copy of our latest (DRAFT) Technical Bulletin for the Ready Mix
industry. This document explains many of the things I have discussed in this letter. You are
embarking on a significant project. I encourage you to call me at 828-296-4659 any time you
need'to.di.scuss'this project.
r
Sincerely,
Roy M. Davis
Environmental Engineer
_ Xc: Bethany Georgoulias
NCG140325letter

}
r
1 �0F W A'k
�Q
10 G
Q �c
October 11, 2002
Mr. Robert H. Boone, Pres.
McDowell Cement Products, Inc.
PO Box 1147
Marion, NC 28752
Michael F. Easley
Governor
William G. Ross Jr., Secretary
Department of Environment and Natural Resources
Subject: General Permit No. NCG140000
McDowell Cement Products, Inc.
COC NCG140325
McDowell County
Dear Mr. Boone:
Alan W. Klimek, P.E., Director
Division of Water Quality
In accordance with your application for discharge permit received on August 6, 2002, we are forwarding herewith
the subject certificate of coverage to discharge under the subject state - NPDES general permit. This permit is issued
pursuant to the requirements of North Carolina General Statute 143-215 .1 and the Memorandum of Agreement between
North Carolina and the US Environmental Protection agency dated December 6, 1981
The stormwater permit you are receiving, NCG140000, does not permit wasting concrete, dumping excess
concrete, directly into storm sewer outfalls or into waters of the state. Any facility which either dumps excess concrete or
washes excess concrete into storm sewers or waters of the state will be operating in direct violation to both the terms of
this permit and the North Carolina General Statutes. Such a discharge shall be considered an illegal discharge and may
subject the owner to enforcement actions in accordance with North Carolina General Statutes 143-215.6A
If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable to
you, you have the right to request an individual permit by submitting an individual permit application. Unless such
demand is made, this certificate of coverage shall be final and binding.
Please take notice that this certificate of coverage is not transferable except after notice to the Division of Water
Quality. The Division of Water Quality may require modification or revocation and reissuance of the certificate of
coverage.
This permit does not affect the legal requirements to obtain other permits which may be required by the Division
of Water Quality or permits required by the Division of Land Resources, Coastal Area Management Act or any other
Federal or Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Mr. Mack Wiggins at telephone number 9191733-
5083 ext. 542-
Sincerel�y,r�t1
Alan Klimek, P.E-
cc: Asheville Regional Office
Central Files
Stormwater and General Permits Unit Files
VWV
,'14CUEiCR
Customer Service Division of Water Quality 1617 Mail Service Center Rateigh, NC 27699-1617 [phone]
1 800 623-7748

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG140000
CERTIFICATE OF COVERAGE No. NCG140325
STORMWATER AND PROCESS WASTEWATER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the
Federal Water Pollution Control Act, as amended,
McDowell Cement Products, Inc.
Is hereby authorized to discharge stormwater and wastewater from mixing drum cleaning from a facility Rocated at
McDowell Cement Products,Inc.
South Garden Street
Marion
McDowell County
to receiving waters designated as an unnamed tributary to Youngs Fork, Class C waters in the Catawba Raver Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Pacts I, It, III,
IV, V, and VI of General Permit No, NCG 140000 as attached.
This certificate of coverage shall become effective October 11, 2002.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day October 11, 2002.
WIL iAM C.'IA 1L S
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

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Markers
Name: Discharge Site-NCG140325
Short Name: Dschrg
Coordinates: 0350 40' 59.3" N, 0820 00' 23.0" W
Comment: McDowell Cement Products,inc., Subbasin 030830, Catawba River Basin, McDowell
County, Youngs Fork, Class C, Quad PONE

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