NCG180015_COMPLETE FILE - HISTORICAL_20061122

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STORMWATER DIVISION CODING SHEET
RESCISSIONS.
PERMIT NO.
DOC TYPE]
COMPLETE FILE - HISTORICAL
DATE OF
RESCISSION
❑O lJ )� ��
YYYYMMDD

22 November 2006
Mr. Roy Edgerton
Manager Industrial and Facilities Engineering
Barcalounger Company
1450 Atlantic Avenue
Rocky Mount, NC 27801
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
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
7006-0100-0001-7833-3094
Subject: Compliance Evaluation Inspection & Notice of Violation
NOV-2006-PC-0510
NPDES General Stormwater Permit No. NCG180015
Barcalounger Company, Rocky Mount
Nash County
Dear Mr. Edgerton,
On 15 November 2006, Ron Boone, of the NC Division of Water Quality (DWQ), Raleigh Regional Office (RRO),
conducted a stormwater compliance evaluation inspection at Barcalounger Company's Rocky Mount, NC plant. Your
assistance and cooperation was helpful and appreciated. An inspection report is attached for your records and inspection
findings are listed below.
Barcalounger Company's plant in Rocky Mount manufactures furniture using primarily leather and other upholstery products
and wood. Many of the parts are manufactured by other industries and used by Barcalounger to build the finished furniture.
Stormwater generated at the site flows to the west, north and south of the facility and is discharged into receiving waters
known as Holly Creek, a class C, nutrient sensitive water (NSW) in the Tar -Pamlico river basin.
All industrial activity takes place inside the plant with the exception of loading/unloading activities, disposal activities and
some outside storage of old equipment. Of these activities only disposal activities are exposed to precipitation. No vehicle
maintenance is performed on site.
In general the site was clean and well maintained. Some trash has accumulated in the drainage areas around the facility.
One item of concern was a 2-foot piece of pipe found on the west side of the facility. The pipe appeared to be asbestos.
Please positively identify the type of material the pipe is made of and dispose of it accordingly.
It was noted during the inspection that you are currently storing a large amount of old equipment on the loading dock on the
west side of the facility. You stated that the equipment is awaiting disposal. The equipment is currently covered and meets
the definition of no exposure. Please ensure this equipment stays on the loading dock protected from the rain until it can be
properly disposed of. This will prevent any pollution from occurring from rain falling on the old equipment.
In addition, there were several 55-gallon drums of waste on the western loading dock just outside the maintenance shop.
This dock is not covered and the drums are exposed the precipitation. You stated that the waste company has been delayed
in its pick up of the wastes. Regardless, please ensure all such waste is properly stored inside, away front the elements, until
they can be properly disposed of.
You currently do not have any stormwater discharge outfalls (SDO) identified and no stormwater pollution prevention (SP3)
plan. As a result, the following violations were noted:
N""o ��`hhrolina
ro CaCaa/!y
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
Internet: www.ncu, ucnqLmfitv.org 1Acation: 512 N. Salisbury St. Raleigh, NC 27604 Fax [phone]
An Equal OpportunitylARnnative Action Employer — 50% Recycled110% Post Consumer Paper

Barca lounger Company, Compliance Evaluation Inspection, 22 November 2006, NCG I80015 Page 2 of 2
e
No qualitative monitoring has been accomplished.
No site plan or any of its required components. -
No stormwater management plan or any of its required componbirts-
It is suggested that you try to obtain a no exposure certification (NEC). If DWQ were to grant you a NEC, your NCG19
stormwater permit would be rescinded and replaced with the NEC, as long as you maintain the conditions under which you
were granted the NEC. In order to do so you must meet all of the requirements specified in attachment 2 to this letter.
Filing a NEC form with DWQ certifies you as having a condition of no exposure at your facility but you are still subject to
inspection by DWQ personnel at any time to verify that the condition of no exposure still exists. NECs must also be
renewed every five years. If you would like to apply for a NEC please go to:
http://h2o.enr.state.nc.us/su/Forms Documents.htm#stormwaterGP
Once on this page you need to find the EPA Form 3510-11 No Exposure Certification, located at the bottom of the web
page. Print this form, fill it out and send it to:
The Stotmater Permitting Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Also noted during the inspection was a 3" PVC drain pipe attached to a cooling tower on the west side of the facility. You
stated that Barcalounger formerly had a NCG50 permit for non -contact cooling water but that they retrofitted their cooling
system to be non -discharge and had the permit rescinded. However, you also stated that once per year the contents of the
cooling tower are drained into the forest to the west of the facility in order to renew the water supply. A proprietary biocide
chemical is also added to the cooling tower to help control bacterial levels within the system and no neutralization or
measurement of chemical residual is taken prior to discharging the water. Please note that this is considered an illegal
discharge. You must stop this discharge immediately. You can either reapply for another NCG50 permit or find another
way of discharging the water. One option that Mr. Boone discussed with you was discharging the waste into a nearby
sanitary sewer. This would be acceptable but please note that you would need to contact the City of Rocky Mount prior to
any such discharge to ensure that they can accept the waste.
Please be aware that the above -mentioned issues constitute violations of your stormwater discharge permit and that such
violations may result in the assessment of civil penalties in an amount of up to $25,000 per day per violation. Please provide
a response to the issues identified above within 30 days of your receipt of this letter. Your response should include a
narrative as well as a .tentative schedule for you to correct the identified issues. If you or your staff has any questions
regarding the inspection, this letter or the NEC process, please feel free to call Ron Boone for assistance at 919-791-4200.
Sincere] ,
C t rles Wakild, P.E.
Surface Water Protection Supervisor
Raleigh Regional Office
Attachments:
1. Final Inspection Checklist
2. EPA Storm Water Phase Il Final Rule, Conditional No Exposure Exclusion for Industrial Activity
cc: Stormwater Permitting Unit
Central Files
Non -Point Source Compliance Enforcement Unit

rotes
United States Environmental Protection Agency
Form Approved.
EPA Washington, D C.
OMB No. 2040-0057
Water Compliance Inspection Report
Approval expires8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fad Type
1 Iml 2 I5I 11 OCGI80015 111 121 06/11/15 17
J
18I SI 191 gI 201
Remarks
21111111111111111111111111111111111111111111111116
Inspection Work Days Facility Self -Monitoring Evaluation Rating 61 CIA
---------------- ----- ---- Reserved ----------------------
67I 169 701_1 711 I 721 NI
731I 74 75I I I 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
01:45 PM 06/11/15
04/09/01
Barcalounger Company
Exit Time/Date
Permit Expiration Date
1450 Atlantic Ave
Rocky Mount NC 27801
03:30 PM 06/11/15
09/08/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Roy Edgerron,PO Box 6157 Rocky MounC NC 27801//919-977-6395/ No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Storm Water
Section D: Summary of Finding/Comments Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Ron Boone RP.O WQ//919-791 -4200/
7la
Signature o nagement O A Revi wer Agency/Office/Phone and Fax Numbers Date
/
��r-- -
,_: i oil
(mil _J
EPA Form 3560-3 (Rev 9-94) Previous. itions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type
3I NCG180015 It' 121 06/11/15 I " ,.ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Permittee has no SP3 or any of the required components. Permittee has not identified SW outfalls and has
not monitored them accordingly.
Page # 2

General Stormwater Inspection Checklist
Type of Visit compliance Inspection/Program Audit ❑Tech Assistance or Recon
Location: !usoAlkw,�i� vex /(EcEy,,c/any-d!C Qi•r; �cC..n cr (t^ /a�`
Facility Number NCE.Ifccti'5 Date i S /✓A r �1L Time In i3-/ sTime Out 1,53v
People Interviewed, and Titles: i(„' E�k�..r' `� <' Z, sir �f •' f G%' c`• �;.,: , , • s
Name of Inspector: , r.
SPPP Documentation (Site Plan Partll (A)(1)) '�
1. Copy of Certificate of Coverage [la'res ❑No Copy of Permit Yes ❑No Requested but not required
2. General Location USGS Map shows plant [E<es ❑No, lines of discharge Part II(A)(1)(a)
to water of State []Yes ®'o, Stream labeled ❑Yes [gKfo, Latitude and longitude []Yes , o
Comments:
3. Narrative Description of Practices ❑Yes [vivo Part Il(A)(1)(b)
4. Site map 2fes ❑No Shows flows & areas s9,rvedL%yith arrows and -- // Part II(A)(1)(e)
i�o % impervious surface oyes p, buildings es AM�process areas ❑Yes QNo,
disposal areas []Yes 21Qo, drainage structures ❑Yes [ existing BMPs such as secondary containment
❑Yes EKo, list of potential pollutants []Yes [}Kro
Comments:
5. List of significant spills in last 3 years or certif. if none ❑Yes 2<0 Part II(A)(1)(d)
PRO called? ❑Yes ❑No
6. SW outfalls have been evaluated for processwater ❑Yes T<0 Part II(A)(1)(e)
7. Feasibility of Changing Practices ❑Yes DKO / Part II(A)(2)(a)
8. Secondary Containment es ❑No Schedule needed? ❑Yes 2<0 Part II(A)(2)(b)
Records of Draining Containment, Observations Made ❑Yes � o
9. BMP Summary ❑LgYes o Part II(A)(2)(c)
10. SPRP Plan ❑Yes o, Responsible personnel still employed here? []Yes ❑N'o 414 Part II(A)(3)
11. PM and Housekeeping Plan ❑Yes 0j<oo Record of Inspections? ❑Yes ❑Nod/fiPart II(A)(4)
12. Employee training ❑Yes Elliqo — for everybody ❑Yes. ^❑/No N/19 Part II(A)(5)
13. Responsible parties, chain of command page []Yes1211 0 Part II(A)(6)
14. Plan updated/reviewed annually []Yes RK0 Part II(A)(7)
15. Stormwater Facility Inspection Program ❑Yes 2<0 Part II(A)(8)
I6. This Plan Has Been Im lemented documents in manual, Part II(A)(9)
employees show awareness []Yes lly,No Comments:
Sampling and Analytical Data Part II(C)
All Stormwater and Process Water is Rec ed I1C 3 oyes 'o
Rain Gauge on site (not required) ❑Yes o
Record of an overflow ❑Yes 21K0 Details
if not all recycled, what is allowed to discharge? Vehicle Cleaning (IIC2) ❑ Recycle overflow (IIC3
above) ❑ Wetting of Aggregate (IIC4)0 Mixing drum cleanout (IIC5) ❑ Vehicle Maintenance ❑
Note: this checklist does not take the place of your permit. You are fully responsible for
following the permit.
jV UV - t lG

For the topics checked in last question, Analytical data present ❑Yes/ No, Compliant? ❑Yes ❑No
Details:
Total precip ❑Yes []No, Storm duration ❑Yes ❑No, Total flow Est. ❑Yes ❑N'o,Field pH ❑Yes []No,
Chain of custody ❑Yes ❑No
Qualitative Monitoring performed semiannually ❑Yes , o
Stormwater not combinedwith process wastewater - general runoff
Part II(F)
Part1I(C)(1)
Analytical data ❑Yes FLKo, Chain 9f Custody ❑Yes o, Qualitative Monitoring performed
semiannually (Section F) []Yes o,
If using cutoff policy, how many sample rounds f'I
Cutoff Concentrations met ❑Yes ❑No Ever ave a Bypass? ❑Yes ❑No (III (C)(4)al &2)
Notification given? ❑Yes ❑No
Outdoor Inspection -�/
I located all discharge points ❑Yefs�
s �O No. of areas served /J
f crW? LCeO.4f,Vt441VW
Sample points appropriate []Yes ❑No ,yl�/t V
Location if different from discharge point
Housekeeping: Trash ❑Yes ❑No Dust ❑Yes ❑No
Take pH ❑Yes M?o Value(s)
Take photos ❑Yes 2<0
Containment Area satisfactory es ❑No, Loose drums ❑Yes p<o, Locked drain ❑Yes []No
N/ /�-
Inspection Summary Comments
/J"- e<T,ae�� - ti'Cv.
Recommendations:
Requirements: 99
Letter is to go to:
Name
Title
Address
Helpful Information at http://h2o.enr.state.nc.us/su/Manuals Factsheets.htm
Note: this checklist does not take the place of your permit. You are fully responsible for
following the permit.
Revised 7/23/03, 10/21/03, 4/13/05

11/16/2006 12:50 9157339612 ©© WET AND SH2O BRANCH PAGE 02/05
A&
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
September 10, 2004
Roy Edgerton
Barcalounger Company
PO Box6157
Rocky Mount, NC 27801
Subject: NPDES Stormwater Permit Coverage Renewal
Barcalounger Company
COC Number NCG 190015
Dear permittee; Edgecombe County
In response to your renewal application for continued coverage under general permit NCG 180000 the Division of
Water Quality (DWQ) is forwarding herewith the reissued stormwater general permit. This permit is reissued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between the state of North Carolina and the U.S. Environmental Protection Agency, dnted December 6, 1983.
The following information is included with your permit package:
• A new Certificate of Coverage
• A copy of General Stormwater Permit NCG180000
• A copy ora discharge monitoring report form
• 5 topics of the qualitative monitoring report form
Your coverage under this general permit is not transferable except after notice to DWQ. The Division 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 Department of Environment and Natural
Resources, or relieve the permitter from responsibility for compliance with any other applicable federal, state, or
local law, ride, standard, ordinance, order, judgment, or decree.
If you have any questions regarding this permit package please contact Aisha Lau of the Central Office Stormwatcr
Permitting Unit at [phone], ext. 578,
Sincerely,
for Alan W. Klimek, P.E.
cc: Central Files
Stormwater Permitting Unit
Raleigh Regional Office
SUdace Water Protection Section
1617 Mall Service Center, Raleigh, Nodh Carolina 27699.1617
512 N. Salisbury St., Ra!elgh, North Carolina 27604 �TOne
Phone:919-733,7015/FAX[phone]/Internet:http://h2aencsiate.nc.us/su/stornwiatethtml Ni Carohna
An Equal Opportunity/AlHrmative Aclion Employer —50%, Recycled/10%a Post Consumer Paper atirally

11/16/2006 12:50 9197339612 WET AND SH2O BRANCH PAGE 03/05
STATE- OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG180000
CERTIFICATE OF COVERAGE No- NCG180015
STORMWATER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawfid standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission,
and the Federal Water Pollution Control Act, as amended,
Barealounger Company
is hereby authorized to discharge stormwater from a facility located at
Barcalounger Company
1450 Atlantic Ave
Rocky Mount
Edgecombe County
to receiving waters designated as Compass Creek, a class C NSW stream, in the Tar - Pamlico River
Basin in accordance with the effluent limitations, monitoring requirements, and other conditions set forth
in Parts I, II, ITT, TV, V, and VI of General Permit No. NCO180000 as attached.
'This certificate of coverage shall become effective September 1, 2004,
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day September 1, 2004.
for Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental 'Management
Commission