NC0005461_Regional Office Physical File Scan Up To 1/15/2021

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State of North C"arolina
Department of Environment;
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Richard H. Kerns
Highway 221 North
Rutherfordton, NC 28139
Dear Mr. Kerns:
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November 30, 1993
Subject: Permit No. NC0005461
Broyhill Furniture - Rutherford Plant
Rutherford County
In accordance with your application for discharge. permit received on January 5, 1993, we
are forwarding herewith the subject state - NPDES 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, 1983.
If any parts, measurement frequencies or sampling requirements contained in this permit
are unacceptable to you, you have the right to an adjudicatory hearing upon written request
within thirty (30) days following receipt of this letter. This request must be in the form of a
written petition, conforming to Chapter 150B of theNorth Carolina General Statutes, and filed
with the Office- of Administrative Hearings, Post Office Drawer 27447, Raleigh, North
Carolina 27611 -7447. Unless such demand is made, this decision shall be final and binding.
Please take notice this permit is not transferable. Part H, E.4. addresses the requirements
to be followed in case of change,in ownership or control of this discharge.
This permit does not affect the legal requirements to obtain other permits which may be.
required by the Division of Environmental Management 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 Ms. Susan Robson' at
telephone number 919/733-5083.
Since-ml
- Origeer► H. u�t n
Co s
A. Preston Howard, Jr.
Director
cc: Mr. Jim Patrick, EPA `
A&MMEW W-EMPAW—W.H.Fir-
P.Q. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An'Equal Opportunity Affirmative Action Employer 50% recycled/ 10% pos'-;.nsumer paper

NC0005461
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In 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,
Broyhill Furniture Industries
is hereby authorized to discharge wastewater from a facility located at
Rutherford Plant
NC Highway 90
Taylorsville
Rutherford County
to receiving waters designated as an unnamed tributary to Catheys Creek in the Broad River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, 11, and III hereof.
This permit shall become effective January 1, 1994
This permit and the authorization to discharge shall expire at midnight on November 30, 1998
Signed this day November 30, 1993
Original Signed By
Coleen H. Sullins
A. Preston Howard, Jr., P.E., Director
Division of Environmental Management
By Authority of the Environmental Management Commission

Permit No. NC0005461
SUPPLEMENT TO PERMIT COVER SHEET
Broyhill Furniture Industries
is hereby authorized to:
1. Continue to operate two extended aeration wastewater treatment units in parallel followed by
effluent polishing and chlorination for outfall 001, continue to discharge non -contact cooling
water from outfall 002, and continue to discharge kiln condensate from outfall 003 from a
facility located on NCSR 1535, North of Rutherfordton, Rutherford County (See Part III of
this Permit), and
2. Discharge from said treatment works, at the location specified on the attached map into
an. unnamed tributary to Cathey's Creek for outfalls. 001 and 002 which is classified as WS
V, and into a dry ditch to Holland's Creek which is classified as WS IV for outfall 002 in
the Broad River Basin.

7 r
A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NCO005461
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 001-DOMESTIC WASTEWATER. Such discharge's shall be limited and monitored by the permittee as specified below:
Effluent Characteristics Discharge Limitations Monitoring Requirements
Measurement Sample *Sample
Monthly AVQ. Weekly Avg, Daily Max Frequency Iyae Location
Flow 0.026 MGD Weekly Instantaneous 1 or E
BOD, 5 day, 200C 30.0 mg/I - 45.0 mg/I Weekly Grab E
Total Suspended Residue 30:0 mg/I 45.0 mg/I, Weekly Grab E
NH3 as N Weekly Grab E I )
Fecal Coliform (geometric mean) 200.0 /1.00 ml 400.0 /100 ml Weekly Grab E
Total :Residual Chlorine 2/Week Grab E
Temperature Daily Grab E
* Sample locations: E - Effluent, I - Influent
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

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A. (): EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NC0005461
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfalt(s) serial number 002-NON-CONTACT COOLING WATER. Such discharges shall be limited and monitored by the permittee as
specified below:
Effluent Characteristics Lbs/day Discharge Limitations -
Units (specify)'
Mon. Avg: Daily Max Mon, Avg. Daily Max.
Flow
Temperature
Total Residual Chlorine***
Monitoring Requirements
Measurement Sample
Frequency Type
Monthly Instantaneous
Monthly Grab
Monthly Grab
*Sample
Location
E
E, U, D
E
THERE SHALL BE NO CHROMIUM, ZINC, OR -COPPER ADDED TO THE TREATMENT. SYSTEM EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS (See Part III of this permit).
* Sample Locations: E - Effluent, U - Upstream, D - Downstream
** The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in
no case cause the ambient water temperature to exceed 29°C.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
The permitted shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See
Part III of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored monthly at the effluent by -,grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (): EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL' Permit No. NC0005461
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 003-KILN CONDENSATE. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics Lbs/dav Discharge Limitations
Units(specify)
Mon. Avg. Daily' Max Mon. Avg, Daily Max.
Flow
Temperature
Monitoring Requirements
Measurement Sample *Sample
Frequency Tvoe Location
Monthly Instantaneous E
Monthly Grab E, U, D
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS (See Part III of this permit).
c
* Sample Locations: E - Effluent, U - Upstream, D - Downstream
The permittee shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See z
Part III of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0. standard units and shall be monitored monthly at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

` PART I
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Section B. Schedule of Compliance
I. The permittee shall comply with Final Effluent Limitations specified for discharges in
accordance with the following schedule:
Permittee shall comply with Final Effluent Limitations by the effective date of the permit unless
specified below.
2. Permittee shall at all times provide the operation and maintenance necessary to operate the
existing facilities at optimum efficiency.
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3: No later than 14 calendar days following a date identified in the above schedule of compliance,
the permittee shall submit either a report of progress or, in the case of specific actions being
required by identified dates, a written notice of compliance or noncompliance. In the latter
case; the notice shall include the cause of noncompliance, any remedial actions taken, and the
probability of meeting the next schedule requirements.

. Part II
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PART II
STANDARD CONDITIONS FOR NPDES PERMITS
SECTION A. DEFINITIONS
1. Permit Issuing,, Authority
The Director of the Division of Environmental Management.
2. DEM or Division
Means the Division of Environmental Management; Department of Environment, Health and
Natural Resources,
3. EMC
Used herein means the North Carolina Environmental Management Commission.
4. Actor "the Act"
The Federal Water Pollution Control Act, also known as ,the Clean Water Act, as amended, 33
USC 1251, et. seq.
5. , Mass/Dav Measurements
a. The "monthly average discharge" ,is defined as the total mass of all daily discharges
sampled and/or measured during a calendar month on which daily discharges are sampled
and measured; divided by the number of daily discharges sampled and/or measured during
such month. It is therefore, an arithmetic mean found by adding the weights of the
✓ pollutant found each day of the month and then dividing this sum by the number of days
the tests were reported. The limitation is identified as "Monthly Average" in Part I of the
permit.
b. The "weekly average discharge" is defined as the total mass of all daily discharges sampled
and/or measured during the calendar week (Sunday - Saturday) on which daily discharges
are sampled and measured, divided by the number of daily discharges sampled and/or
measured during such week. It is,. therefore, an arithmetic mean found by adding the
weights of pollutants found each day of the week and then dividing -this sum by the
number of days the tests were reported., This limitation is identified as "Weekly Average" -
in Part I of the permit.
c. The "maximum daily discharge" is the total mass (weight) of a pollutant discharged during
a calendar day. If only one sarnple is taken during any calendar day the weight of pollutant
calculated from it is the "maximum daily discharge." This limitation is identified as "Daily
Maximum," in Part I of the permit.
d. The "average annual discharge" is defined as the total mass of all daily discharges sampled
and/or measured during the calendar year on which daily discharges are sampled and
measured, divided,by the number of daily discharges sampled and/or measured during such
year. It is, therefore, an arithmetic mean found by adding the weights of pollutants found
each day of the year and then dividing this sum by the _number of days the tests were
reported. This limitation is defined as "Annual Average" in Part I of the permit.

Part 11
Page 2 of 14
6. Concentration Measurement
a. The "average monthly concentration," other than for fecal coliform bacteria, is the sum of
the concentrations of all daily discharges sampled and/or measured during a calendar- month
on which daily discharges are -sampled and. measured, divided'by the number of daily
discharges sampled and/or measured during such.month (arithmetic -mean of the daily
concentration values). The daily concentration value is equal to the concentration of a
composite sample or in the case of grab samples is the arithmetic mean (weighted by flow
value) of all the samples collected during that calendar day. The average monthly count for
fecal coliform bacteria is the geometric mean of the counts for samples collected during a
calendar month. This limitation is identified as "Monthly Average" under "Other Limits" in
Part I of the permit.
b. The "average weekly concentration," other than for fecal coliform bacteria, is the -sum of the,
concentrations. of all daily discharges sampled and/or .measured during a calendar week
(Sunday/Saturday) on which daily discharges are sampled and measured divided by the
number of daily discharges sampled and/or measured during such week (arithmetic mean of
the daily concentration values): The daily concentration value is equal to the concentration
of a composite sample or in the case of grab samples is the arithmetic mean (weighted by
flow value) of all the samples collected during that calendar day. -The average weekly count
for fecal coliform bacteria is the geometric mean of the counts for samples collected during
a calendar week. This limitation is identified as "Weekly Average" under "Other Limits" in
Part I of the permit.
c. The "maximum daily concentration" is the concentration of a pollutant discharge during a
calendar day. If only one sample is taken during any calendar day the concentration of
pollutant calculated from it is the "Maximum Daily Concentration". It is identified as
"Daily Maximum" under "Other Limits" in Part I of the permit.
d. The "average annual concentration," other than for fecal coliform bacteria, is the sum of the
concentrations of all daily discharges sampled and/or measured during a calendar year on
which daily. discharges are sampled and measured divided by the number of -daily
discharges sampled tand/or measured during such year (arithmetic mean of the daily
concentration values). The daily concentration value is equal to the concentration of a
composite sample or in the case of grab samples is the arithmetic mean (weighted by flow
value) of all the samples collected during that calendar day . The average yearly count for
fecal coliform bacteria is the geometric mean of the counts. for samples collected during a
calendar year. - This limitation is identified as "Annual Average under "Other Limits" in
Part I of the permit.
e. The "daily average concentration" (for dissolved oxygen) is the minimum allowable amount
of dissolved oxygen required to be available in the effluent prior to discharge averaged
over a calendar day. If only -one dissolved oxygen sample is taken over a calendar day, the
sample is considered to be the "daily average concentration" for the discharge. It is
identified as "daily average" in the text of Part I.
f. The ."quarterly average concentration" is the average of all samples taken over a calendar
quarter. It is identified as "Quarterly Average Limitation" in the text of Part I of the permit.
g. A calendar quarter -is defined as one of the following distinct periods: January through
March, April through June, July through September, and October through December. ,

Part II
l Page 3 of 14
7. Other Measurements
a. Flow, (MGD): The flow limit expressed in this permit is the 24 hours average flow,
averaged monthly. It is determined as the arithmetic mean of the total daily flows recorded .
during the calendar month
b. An "instantaneous flow measurement" is a measure of flow taken at the time of sampling,
when both the sample and flow will be representative of the total discharge.
c. A "continuous flow measurement" is a measure of discharge flow from the facility which
occurs continually without interruption throughout the operating hours of the facility. Flow
shall be monitored continually except for the infrequent times when there may be.no flow
of for infrequent maintenance activities on the flow device.
a. Composite Sample: A composite sample shall consist of:
(1) a series of grab samples collected at equal time intervals over a 24 hour period of
discharge and combined proportional to the rate of flow measured at the time of
individual sample collection, or
(2) a series of grab samples of equal volume collected over a 24 hour period with the time
intervals between samples determined by a preset number of gallons passing the
sampling point. Flow measurement between sample intervals shall be determined by
use of .a flow recorder and.totalizer, and the present gallon interval between sample
collection fixed at no greater than 1/24 of the expected total daily flow at the treatment
system, or
(3) a single, continuous sample. collected over a 24 hour period proportional- to the rate of
flow.
In accordance with (1) above, the time interval between influent grab samples shall be no
greater than once per hour, and the time interval between effluent grab samples shall be no
greater than once per hour except at wastewater treatment systems, having a detention time
of greater than 24 hours. In such cases, effluent grab samples may be collected at time
intervals evenly spaced over the 24 hour period which are equal in number of hours to the
detention time of the system in number of days. However, in no case may the time interval
between effluent grab samples be greater than six (6) hours nor the number of samples less
than four (4) during a 24 hour sampling period.
b. Grab Sample:, Grab samples are individual samples collected:over a period of time not
exceeding 15 minutes; the grab sample can be taken manually. Grab samples must be
representative of the discharge or the receiving waters.
9. Calculation of Means
a Arithmetic Mean: The arithmetic mean of any set of values is the summation of the
individual values divided by the number of individual values.
b. Geometric Mean: The geometric mean of any set of values is the Nth root of the product of
the individual values where N is equal to the number, of individual values. The geometric
mean is equivalent to,the antilog of the arithmetic mean of the logarithms of the individual
values.. For purposes of calculating the geometric mean, values of zero (0) shall be -
considered to be one 0). _ _

Part 11
Page 4 of 14
c. Weighted by Flow Value: Weighted by flow value means the summation of each
concentration times its respective flow divided by the summation of the respective flows.
10. Calendar Day
A calendar day is defined as the period from midnight of one day until midnight of the next
day. However, for purposes of this permit, any consecutive 24-hour period that reasonably
represents the calendar day may be used for sampling.
11. Hazardous Substance
A hazardous substance means any substance designated under 40 CFR Part 116 pursuant to
Section 311 of the Clean Water Act.
12. Toxic Pollutant
A toxic pollutant is any pollutant listed as toxic under Section 307(a)(1) of the Clean Water Act.
SECTION B. GENERAL CONDITIONS .
1. 1ha to Comply_
The permittee must comply with all conditions of this permit. Any permit noncompliance
constitutes a violation of the Clean Water Act and is grounds for,enforcement action; for permit
termination, revocation and reissuance; or modification; or denial of a permit renewal
application.
a. The permittee shall ,comply with effluent standards or prohibitions established under
section 307(a) of the Clean Water Act for toxic pollutants and with standards for sewage
sludge use or disposal established under section 405(d) of the Clean Water Act within the
time provided in the regulations that establish these standards or prohibitions or standards
for sewage sludge use or disposal, even if the permit has not yet been modified: to
incorporate the requirement.
b. The Clean Water Act provides. that any person who violates a permit condition is subject to
a civil penalty not to exceed $25,000 per day for each violation. Any person who,
negligently violates any permit condition is subject to criminal penalties of $2,500 to
$25,000 per day of violation, or imprisonment for not more than 1 year, or both. Any
person who knowingly violates permit conditions is subject to criminal penalties of $5,000
to $50,000 per day of violation; or imprisonment for not more than 3 years, or both. Also,
any person who violates a permit condition may be assessed an administrative penalty not
to exceed $10,000 per violation with the maximum amount not to exceed $125,000. [Ref:
Section 309 of the Federal Act 33 U.S.C. 1319 and 40 CFR 122.41(a)]
c.. Under state law, a civil penalty of not more than ten thousand dollars ($10,000) per
.violation may be assessed against any person who violates or fails to act in accordance with
the terms, conditions, or requirements of a permit. [Ref: North Carolina General Statutes
§ 143-215.6A] o
d. Any person may be assessed an administrative penalty by the Administrator for violating
section 301, 302, 306, 307, 308, 318, or 405 of the Act,. or any permit -condition or
limitation implementing any of such secti.o?7,s in a permit issued under section 402 of the
Act. Administrative penalties for Class I violations are not to exceed $10,000 per violation,
with the maximum amount of any f'1a.gc I penalty assessed - not to exceed $25,000.

=�< PartII
Page 5 of 14
Penalties for Class II violations are not to exceed $10,000 per day for each. day during
which the violation continues, with the maximum amount of any Class II penalty not to
exceed $125,000.
2. Duty to Mitigate
The permittee shall take all reasonable steps to minimize or prevent any discharge or sludge use
or disposal in violation of this permit which has a reasonable likelihood of adversely affecting
human health or .the environment.
3. Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part II, C-4) and "Power Failures"
(Part II, C-7), nothing in this permit shall be construed -to relieve the permittee from any
responsibilities, liabilities, or penalties for noncompliance- pursuant to NCGS 143-215.3,143-
215.6 *or Section 309 of the Federal Act, 33 USC 1319. Furthermore, the permittee is
responsible for consequential damages, such as fish kills, even though the responsibility for
effective compliance may be temporarily suspended.
4. Oil and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the institution of any legal action or relieve
the permittee from any responsibilities, liabilities, -or penalties to which the permittee is or may
be subject to under NCGS 143-215.75 et seq. or Section 311.of the Federal Act, 33 USG 1321.
Furthermore, the permittee is responsible for. consequential damages, such: as fishkills, even
though the responsibility for effective compliance may be temporarily suspended.
5. Property Rights
The issuance of this permit -does not convey any property rights in either real or personal
property, or. any exclusive privileges, nor does it authorize any injury to private property or any
invasion of personal rights, nor any infringement of Federal, State or local laws or regulations.
6. Onshore or Offshore Construction
This permit does not authorize or approve the construction of any - onshore or offshore physical
structures or facilities or the undertaking of any work in any. navigable waters.
7. Severability
The, provisions. of this permit are severable, and if any provision of this permit, or the
application of any provision of this permit to any circumstances, is held invalid, the application
of such provision to other circumstances, and the remainder of this permit, shall not be affected
thereby.
8. Duty to Provide Information
The permittee shall furnish to the Permit Issuing Authority, within. a reasonable time, any
information which the Permit Issuing Authority may request to determine whether cause exists
for modifying, revoking and reissuing, or terminating -this permit or to determine compliance
with this permit. The permitted shall- also furnish to the Permit Issuing Authority upon
request, copies of records required to be kept by this permit.

Page 6 of 14
9. Duty to Reapply
If the permittee wishes to continue an activity regulated by this permit after the expiration date
of this permit, the permittee must apply for and obtain a new permit.
1.0. Expiration of Permit
The permittee is not authorized to discharge after the expiration date. In order to � receive
automatic authorization to discharge beyond the expiration date, the permittee shall submit such
information, forms, and fees as are required by the agency authorized to issue permits no later
than 180 days prior to the expiration date. Any permittee that has not requested renewal at least
180 days prior to expiration, or any permittee that does not have a permit after the expiration
and has not requested renewal at least 180 days prior to expiration, will subject the permittee to
enforcement.procedures as provided in NCGS 143-215.6 and 33 US.0 1251 et. seq.
11. Si ng atory Requirements
All applications, reports, or information submitted to the Permit Issuing Authority shall be
signed and certified.
a. All permit applications shall be signed as follows:.
(1). For a corporation: by a responsible corporate. officer. For the purpose of this Section,
.a responsible corporate officer means: (a) a president, secretary, treasurer or vice
,president of the corporation in charge of a principal business function, or any other
person who performs similar policy or decision making functions for the corporation,
or (b) the manager of one or more manufacturing production or operating facilities
employing more than 250 persons or having gross annual sales or expenditures
exceeding 25 million (in second quarter 1980 dollars), if authority to sign documents
has been assigned or delegated to the manager in accordance with corporate procedures.
(2) For a partnership or sole proprietorship: by a general partner, or the proprietor,
respectively; or
(3) For a municipality, State, Federal, or other public agency: by either a principal
executive officer or ranking elected official.
b. All reports required by the permit and other information requested by the Permit Issuing
Authority shall be signed by a person described, above or .by a duly authorized
representative of that person. A person is a duly authorized representative only if:
(1) The authorization is made in writing by a person described above;
(2) The authorization specified either an individual or a position having responsibility for
the overall operation of the regulated facility or activity, such as the position- of plant
manager, operator of a well or well field, superintendent; a position of equivalent
responsibility, or an individual . or position having overall responsibility for
environmental matters for the company. (A duly authorized representative may thus be
either a,named individual or any individual occupying a named position.); and
(3) The written authorization is submitted to the.Permit Issuing Authority.

Part 11
Page 7 of 14
c., Certification. Any person signing a document under paragraphs a, or b. of. this section
shall make the following certification:
"I certify, under penalty of law, that this document and all attachments were prepared under
my .direction or supervision in accordance with a system designed to assure that qualified
personnel properly gather and evaluate the information submitted. Based on my inquiry of
the person or persons who manage the. system, or those persons directly responsible for
gathering the information, the information submitted is, to the best of my knowledge and
belief, true, accurate, and complete. I am aware that there are significant penalties for
submitting false information, including the possibility of fines and imprisonment for
knowing violations."
12. Permit Actions
This permit may be modified, revoked and reissued, or terminated for cause. The filing of a
request by the permittee for a permit modification, revocation and reissuance, or termination,
or a notification of planned changes or anticipated noncompliance does not stay any permit
condition.
11 Permit Modification. Revocation and Reissuance, or Termination
The issuance of this permit does not prohibit the permit 'issuing authority from reopening and
modifying the permit, revoking and reissuing the permit, or terminating the permit as allowed
by the laws, rules, and regulations contained in Title 40, Code of Federal Regulations, Parts
122 and 123; Title 15A of the North Carolina Administrative Code, Subchapter 2H .0100; and
North Carolina General Statute 143-215.1 et. al.
14. Previous Permits
All previous National Pollutant Discharge Elimination System Permits issued to this facility,
whether for operation or discharge, are hereby revoked' by issuance of this permit. [The
exclusive authority to operate this facility arises under this permit. The authority to operate the
facility under :previously issued permits bearing this number is no longer effective. ] The
conditions, requirements, terms; and provisions of this permit authorizing discharge under the
National Pollutant Discharge Elimination System govern discharges from this facility.
SECTION C. OPERATION AND MAINTENANCE OF POLLUTION CONTROLS
1. Certified Operator
Pursuant to Chapter 90A-44 of North Carolina General Statutes, and upon classification of the
facility by the Certification Commission, the permittee shall employ a certified wastewater
treatment plant operator in responsible charge. (ORC) of the wastewater treatment facilities.
Such operator must hold a certification of the grade equivalent to or greater than the
classification assigned to the wastewater treatment facilities by the Certification Commission.
The permittee must also employ a certified back-up. operator of the appropriate type and any
grade to comply with the conditions of Title 15A, Chapter 8A .0202. The ORC of the facility
must visit each Class I facility at least weekly and each Class II, III, and IV facility at least
daily, excluding weekends and holidays, and must properly manage and document daily
operation and maintenance of the facility and must comply with all other conditions of Title
15A, Chapter 8A .0202. Once the facility is classified, the permittee shall submit a letter to the
Certification Commission which designates the operator in responsible charge within thirty
days after the wastewater treatment facilities are 50% complete.-
t;I'I v

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Part II
Page 8 of 14
2. Proper Operation and Maintenance
The permittee shall at all times properly operate and maintain all facilities and systems of
treatment and control (and related. appurtenances),which are installed or used by the permittee to
achieve compliance. with the conditions of this permit. Proper operation and maintenance also
includes adequate laboratory controls and appropriate quality assurance procedures. This
provision requires the operation of back-up or auxiliary, facilities or similar systems which, are
installed by a permittee only when the operation is necessary to achieve compliance with the
.conditions of the permit.
3. Need to Halt or Reduce not a Defense
It shall not be a defense for_ a permittee in an enforcement action that it would have been
necessary to halt or reduce the permitted activity in order to maintain compliance with the
.condition of. this permit.
4. Bypassing of Treatment Facilities,.
a. Definitions,
(1) "Bypass" means the known diversion of waste streams from any portion of a treatment
facility including the collection system, which is not a designed or established or
operating mode for the facility.
(2) "Severe property damage" means substantial physical damage to property, damage to
the treatment facilities which causes them to become inoperable, or substantial and
permanent loss of natural resources which can reasonably be expected to occur in the
absence of a bypass. Severe property damage does .not mean economic loss caused by
delays.in production.
b. Bypass not exceeding limitations.
The permittee may allow any bypass, to occur which does -not cause effluent limitations to
be, exceeded, but. only if it also is for essential maintenance to assure efficient operation.
These bypasses are- not subject to the provisions of Paragraphs c. and d. of this section.-
c.. Notice
(1) Anticipated bypass. If the-permittee knows in advance of the need for a bypass, it
shall submit prior notice, if possible at least ten days before the date of the bypass;
including an evaluation of the anticipated quality'and affect of the bypass.
(2) Unanticipated bypass.' The permittee shall submit notice of an unanticipated bypass as
required in. Part 11, E..6.' of this permit. (24 hour notice).
d. Prohibition of Bypass
(1) Bypass is prohibited and the Permit Issuing Authority may take enforcement action
against a permittee for bypass, unless:
(A) Bypass was unavoidable to prevent loss of life, personal.injury or severe property
damage;
(B) There were no feasible alternatives to the bypass, such as the use of auxiliary
�, treatment facilities, retention of untreated wastes or maintenance during normal

PartII
'.Page 9 of 14
periods of equipment downtime. This condition is not satisfied if adequate backup
equipment should have been installed in the exercise of reasonable .engineering
judgment to prevent a bypass which occurred during normal periods of equipment
downtime orpreventive maintenance; and
(C) The permittee submitted notices as required under, Paragraph c. of this section.
(2) The Permit Issuing Authority may.approve an anticipated bypass, after considering its
adverse affects, if the Permit Issuing Authority determines that it will meet the three
conditions listed above in Paragraph d. (1) of this section.
5. Upsets
a. Definition.
"Upset " means an exceptional incident in which there is unintentional and temporary
noncompliance with technology, .based - permit effluent -limitations because of factors
beyond the reasonable control of the permittee. An upset . does not include noncompliance
to -.the extent caused by operational error, improperly designed treatment facilities,
inadequate treatment facilities, lack of preventive maintenance, or careless or improper
operation.
b..Effect of an upset.
An upset constitutes an affirmative defense to an action brought.for noncompliance with
such technology based permit effluentlimitations if the requirements of paragraph c. of this
condition are met. No determination made during administrative review of claims that
noncompliance. was caused by upset, and before any action fornoncompliance, is final
- administrative action subject to judicial review.
c. Conditions necessary for a demonstration of upset.
A permitted who wishes to establish the affirmative defense of upset shall demonstrate,
through properly -signed, contemporaneous operating logs, or other relevant evidence that: .
(1) An upset occurred and that the permittee can identify the cause(s) of the upset;
(2) ' The permittee facility was at the time being properly operated; and
(3) The permitted submitted notice of the upset as.required in Part II, E. 6. (b) (B) of this
permit.
(4) The permittee complied with any remedial measures required under Part II; B. 2. of this
:.permit.
d. Burden of proof.
In any enforcement proceeding the permittee seeking to establish the occurrence of an upset
has the burden of proof.
6. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or
control of wastewaters shall be utilized/disposed of in accordance with NCGS 143-215.1 and in
a manner such as to prevent any pollutant from such materials from entering waters of the State
or navigable wl%:asof the United States. The: permittee shall comply with all existing federal

Part II
�-� Page 10.of 14
F
regulations governing the disposal.of sewage sludge. Upon promulgation of 40 CFR Part 503,
any permit issued -by the Permit Issuing Authority for the utilization/disposal of sludge'may be
reopened and modified, or revoked and reissued, to incorporate applicable requirements at,40
CFR Part 503. The permittee shall comply with applicable 40 CFR Part 503 Standards for the
Use .and Disposal of Sewage Sludge (when promulgated) within the time provided in the
regulation, even if the permit is not modified to incorporate the requirement. The permittee
shall notify the Permit Issuing Authorityof anysignificant change in its sludge use -or disposal
practices.
7. Power Failures
The-permittee is responsible for maintaining adequate safeguards as required by DEM
Regulation, Title 15A, North Carolina Administrative Code, Subchapter 2H, .0124,Reliability,
to prevent the discharge of untreated or inadequately treated wastes during electrical power
failures either by means of alternate power sources,.. standby generators or retention of
inadequately treated effluent.
SECTION D. MONITORING AND RECORDS
1. Representative Sampling
Samples collected and measurements taken,`as required herein, shall':be characteristic of the
volume and nature of the permitted discharge. Samples collected at afrequency less than daily
-shall be taken on a- day and time that is characteristic of the discharge over the entire period
which -the sample represents. All samples shall betaken .at the monitoring points specified in
this permit and, unless otherwise specified, before the°effluent joins or is diluted by any other
wastestream, body, of water', or substance. Monitoring points shall not be changed without
notification to and the approval of the Permit Issuing Authority:
2. Reporting
Monitoring results obtained during the previous month(s) shall be summarized for each month
and reported on a monthly Discharge Monitoring Report (DMR) Form (DEM No. MR 1, l.l, 2,
3) or alternative forms approved by the Director, DEM, postmarked no later than the 30th.day
following the completed reporting'period.
The fast DMR is due on the last day of the monthfollowing the. issuance of the permit or in the
case of a new facility,' on the last day of the month following the commencement of discharge.
Duplicate signed copies of these, and all other.reports required herein, shall be submitted to the
following address:
Division of Environmental Management
Water Quality -Section
ATTENTION: Central Files
Post Office,Box 29535
.Raleigh, North-Carolina'27626-0535
3. Flow Measurements
6
Appropriate flow measurement devices and methods consistent with accepted scientific,
practices shall be selected and used to ensure,the accuracy and reliability of measurements of
the volume of monitored discharges. The devices shall be installed, calibrated and maintained
to ensure that, the accuracy of the measurements are consistent with the accepted capability -of
that type of device. Devices selected shall be capable of measuring flows .with a maximum
deviation of less than + 10%v f ccm the true discharge rates throughout the range of expected

Part Il
Page 11 of 14
discharge volumes. Once -through condenser cooling water flow which is monitored by pump
logs, or pump hourmeters as specified.,in Part I of this permit and based on the manufacturer's
pump curves shall not be subject to this requirement.
4. Test Procedures
Test procedures for the analysis of pollutants shall conform to the EMC regulations published
pursuant to NCGS 143-215.63 et. seq, the Water and Air Quality Reporting Acts, and to
regulations published pursuant to Section 304(g), 33, USC 1314, of the Federal Water
Pollution Control Act, as Amended, and Regulation 40 CFR 136; or in the case of sludge use or
disposal, approved under 40 CFR 136, unless otherwise specified in 40 CFR 503, unless
other test procedures have been specified in this permit.
To meet the intent of the monitoring required by this permit, all test procedures must produce
minimum detection and reporting levels that are below the permit discharge requirements and
all data generated must be reported down to. the minimum detection or lower reporting level of
the procedure. If no approved methods are determined capable of achieving minimum
detection and reporting levels below permit discharge requirements, then -the most sensitive
(method with the lowest possible detection and reporting level) approved method must be used.
5. Penalties for Tampering
The Clean Water Act provides that any person who falsifies, tampers with, or knowingly
renders inaccurate, any monitoring -device or' method required to be maintained under this
permit shall, upon conviction, be punished by a fine of not more than$10,000 per violation, or
by imprisonment,for not more than two -years per, violation, or by both. If a conviction of a
person is for a violation committed after a first conviction of such person under this paragraph,
punishment is a fine of not more than $20,000 per day of violation, or by imprisonment of not
more than 4 years, or both.
6. Records Retention,
Except for records of monitoring information required by this permit related to the permittee's
sewage sludge use and disposal activities, which shall be retained for a period of at least five
years (or longer as required by 40,.,CFR 503), the permittee shall retain records of all
monitoring information, including all calibration and maintenance records and all original strip
chart recordings for continuous monitoring instrumentation, copies of all reports required by
this permit, for a period of at least 3 years from the date of the sample, measurement, report
or application. This period may be extended by request of the Director at any time.,
7. Recording Results
For each measurement or sample taken pursuant to the requirements of this permit, the
permittee shall record the.following information:
a. The date, exact place, and time of sampling or measurements;
b. The individual(s) who performed the sampling or measurements;
c. The date(s) analyses were performed;
d. The individual(s) who performed the- analyses;
e. The analytical techniques or methods used; and
f. The results of such analyses.

(� Part Il
Page 12 of 14
8. Inspection and Entry
The permittee shall allow the Director, or an authorized representative (including an authorized
contractor acting 'as a representative of the Director), upon the presentation of credentials and
other documents as may be required bylaw, to;
a. Enter upon the permittee's premises where a regulated facility or activity is located or
conducted, or where records must be kept under the conditions of this permit;
b. Have access to and copy, at reasonable times, any records that must be kept under the
conditions of this permit; -
c. Inspect at reasonable times any facilities, equipment (including monitoring and control
equipment), practices, or operations regulated or required under this permit;'and
d. Sample or monitor at reasonable times, for the purposes of assuring permit compliance or
as otherwise authorized by the Clean Water Act, any substances or parameters at any
location.
SECTION E. REPORTING REQUIREMENTS
1. Change in Discharge
All discharges authorized herein shall be consistent with the terms and conditions of this
permit. The discharge of any pollutant identified in this permit more frequently than or at a
level in excess of that authorized shall constitute a violation of the permit.
2. Planned Changes
The permittee- shall give notice to the Director as soon as possible of any planned physical
alterations or additions to the permitted facility. Notice is required only when:
a. The alteration or addition to a permitted facility may meet one of the criteria for determining
whether a facility is -a new source in 40 CFR Part 122.29 (b); or -
b-. The alteration or addition could significantly change the nature or increase the quantity of
pollutants discharged.. This notification applies to pollutants which are subject neither to
effluent limitations in the permit, nor to notification requirements under 40 CFR Part 122.42
(a) (1)•
c. The alteration or addition results in a significant change in the permittWs sludge use or
disposal practices, and such alternation, addition or change may justify the application of
permit .conditions that are different from or absent in the existing permit, including
notification of additional use or disposal sites not reported during the permit application
process or not reported pursuant to an approved land application plan.
3: Anticipated Noncompliance
The permittee shall give advance notice to the Director bf any planned changes in the permitted.
facility or activity which may result in noncompliance with permit requirements.

Part II
` Page 13 of 14
4. Transfers
This permit is not transferable to any person except after notice to the Director. The Director
may require modification or revocation and reissuance of the permittee and incorporate such
other requirements as may be necessary under the Clean Water Act.
5. Monitoring Reports
Monitoring results shall be reported at the intervals specified elsewhere in this permit.
a. Monitoring results must be reported on a Discharge Monitoring Report`(DMR) (See Part 11.
D. 2 of this permit) or forms provided by the Director for reporting results of monitoring of
.sludge use or disposal practices.
b. If the permittee monitors any pollutant more frequently than required by the permit, using
test procedures specified in Part II, D. 4. of this permit or in the case of sludge use or
disposal, approved under 40 CFR 503, or as specified in this permit, the results of this
monitoring shall be included in the calculation and reporting of the data submitted in the
DMR.
c. Calculations for all limitations which require averaging of measurements shall utilize an
arithmetic mean unless otherwise specified by the Director in the permit.
6. Twenty-four Hour Reporting
a. ,The permittee shall report to the central office or the appropriate regional office any
noncompliance which may endanger health or the environment. Any information shall be
provided or within 24 hours from the time the permittee became aware of the
circumstances. A written submission shall also be provided within 5 days of the time the
permittee becomes aware of the circumstances. The written submission shall contain a
description of the noncompliance, and its cause; the period of noncompliance, including
exact dates and times, and if the noncompliance has no been. corrected, the anticipated time
it is expected to continue; and steps taken or planned to reduce, eliminate, and prevent
reoccurrence of the noncompliance.
b. The. following shall be included as information which must be reported within 24 hours
under this paragraph:
(1) Any unanticipated bypass which exceeds any effluent limitation in the permit.
(2) Any upset which exceeds any effluent limitation in the permit.
(3) Violation of a maximum daily discharge limitation for any of the pollutants listed by the
Director in the permit to .be reported within 24 hours.
c. The Director may waive the written report on a case -by -case basis for reports under
paragraph b. above of this condition if the oral report has been_received within 24 hours.
7. Other Noncompliance
The permittee shall report all instances of noncompliance not reported under Part H. E. 5 and 6.
of -this permit at the time monitoring reports are submitted.' The reports shall contain the
information listed in Part II. E. 6. of this permit.

Part II
Page 14 of.14
8. Other Information
Where the permittee becomes aware that it failed to submit any relevant facts in a permit
application, or submitted incorrect information in a permit application or in any report to the
Director, it shall promptly submit such facts or information.
9. Noncompliance Notification
The .permittee shall report by telephone to either the central office or the appropriate regional
office of the Division as soon as possible, but in no case more than 24 hours or on the next
working day following the .occurrence or first knowledge of the occurrence of any of the
following:
a. Any occurrence at- the water pollution control facility which results in the discharge of
significant amounts of wastes which are abnormal in quantity or characteristic, such as the
dumping of the contents of a sludge digester; the known passage of a slug of hazardous
substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons,. that render the facility
incapable of adequate wastewater treatment such as 'mechanical or electrical failures of
pumps, aerators, compressors, etc.
c. Any .failure of a pumping station, sewer line, or treatment facility resulting in a by-pass
directly to receiving waters without treatment. of all or any portion of_the influent to such
station or facility.
Persons reporting such occurrences by telephone shall also �file wwritten report ini letter form_
within 5 days following first knowledge of the occurrence.
10. Availability of Reports
Except for data determined to be confidential under NCGS 143-215.3(a)(2) or Section 308 of
the Federal. Act, 33.USC 1318, all reports prepared in accordance with the terms shall -be
available for public, inspection at the offices of the Division. of Environmental Management. As
required by the Act, effluent data shall not be consideredconf dential. Knowingly making any
false statement on any such report -may result in the imposition of criminal penalties as provided
for in NCGS -143-215.1(b)(2) or in Section 309 of the Federal Act.
11. Penalties for Falsification of Reports
The Clean Water Act provides that any person who knowingly makes any false statement,
representation, or certification .in any record or other document submitted or required to be
maintained under this -permit, including monitoring reports or .reports of compliance or
noncompliance shall', upon conviction, be punished -by a fine of not more than $10,000 per
violation, orb imprisonment for not more than two years per violation, or by both. .
r

PART III
OTHER REQUIREMENTS
No construction of wastewater treatment facilities or additions to add to the plant's treatment
capacity or'to change the type of process utilized at the treatment plant shall be begun until
Final Plans and Specifications have been submitted to the Division of Environmental
Management and written approval and Authorization ,to Construct has been issued.
jsE WSM(MIM
The permittee shall, upon written notice from the Director of the Division of Environmental
Management, conduct groundwater monitoring as may be required to determine the
compliance of this NPDES permitted facilitywith the current groundwater standards.
C. Changes in Discharges of Toxic Substances
The permittee shall notify the Permit Issuing Authority as soon as it knows or has reason to
believe:
a.That any activity has occurred or will occur which would result in the discharge, on a
routine or frequent basis, of any toxic pollutant which is not limited in the permit, if that
discharge will. exceed the highest of the following "notification levels';
(1) One hundred micrograms per liter (100 ug/1);
(2)Two hundred micrograms per liter (200 ug/1) for acrolein and acrylonitrile; five
hundred micrograms per, liter (500 ug/1) for 2.4-dinitrophenol and for 2-methyl-4.6-
dinitrophenol; and one milligram per liter (1 mg/1) for antimony;
(3) Five (5) times the maximum concentration value reported for that pollutant in the
permit application.
b. That any activity has occurred or will occur which would result in any discharge, on a
non=routine or infrequent basis, of a toxic pollutant which is not limited in the permit, if
that discharge will exceed the highest of the following "notification levels";
(1) Five hundred micrograms per liter (500 ug/1);
(2) One milligram per liter (1 mg/1) for antimony;
(3) Ten (10) times the maximum concentration value reported for that pollutant in the
permit application.
D. Requirement to Continually Evaluate Alternatives to Wastewater Discharges
The. permittee shall continually evaluate all wastewater disposal alternatives and pursue the
most environmentally sound alternative of the reasonably cost effective alternatives. If the
facility is in substantial non-compliance with the terms and conditions of the NPDES permit
or, governing rules, regulations or laws, the permittee shall submit a report in such form and
detail as required by the Division evaluating these alternatives and a plan of action within
sixty (60) days of notification by th-, Division.

Part III Permit No. NC0005461
E. The Permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water. The Permittee shall notify the Director in writing not
later than ninety (90) days prior to instituting use of any additional biocide used in the treatment
system which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map indicating the discharge --point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving. stream, as determined by calculations from, the Biocide Worksheet
Form 101 with Supplemental Metals Analysis Worksheet.
F. The facility discharges into a stream with 7Q10/30Q2=0 cfs. Removal of discharge is
recommended if a more environmentally sound alternative is available at an economically
reasonable cost.. An engineering report evaluating alternatives to discharge is due 180 days prior to
permit expiration alon- ' with -the permit renewal application. As part of the report, the cost of
constructing a treatment plant at. the discharge point to meet limits of 5 mg/1 BOD5, 2 mg/l NH3 as
N, 6.0 mg/l DO, and 17.0 µ.g/l chlorine should also be included if there are no feasible alternatives
to a surface discharge. Upon review,of .the results of the engineering report, the Division retains
the right to reopen and modify this NPDES permit to require removal of the discharge or to revise
the permit limitations within a specified time schedule.

r vn.
PART IV
ANNUAL ADMINISTERING AIr"D. COMPLIANCE MONITORING FEE REQUIREMENTS
A. The permittee must pay the annual administering and compliance monitoring fee within 30
(thin y).days after being billed by the Division. Failure to pay the fee in a timely manner m
accordance with 15A NCAC 2H .0105(b)(4) may cause this Division to initiate action to
revoke the permiL
J

rte4p
State of North Carolina
Department of Natural Resources and -Community Development
— Division of Environmental Management
512 North Salisbury Street • Raleigh, -North Carolina 27611
James G. Martin, Governor R. Paul Wilms
S. Thomas Rhodes, Secretary February 29, 1988 Director
Mr. Max Smallwood, Plant Manager
Rutherford Furniture Company - —
P.O. Box 6.9
Rutherfordton, North Carolina 28139
- SUBJECT: :Effluent Toxicity Testing.
- ..Rutherford Furniture. Co. -002
=NPDES No.-N00005461
- :'Rutherford.. County
Dear Mr. Smallwood:
An- extremely important issue that must:be addressed by dischargers and.
regulatory ag.enc-ie.s._is that of toxics and the potential impacts of toxic
„ discharges to the surface waters of North Carolina. Title 15- of the North
Carolina .Adminis.trative--Code,_ Section .. 0200 �sp.ecif i.cally_..addre.sses - those-
standards- and regulations which pertain to. 6 is issue..
Toxicity testing and evaluations were conducted by the Division of
Environmental -Management employing effluents obtained at the subject facil
ity on January 20, 1988. A result of these'.evaluations.(LC50 value of
<5.0%) indicates the subject outfall 002 effluent causes toxic responses in
the. test species employed= (Cer• iodaphriia)
- As - these tests have determined•that_.ahe effluent of this facility exhi-
bits toxicity, it is essential that a plan of action be prepared, and appro-
priate actions pursued, to eliminate or reduce those effluent constituents
that may be associated with' the observed toxic responses. I-t is recommended --
that you contact Mr. Forrest Westall of the Asheville Regional Office at
[phone]_for additional guidance in your toxicity reduction program.. _
Based on the toxicity results obtained to date, the Division of-Envi-
ronmental Management ..therefore requires that__monthly s.tatic.acute bioassay
analysis be conducted' -on representative 24-h6ur -composi.te . effl.uent --samples.__ _. .'._
-' from outf.all 002,-and that the results be reported to this office within 15'
days following each test. Test results should. be sent to the following
address:
_ Mr Steve W. Tedder -
-. _-- _- .-- --_- Technical- Services .Branch
N.. C_. -D-ivis.ion' of Env ironmental__-Management.
P.O._".Box=2±7687
__.Rale.igh,__,North Carolina 2761.1- --
-
ton even ton a s
P.O. Box 27687, Raleigh, North Carolina 27611-7687 Telephone-919-733-MI5 - -
An Equal Opportunity Affirmative Acfion Employer

Please note that the test results are to be -submitted with all supporting
data (mortality and reproduction results, water chemistry, laboratory obser-
vations, -etc.) on the State -Form AT-1, which: -can be copied from the enclosed
original. The initial test should be conducted within 30 days following
receipt of this correspondence.
The species to be employed for testing should be Daphnia pulex or
Ceriodaphnia sp.- Additional and/or alternative species may be employed if
deemed appropriate by the Division. The test method shall be 48 hour static
bioassays as described in Peltier, W.H., and-C.I Weber. 1985. Methods for
Measuring the Acute Toxicity of Effluents to'Freshwater and Marine
Organisms. Third Edition. EPA/600/4-85/013.=Environmental Monitoring and
Support Laboratory, U.S. Environmental Protection Agency, Cincinnati, Ohio.
Attached is a listing of consultants who have been provided a description of
the prescribed -test methodology. We encourage you to consult with the labo----
ratory performing your testing to gain a complete understanding of the data
produced. _
The samples of wastewater to be tested are.to-be collected on a repre-
sentative workday, preferably Wednesday or Thursday below all waste treat-
ment. Based on the discharge volume of the permitted outfall 002 (0.045
MGD),- and the 7Q10 flow of the receiving stream (0.10 cfs), there should be'
no significant mortality in a 90% effluent concentration during this initial
monitoring requirement.
The required -.acute bioassaytesting is to continue until it can be
demonstrated. that- significant toxicity reductions have been cons- --n-
i.statly
- - --- achieved. -- At, such- t-i_me,-this --requirement may, be modi.f.ied-:.by the .D.ivision..- ... ,.
Final -whole effluent toxicity objectives i-nclude reduction of chronic
--impacts so that no detrimental effects are observable at the instream.waste
concentration specified by the 7Q10 of your receiving stream and your per-
mitted discharge volume (41%).
Should you be unable to consistently achieve the previously specified
target level. a,.deta led evaluation: -report will be-r•equ.ire'd, within s-ix .
months. -following -issuance of this letter. - _This.- report.is to, outline- those,
- actions' taken' to: achieve compliance;s= `-and- to addresthose o cnstituents -that-
may result in -associated toxic conditions of�the subject effluent.. Please
be advised it -is likely upon reissuance of your NPDES.Permit thatwhole
effluent toxicity will be included as a limit-ed parameter. It is.to'your
advantage to deal effectively with this issuenow•.
Should there be any --questions, please contact Steve Tedder or. Mr.. Ken
Eagleson, Supervisor, Biological -Services Unit at [phone].
Sincerdily,.
Charles. Wa ld, Chief R EE C E I V E D
Water Quality Section Water Quality Section
cc: Steve W.-Tedder
Np
Dennis _ Rams.ey
r
- - -._ - Ken�Eag-l-eson- __. - _ - -• .IyAHI�:..1 I -i���U
We+t�a�l�lo
Cef r-al -Files.
y - Asheville Regional'Office
- - _
Asheville, North Carolina

State of North Carolina
Department o_f.Environment
and Natural Resources
Asheville Regional Office
Michael F. Easley, Governor
Sherri Evans -Stanton, Acting Secretary
Kerr T. Stevens, Director
Division of Water Quality
WATER QUALITY SECTION
January ll,. 2001
Ms. Barbara M. Hobson
Rutherford County Tax Department
P.O. Box 143
Rutherfordton, North Carolina 28139
Dear Ms. Hobson:
NCDENVI.
NORTH. CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Tax Certification
Number TCS-AV-007
Broyhill Furniture -Rutherford Plant
.Wastewater Treatment Facility
Rutherford County
Transmitted herewith is Tax Certification Number TCS-AV-007
covering the construction. and operation of the oil water separator at
Broyhill'Iridustries; Inc. as described in amendment to Permit -Number
NCG180074, dated August 27, 1999.
The Company may use -this Certification to obtain tax benefits in
keeping with the appropriate Statutes. Detailed descriptions of these
wastewater treatment facilities are available in the files of the
Division of Water Quality.
Sincerely,
Kerr T. Stevens
Enclosure
xc : Roger . C . Edwards.

DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
TAX CERTIFICATION
(Franchise/privilege; Amortization; Property)
In accordance with the provisions of the General Statutes of North Carolina (G.S> 105-122(d),
105-130.10, 105-147(13), 105-275(8), this is to certify that:
Broyhill Furniture Industries, Inc.
Rutherford Plant
Rutherford County
HAS BEEN ISSUED
The Environmental Management Commission and the Department of Environment and Natural
Resources have found that the facility:
a. has been constructed or installed;
b. complies with the requirements of the Commission;
C. is being effectively operated in accordance with the terms
and conditions of the permit, certificate of approval, or
other document of approval issued by the Commission; and
d. has as its primary rather than incidental purpose the
reduction of water pollution resulting from the discharge of
sewage and waste.
Issued at Raleigh, North Carolina, this the 11t" day of January 2001 by the Director of the North
Carolina Environmental Management Commission and the North Carolina Department of
Environment and Natural Resources.
err T. Stevens

r
hate of North Carolina
Department of Environment
and Natural Resources
•� Asheville Regional Office / .
Michael F. Easley, Governor NCDENR
Sherri Evans-Stanton:,'Acting Secretary
Kerr T. Stevens,' Director NORTH CAROLINA DEPARTMENT OF
Division of Water Quality ENVIRONMENT AND NATURAL RESOURCES
WATER QUALITY SECTION
January 11, 2001
MEMORANDUM
TO: Forrest R. Westall
Water Quality Regional Supervisor
FROM: Roger C. Edwards-R&
Wastewater Consultant
SUBJECT: Tax Certification
Broyhill Furniture Industries, Inc.
Rutherford Plant
Wastewater Treatment Facilities
Rutherford County, North Carolina
I have confirmed the construction and operation of the oil water
separator facility at Broyhill Furniture -Rutherford Plant. The
facility, as described in amendment to Rutherford County Tax
Department, is being operated satisfactorily. Therefore, the attached
Tax Certification has been prepared for the Director's signature.
If you should have any questions or require additional
information, please do not hesitate ;to contact us.
Enclosure
xc: Coleen Sullins

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
Kerr T. Stevens, Director
April28, 1999
JERRY CHURCH
BROYHILL FURN IND-RUTHERFO_ RDT
ONE BROYHILL PARK - -
LENOIR, NC 28633
Subject: CERTIFICATE OF COMPLETION
PERMIT NO. WQ0015004
BROYHILL FURNN IND-RUTHERFORDT
RUTHERFORD COUNTY
Dear Permittee:
On March 12, 1998 the Division of Environmental Management issued you the subject permit. One of the
conditions of the subject permit read as follows:
Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted
facility has been installed in accordance with the requirements of this permit and the
approved plans and specifications. Mail certification to the Permits and Engineering
Unit, P.O. Box 29535, Raleigh N.C., 27626-0535.
To date, our records show that no certification has been received for the subject permit. If the permitted
facility has been constructed and placed into operation please submit the required certification immediately.
Operation of the treatment system prior to submission of the required certification is in violation of your permit
and is subject to enforcement action. If you have any questions, please contact consulting engineer for this
project, WEST & ASSOC, PA at [phone]. If the facility has not been constructed, please contact the
Asheville Regional Office at [phone], so that they can update their records.
Thank you for your prompt attention to this matter.
Sincerely,
,A,Mb-"--q �tt-P)
-Kim H. Colson, P.E., Supervisor
State Engineering Review Group
cc: Asheville Regional Office
File
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

01/04/1994 '19:15 8284335662 WEST & ASSOCIATES PAGE 05
't No. WQ0015004
arch 12, I998
ENGINEERS 6R- TIFICATION
Partial, Final
I, K'ausFK 1�'rltout , as a duly a istered Professional Engineer in the State of North
Carolina, having been authorized to observe e o ical weekly, full time) the construction of the
project. 1►4A�n-eS Se4- - GA-4 s►e" .er�rd Tan +e--�4br the
Project Name Location and County
Perraittee hereby state that, to the best of my abilities, due care and diligence was used in the observation.
of the construction such that the construction was observed to be built within substantial compliance and
intent of this rzx ,t the approved pla and specifioations,_ nd outer supporting_materials.----
Signs Registration No. 7,-�>-T 57
Date 1 (
1�;1��`N�S a►� SE 57 ' qt
Ll
NOW
w
e

NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
a i - ASHEviLLE RMIONAL OFFICE
W4WATER QUALITY SECTION
IN t ; June 15, 1998
JAMES B. HUNTJR:'=�:': :•� Mr. David Stout, Environmental Manager
"GOVERNOR Broyhill Furniture Industries
One Broyhill Park
Lenior, North Carolina 28633
Subject: NOTICE OF VIOLATION
AP—CRETARY • •
Effluent Limitations
NPDES Permit Number
NC0005461
IBYbyhll "Furniture
Industries
Rutherford County
ter•.• .'� 4''.�T£F,f,
LUI Dear Mr. Stout:
I p;:;r:'9.:; • Review of subject self -monitoring report for the month
N.
of April, 1998, revealed a violation of the following
parameter:
..� Reported Limits
Pipe Parameter Value/Unit Value/Unit
- A; 001 Fecal Coliform 2080/100 ml 400.0/100 ml
rt.r; Remedial actions if not already implemented, should be
taken to correct the problem(s). The Division may pursue
,.�; ' .p l:-.,_ enforcement actions for this and any additional violations
• �,'.: ' ` �.'=>',°::.' ; of State Law or permit requirements. If you have need to
discuss this p lease call Forrest R. Westall at 828/251-
6208.
;'f Sincerely,
a h•�.Tqi
f •t,z.r oy M. avic
Regional Supervisor
Division of Water Quality
`•`r.Y t • f-.0 xc - Rutherford " �' •. ��:�', � :'' County Health Department
Dean Conner ORC
;•
�.rg ..f +r•:
INTERCHANGE BUILDING, 59 WOODFIN PLACE, ASHEVILLE, NORTH CAROLINA 28801
PHONE [phone] FAX [phone]
g _3: 0 AN EQUAL OPPORTUNITY/AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/10% POST -CONSUMER PAPER

tate of North Carolina
r
epartment of Environment
ndNatural Resources
ivision of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
March 12, 1998
Mr. Jerry Church, Chief Financial Officer
Broyhill Furniture Industries, Inc.
One Broyhill Park
Lenoir, North Carolina 28633
Dear Mr. Church:
r�
A141 • •
NCI
Subject: Permit No. WQ0015004
Broyhill Furniture Industries, Inc.
BBroyhill Industries = Lenoir_ _P1an_ t,,
Sewer Extension
Rutherford County
In accordance with your application received February 23, 1998, we are forwarding herewith
Permit No. WQ0015004, dated March 12, 1998, to Broyhill Furniture Industries, Inc. for the
construction and operation of the subject wastewater collection extension.
This permit shall be effective from the date of issuance until rescinded and shall be subject to the .
conditions and limitations as specified therein.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the
right to request an adjudicatory hearing upon written request within thirty (30) days following receipt of
this permit. This request must be in the form of a written petition, conforming to Chapter 150B of the
North Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer
27447, Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Rick Moore at [phone] extension 527.
Sincerely,
WW, C&
/,--
A. Preston Howard, Jr., P.E.
cc: Rutherford County Health Department
At-ZeWmidllM�Reg� I�1, , ce, .'ba erg+,u i't3%5 cf on
West and Associates, P.A.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper
r�� �1

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
1­ 7:, n RALEIGH
a," ',,WASTEWATER COLLECTION PERMIT
F In accordance with:the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
- :amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Broyhill Furniture Industries, Inc.
Rutherford County
FOR THE
construction and operation of approximately 38 linear feet of 8 inch gravity sewer, a 125 GPM pump
station with duplex pumps, on -site audible and visual high water alarms, telemetry monitoring system,
plant shutdown upon power failure, and approximately 4,890 linear feet of 4 inch force main to serve the
existing employees, 200 additional employees and the cooling water discharge from Broyhill Furniture
Industries, Inc.'s Lenoir Plant and the discharge of 67,000 GPD of collected domestic and industrial
wastewater into the Town of Rutherfordton's existing sewerage system, pursuant to the application
received February 23, 1998, and in conformity with the project plan, specifications, and other supporting
data subsequently filed and approved by the Department of Environment and Natural Resources and
considered a part of this permit.
This permit shall be effective from the date of issuance until rescinded and shall be subject to the
following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with the
conditions of this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the
application and other supporting data.
3. The facilities must be properly maintained and operated at all times.
4. The sewage and wastewater collected by this system shall be treated in the Town of
Rutherfordton's Wastewater Treatment Facility prior to being discharged into the receiving
stream.
5. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be submitted
to the Division of Water Quality (Division) accompanied by an application fee, documentation
from the parties involved, and other supporting materials as may be appropriate. The approval of
this request will be considered on its merits and may or may not be approved.
6. Construction of the sewers, pump station(s) and force main shall be scheduled so as not to
interrupt service by the existing utilities nor result in an overflow or bypass discharge of
wastewater to the surface waters of the State.

7. Upon completion of construction and prior to operation of this permitted facility, a certification
must be received from a professional 'engineer certifying that the permitted facility has been
installed in accordance with this permit, the approved plans and specifications, and other
supporting materials. If this project is to be completed in phases and partially certified, you shall
retain the responsibility to track further construction approved under the same permit, and shall
provide a final certificate of completion once the entire project has been completed. Mail the
Certification to the Non -Discharge Permitting Unit, P.O. Box 29535, Raleigh, NC 27626-0535.
8. A copy of the approved plans and specifications shall be maintained on file by the Permittee for a
minimum of five years from the date of the completion of construction.
9. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division, in accordance with North Carolina General
Statute 143-215.6A to 143-215.6C.
10. The issuance of this permit does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances which may be imposed by other government agencies
(local, state, and federal) which have jurisdiction.
11. The Permittee shall provide for the pump station and force main the following items:
a. Pump on/off elevations located so that 2-8 pumping cycles may be achieved per hour in the
pump station,
b. An air relief valve located at all high points along the force main,
c. A screened vent for the wet well,
d. Fillets located in the wet well at the intersection of the flooring and sidewalls,
e. Three feet of cover (minimum) over the force main or the use of ferrous material where three
feet cannot be maintained,.
f. Sufficient devices which will protect the pump station from vandals, and
g. Flood protection if the pump station is located below the 100-year flood elevation.
12. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance
conditions, the Permittee shall take immediate corrective action, including those as may be
required by this Division, such as the construction of additional or replacement wastewater
collection facilities.
13. NONCOMPLIANCE NOTIFICATION:
The Permittee shall report by telephone to the Asheville Regional Office, telephone number
[phone], as soon as possible, but in no case more than 24 hours or on the next working
day following the occurrence or first knowledge of the occurrence of either of the following:
a. Any process unit failure, due to known or unknown reasons, that renders the facility
incapable of adequate wastewater transport, such as mechanical or electrical failures of
pumps, line blockage or breakage, etc.; or
b. Any failure of a pumping station or sewer line resulting in a by-pass directly to receiving
waters without treatment of all or any portion of the influent to such station or facility.
Persons reporting such occurrences. by telephone shall also file a written report in letter form
within five (5) days following first knowledge of the occurrence. This report must outline the
actions taken or proposed to be taken to ensure that the problem does not recur.

F
I
14. This permit shall�ai come voidable unless the agreement between Broyhill Furniture Industries,
Inc. and the Town of Rutherfordton for the collection and final treatment of wastewater is in full
force and effect.
Permit issued this the twelfth day of March, 1998.
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Pllv�fi AL X'-,
Preston Ho ard, Jr., P.E., D' ector
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0015004

Permit No. WQ0015004
March 12, 1998
ENGINEER'S CERTIFICATION
Partial Final
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, for the
Project Name Location and County
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of this permit, the approved plans and specifications, and other supporting materials.
Signature Registration No.
Date
4

NC DENR / DWQ / NPDES
f" Permit Renewal Applications
Renewal Package Checklist
NPDES Permit No. NC0005461
Broyhill Furniture Industries .
Rutherford County
The following items are REQUIRED for all renewal packages:
F-1 A cover letter requesting the renewal and documenting any changes at the facility
since issuance of the last permit. Submit one signed original and two copies.
1-1The completed application form (copy_ attached), signed by the permittee or an
Authorized Representative. Submit one signed original and two copies.
If an Authorized Representative is preparing the renewal package, documentation
F1 must be provided from the permittee defining the person or company preparing the
renewal package as an Authorized Representative (see Part II.B.H.b. of the NPDES
._permit).
F-1
A renewal fee of $200 in accordance with 15A NCAC 2H .0105(b). The fee is based
on wastewater flow from the Broyhill Furniture Industries discharge. Make checks
payable to NC DENR. See the note below, concerning fee amounts.
F-1
A narrative description of the sludge management plan at the subject facility. If your facility has no sludge management plan, explain the reason for this in your
cover letter. Submit one original and two copies.
The following requirement does NOT apply. to municipal or non -industrial facilities.
The following item applies to Industrial facilities only:
F-1.
Industrial facilities classified as Primary Industries (listed in Appendix A of Title 40 of
the Code of Federal Regulations, Part 122) must submit a Priority Pollutant Analysis
in accordance with 40 CFR Part 122.21.
Send the completed renewal package and appropriate fee to:
'Mr. Charles H. Weaver, Jr.
NC DENR / DWQ / NPDES
P.O. Box 29535
Raleigh, North Carolina 27626-0535
For renewal packages postmarked on or prior to June. 3, 1998, submit a fee of $200.
For renewal packages postmarked AFTER June 3, 1998, submit a fee of $400.

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
March 5, 1998
David Stout
Broyhill Furniture Industries
One Broyhill Park
Lenoir, NC 28633
NC DENR
Subject: Renewal of NPDES Permit No. NC0005461
Broyhill Furniture Industries
Rutherford County
Dear Permittee:
The subject permit expires on November 30, 1998. North Carolina General Stature 143215.1(c) requires that an
application for permit renewal be filed at least 180 days prior to the expiration date.
To satisfy this requirement, your renewal package must be sent to the Division postmarked no later than June 3,
1998. Failure to request renewal by June 3, 1998 will result in a civil assessment of at least $250.00. Larger
penalties may be assessed depending upon the delinquency of the request.
If any wastewater discharge will occur after November 30, 1998 (or if continuation of the permit is desired), the
permit must not be allowed to expire. Operation of waste treatment works or continuation of a discharge after
November 36, 1998 would violate NCGS 143-215.1 and could result in assessment of civil penalties of up to
$10,000 per day.
If all wastewater discharge has ceased at the subject facility and you wish to rescind this permit, contact Robert
Farmer of the Division's Compliance Enforcement Unit at [phone], extension 531. You may also contact
the Asheville Regional Office at [phone] to begin the rescission process.
Use the enclosed checklist to complete your renewal package. The checklist identifies the items which you must
submit when applying for renewal of the subject permit.
If you have any questions, please contact me. My telephone number, fax number and e-mail address are listed
below.
Sincerely, cam
arles H. Weaver, Jr.
NPDES Unit
cc: Central Files
Asheville Regional. Office, Water Quality Section�r
P.O. Box 29535, Raleigh, North Carolina 27626-0535
An Eaual Ogoortunity Affirmative Action Emolover
919 733-5083, extension 511 (fax) 919 733-0719
Charles [e-mail]

Broyhill Furniture Industries, Inc.
One Broyhill Park, Lenoir, North Carolina 28633
BROYNIL
December 31, 1997
Mr. Roger Edwards
North Carolina Dept. Of Environment, and Natural Resources
Division of Water Quality
Interchange Building
59 Woodfin Place
Asheville, North Carolina 28801
Dear Roger:
SUBJECT: BROYHILL FURNITURE INDUSTRIES, INC.
RUTHERFORD PLANT
RUTHERFORD, NORTH CAROLINA svq; �log8
RUTHERFORD COUNTY
This letter is in response to your inspection of December 3, 1997, and Ali se
December 12, 1997. In that letter you listed several points of concern and recommendal
would like to respond to each. They are as follows:
of
1) concerning the presence of grease in the clarifiers: as you are aware, we have installed grease
traps in our sewer system. Mr. Conner cleans these on a set schedule. He will continue to clean
these on a scheduled basis and monitor the pretreatment plant to assure that the amount of grease
that gets through the traps will not be a problem.
2) airline leak in clarifier No.2 - Mr. Conner has plans to pump the solids & sludge from the
facilities as soon as the ground gets dry enough to get a pump truck to the facility. When this
happens, Mr, Conner will be able to get to the airline to make repairs. Mr. Conner will continue
to monitor the situation and schedule this as soon as possible.
3) low Ph in aeration basin - the Ph has been adjusted and monitored by Mr. Conner. The Ph has
been within the 6.5 to 7.5 range since the inspection.
4) recommendation to pump solids from facility - see response No.2.
5) corrosion of structural supports - we are in the process of connecting onto the City of
Rutherford's pretreatment facility and we anticipate that to happen before November 30, 1998,
which is when our permit expires: Currently, it is difficult to make repairs on our facility. without
totally replacing parts of it. Mr. Conner will monitor the -structure of our facility and attempt -for'

it will last until we make the connection to the city system. Repairs or replacements will be made
as needed.
6) recommend cleaning diffusers - Mr. Conner closely monitors the operation of our facility. On
the afternoon of December 3, the day of the inspection, all diffusers were working properly.
Currently all diffusers are working properly.
7) low Ph of effluent the Ph of the effluent has come up and is currently within our permitted
range. See response No.3.
8) recommendation to connect to City of Rutherford - see response No.5.
9) comment on DMR reports - Mr. Conner will continue to operate and monitor our facility so
that all DMR reports are within permitted limits. -
Thank you for your assistance in the operation of our facility. If you need further
information please call me at 704-758-3374.
Sincerely,
BROYHILL FURNITURE INDUSTRIES, INC.
David Stout -
Corporate Environmental Manager
cc
Bill Sale
Tom Ingram
Dean Conner
hAwp\1et\3101297.1et

State of North Carolina
Department of"E ivironment
and Natural Resources
Asheville Regional Office
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
December 12, 1997
Mr. David Stout
Corporate Environmental Manager
Broyhill Furniture Industries, Inc.
One Broyhill Park
Lenior, North Carolina 28633
i
A
•
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT ANo NATURAL RESOURCES
Subject: Notice of Deficiencies
Compliance Sampling Inspection
NPDES Permit Number NC0005461
Broyhill -Rutherford Plant
Wastewater Treatment Facility
Rutherford County
Dear Mr. Stout:
I conducted the above referenced inspection of discharges 001,
002, and 003 on December 3, 1997. The treatment facility, -discharge
001, was operating satisfactory, however there is a need for minor
adjustment of the treatment process. Both 002 and 003 were
satisfactory as well. During the inspection I did notice several
points of concern which are listed by item below.
1) Grease was evident in the clarifiers. However,
the amount of grease in the treatment facility
appears to be less than during previous inspections.
2) The air line for the sludge return in`clarifier
number two (2) are leaking. This prevents the
clarifier from preforming efficiently, as the air
escaping causes the solids to remain in suspension.
This air line should be repaired as soon as possible
to prevent degradation of the effluent.
3) The.pH in the aeration basin of each treatment
plant was low, plant number one (1) 5.09 s.u., plant
number two (2) 3.61 s.u. The normal operating range
for pH in an activated sludge system is 6.5 to 7.5
standard units (s.u.). The organisms that treat the
wastewater do not adjust well to rapid pH changes,
therefore -the pH of the treatment plants should be
adjusted up gradually with soda ash. Methods of
59 Woodfin Place, Asheville, North Carolina 28801
Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer

Mr. Stout
December 12, 1997
Page Two
making pH adjustment were discussed with the ORC during the
inspection.
4) The aeration basin mixed liquor was very dark,
settled rapidly, and has a grainy appearance. This
indicates that solids should be wasted from the
treatment facilities. The procedure for wasting was
discussed with the operator. This will be a
opportune time to make air line repairs in the
clarifiers.
5) In treatment plant two (2) the structural supports
exhibit excessive corrosion. These supports will
require repair in the near future.
6) There are diffusers in both treatment facilities
that need cleaning. In number one (1) the second
diffuser from the influent end of the facility and
the diffuser closest to the clarifier. In number two
(2) the diffuser closest to the clarifier.
7) The effluent pH was below the range set in your
NPDES Permit. The NPDES Permit states the pH shall
not be less than 6.0 standard units nor greater than
9.0 standard units. On the date of inspection the
effluent pH measured 5.51 standard units.
8) The wastewater, collection system for the Town of
Rutherfordton is approximately one (1) mile from the
Broyhill -Rutherford Plant. I understand from
discussions with the operator that connection to the
Town of Rutherfordton wastewater collection system
are anticipated before your NPDES Permit expires
November 30, 1998. If this is not the case, remember
that application for renewal must be in Raleigh 180
days prior to expiration of your present NPDES
Permit.
9) In reviewing discharge monitoring reports (DMR)
from October 1996 through September 1997 only one
violation occurred. This violation was a daily
maximum for total suspended solid.
The samples collected on the date of the inspection indicate
compliance with your National Pollutant Discharge Elimination System
(NPDES) Permit with the exception of effluent pH.

• ..
Mr. Stout
December 12, 1997
Page Three
The time and assistance of Mr. Dean Conner during this
inspection is much appreciated. Please respond in writing on or
before January 15th regarding the time frame that corrective actions
will be taken. If you or your staff have questions in regard to this
report, please do not hesitate to contact me at 704-251-6208.
Sincerely,
_cCurELS.4_
Roger C. Edwards
Wastewater Consultant
Enclosure
cc: Mr. Dean Conner, ORC
Rutherford County Health Department

United S :nvironmental Protection Agency
Form Approved
shington, D.C. 20460 +
;]Mg No. 2040-0003
EPA NPDES Compliance Inspection Report
Approval Expires 7-31-85
Section A: National Data System Coding
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 i N I 2 15 � 3 N C0005461 11 12 97/12/03 17 18 �y J 19 IS � 20 u
I�-�--J� t--�
Remarks
I
II!!!Illillilli!Illllllllllllllllllilllllllllll�
2' Reserved Facility Evaluation Rating BI QA Reserved 6G
I 72 I I 73 74 75 Ll 8o
67 I I I 169 70 13 I 71 Ionu
�J u
SectionB: Facility Date
Name and Location of Facility Inspected
Entry Time
Permit Effective Date
Broyhill Furniture Industries, Inc.
9:45 am
January 1, 1994
Rutherford Plant
Exit Time/Date
Permit Expiration Date
One Broyhill Park
Lenior, North Carolina 28633
11:15 am
Nov. 30, 1998
Name(s) of On -Site Representative(s)/Title(s)
Phone No(s)
Mr. Dean Conner, ORC
704-287-4276
Name, Address of Responsible Official
Title
Mr. David Stout
Corporate Enviornmantal Manager
One Broyhill Park
Phone No. _T
Contacted
Lenior, North Carolina 28633
704-758-3111
No
Section C: Areas Evaluated During Inspection CODES S - Satisfactory M - Marginal U - Unsatisfactory N - Not evaluated/Not applicable
S
Permit
Records/Reports
Facility Site Review
S
Flow Measurement
Laboratory
Effluent/Receiving Waters
N
Pretreatment
Compliance Schedules
Self -Monitoring Program
M
Operations &Maintenance
Sludge Disposal
Other: row 17
S
N
N
S
M
M
S
Section D: Summary of Findings/Comments (Attach additional sheets if necessary)
Grease entering the treatment facility should be monitored closely to avert future problems.
Air line for sludge return in clarifier number two (2) is leaking. This should be repaired as soon as possible to prevent effluent degradation.
Plant two (2) the structural supports will require repair in the future due to corrosion.
The pH is both aeration basins is below the recommended range. This can be corrected with the addition of soda ash, as discussed with the ORC during the
inspection. The effluent pH is below NPDES Permit limit of 6.0 standard units.
Solids need to be wasted form both treatment facilities based on settleability test and field observations.
Diffusers need to be cleaned in each treatment facility. Plant #1 the second diffuser for the influent end and diffusers closest to the clarifier. Plant #2 diffuser
closest to the clarifier.
Suggest the Broyhill -Rutherford Plant investigate the connection to the Town of Rutherfordton collection system which is approximately one (1) mile away.
Discharge Limitations Measurement Sample Results
Monthly Avg. Daily Max. Frequency
Flow 0.026 MGD Weekly
BOD 30.0 mg/I 45.0 mg/I Weekly <2.0 mg/I
TSS 30.0 mg/I 45.0 mg/I Weekly 3.0 mg/I
NH, NL Weekly 3.8 mg/I
Fecal Coliform 200/100 ml 400/100 ml Weekly <4/100 ml
Name(s) and Signature(s) of Inspector(s)
Agency/Office/Telephone
Date
ROGER C. EDWARDS
DWQ/ARO 704-251-6208
-
Agency/Office
Da e
=jfevie;er
DWQ/ARO 704-251-6208
�
Regulatory Office Use Only
Action Taken
Date
Compliance Status
Noncompliance
Compliance

For Lab Use ONLY
DIVISION OF ENVIRONMENTAL MANAGEMENT WATER QUALITY FIELD -LAB FORM (DM1)
COUNTY jR ,k A
PRIORITY
SAMPLE TYPE
RIVER BASIN D/-04
_
❑AMBIENT
❑ QA
❑ STREAM
LJ EFFLUENT
REPORT TO: A O RO MRO RRO WaRO WiRO WSRO TS
AT BM
❑
❑ CHAIN
❑ LAKE
❑ INFLUENT
Other
COMPLIANCE
❑EMERGENCY
OF CUSTODY
Shipped by: Bus Courier taff, Other
ESTUARY
Lab Number: O6 2(I
Date Received: —S -% Time: -2: 3
Rec'd by: S H From: Bus-Couri -Hand Del
DATA ENTRY BY: r CK: S
DATE REPORTED:
COLLECTOR(.S): r" L11R1RJ±5
Estimated BOD Range: G-5Aft 25-65/40-130 or STATION STATION LOCATION:
)J? ID XV A 4 R N k4F7
Seed: Yes ENo ❑ Chlorinated: Yes LD No ❑ REMARKS:
1 # Date Begin (yy/mm/dd) Time Begin I Date End Time End Depth DM DB DBM Value Type Composite Sample - Ty
I /'/ Z .©3 A H L T S B C G GNXX
1
XBOD5
310 C mg/1
2
COD High 340 mgA
3
COD Low 335 mg/I
4
Coliform: MF Fecal 31616 C /100m1
5
Collform: MF Total 31504 /100ml
6
Coliform: Tube Fecal 31615 /100ml
7
Coliform: Fecal Strep 31673 /100ml
8
Residue: Total 500 mg/I
9
Volatile 505 mg/I
10
Fixed 510 mg/I
11
Residue: Suspended 530 3 mg/1
12
Volatile 535 mg/I
13
Fixed 540 mg/1
14
PH 403 units
15
Acidity to PH 4.5 436 mg/I
16
Acidity to pH 8.3 435 mg/I
17
Alkalinity to pH 8.3 415 mg/l
18
Alkalinity to pH 4.5 410 mg/I
19
TOC 680 mg/I
20
Turbidity 76 NTU
Chloride 940 mg/I
Chi a: Tri 32217 ug/I
Chi a: Corr 32209 ug/I
Pheophytin a 32213 ug/l
Color: True 80 Pt -Co
Color:(pH ) 83 ADMI
Color: pH 7.6 82 ADMI
Cyanide 720 mg/I
Fluoride 951 mg/I
Formaldehyde 71880 mg/I
Grease and' 011s 556 mg/l
Hardness Total900 mg/1
Specific Cond. 95 uMhos/cm2
MBAS 38260 mg/I
Phenols 32730 ug/I
Sulfate 945 mg/l
Sulfide 745 mg/1
NH3 as N 610 3 Sj mg/l
TKN as N 625 mg/I
NO2 plus NO3 as N 630 mg/1
P: Total as P 665 mg/I
PO4 as P 70507 mg/l
P: Dissolved as P 666 mg/l
Cd-Cadmium 1027 ugA
Cr Chromium:Total 1034 ug/I
Cu-Copper 1042 ug/I
Ni-Nickel 1067 ug/I
Pb-Lead 1051 ugA
Zn-Zinc 1092 ug/l
Ag-Silver 1077 ugA
Al -Aluminum 1105 ug/I
Be -Beryllium 1012 ug/I
Ca -Calcium 916 mg/l
Co -Cobalt 1037 ugA
Fe -Iron 1045 ugA
Sampling Point %
Conductance at 25 C
Water Temperature (C
D.O. mg/l
PH
Alkalinity
Acidity��v g
Air-_Temperature5(C)
c
PH 83 pH 4.5
pH 4.5 PH 8.3'3'-,
2
94
10
300 1•
400 •
82244 431
82243 182242
20
Salinity %
Precipition Wday)
Cloud Cover %
Wind Direction (Deg)
Stream Flow Severity
Turbidity Severity Wind Velocity M/H can Stream Depth ft.
Stream Width ft.

State of North Carolina
Department of Environment and
Natural Resources
Division of Water Quality - Non Discharge Branch
Non-Dishcharge Permitting Unit
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
4••
C) E N F
February 24, 1998 r
MR. JERRY CHURCH FEB 2 6 1998
BROYHILL FURNITURE INDUSTRIES
ONE BROYHILL PARK SFi WAFER UALfTY SECTION a
LENOIR, NORTH CAROLINA 28633 Ad�!Q�AL OFFICESubject: Application No. WQ0015004
Broyhill, Rutherfordton Site
Sewers
-Private
Ritfherford County
Dear MR. CHURCH:
The Division's Permits and Engineering Unit acknowledges receipt of your permit application and
supporting materials on February 23, 1998. This application has been assigned the number listed
above.
Your project has been assigned to Mr. Rick A. Moore for a detailed engineering review. Should there be
any questions concerning your project, the reviewer will contact you with a request for additional
information.
Be aware that the Division's regional office, co iced below, must provide recommendations from the
Regional Supervisor or aJProcedufe Four Evaluation for this project, prior to final action by the
Division.
If you have any questions, please contact Mr. Rick A. Moore at [phone] extension 527. If the
engineer is unavailable, you may leave a message on their voice mail and they will respond promptly.
PLEASE REFER TO THE ABOVE APPLICATION NUMBER WHEN MAKING
INQUIRIES ON THIS PROJECT.
cc: 'AshevlleRegional-Office
West & Associates, PA
Sincerely,
(y/)Mr. 'm H. Olson, P.E.
0 Supervisor, Non -Discharge Branch, Permitting Unit
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management KAT R QU ,� 8E 7 o�
Non -Discharge Penn it Application V
.(THIS FORM MAY BE PHOTOCOPIED FOR USE AS AN ORIGINAL) Erb 2 j f 9
GRAVITY SEWER EXTENSION,'°n-Disch�
PUMP STATIONS, AND PRESSURE SEWERS. _
I. GENERAL INFORMATION: SOC Project: Yes, X No.
1. Applicant's name (please specify the name of the municipality, corporation, individual, etc.): -
Broyhill Furniture Industries
2. Print Owners or Signing Official's name and title (the person who is legally responsible for the facility and its compliance):
-Jerry Church Chief Financial
3. Mailing address: One Br
City:
Lenoir State: NC Zip: 28633 r�
Telephone Number: ( 704 ) 758-3472 Frank Jenkins Staff Engineer
4. Project Name (please specify the name of -the subdivision, facility, or establishment.-, should be consistent with project
name on plans, specifications, letters of flow acceptance, Operational Agreements, etc.):
Broyhill Industries Pump Station Q ForrPmain--Rntbarfn-r
5. Application Date: February, 1998 6. Fee Submitted: ci nn nn
6. County wheie project is located:
II. PERMIT INFORMATION: s
I. Application.No. (will be completed by-DEM):
2. Specify whether project is: x new; modification. ;
3. If this application is being submitted as a result of a modification to an existing permit, please complete:
existing permit number and the issue date
4. Specify whether the applicant is public of X private.
III. ,INFORMATION- ON WASTEWATER:
1.. Nature of Wastewater. 30 96 Domestic/Commercial ; % Industrial;
% Otherwaste (specify): Cooling Water
2. Please provide a one or two word description specifying the origin of the wastewater,'such as school, subdivision, hospital,
commercial, industrial, apartments, etc.:, Furniture Industry
3. Indicate any parameter(s) (and their concentration) that will be greater than normal domestic levels: N/A
4. If wastewater is not domestic in nature, what level'of pretreatment has been provided to ensure protection of the receiving
wastewater treatment facility? N/A
5. -If a pretreatment permit is required, has one been issued? NSAYes No. If yes, please attach -a copy of the
pretreatment permit. if No, when will one be issued: N/A
FORM: GSPSA 02/95 Page 1 of 8

6. Volume of wastewater generated by this project: 67, nnn gallons per day.
7. Explanation of bow wastewater volume was determined: _Ac-tual metered flow to plant
(See attached records of Flow) plus additional flow for 200 employee expansion
IV. DESIGN INFORMATION:
1. Brief project description: Pump Station and 4,890 LF of 4" Forcemain to serve an
existing Furniture ManufacturinR Facility
2. Name of wastewater treatment facility receiving wastewater: Town of RntherfrJrIji, , WWTP
a. Facility Permit Number: NC 0025909
b. Engineer should provide statement of his evaluation of downstream sewers ability to accept the wastewater:
Downstream sewers have sufficient sloe and diamenter to accept the waste—
water
No Permit Number available due tot e
c. Permit Number for sewers immediately downstream: age of outfall line
d. Pipe diameter of sewers immediately downstream: 8"
I. Summary of GRAVITY SEWER to be permitted, by diameter, length and pipe material:
Diameter Length
(in) (linear feet)
Pipe
Material
Circle C or
N Factor &
Specify
Value
Minimum Maximum
Slope (%) Slope (%)
Minimum Maximum Minimum
Velocity Velocity Cover (in)
(fps) (fps)
10 26
10.9 10.9 36'
NOTE: The minimum velocity must not be less than 2 fps.
For public sewers the minimum diameter is 8 inches.
For private sewers the minimum diameter is 6 inches.
4. Anchors shall be provided for sewers with slopes greater than 20 %. The anchor spacing shall be a maximum of: 36 foot
separation for slopes of 21% to 35%; 24 foot separation for slopes of 36% to 50%; 16 foot separation for slopes greater
than 50%.
For velocities greater than 15 fps, it is strongly recommended that measures be considered which will protect the sewers and
manholes from erosion. For velocities greater than 20 fps, erosion control measures must be specified
For any excessive slopes or velocities that will occur in any sewer line segment, what measures have been taken to protect
the sewer pipe and manholes? N / A
5. Maximum length of sewer between manholes: 'I8 _ m } linear feet.
6. This sewer line segment occurs between manhole no. Ex. M. H. and manhole no. L-1 ( Pump Sta)
FORM: GSPSA 02/95 Page 2 of 8

7. Does the owner/operator have the ability to clean this length? X Yes No. For sewer reach lengths greater
than 425 feet, please provide a letter from the owner/operator, stating the ability to clean the specified reach and include the
equipment specifications.
8. Sewers subject to existing or planned traffic bearing loads? X Yes No. If yes, what measures are being taken
to enable the sewers to withstand the loads?
Boring/Encasement or adequa e e
9. Outside drop manholes are provided where invert separations exceed: _/ A feet (provide for separations > or = 2.5)
10. Identify (by manhole number) those manholes that have drop connections: None
11. Maximum allowable infiltration/exfiltration test rate: 100 GPD/pipe diameter inch/mile of pipe.
NOTE: Must not exceed 100 GPD/pipe diameter inch/mile of pipe.
12. Minimum separation distances as shown on the plans and addressed in the specifications. If a, b, or c below is no, explain
in an attachment (This section must be completed for all collection systems including force mains and pressures sewers):
a) 100 ft. horizontal separation from wells or other water supplies? X Yes No
b) 12 in. vertical separation from storm sewer or ferrous pipe sanitary sewer specified? _X _ Yes No
c) 10 ft. horiz. sep. from water mains or 18 in vertical Sep. (water over sewer) or ferrous pipe specified? --X-Yes No
13. Are manholes subject to flooding? Yes X No. If Yes, are manhole rim elevations 1 foot above 100-year flood
level, (100 year flood elevation should be indicated on plans)? Yes No; Or, are the manholes watertight, vented
1 foot above the 100-year flood elevation and vented every 1,000 feet (should be shown on plans)? Yes No.
14. Identify (by manhole number) those manholes that are vented: N Z A
15. Does this project involve any stream crossings? Yes X No. If yes, what precautions or special ''features have been
utilized to ensure protection of the sewer line and not restrict stream flow? Identify the sheet of the plans and station
number where stream crossings are located:
Please note: The Division recommends all stream crossings be located three (3) feet below the stream bed or ferrous
material pipe be specified. In addition, all aerial stream crossings must be located above the 25-year flood elevation. Both
the 25-year flood elevation and the 100-year flood elevation should be indicated on the plans.
16. Sewers may n9l be installed in WS-I watersheds. Are any of the subject wastewater collection systems located in a WS-1
watershed? Yes X No.
FORM: GSPSA 02/95 Page 3 of 8

V . PUMP STATION INFORMATION
1. Pump Station No. or Name: PS No. 1 (A separate page 4 of 8 should be submitted for each pump station)
2. Name of closest downslope surface waters: Unnamed tributary to Cathevs Creek
3. Classification of closest downslope surface waters: WSV (as established by the Environmental Management
Commission & specified on sheet 5 of 8 of this application). *See proposed classification
4. In accordance with 15A NCAC 2H .0219 (h)(3), describe the measures that are being implemented to prevent impacts on
downslope surface waters, should a power failure occur at this pump station. NOTE: Alternative power MUST be
addressed for every pump station in accordance with the above regulation. No Pmargen_r_y �nnwPr is being
provided. If power service is interrupted, all employees leave the plant
5. What size pumps are provided: 125 GPM; and how many? 2
6. What is the design total dynamic head? 104 feet
7 How many pumping cycles will occur at average daily flow? 6 cycles per hour.
NOTE: 15A NCAC 2H .0219 (h)(2) requires 2 to 8 pumping cycles per hour be achieved at average daily flow.
8. The following items are typically required in the design for pump stations. Check the appropriate blank to signify that
these items bm )= provided in the design plans and specifications:
Alternate Power Source X
Wet Well Vented with Screen 'y_
Fillets in Wet Well X
Check Valves and Gate Valves X
Security Fencing
Lockable Wet Well Cover _X
Area Light �--
110V Electrical Convenience Outlet
Flood/Buoyancy Protection
High Water Alarm (one choice may be specified) X Audible and Visual X Auto Dialer
9. Summary of FORCE MAIN or PRESSURE SEWER to be permitted, by diameter, length and pipe material:
Diameter
(in)
Length
(linear feet)
Pipe
Material
High
Elevation
(ft
Low
Elevation
(ft)
Minimum
Velocity
(
Maximum
Velocity
Minimum
Cover (in)
4
4,790
PVC
4
100
1 DIP
00
10. Are air release valves provided at all high points along the force main (must be provided where the elevation difference
exceeds 10 feet)? —Y-- Yes No
11. Is the pump station subject to flooding? _ Yes -L No. If Yes, what measures are being taken to protect against flooding?
12. If subject to flooding, specify the 100-year flood elevation: Feet MSL
13. Are there existing or planned pump stations downstream of this station? X Yes No. If Yes, the engineer
shall evaluate the ability of those pump stations to adequately handle the subject flows and shall include that evaluation as
an attachment to this application.
FORM: GSPSA 02/95 Page 4 of 8

1 13:51 7042516452 \ICDENR - PAGE 02
01/21:1998 16:36 704433( wE'91 S ASSOCIATES i PAGE 01
.e
Thk fbM BtaaI be ooeapkod br 09 $PDCWfhte DRM Rerjloani oMte Bad lacladed as a part of the prgjoct
tcobaUtW tafaruatlon.
INSMUCTIONS TO NC MOFENIONAL ENGWEER:
Tbc dssMktctkn of -- - tiitoe wafts Oe aa<fir+as W om ex Jay ovaug ► Liam dw fixity wvAd glow tows<d)
In wWb d mR awes wM bu m6mucmd Bout bo'dowt iced by die ae DEM CO&Cat afrim Tbmcdxr, you aK
>' 4, prlor' to mba t" of a w appandom pacham to W=item, arhh lmmt i Unmeb 7 aomplctod. to
at qvvopdm Dbidoe of lm,h woe RAttft t Watcr Qadiry 8aypesdw 0= Pop 8 of 8). At a
magic Ir�dde a4 8i" by i l" ! of the poetJm of a 7s . USG' TopoperpUc Map wbkb sit tbo
locoW of dvAc aewas and *a do.tidepe wnfsece wafts In wMch *my will be locowd. Weadfy as edootat dow"Ve
lorfaee wags as do 0029hd mar oegy. Omm the sftlaval eflke bran oomple[sd the elsadJ:ttsacm.
sdBCecPmly tkIm e"Wi s lw so ac b*otlapm asap lab am amowe appllcsd" torn: and
ntbtc sw appikaWB fie.
1. APOkot( 11 E':Y=jt_ irR Indimtri,ts. Tnr_
RUther ordtou - ltC Plant-
Z KBrJon aawpirltadd oicaodBoedBBhffi Vest and„A42ociates, .PA
405 South Sterling Street
M2ELj=gS4 NC 28655
( 704 ) 433-5661
3_ %%&ago= '_SSy rer Improve�oenta---B�osl>iil_Furniture Industries — Rutherfurdton Plant
a. Pirated'dmW&vW opoactdbttatrro= Unnamed Tributary to Catheys Creek
S- O�eyOe�wbp�oaowaesaBdrta�oew�alaarC�_lh?. herford
6. lsvvp vddrwUS69_ Ruthe'rfnrdtnn. North%6
7.
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in Z.
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QortleeatlaB lm Mte68id dr tbt llRam�aR.Ca�vo?:
84mm" d
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1p
. - ���`-�1 ll � � .-,� ,_�>> _ � `�� it �:� I f �� - � �II,� �• l \.,.�,
la 64
A��; + tehel! 1' +. If 1� '.
- - _- \ •�.� 11 \ f'\ ` •\ � / � • I • \ N_.\ , //
FEET :411 412 FOREST CITY 6 All. 557•30•• POST OF ICE 0.6 Ml. 414 (RUTHERFOROTON SOUTH)
SHELBY 27 MI. y SPARTANBURG. S.0 30 Mi. 4654 IV SW
FHERFORDTON NORTH N. C. \ 1 7 SCALE 01:24000
N3522.5—W8152.5/7.5 * ��
N 1000 0 1000 2000 3000 4000 5000
1966 GN t 5 0
AMS 4654 WNW —SERIES V842 II 0' 3 3' ! 0NTr)I ly CC
IAITDW61 '30 CCT

t
ddress of Engineering Fum: west and Associates, PA
40.5 South Sterling Street
City: Morganton State: NC Zip: 28655
Telephone Number: ( ' 704 ) 433-5661
Professional Engineer's Certification:
I, Benjamin B. Thomas , attest that this application for Broyhill Industries
Pump'Station and Forcemain = Rutherfordton, North -Carolina
has been reviewed by me and is. accurate and complete to the best of my knowledge: I further -attest that to the best,of my knowledge.
the been
design has, been prepared in accordance with the applicable regulations. Although certain portions of this submittal,
package may have been developed by other professionals, inclusion of these materials under my signature and seal signifies that I have
reviewed this material and have judged it to be consistent with the proposed design.
North Carolina Professional Engine Signature, and Date: _ _
o`A`LjH CAR®
*Geeae°OD
DES
S
co
66,
Applicant's :,Certification:
I Jerry.' , Church ¢ 1 ; attest at. apphcatoa for Broyh
,-
ill Industri
Pump Station. arid Torcemain. — Rutherfordton, •:.Nor.th °Carolina.
has-been reviewed by. me and is accurate and complete to the best of my:knowledge .1 understand that if all required parts of this ;
application are not completed and that if all required supporting information and attachments are not included, this application package
will be returned to me as incomplete.
Date ,
THE : COMPLETED :_ APPLICATION : PACKAGE; INCLUDING ALL SUPPORTING. INFORMATION.- AND
MATERIALS, SHOULD BE SENT, TO THE FOLLOWING ADDRESS:
�L
NORTH CAROLINA DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
PERMITS AND ENGINEERING UNIT
POST OFFICE BOX 29535
RALEIGH, NORTH CAROLINA 27626-0535 - - •
TELEPHONE NUMBER: [phone]
h<
FORM:: GSPSA 02/95 Pap-,T-. of...8

C.
DIVISION OF ENVIRONMENTAL MANAGEMENT REGIONAL OFFICES (12/94)
Asheville Regional WQ Supervisor
Washington Regional WQ Supervisor
Raleigh Regional WQ Supervisor
59 Woodfin Place
Post Office Box 1507
Post Office Box 27687
Asheville, NC 28801
Washington, NC 27889
Raleigh, NC 27611
[phone]
[phone]
(919) 5714700
Fax [phone]
Fax [phone]
Fax [phone]
Avery Macon
Beaufort Jones
Chatham Nash
Buncombe Madison
Bertie 'Lenoir
Durham Northampton
Burke McDowell
Camden: Martin
Edgecombe Orange -.
Caldwell' Mitchell
Chowan Pamlico
Franklin Person '
Cherokee Polk
Craven Pasquotank
Granville Vance
Clay Rutherford
Currituck Perquimans
Halifax Wake
Graham Swain
Dare Pitt
Johnston Warren'
Haywood Transylvania
Gates Tyrell
Lee Wilson
Henderson Yancy
Greene , Washington
Jackson
Hertford Wayne
Hyde -
-
Fayetteville Regional WQ Supervisor
Mooresville Regional WQ Supervisor
Wilmington Region. WQ Supervisor
Wachovia Building, Suite 714
919 North Main Street
127 Cardinal Drive Extension
Fayetteville, NC 28301
Mooresville, NC 28115
Wilmington, NC 28405-3845 =
E
[phone]
[phone]
[phone]
Fax [phone]
Fax [phone] -. "
Fax [phone]
Anson Moore -
Alexander,._ : Mecklenburg
Brunswick New Hanover,
Blades Robeson
Cabaiius' "` :"'Rowan _
Carteret Onslow..:... .... ... _ . _.-...
Cumberland Richmond
Catawba Stanly
Columbus Pender .
Harnett. .:Sampson
Gaston ; :..Union
Duplrn :e
Hoke :. :Scotland
Irede11 . ? Cleveland "
Montgomery.
Lincoln
Winston-Salem Regional WQ Supervisor
585 Waughtown Street"
Winston-Salem, NC 27107
[phone]
Fax [phone]I
Alamance Rockingham
Allegbany Randolph .
Ashe Stokes
Caswell Suny
Davidson Watauga
Davie Wilkes
Forsyth Yadkin
Guilford
;
a?
2
FORM: GSPSA 02/95
Page 8 of 8
- - +

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Water Quality
59 W'oodfin Place Asheville, North Carolina 28802
March 30,.1998
DAVID STOUT, ENV MGR
BROYHILL FURNITURE INDUSTRIES
ONE BROYHILL PARK
LENOIR NC 28633
-SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461 _
`BROYHILI; FURN-ITURF INDU__S_TRIES
RUTHERFORD-County _
Dear DAVID STOUT, ENV MGR:
Review of subject self -monitoring report for the month
of February, 1998 revealed violation(s) of the following
parameter(s)
Reported Limits
Pipe Parameter Value/Unit Value/Type/Unit
001 00530 RES/TSS 155.0 MG/L 30.0 FIN MG/L
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division of Water
Quality may pursue enforcement actions for this and -any
additional violations of State Law. If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality Supervisor, at 704/251-6208.
Sincerely,
Roy Davis
Regional Supervisor
CC: Central Files
GKBDEX96/BL

CAP
/PermitN'o-.-W 00 i 3004—'=
March 12,11-998
ENGINEER'S CERTIFICATION
Partial X Final
I, 2vc�atmfKx -go5, as a duLenRd—ic�a
istered Professional Engineer in the State of North
Carolina, having been authorized to observeweekly,full time) the construction of the
project, —brbk il l Fo ,.,,4yH— 1 "A,5�nes e7&ov Pz " for the
Project Name Location and County
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and
intent of this permit the approved planand specifications, and other supporting materials.
Date t f A
L�t--
rDl' rf, lhiJ
1�" � dL „
Registration No. 2-�,7 57
• SC {, r pp
%
a,
d' `
,�E�r�T��fF��}
a o�S�A Ca
t'tf g.
c17
4

I
STORMWATER DISCHARGE OUTFALL (SDO)
MONITORING REPORT
GENERAL PERMIT NO. NCG180000
CERTIFICATE OF COVERAGE NO. NCGIS 0 0 7 4',
FACILITY NAME BR'OY-,,H-'ILl--,L)E-,FURN.,,"."IND�-,.J.-,L',T..RUTHERFORD PLT,
PERSON COLLECTING SAMPLE(s)#qAY1U 0-. DEAN Ci
CERTIFIED LABORATORY(S) BLUE RIDGE ,.LAB . -Lab #-Ej-L—
WATER TECH LAB. -Lab #--L0—
Part A: Specific Monitoring Requirements
SAMPLES COLLECTED DURING CALENDAR YEAR: L?
(all samples collected during a calendar year, shall be reported no later than
January 31 of the following year)
#310 COUNTY RUTHERFORD
INNER MHONX NO. (1-0 4 ) 2 -4276
ate
"50050'
-00340�f,�'.*,'..�.-..;,-,'...�,,�.�
00545,
r,fill"
Chemical
Di
8
#3
04/26/96
0b.-29-
117
26
# 4
2.6 6
�4 / 9
90
-
-2
W PERMITTEE OR DESIGNEE)
re, I certify that this report is accurate
best of my knowledge
Does this facility perform Vehicle Maintenance Activities using more than 55 gallons of new motor oil per month? — yes !no
(if yes, complete Part B)
n--& U. ILAI-1.a..—..—.... A ILAF--26--t--
it i MCI
gmp#"D
'Louu�rjo. . 4f.'V�
R, Kl--I.�
R
',0101990W
;382
t"
4WIS
�Awtftuw
All"m
Aft &6
4
.1
STORM EVENT CHARACTERISTICS:
Date. 04-26-96
Total Event Precipitation (inches): -70
Event Duration (hours): - • 2 5.
(if more than one storm event was sampled)
Date NIA
Total Event Precipitation (inches):
Mail Original and one copy to:
Attn: Central Files
DEHNR
Division of Environmental Mgt.
P.O. Box 19535
Raleigh, NC 27626-0535
Form MR18
Page 1 of 2

Event Duration (hours):
Footnotes:
1 Applies only for facilities at which fueling occurs.
2 Detergent monitoring is.required only at facilities which conduct vehicle cleaning operations.
"I certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a
system, designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person
or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best
of my knowledge and belief_, true, accurate, and complete. I am aware that there are significant penalties for submitting false information,
Including the -possibility of fines and imprisonment for knowing violations."
(Signature of ermittee) (D e)
L
< ;
�- CO
L1 N
�3
Form MR 18
Page 2 of 2

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Water Quality
59 Woodfin Place Asheville, North Carolina 28802
December 30; 1996
DAVID STOUT, ENV MGR
BROYHILL FURNITURE INDUSTRIES
ONE BROYHILL PARK
LENOIR NC 28633
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE INDUSTRIES
RUTHERFORD County
Dear DAVID STOUT, ENV MGR:
. Review of subject self -monitoring report for the month
of October, 1996 revealed violation(s) of the following
parameter(s):
Reported. Limits
Pipe Parameter Value/Unit" Value/Type/Unit
001 00530 RES/TSS 35.0 MG/L 30.0 FIN MG/L
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division of Water
Quality may pursue enforcement actions for this and any
additional violations of State Law. If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality Supervisor, at 704/251-6208.
Sincerely,
Roy Davi
Regional Supervisor
CC: Central Files
GKBDEX96/BL

Broyhill Furniture Industries, Inc.
One Broyhill Park, Lenoir, North Carolina 28633
BROYHILL
August 7, 1996
Mr. Roger Edwards,
North Carolina Dept. of Environment!
Health, and Natural Resources
Division of Environmental Management
Water Quality Section
Interchange Building
59 Woodf in Place
Asheville, North Carolina 28801
Dear Roger:
SUBJECT:
-This
1996, and
the points
Broyhill Furniture Industries, I
Rutherford Plant
NPDES Permit Number NC0005461
Wastewater Treatment Facility
Rutherford County
letter is in. response to your, inspection of July 11,
subsequent letter of July 29, 1996. I will respond to
of concern as follows:
Item No. 1
Dean Conner of the Rutherford Plant is in the process of pricing
grease traps. As soon as one can be purchased, installation of a
grease trap will be scheduled.
Item No.2
Repair or replacement of this airline will need to be scheduled for
a weekend because the No. 1 treatment plant will need to be pumped
out. Dean Conner will schedule this after he -returns from vacation
late in August, and will be completed by September 30, 1996.
Item No.3
Lime has been added by Dean Conner as recommended by the Water
Quality Section during the July 11th inspection. The Ph has come
up and Mr. Conner will continue to monitor and add lime as needed.
Item No.4
The support beam has been installed in treatment plant No. 2. Dean
Conner will remove the old support sometime within the near future.
Item No:5
Dean Conner is currently adding lime to the ground area daily. We
are working with the City of Rutherford to be get onto their
treatment plant, and for this reason are hoping to avoid any major

modifications to or _ rebuilding of our treatment plant. We have
been told by the City of Rutherford that they will need to,enlarge
their plant capacity before adding us. We hope to get'on'sometime
in 1997. They_are,aware that our, NPDES Permit expires in November
of 1998.
Item No.7.
Mr. Conner is aware of the need to keep the TRC as low as possible,
while attaining his limit on'fecal coliform. He will make every
effort: to keep the TRC as low as.'possible.
Item No.8
See Item No.5.
Thank' you for your help. Your assistance and input into
maintaining- our: treatment -plant is. appreciated. If you have
further comments or need" further "information, - pl,ease' give me a call
at 704-758-3374.
Sincerely,
BROYHILL FURNITURE INDUSTRIES, INC.
David Stout
-Corporate Environmental Manager
cc
Bill Sale
Ron Jarrett
Dean Conner

DIVISION OF ENVIRONMENTAL MANAGEMENT F
WATER QUALITY FIELD -LAB FORM (DM1) or Lab Use ONLY
COUNTY Lab Number:
PRIORITY SAMPLE TYPE
RIVER BASIN C� Date Received: %^ �% -�j Time: 41- 00
REPORT TO: R FRO MRO RRO WaRO WiRO WSRO TS ❑AMBIENT ❑ QA ❑ STREAM �/
AT BM LI EFFLUENT Rec'd by: rY'� From: Bus -Cowrie and Del
Other ❑COMPLIANCE ❑ CHAIN ❑ LAKE ❑ INFLUENT
OF CUSTODY DATA ENTRY BY: �"`, CK. S N-
Shipped by: Bus Courier, Staff Other ❑EMERGENCY ❑ESTUARY
DATE REPORTED: 7 f 7 - C! 6
COLLECTOR(S): �����djr / i2ddd /
1
Estimated BOD Range: 0-5 5-25/25-65/40-130 or 100 plus STATION LOCATION: (�I ���
�+
Seed: Yes 2--No ❑ Chlorinated: Yes D--No ❑ REMARKS:
Station #Date Begin (y
BUD5 310
COD High 340
COD Low 335
oliform: MF Fecal 31616
Coliform: MF Total 31504
Coliform: Tube Fecal 31615
Coliform: Fecal Strep 31673
Residue: Tota1'500
EEVolatile 505 EEE
Fixed 510
esidue: Suspended 530
Volatile 535
Fixed 540
PH 403
Acidity to pH 4.5 436
Acidity to pH 8.3 435
Alkalinity to pH 8.3 415
Alkalinity to pH 4.5 410
TOC 680
Turbidity 76
y ram ) i Tlme Begin Date End
mg/1
Chloride 940
mg/I
Chi a: TrI 32217
mg/1
Chl I. Corr 32209
/100m1
Pheophytin a 32213
lor: True 80loz;(pH
) gglor:
pH 7.682anide
720oride
W
951rmaldehyde
71880ase
and Oils 556rdness
Total900
Time End j Depth DM DB D13M
to iype I Composite
—
A H L T S B
Pie T e
C GNXX
—&—evised 10/86

f'
Pof North Carolina
HealtFh and Natural Resources •
Division of Environmental Management , •
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary 1:3 E H N
A. Preston Howard, Jr., P,E., Director
WATER QUALITY SECTION
July 29; 1996
Mr. David Stout
Corporate Environmental Manager'
Broyhill Furniture Industries, Inc.
One Broyhill Park
Lenior, North Carolina 28633
Subject: Compliance'Sampling Inspection
Status:.In Compliance
NPDES Permit Number NC0005461
Broyhill -Rutherford Plant
Wastewater Treatment Facility
e Rut erford County
Dear Mr: Stout:
I conducted the above referenced inspection of discharges 00.1,
002, and 003 on July 11; 1996. The treatment facility, discharge
001, was operating satisfactory, -however there is a need for.minor
adjustment of the treatment process. Both 002 and 003 were
satisfactory as well.. During the inspection I did notice several
points of concern which•are•listed by item below.
1) Grease was evident in' the aeration basins and
clarifiers. Grease adds to the organic loading of,
the treatment plants and causes-settleability
problems. _Based on results -of samples collected the
day of inspection the grease is not having an adverse
impact on the treatment facility at this time
however, measures_ to reduce or eliminate the grease
are suggested to avert -future problems.-
2) The air line:
.for the sludge return in clarifier
number one (1) was leaking. This prevents"the
clarifier from preforming efficiently, as the air
escaping causes the solids to remain in suspension.
This air line should be -repaired as -soon as possible
to prevent degradation of the effluent.
3) The pH in'the aeration basin of each treatment
plant was low, plant number one (1) 5.09 s.u., plant
number two (2) 3.61 s.u.`The normal operating range
P.O. Box 29535, Raleigh, North'Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 60% recycled/ 1-0% post -consumer paper

Mr. Stout
July 29, 1996
Page Two
for pH in an activated sludge system is 6.5 to 7.5
standard units (s.u.). The organisms that treat the
wastewater do not adjust well to rapid pH changes,
therefore the pH of the treatment plants should be
adjusted up gradually with soda ash. Methods of
making pH adjustment were discussed with the ORC
during the inspection.
4
4) In treatment plant two (2) the structural
supports exhibit excessive corrosion. These supports
will.require repair in the near future.
5) The effluent polishing basin (old sand filter)
has cracks in the retaining wall. The cracks allows
effluent that has not been disinfected to leak on to
the ground. This leakage attracts insects, rodents,
and other animals. This is a possible pathway for
the spread of disease. The affected ground area
should be limed daily to reduce the possibility of
disease being spread. Repairs should me made as soon
as possible.
6) The relocation of gas chlorination equipment and
replacement of the storage cabinet was a much needed
improvement. This.improved working conditions for
the operator and improved on the overall safety of
the area.
7) The total residual chlorine (TRC) was 2.2 mg/l
in the effluent on the date of inspection. This
exceeds the water quality standard, which is 17
micrograms per liter (ug/1). This dosage of chlorine
is toxic to the aquatic life in the receiving stream.
The TRC should be maintained as low as possible while
attaining the fecal coliform limit set in your NPDES
Permit. If your NPDES Permit renews in November 1998
de -chlorination will be required. De -chlorination
can be required at any time if there are problems in
the receiving stream.
8) The wastewater collection system for the Town of
Rutherfordton is approximately one (1) mile from the
Broyhill -Rutherford Plant. I suggest that connection
to the Town of Rutherfordton collection system be
investigated both for the environmental and
economical benefits.

w
Mr. Stout
July 29, 1996
Page Three
9) In reviewing discharge monitoring reports (DMR)
from June 1995 through May 1996 the following
violations occurred. In June 1995, a monthly fecal
coliform violation. Fecal coliform daily maximum
limit was violated once'in July, three times in
August, and once in November.
The samples collected on the date of the inspection indicate
compliance with your National Pollutant Discharge Elimination System
(NPDES) Permit.
The time and assistance of'Mr. Dean Conner during this
inspection is much appreciated. Please respond in writing on or
before August 15th regarding the time frame that corrective actions
will be taken. If you or your staff have questions in regard to this
report, please do not hesitate to contact me at 704-251-6208.
Sincerely,
Eg
C. �a
C. Edwards
Wastewater Consultant
Enclosure
CC: Mr. Dean Conner, ORC
Rutherford County Health Department

United States E' mental Protection Agency
Wasp .� ,gym, D.C. 20460 Form Approve
EOMB No. 2040-0003
n NPDES Compliance Inspection Report Approval Expires 7-3
Section A: National Data System Coding
Transaction Code NPDES �
�� � yr/mo/day Inspection Type Inspector Fac Type
1 L'-J 2 u 3 NC0005461 11 12 96/07/11 17 18 IS I 19 S 2012 1
. . _ Remarks u
21 Reserved Facility Evaluation Rating
BI QA
67I I I I69 70 I3 71I I 72I I
I I I I �J �JDu
Name and Location of Facility Inspected SectionBc Facility ate
Broyhill Furniture Industries, Inc.
Rutherford Plant
One Broyhill Park
Lenior, North Carolina 28633
Name(s) of On -Site Representative(s)/Title(s)
Mr. Dean Conner, ORC
Reserved
73I I I I74 75 80
Entry Time
9:15 am
Exit Time/Date
10:20 am.
Name, Address of Responsible Official Title
Mr. David Stout Corporate Enviornmantal Manager One Broyhill Park
Lenior, North Carolina 28633 Phone No.
704-758-3111
Section C: Areas Evaluated During Inspection
TMFacility
S Flow Measurement
N •Pretreatment
eports N Laboratory
N Compliance Schedules
te Review M Effluent/Receiving Waters
M Self- Monitoring Program
Section D: Summary of Findings/Comments (Attach additional sheets if necessary)
Permit Effective Date
January 1, 1994
Permit Expiration Date
Nov. 30, 1998
Phone No(s)
704-28 7-42 76
Contacted
No
M Operations & Maintenance
S 4ludge Disposal
Other: row 17
%Jiedse entering the treatment facility should be monitored closely to avert future problems.
Air line for sludge return in clarifier number one (1) is leaking. This should be repaired as soon as possible to prevent Plant two (2) the structural supports will require repair in the future due to corrosion. effluent degradation.
The pH is both aeration basins is below the recommended range. This can be corrected with the addition of soda ash, as discussed with the ORC during the
inspection.
The,effluent polishing basin (old sand filter) has cracks in the side walls, allowing wastewater that has not been disinfected to leak on the ground. The area
affected should be limed daily and the leaks be repaired as soon as possible.
rhe TRC should be maintained as low as possible while attaining the fecal coliform limit set in your NPDES Permit.
iuggest the Broyhill -Rutherford Plant investigate the connection to the Town of Rutherfordton collection system which is approximately one (1) mile away.
Discharge Limitations
Monthly Avg.
Daily Max.
low
0.026 MGD
30D
-SS
30.0 'mg/I
45.0 mg/I
30.0 mg/I
45.0 mg/I
JH,
NL
'ecal Coliform
200/100 ml
4001100 ml
lames) and Signature(s) of Inspector(s)
OGER C. EDWARDS
Measurement
Sample Results
Frequency
Weekly
Weekly
<2.0 mg/I
Weekly
4.0 mg/I
Weekly
2.2 mg/I
Weekly
< 10/100 ml
I C. � � DWQ/ARO 704-251-6208
WMA
Reviewer
Agency/Office
DWQ/ARO 704-251-6208
Regulatory Office Use Only
ction Taken /
Date Compliance Status
D �loncompliance
E/ Compliance

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Environmental Management
59 Woodfin Place Asheville, North Carolina 28802
October 30, 1995
DAVID STOUT, ENV MGR
BROYHILL FURNITURE INDUSTRIES
ONE BROYHILL PARK
LENOIR NC 28633
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE INDUSTRIES
RUTHERFORD County
Dear DAVID STOUT, ENV MGR:
Review of subject self -monitoring report for the month
of August, 1995 revealed violation(s) of the following
parameter(s):
Reported Limits
Pipe Parameter Value/Unit Value/Type/Unit
001 31616 FEC COLI 351.0 #/100M 200.0 FIN #/100M
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division of Environmental
Management may pursue enforcement actions for this and any
additional violations of State Law. If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality Supervisor, at 704/251"=6208.
Sincerely,
Roy Davis
Regional Supervisor
CC: Central Files
GKBDEX96/BL

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Environmental Management
59 Woodfin Place Asheville, North Carolina 28802
August 22, 1995
DAVID STOUT, ENV MGR
BROYHILL FURNITURE INDUSTRIES
ONE BROYHILL PARK
LENOIR NC 28633
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE INDUSTRIES
RUTHERFORD County
Dear DAVID STOUT, ENV MGR:
Review of subject self -monitoring report for the month
of June, 1995.revealed violation(s) of the following
parameter(s):
Reported Limits
Pipe Parameter Value/Unit Value/Type/Unit
001 31616 FEC COLI 1938.0 #/100M-200..0 FIN #/100M
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division of Environmental
Management may pursue enforcement actions for this and any
additional violations of State Law. If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality Supervisor, at 704/251-6208.
Sincerely,
Roy Davi
Regional Supervisor
CC: Central Files
GKBDEX96/BL

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B: Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
WATER'QUALITY SECTION
August '2, 1995
Mr. David Stout
?; Corporate Environmental Manager
Broyhill Furniture Industries, Inc.
One Broyhill Park
Lenior, North Carolina 28633
Subject: Compliance Sampling Inspection
Status: In.Compliance
NPDES Permit Number NC0005461
Broyhill -Rutherford Plant
Wastewater Treatment Facility
N Rutherford County
Dear Mr: Stout:.
I conducted the above referenced inspection of discharges
001,.002, and 003 on July 11, 1995.• The treatment facility, 001,
was operating -in a satisfactory manner considering the furniture
plant had be shutdown for twelve days'for July 4th holiday. Both
002 and 003 were satisfactory as well. During thejnspection I
did notice several points of concern which are listed by item
below.
1) The influent bar screen.is in use however, the spacing
between the -bars allows inert material to enter the
treatment plants.' In discussion with the operator he has
tried several different types of finer. screens.. All of the.
finer screens that were tried blocked, causing flow to back-
up the pipe. The backed -up flow caused a surge on the
treatment..facility when the bar screen was cleaned. The
solution-appears.to be more frequent visits for the cleaning
of the finer screens to keep the inert material`out of the
treatment plants and to reduce surge flows on'the treatment
facility.
2) Grease was evident in the aeration basins and
clarifiers. Grease adds to the organic loading of the
treatment plants and causes settleability problems. Based
on ..results of samples collected the.day of inspection the
grease is not having an adverse impact on the treatment
facility at this time however, measures to reduce or
eliminate the grease are suggested to avert future problems.
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

Mr. Stout
August 2; 1995
Page Two_
i
3) In treatment plant two (2) the dissolved oxygen (D.O.)
wasat the bottom end of the recommended range of 1.0 mg/1
to 3.0 mg/l. This could be'due to three (3) diffusers not
operating. These diffusers must be removed cleaned or'
repaired and placed back in service. If the D. O. does not
increase afterwards adjustment should be made to the blower.
4) In treatment plant two
exhibit excessive corrosion.
repair in the near future.
( 2 ) the structural suppof is .
These supports will require
5) I The storage building for gas chlorination equipment and
gaseous chlorine is in very poor condition to a point of
being unsafe. This storage building must be replaced or
repaired as soon as possible.
6) The fecal coliform results of samples collected the day
of inspection indicate a violation of your NPDES Permit
limit. The operator has ordered a new 41b/day rotameter for
the -chlorinator to allow better adjustment of the chlorine
feed. The rotameter should be installed as soon as it is
received.
7) ! The wastewater collection system for the Town of
Rutherfordton is approximately one (1) mile from the
Broyhill -Rutherford Plant. I suggest that connection to the
Town of Rutherfordton collection system be investigated both
for,the environmental and economical benefits.
8) . In reviewing discharge monitoring reports (DMR) from
December 1994 through May 1995 the following violations
occurred. In December 1994, insufficient samples were
collect from discharge 001 for BOD, TSS, NH3,' and fecal
coliform. Attention by the person collecting samples
appears to have corrected this violation. -Fecal coliform
daily maximum limit was violated in January, March, and May
with a monthly average limit violation in April. Item
number six (6) of letter addresses fecal coliform and the
corrective action to be taken by the operator is expected to
eliminate the fecal coliform violations.
The samples collected on the date -of the inspection indicate
compliance with your National Pollutant Discharge Elimination
System (NPDES) Permit with the exception of fecal coliform. The
fecal coliform sample analysis indicated a daily maximum
violation of your permit,.while one samples is not sufficient to

Mr. Stout
August 2, 1995
Page Three
judge monthly compliance. Adjustment must be made to achieve
effluent limits stated in your NPDES-Permit.
The time and assistance of Mr. Dean Conner during this
inspection is much appreciated. Please respond in'writing on or
before August 15th regarding the time frame that.corrective
.actions will be taken. If you or your staff have questions in
regard to this.report,.please do not hesitate to contact me at
704-251-6208. -
Sincerely,
Roger C. Edwards
Wastewater Consultant
Enclosure
cc: Mr. Dean Conner, ORC
Rutherford County Health Department
m

United States E `' .imental Protection Agency
Form Approved
Wa!\`J.on, D.C. 20460 J
OMB No.
2040-71.q
EPA NPDES Compliance Inspection Report
Approval Expire
Section A: National Data System Coding
Transaction Code NPDES yr/mo/day Inspection Type
Inspector Fac Type
1 IN 215 3 NC0005461 11 12 95/07/11 17 18 Li
u u
19 IJ I 20 u
Remarks
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
I I I I I I I I I I
21 Reserved Facility Evaluation Rating BI QA
Reserved cc
67 LLJJ 69 70 13 I 71 I onI 72 IuI 73 I I I 174 75 I I I� 80
u I I I
Section B: Facility Date
Name and Location of Facility Inspected
Entry Time
Permit Effective Date
Broyhill Furniture Industries
12:40 P. M.
94/01/01
SR 1535 north of Rutherfordton
Exit Time/Date
Permit Expiration Date
Rutherford County
1:40 P. M.
98/11/30
Name(s) of On -Site Representative(s)/1-itle(s)
Phone No(s)
Dean Conner, ORC
704-2874276
Name, Address of Responsible Official
Title
Mr. David Stout
Corporate Environmental Manager
One Broyhill Park
Phone No.
Contacted
Lenior, NC 28633
704-758-3111
No
Section C: Areas Evaluated During Inspection
S
Permit
Records/Reports
Facility Site Review
S
Flow Measurement
Laboratory
Effluent/Receiving Waters
N
Pretreatment
Compliance Schedules
Self -Monitoring Program
M
Operations & Maintenance
Sludge Disposal
Other: ROW 28
S
N
N
S
S
M
S
Section D: Summary of Findings/Comments (Attach additional sheets if necessary)
Install a finer bar screen and clean screen more frequently.
Grease entering the treatment facility should be monitored closely to avert future problems.
Diffusers 3, 4, and 5 in plant (2) need to be removed cleaned/repaired and placed back in service.
Dissolved Oxygen in plant two (2) should increase when diffusers are cleaned, if not adjustment must be made to the blower to achieve D.O. in the 1.0 mg/I to
3.0 mg/I range.
Plant two (2) the structural supports will require repair in the future due to corrosion.
The storage building for gas chlorination equipment and gaseous chlorine must be repaired or replaced for the safety of the operator and community.
New rotameter must be installed as soon as received for better chlorine feed adjustment.
Suggest the Broyhill -Rutherford Plant investigate the connection to the Town of Rutherfordton collection system which is approximately one (1) mile away.
Discharge Limitations Measurement Sample Results
Monthly Avg. Daily Max. Frequency
Flow 0.026 MGD Weekly
BOD 30.0 mg/I 45.0 mg/I Weekly <2.0 mg/I
TSS 30.0 mg/I 45.0 mg/I Weekly 6.0 mg/I
NH, NL Weekly
Fecal Coliform 200/100 ml 400/100 ml Weekly 500/100 ml
Name(s) and Signature(s) of Inspector(s)
Agency/Office/Telephone
Date
C.
DEM/ARO 704-251-6208
Si of Revwer
Agency/Office
D to
dqAt.-O 0,
DEM/ARO 704-251-6208
1
4;�� -
Regulatory Office Use Only
Action Taken
Date
Compliance Status
❑ Noncompliance
Compliance'

:+ Broyhill Furniture .
Comments Cont.
Page Two
Discharge Limitations Measurement Sample Results
Frequency
Monthly Avg. Daily Max.
' TRC 2/week 0.31 mg/I
Temperature Daily 25.2° C
0
e

Broyhill Furniture Industries, Inc.
One Broyhill Park, Lenoir, North Carolina 28633
BROYHIL�
August 8, 1995
Mr. Roger C. Edwards
State of North Carolina
Dept. of Environment, Health,
and Natural Resources
Interchange Building
59 Woodfin Place,
Asheville, N.C. 28801
SUBJECT: NPDES Permit Number NC0005461
Broyhill Rutherford Plant
Wastewater Treatment facility
Rutherford County
Dear Mr. Edwards:
This letter is in response to your
which referenced your July 11, 1995 inspection of
Rutherford Plant. I will address each item as listed
llth letter. They are as follows:
the
on
5 letter,
Broyhill
your July
1) influent bar screen - according- to Dean Conner., a finer bar
screen has been tried and unless someone is present all of the
time, it plugs up causing flow to back-up in the pipe. We are
currently trying to find a solution to this problem.
2) grease in aeration basins - one of the two canteens have been
closed. The oils in the remaining canteen is being collected for
recycle. Mr. Conner will pursue the installation of a grease trap
on -the discharge line from -the existing canteen.
3) diffusers - Mr. Conner has cleaned the diffusers and returned
them to service. The D.O. has come up due to this. Mr. Conner
will maintain the diffusers.
4) structural support corrosion - Mr. Conner has replaced some of
the structure and he will repair as needed. We will pursue
connecting our sewage discharge to the City of Rutherfordton.
5) storage building for chlorination equipment - the building will
be repaired and moved from the treatment pit to solid ground
eliminating the safety problem. This will be done as soon as
possible.
6) fecal coliform results - The plant was using a 10 lb/day
rotameter for chlorination. After trying to properly adJust this

system, it was decided that this was not going to work properly.
Mr. Conner has installed a 4 lb/day rotameter for chlorination.
Mr. Conner is presently adJusting the chlorination operation to
achieve optimum results.
7 ) connection to Town of Rutherfordt.on - as stated in No. 4, we
are going to pursue this..
8) fecal coliform - see No. 6.
Thank you for your suggestions and assistance in our
wastewater treatment operation. If I can be of further help,
please call me at 704-758-3374.
Sincerely,
BROYHILL FURNITURE INDUSTRIES, INC.
David Stout
Corporate Environmental Manager
cc
Bill Sale, Manager of Broyhill Engineering and Construction
Bob West, Plant Manager of Broyhill Rutherford Plant
Dean Conner, ORC, Broyhill Rutherford Plant

State of North Carolina =
Department of Environment,
Health and Natural Resources • `
Division of Environmental Management
t:dft
'
James B. Hunt, Jr„ Governor F
Jonathan B: Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
..WATER'QUALITY SECTION
Mr. David Stout
Corporate. Environmental Manager
Broyhill Furniture, Industries, Inc. One Broyhill Park
Lenior, North Carolina 28633
Subject: Compliance.Sampling Inspection
Status:-In.Compliance
NPDES•Permit Number NCOOd5461
Broyhill -Rutherford Plant
Wastewater Treatment Facility
Rutherford County
Dear Mr. Stout:.
I conducted the above referenced inspection of. discharges
001,•002, and 003 on July 11, 1995. The treatment facility, 001,
was operating,•in.a satisfactory manner considering the furniture
plant had be shut down for.twelve days',for July 4th holiday, Both
002 and 003 were satisfactory,as well.. During the,inspection I.
did notice•:several points of,.concern which are listed,by:item
below.
. •, 1) ;The influent •bar ,.screen..,- is in •use •however, the spacing
between the bars _•allows inert material. to enter;• the.
• treatment plants, •" In discussion with the operator , he ,has .
••• • tried several different types; of finer. screens. • All, of the..
� . finer .screens that were'tried blocked, causing ,flow. to back-
. _ ;up the pipe. The backed-upflow caused a surge on the •• •-
• treatment facility. •when .the, bar screen was.,cleaned. ; ;The
•solution.appears to, be more frequent visits for -;the cleaning ••
• of the finer screens to keep the•inert material` out,of the
;•,'.. treatment plants and;to reduce surge flows ;on:the:treatment
facility. . , , • • �.• � ., .. •" ' • .
.. 2)Grease was evident in the aeration basins and ,.
clarifiers.. .Grease • adds:;.to the organic loading , of.„the,• .. .
' • treatment. plants and caus.es'-settleability problems . .,,.•; Based r,'.;
on ;results of •samples .,collectedthe :day.; of •-inspection •the•,:=_,�;- =. ;•'., , =••
• grease . is not having an. adverse "impact on .,the treatment, ,:;.
. facility. -,at this time „however, ,measures to :reduce or
• eliminate the grease are suggested to avert future problems.' -
Interchange Building, 59 Woodtin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
' t An Equal Opportunity Affirmative Action Employer 6096 recycled/ 1096 post -consumer paper '

`fit
Mr. Stouts, ;
August 2;', 1995,E
Page Two
3) In treatment plant two (2) the dissolved oxygen
was at the bottom end of the recommended range of 1.0 mg/l
to 3.0 mg/l. This could bedue•to three (3) diffusers not
operating. These diffusers must be removed cleaned or'
repaired and placed back in service. If the D. 0. does not
increase afterwards adjustment should be made to the blower.
4) In treatment plant two (2)•the'structural'suppofts'•
exhibit excessive corrosion: These supports will require`-`
repair in the near future. `
5) The storage building for gas chlorination equipment and
gaseous.chlorine is in very poor condition to a point of
being unsafe'. This'storage building must be replaced or
repaired as soon as possible.
6) The•fecal coliform results of samples collected the day
of inspection indicate 'atviolation of your NPDES Permit
limit. The operator has ordered a new.4lb/day rotameter for
the chlorinator to allow better adjustment of the chlorine
feed. The rotameter should be installed as soon as it is
" received . ' '
` 7) The wastewater collection system -for the Town of
Rutherfordton is approximately one (1) mile from the
Broyhill -Rutherford Plant.'' I'suggest that connection to the
Towniof Rutherfordton collection system be investigated'both
for -the environmental and economical benefits.
BY,In reviewing discharge monitoring reports (DMR) from
December'1994 through May,1995'the following violations
occurred:"' "In December 1994'; 'insufficient samples were
collect from discharge•001•for BOD,:TSS, NH3, and fecal
.. coliform.''Attention by'the person collecting samples''
appears to'have corrected this'violation. Fecal coliform
`daily maximum'limit'was violated'in'January, March,'and May
with a*monthly average''limit'.violation in April. Item
number six (6) of letter'addresses fecal coliform and the
corrective action to be taken by the operator is expected to
eliminate the fecal coliform violations.
The samples collected on the date -of the -inspection indicate
compliance with your.National Pollutant Discharge Elimination
System (NPDES) Permit with the exception of fecal coliform. The
fecal coliform sample analysis indicated a daily maximum
violation of your permit,.while one samples is not sufficient to

Mr. Stout
• i
j
.August 2, 1995 ,
-'Page Three
!
'i ';judge monthly .compliance. Adjustment, must be made
to achieve
; • .
ffluent limits stated in your NPDES -•,Permit , .
=
'.The time and assistance 'of Mr." Dean Conner
during this
inspection is much appreciated. Please ,respond
in. writing :
on°.or ; `•• . }.I�•,: ,i t, l_
'i
before August 15th- regarding the time frame that
corrective-,,.r.;
t ,
actions will be taken. ; ,. If you or your staff have
questions
in i _ ,1.=' : •' . ' `"
,..
_.regard to• this . report, .please do,,not hesitate to,
contact me.
at,_..
'
704-251-6208.
':'; .. :, „ :�• a
1
Sincerely,
Roger C. Edwards
'
Wastewater Consultant
.
'
Enclosure 5
'
CC: Mr. Dean Conner, ' ORC
Rutherford County Health Department
y
E
F

United States E ' '-imental Protection Agency Form Approved
Wasl�,on; D.C. 20460 OMB No. 2040-0003 t
Approval Expires 7-31 85
EPA NPDES Compliance Inspection Report
Section A: National Data System Coding
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 IN 1 2 u 3 1 NC0005461 11 12 95/07/11 17 18 lJ ' 19, U 4o U
Remarks
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I :!.
'r Reserved Facility Evaluation Rating BI QA Reserved
67 69 70' 71 72 73 74 75 80
LI L onDaJ
Ll
SectionB: FacilityDate11: ;
Name and Location of Facility'Inspected Entry Time Permit Effective Date
Broyhill Furniture Industries ': ,I; ; �,, 12:40 P. M. 94/01/01 .. , .
SR 1535 north of Rutherfordton
Rutherford County: E ; r. Exit Time/Date Permit Expiration Date
1:40 P. M. 98/11/30
Names) of On -Site Representative(s)/Title(s) Phone No(s) .
Dean Conner, ORC 1704-2874276
Name, Address of Responsible Official
Title
Mr. David Stout
Corporate Environmental Manager
One Broyhill Park
Phone No.
Contacted
Lenior, NC 28633
704-758-3111
No
Section C: Areas Evaluated During Inspection
S
Permit
S
Flow Measurement
N
Pretreatment
M
Operations & Maintenance
Records/Reports
Laboratory
Compliance Schedules
Sludge Disposal
S
N
N
S
Facility Site Review
Effluent/Receiving Waters
Self -Monitoring Program
Other. ROW 28
S
M
S
Section D: Summary of Findings/Comments (Attach additional
sheets if necessary)
Install a finer bar screen and clean screen more frequently. ; ; ,• ..
Grease entering the treatment facility should be monitored closely to avert future problems.
Diffusers 3, 4, and 5 In plant (2) need to be removed cleaned/repaired and placed back In service.
Dissolved Oxygen In plant two (2) should increase when diffusers are cleaned, if.not adjustment must be made to the blower to achieve D.O. in the 1.0 mg/I to
3.0 mg/I range.
Plant two (2) the structural supports will require repair in the future due to corrosion.
"
The storage building for gas chlorination equipment and gaseous chlorine must be repaired or replaced for the safety of the operator and community.
New rotameter must be installed as soon as received for better chlorine feed adjustment.
Suggest the Broyhill -Rutherford Plant investigate the connection to the Town of Rutherfordton collection system which is approximately one (1) mile away.
Discharge Limitations Measurement Sample Results
Monthly Avg. Daily Max. Frequency
Flow 0.026 MGD Weekly
BOD 30.0 mg/I 45.0 mg/I Weekly <2.0 mg/I
TSS 30.0 mg/I 45.0 mg/I Weekly 6.0 mg/1
NH3 NL Weekly
Fecal Coliform 200/100 ml 400/100 ml Weekly 500/100 ml
Name(s) and Signature(s) of Inspector(s)
Agency/Office/telephone
Date
•;
(� . �,
DEM/ARO 704-251-6208
0
$ Z 3
p
Si of Rev' wer
Agency/Office
D to
r
DEM/ARO 704-251-6208
74 Regulatory Office Use Only
Action Taken
Date
Compliance Status
Noncompliance ,
i ' .
Compliance . .

Broyhill Furniture .
j: Comments Cont.
Page Two
Discharge Limitations
Measurement
i
Frequency
Monthly Avg. _ Daily Max.
TRC
2/week
Temperature
Daily
/
Sample Results
0.31 mg/I
25.2° C

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL.RESOURCES
Division of Environmental Management
59 Woodfin Place Asheville, North Carolina 28802
June 6; 1995
DAVID STOUT, ENV MGR
BROYHILL FURNITURE INDUSTRIES
ONE BROYHILL PARK
LENOIR NC 28633
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE INDUSTRIES
RUTHERFORD County
Dear DAVID STOUT, ENV MGR:
Review of subject self -monitoring report for the month
of April, 1995 revealed violation(s) of -the following
parameter(s):
Reported Limits
Pipe Parameter Value/Unit Value/Type/Unit
001 31616 EEC COLI
311.0 #/100M.- 200.0 FIN #/100M
Remedial actions, if not already implemented, should be
taken to correct the.problem(s). The Division of Environmental
Management may pursue enforcement actions for this and any ,
additional violations of State Law. If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality'Supervisor, at 704/251-6208.
Sincerely,
Roy Davis
Regional Supervisor
CC: Central Files
GKBDEX96/BL

Broyhill Furniture Industries, Inc.
One Broyhill Park, Lenoir, North Carolina 28633
BROYHILL
March 10, 1995
Mr. Roger Edwards
North Carolina Dept. of Environment,
Health, and Natural Resources
Division of Environmental Management
Water Quality Section
Interchange Building
59 Woodfin Place
Asheville, North Carolina 28801
Dear Roger:
SUBJECT: NPDES Permit Number NC0005461
Broyhill Furniture Industries, Inc.
Rutherford Plant
Rutherford County
This letter is in response to your February 9, 1995 inspection
and subsequent letter of February 24, 1995 which listed maintenance
concerns and recommended corrections. I will address each concern
as numbered in your letter:
1) The bar screen will be replaced with one that has a spacing of
3/8" between bars. When the new screen is put in place, Dean
Conner(ORC) will monitor the debris captured and clean the screen
accordingly. This will be completed by March 31, 1995.
2) As recommended, Dean Conner will monitor the D.O. more
frequently.
3) The treatment plant number 1 skimmer piping has been repaired.
4) All diffusers at the plant will be inspected and repaired as
needed, no later than March 31, 1995.
5) Number two sludge return piping and skimmer piping will be
repaired by March 31, 1995.
6) The motor has been repaired and a new gully is being made.
This will be installed no later than March 31, 1995.
7) See item number 4.
8) This amount of water returned varies according to the flow
through the plant. Dean Conner will monitor more closely and
adJust accordingly.

9) Dean is keeping all'plant logs'in a 3-ring binder notebook as
a result of your recommendation.
10) Since the February 9th inspection, 3 samples have been
collected and tested for fecal coliform. All three samples were
within the permitted limits. 'Our February NPDES Monthly report
shouldreflect compliance for fecal coliform.
All repairs mentioned above, will be made as soon as possible,
,and -no-later—than -March 31, 1995, unless weather' or some other
unseen circumstance would delay,'us. Thank you for your assistance'
in this matter. Should you have further questions or concerns,
please give me a call at 704-758-33.74.
Sincerely,,
BROYHILL FURNITURE INDUSTRIES, INC.
David Stout
Corporate Environmental Manager.
cc
Bill Sale, Manager of Broyhill Engineering and Construction
Dean Conner, ORC,, Broyhill Rutherford Plant

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
n
A w
T44i e
1VW . A
DEHNR
Asheville Regional Office
WATER QUALITY SECTION
February 24, 1995
Mr. David Stout
Corporate Environmental Manager
Broyhill Furniture Industries, Inc.
One Broyhill Park
Lenior, North Carolina 28633
Subject: Compliance Sampling Inspection
Status: In Compliance
NPDES Permit Number NC0005461
Broyhill Furniture -Rutherford
Plant
Rutherford County
Dear Mr. Stout:
The above reference inspection was conducted'on February 9,
1995. The parallel extended aeration wastewater treatment
facility was observed during operation and discussed with the
Operator in Responsible Charge (ORC). There were some
maintenance concerns and effluent monitoring concerns. Following
is an itemized list of�concerns and recommended corrections.:
1) The influent bar screen was being by-passed which
allows paper products, plastics, and other materials to
enter the treatment facility. The present bar screen
should be replaced with one that has a spacing
of 3/8" between bars. The bar screen needs cleaning
more than once per day, which is the present
schedule. I suggest three (3) times per day to
avoid an overflow at the bar screen.
2) Treatment plant number one (1) the dissolved oxygen (D.
0.) was 1.7 mg/1 which is within the acceptable range
of 1.0 mg/1 to 3.0 mg/l. Treatment plant number two (2)
was slightly above the acceptable range at.4.2 mg/l. I
suggest the operator monitor the D. 0. more frequently
for better efficiency of operation.
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

Page 2
Mr. Stout
3) Treatment plant number one (1) skimmer piping needs to
be repaired. During inspection the piping was observed
to have rusted off at the point where it go through the
wall between the aeration basin and clarifier.
4) Treatment plant number one (1) the first diffuser
appeared to have a hole below the water line or
missing diffuser caps by the excessive turbulence
observed. The third diffuser drop appeared to be
clogged being that no turbulence was observed at that
location. These diffusers should be removed, cleaned,
repaired and placed back in service for better air
distribution and waste treatment.
5) Treatment plant number two (2) requires repair of the
sludge return piping and the skimmer piping due to
excessive corrosion causing piping failure.
6) Treatment plant number two (2) is operating with one
(1) blower in service. The blower that is out of
service requires a new electric motor. This should be
purchased and install as soon as possible. Operation
in this manner is in violation of Broyhill Furniture
NPDES Permit.
7) Treatment plant number two (2) diffusers three, four,
and five are clogged and diffusers one and two exhibit
excessive turbulence. Corrective action should be
taken to improve efficient of the treatment plant.
Follow procedure outlined in item number 4.
8) The skimmers of each treatment plant appear to be
returning an excessive amount of water. Adjusting the
skimmers so less water would be returned will improve
the efficient of the clarifiers.
9) The operator is maintaining a log of treatment plant
conditions on individual sheets of paper. The log
should be maintained in a bound notebook with date,
time of visit to treatment plant, maintenance
activities, process control testings, general
treatment plant observations, and the operators
signature.
ce

Page 3
Mr. Stout
10) The results of samples collected on the date of
inspection are within NPDES Permit limits with the exception of
fecal coliform. This single samples is not sufficient to judge
compliance, however this results indicates that corrective
actions must be made for the facility to attain monthly
compliance. The chlorine residual should be increase in the
effluent to achieve a better disinfection of the effluent. Care
must be taken not to use excessive chlorine as this is toxic to
aquatic life in the receiving stream.
Please respond in writing by March 27, 1995, as to the time
frame that these operation concerns will be corrected. If you or
your staff have questions regarding this report or if we may be
of assistance please, contact me at 704-251-6208.
Sincerely,
R gel CC
Edwards
Wastewater Consultant
cc: Dean Conner, ORC
Rutherford Co. Health Dept.

United States Ei imental Protection Agency
Form Approved
Washington, D.C. 20460
OMB No. 2040-0003
NPDES Compliance Inspection Report
7P7A
Approval Expires 7-31-85
Section A: National Data System Coding
ction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
215 5 1 3 N C0005461 11 12 95/02/24 17 18 I$ I 19 IS I 20 I Z I
I�—�—� �--t
Remarks
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
" Reserved Facile Evaluation Rating BI 66
h' g QA Reserved
67 LLU 69 70 13 I 71 onI I 72 IDafI 73 � 74 77-180
�J
Section B: Facility Date
Name and Location of Facility Inspected
Entry Time
Permit Effective Date
Broyhill Furniture Industries, Inc.
11:45 am
January 1, 1994
Rutherford Plant
Exit Time/Date
Permit Expiration Date
One Broyhill Park
Lenior, North Carolina 28633
12:50 pm
Nov. 30, 1998
Name(s) of On -Site Representative(s)/Title(s)
Phone No(s)
Mr. Dean Conner, ORC
704-287-4276
Name, Address of Responsible Official
Title
Mr. David Stout
Corporate Enviornmantal Manager
One Broyhill Park
Phone No.
Contacted
Lenior, North Carolina 28633
704-758-3111 TNo
Section C: Areas Evaluated During Inspection
S
Permit
Records/Reports
Facility Site Review
S
Flow Measurement
Laboratory
Effluent/Receiving Waters
N
Pretreatment
Compliance Schedules
Self -Monitoring Program
M.
Operations &Maintenance
Sludge Disposal
Other: row 17
M
M
N
S
S
M
M
Section D: Summary of Findings/Comments (Attach additional sheets if necessary)
Influent bar screen should have spacing between bars of 3/8". This will reduce the amount of paper products and plastic material entering the treatment plants.
The bar screen should be cleaned more frequently than once per day. I suggest three times per day for the bar screen to be cleaned of avoid overflows.
Plant number two requires the replacement of an electric blower motor. Operating with only one (1) blower on a treatment plant is a NPDES Permit violation.
Plant number one the skimmer piping needs to be repaired.
Plant number one the first diffuser appears to have a hole below the water line or missing diffuser caps, with the third diffuser being clogged.These diffusers should
be removed, cleaned, repaied, and placed back in service.
Plant number two return sludge piping and skimmer piping needs to be repaired.
Plant number two diffusers 3,4, and 5 are clogged. These need to be removed , cleaned, repaired ,and placed back in service.
Plant number two diffusers 1 and 2 appear to have a hole below the water line or missing diffuser caps. This should be corrected as soon as possible.
Operator is maintaining a log for treatment plant on individual sheets of paper. The log should be maintained in a bound notebook with the date, time of visit,
maintenance activities, process control testing, and general treatment plant observations.
Effluent Characteristics Monthly Average Sample Results
BOD 30.0 mg/I 4.2 mg/I
Total Suspended Solids 30.0 mg/I 4 mg/I
NH3.as N monitor only 2.4 mg/I
Fecal coliform 200/100 ml 1700/ 100 ml est. count
Name(s) and Signature(s) of Inspector(s)
Agency/Office/Telep hone
Date
ROGER CARDS
�^
DEWARO 704-251-6208
Z 2 y YS
Signatur v werfi
Agency/Office
Date
DEM/ARO 704-251-6208
g
Regulatory Office Use Only
Action Taken
Date
Compliance Status
❑ Noncompliance
compliance

t,
A
State'of North Carolina
Department of Environment,
Health and Natural Resources 4 • •
/ Division of Environmental Management
James B. Hunt, Jr., Governor CC
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
WATER QUALITY SECTION
February 24, 1995
Mr. David Stout
Corporate Environmental Manager
Broyhill Furniture Industries, Inc-.
One Broyhill Park
Lenior, North Carolina 28633
Subject: Compliance Sampling Inspection
Status: In Compliance
NPDES Permit -Number NC0005461
Broy; ' -1-.Furniture-Rutherford
Pi 1j.t
therford County
Dear Mr. Stout:
The above reference inspection was conducted on.February 9,
1995. The parallel extended aeration wastewater treatment
facility was.observed during operation and discussed with the
Operator in Responsible Charge (ORC). There were -some
maintenance concerns and effluent monitoring concerns. Following
is an itemized list of concerns and recommended corrections:
1) The influent bar screen was being by-passed which
allows paper products, plastics, and other materials to
enter the treatment facility. The present bar screen
should be replaced with one that has a spacing
of 3/8" between bars. The bar screen needs cleaning
more than once per day, which is the present
schedule: I suggest three (3) times per day to
avoid an overflow at the bar screen.
2) Treatment plant number one (1) the dissolved oxygen (D.
O.) was 1.7 mg/l which is within the acceptable range
of 1.0 mg/l to 3.0 mg/l. Treatment plant number two (2)
was slightly above the acceptable range at-4.2 mg/l. I
suggest the operator monitor the D. O. more frequently
for better efficiency of operation.
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% past -'consumer paper

Page 2
Mr. Stout
3) Treatment plant number one (1) skimmer piping needs to
be repaired. During inspection the piping was observed
to have rusted off at the point where it go through the
wall between the aeration basin and clarifier.
4) Treatment plant number one (1) the first diffuser
appeared to have a hole below the water line or
missing diffuser caps by the excessive turbulence
observed. The third diffuser drop appeared to be
clogged being that no turbulence was observed at that
location. These diffusers should be removed, cleaned,
repaired and placed back in service for better air
distribution and waste treatment.
5) Treatment plant number two (2) requires repair of the
sludge return piping and the skimmer piping due to
excessive corrosion causing piping failure.
6) Treatment plant number two (2) is operating with one
(1) blower in service. The blower that is out of
service requires a new electric motor. This should be
purchased and install as soon as possible. Operation
in this manner is in violation of Broyhill Furniture
NPDES Permit.
7) Treatment plant number two (2) diffusers three, four,
and five are clogged and diffusers one and two exhibit
excessive turbulence. Corrective action should be
taken to improve efficient of the treatment plant.
Follow procedure outlined in item number 4.
8) The skimmers of each treatment plant appear to be
returning an excessive amount of water. Adjusting the
skimmers so less water would be returned will improve
the efficient of the clarifiers.
9) The operator is maintaining a log of treatment plant
conditions on individual sheets of paper. The log
should be maintained in a bound notebook with date,
time of visit to treatment plant, maintenance
activities, process control testings, general
treatment plant observations, and the operators
signature.

Page 3
Mr. Stout
10) The results of samples collected on the date of
inspection are within NPDES-Permit limits with the exception of
fecal coliform. This single samples is not sufficient to judge
compliance, however this results indicates that corrective
actions must be made for the facility to attain monthly
compliance. The chlorine residual should be increase in the
effluent to achieve a better disinfection of the effluent. Care
must be taken not to use excessive chlorine as this is toxic to
aquatic life in the receiving stream.
Please respond in writing by March 27, 1995, as to the time
frame that these operation concerns will be corrected. If you or
your staff have questions regarding this report or if we may be
of assistance please, contact me at 704-251-6208.
Sincerely,
�j�-t C �
R gel C. Edwards
Wastewater Consultant
CC: Dean Conner, ORC
Rutherford Co. Health Dept.

United States Ern nental Protection Agency
Form Approved
Washmgion, D.C. 20460
OMB No. 2040-0003
F!A7 NPDES Compliance Inspection Report
Approval Expires 7-31-85
Section A: National Data System Coding
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 IN I 215 I 3 NC0005461 11 12 95/02/24 17 18 $ 19 I S I 20 [ 2 j
u� u
Remarksi---t
2' Reserved Facility Evaluation Rating BI QA Reserved 66
67 L__l_ U 69 70 13 I 71 I I 72 I-1 73 I I I 174 75 80
L��J
Section B: Facility Date
Name and Location of Facility Inspected
Entry Time
Permit Effective Date
Broyhill Furniture Industries, Inc.
11:45 am
January 1, 1994
Rutherford Plant
Exit Time/Date
Permit Expiration Date
One Broyhill Park
Lenior, North Carolina 28633
12:50 pm
Nov. 30, 1998
Name(s) of On -Site Representative(s)ffitle(s)
Phone No(s)
Mr. Dean Conner, ORC
704-287-4276
Name, Address of Responsible Official
Title
Mr. David Stout
Corporate Enviornmantal Manager
One Broyhill Park
Phone No.
Contacted
Lenior, North Carolina 28633
704-758-3111
No
Section C: Areas Evaluated During Inspection
S
Permit
Records/Reports
Facility Site Review
S
Flow Measurement
Laboratory
Effluent/Receiving Waters
N
Pretreatment
Compliance Schedules
Self -Monitoring Program
M
Operations &Maintenance
Sludge Disposal
Other: row 17
M
M
N
S
S
M
M
Section D: Summary of Findings/Comments (Attach additional sheets if necessary)
Influent bar screen should have spacing between bars of 3/8". This will reduce the amount of paper products and plastic material entering the treatment plants.
The bar screen should be cleaned more frequently than once per day. I suggest three times per day for the bar screen to be cleaned of avoid overflows.
Plant number two requires the replacement of an electric blower motor. Operating with only one (1) blower on a treatment plant is a NPDES Permit violation.
Plant number one the skimmer piping needs to be repaired. -
Plant number one the first diffuser appears to have a hole below the water line or missing diffuser caps, with the third diffuser being clogged.These diffusers should
be removed, cleaned, repaied, and placed back in service.
Plant number two return sludge piping and skimmer piping needs to be repaired.
Plant number two diffusers 3,4, and 5 are clogged. These need to be removed , cleaned, repaired ,and placed back in service.
Plant number two diffusers 1 and 2 appear to have a hole below the water line or missing diffuser caps. This should be corrected as soon as possible.
Operator is maintaining a log for treatment plant on individual sheets of paper. The log should be maintained in a bound notebook with the date, time of visit,
maintenance activities, process control testing, and general treatment plant observations.
Effluent Characteristics Monthly Average Sample Results
BOD 30.0 mg/I 4.2 mg/I
Total Suspended Solids 30.0 mg/I 4 mg/I
NI-13.as N monitor only 2.4 mg/I
Fecal coliform 200/100 ml 17001 100 ml est. count
Name(s) and Signature(s) of Inspector(s)
Agency/Office/Telephone
Date
ROGER CARDS
DEM/ARO 704-251-6208
Zy �s
Signatur v wer
Agency/Office
Date
DEM/ARO 704-251-6208
Regulatory Office Use Only
Action Taken
Date
Compliance Status
❑ Noncompliance
compliance

DIVISION OF ENVIRONMENTAL MANAGEMENT . WATER QUALITY I eXB FORM (DM1)
IR
COUNTY iET ►t ICJ PRIORITY SAMPLE TYPE - 0
RIVER BASIN 'D ❑AMBIENT ❑ QA ❑ STREAM EFFLUENT
REPORT TO: O RO MRO RRO WaRO WIRO WSRO TS
AT BM ❑ COMPLIANCE ❑ CHAIN ❑ LAKE ❑ INFLUENT
Other OF CUSTODY
Shipped by: Bus Courier, Staff, Other EMERGENCY ❑ESTUARY DATE REPORTED:
_. _ I If.... ^MT V
Lab Number: / %
Date Received: „ 2
n
Time: 7
Rec'd by: �'
and
From: Bus -Courier e
DATA ENTRY BY:
v CK:
^
••f — � i " �}
COLLECTOR(.S): 4 0(UjAjed5
Estimated BOD Range:(5S/-25/25-65/40-130 or 100 plus STATION LOCATION
Seed: Yes E No ❑ Chlorinated: Yes 9--No ❑ REMARKS:
Station #
Date Begin (yy/mm/dd)
Time Begin
Date End
Time End
Depth DM DB DBM
Value Type
H L
Composite
T S B
Sample Ty e
C GNXX
O 5' L 7
A
1 ✓
BOD5 310 a mg/1
COD High 340 mg/1
3
COD Low 335 mg/I
4
Coliform: MF Fecal 31616 % L)O /100ml
5
Coliform: MF Total 31504 /100m1
6
Coliform: Tube Fecal 31615 /100ml
7
Coliform: Fecal Strep 31673 /100ml
8
Residue: Total 500 mg/I
9
Volatile 505 mg/I
10
Fixed 510 mg/I
11
Residue: Suspended 530 mg/1
12
Volatile 535 mg/1
13
Fixed 540 mg/I
14
PH 403 units
15
Acidity to pH 4.5 436 mg/l
Acidity to pH 8.3 435 mg/I
Alkalinity to pH 8.3 415 mg/l
18
Alkalinity to pH 4.5 410 mg/I
19
TOC 680 mgA
Turbidity 76 NTU
Chloride 940 mg/I
Chi a: Tri 32217 ug/I
Chi a: Corr 32209 ug/1
Pheophytin a 32213 ug/1
Color: True 80 Pt -Co
Color:(pH ) 83 ADMI
Color: pH 7.6 82 ADMI
Cyanide 720 mg/1
Fluoride 951 mg/1
Formaldehyde 71880 mg/I
Grease and Oils 556 mg/I
Hardness Total900 mg/1
Specific Cond. 95 uMhos/cm2
MBAS 38260 mg/1
Phenols 32730 ug/I
Sulfate 945 mgA
Sulfide 745 mg/I
NH3 as N 610 a , q mg/1
TKN as N 625 mg/I
NO2 plus NO3 as N 630 mg/1
P: Total as P 665 mg/I
PO4 as P 70507 mgA
P: Dissolved as P 666 mgA
CdCadmium 1027 ugA
CrChromium.Tota11034 ugA
Cu-Copper 1042 ug/l
Ni-Nickel 1067 ug/I
Pb-Lead 1051 ug/l
Zn-Zinc 1092 ug/I
Ag ilver 1077 ug/1
Al -Aluminum 1105 ug/1
Be -Beryllium 1012 ug/1
Ca -Calcium 916 mgA
Co -Cobalt 1037 ug/I
Fe -Iron 1045 ugA
Li -Lithium 1132 ug/I
Mg -Magnesium 927 mg/l
Mn-Manganese 1055 ug/I
Na-Sodium 929 mg/l
Arsenic -Total 1002 ug/1
Se -Selenium 1147 ug/l
Hg-Mercury 71900 ug/i
Organochlorine Pesticides
Organophosphorus Pesticides
Acid Herbicides
Base/ Neutral Extractable Organics
Acid Extractable Organics
Purgeable Organics (VOA bottle reg'd)
Phytoplankton
Sampling Point %
Conductance at 25 C
Water Temperature (C)
D.O. mgA
pH
Alkalinity
Acidity
Air Temperature (C)
pH 8.3 pH 4.5
pH 4.5 pH 8.3
2
94
10
300 1•
400 •
82244 1431
82243 182242
20
Salinity %
Precipition On/day)
Cloud Cover %
Wind Direction (Deg)
Stream Flow Severity
Turbidity Severity
Wind Velocity M/H
can Stream Depth ft.
Stream Width ft.
480
45
32
36
1351
1350
35
64
4

State of North Carolim_—_
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
January 17, 1994
Attn: Richard H. Kerns
Broyhill Furniture Industries
Highway 221 North
Rutherfordton, NC 28139
4SOL
••
[) E H N FI
Subject: Units Of Measurement on DMRs
Broyhill Furniture Industries
NPDES No.: NC0005461
Rutherford County -_
Dear Mr. Kerns:
Recent submittals of Discharge Monitoring Reports (DMRs) from the subject facility have shown
values for total residual chlorine reported in micrograms per liter (ug/1). These reported values are well
below, the current detection limit for this parameter and inconsistent with values previously reported by the
facility in milligrams per liter (mg/1). The Division's recent modification of DMRs included a change in the
printed units of measurement for total residual chlorine from mg/l to ug/l. It is believed the facility is
continuing to report mg/1 results for this parameter, but listing those results as ug/l values.
Total residual chlorine is not a limited parameter in this NPDES permit and results of its monitoring
may be reported using units of measurement of either mg/1 or ug/l. If you wish to continue to report total
residual chlorine values in mg/l, clearly mark through the ug/l units on the Division's pre-printed MR-1
form and write "mg/l" above that space. If you wish to report in ug/l, testing results in mg/l may be
converted from mg/1 to ug/l by multiplying the value in mg/1 by 1000. Once a decision has been made as
to which units of measurement will be used, it is requested the facility remain consistent in its reporting
practice. Submitting reports which include correct units of measurement helps ensure efficient computer
data entry and compliance evaluation.
Please make this change in reporting as soon as possible. Facilities which submit DMRs
exhibiting incorrect units of measurement are subject to the issuance of a Notice of Violation.
If you have any questions about this matter or any other questions concerning DMRs, please
contact Mr. Shannon Langley at [phone],,.extension 581.
Sincerely,
�_, jL, LA
Robert L. Sledge, Supervisor
Compliance Group
cc: Compliance/Enforcement
Regional-OC 6_,_:)
Central Files
P.O. Box 29535, Raleigh, North Carolina'27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 1o% post -consumer paper

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
November 8, 1994
Mr. Richard H. Kerns
Broyhill Furniture Industries - Rutherford Facility
Highway 221 N
A74
.V;A
1� i\
Rutherfordton, North Carolina 28139
Subject: Rescission of Administrative Letter Toxicity Monitoring R u" irement
J Y g �
Broyhill Furniture. Industries- Rutherford Facility
NPDES Permit No. NC0005461
Rutherford County
Dear Mr. Kerns:
Broyhill Furniture Industries was issued an administrative letter dated February 29,
1988, requiring monthly acute full range toxicity monitoring for outfa11002. - A subsequent
89 administrative letter dated July 20, 19, was issued to the facility modifying the acute
testing requirement to a quarterly chronic testing requirement. Our records indicate the
facility had been conducting toxicity testing as required by the administrative letter until
December 1993. Broyhill Furniture's NPDES Permit No. NC0005461 reissued on
November 30, 1993,.with an effective date of January 1, 1994.
Information from our Asheville Regional Office not only confirms changes in
characteristics of the discharged wastewater but also substantiates outfall reconfigurations
at the facility. For these reasons the NPDES Permit reissued without a toxicity monitoring
requirement. i
Based upon the information presented to me, I hereby rescind'the_July 20, 1989,
administrative letter toxicity monitoring requirement.
Should you have any questions, please contact Larry Ausley, Supervisor, Aquatic
Survey and Toxicology Unit Supervisor at [phone].
Sincerely,
Steve W. Tedder, Chief
Water Quality Section
cc: IFor=reVestall=Ashevill Ree Office
Larry Ausley
Central Files
Environmental Sciences Branch • 4401 Reedy Creek Road Raleigh, North Carolina 27607
Telephone [phone] FAX # [phone]
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9-
State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
WATER QUALITY SECTION
October 19, 1994
MEMORANDUM
TO: Steve Tedder
Water Quality Section hief
FROM: Forrest West 1
Water Quality 1 Supervisor
SUBJECT: Rutherford Furniture Co.
Toxicity Testing Requirement
NPDES Permit No. NC0005461
Rutherford County
J3k�3
IDEHNF1
An adminstrative letter dated February 29, 1988,required the
subject facility to begin monthly acute monitoring for outfall 002. A
subsequent administrative letter dated July 20, 1989, required that
the facility .change to quarterly chronic monitoring with a target of
410; however, no outfall was specified. When. the Permit was renewed
effective January 1, 1994, toxicity was not included since toxicity was
not deemed to be a problem as_there had' been some changes in the
components of the wastewater discharges. The administrative letter
remained in effect. ,
By this memo, this Office is requesting that the administrative
letter requiring chronic toxicity monitoring be rescinded.
If you have. any questions concerning this matter, or if you need
additional information please advise.
xc: Roger Edwards
Keith Haynes
99,E
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

EffLuent Toxicity Report Form - Chrbni6'Pass/Fail and'•Acute LC50
Date: 10'/kM4
-a•ility: RUTHERFORD FURNITURE COMPANY NPDESN: NC0005461 Pipe#: 003County: RUTHERFORD
.i>o� ry Performing T t: BURLINGTON RESEARCH, INC.
Comments:
y
Signature of Operator in Responsible Charge
Signature of Laboratory Supervisor
Environmental Sciences Branch
MaiL original to: Div. of Environmental Management
N.C. Dept. of EHNR
4401 Reedy Creek Road
Raleigh, North Carolina 27607-6445
North Carolina Ceriodaphnia Chronic Pass/Fail Reproduction Bioassay Work Order: 94-10-353-01
i arrtrol Organisms
-- — -- —r 2 3--4
9 Young Produced 21 M2925ff28 0 25 24 25 28 25 25
Adutt (L)ive Mead IIL IL IL IL IL IL IL IL IL IL IL IL
'EffLuent %: 41%
Treatment 2 Organisms 1 2 3 4 5 6 7 8 9 10 ll 12
F--
9 Young Produced II 27I27I25I27I29I27I21I24I27I21I29I25
r',.& Lt (L)ive (D)ead IIL IL IL IL IL IL IL IL IL IL IL IL
1st sample 1st sample 2nd sample
Control 7.50 7.75 7.99 7.93 F79E3
r?atment 2 7.87 7.85 7.75 7.93 7.88 7.67
s s s
t e t e t e
a n a n a n
r d r d r d
t t t
1st sample 1st sample 2nd sample
Control
Treatment 2 8.3 8.2 8.3 8.55 8.55 8.2
LC50/Acute Toxicity Test.
iNortality expressed as %, combining replicates)
Chronic Test Results
Calculated t = 0.314
Mortality
Avg.Reprod.
0.00
26.08
Control
Control
0.00
25.75
Treatment 2
Treatment 2
control-
PASS FAIL
organisms
producing
X❑ ❑
3rd brood
100%
Check one
Complete This For Either Test
Test Start Date: 10/19/94
Collection (Start) Date
Sample 1: 10/17/94 Sample 2: 10/20/94
Sample Type/Duration 2nd
1st P/F
Grab Comp. Duration D
I S S
Sample 1 X 24 hrs L A A
U M M
Sample 2 X 24 hrs T P P
Hardness(mg/L) 45
Spec. Cond.(gmhos) 94 82.7 62.2
Chlorine(mg/L) n/a n/a
Sample temp. at receipt(°C) 1.3 2.5
%
% % % % % % %
Note: Please
Concentration Complete This
Section Also
Mortality
start/end start/end
LC50 = %
Method of Determination
Control
95:, C`6nfidence Limits
Moving Average _ Probit
High,
rnnc -
_
Spearman Karber Other
Organism Tested: Cer.iodaphnia dubia
Copied from DEM- form',AT-1—(3%87)',�ev:. 8/91,•.

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
WATER QUALITY SECTION
October 19, 1994
TO: Steve Tedder
Water Quality SectionlChief
FROM: Forrest Westa,1l
Water Quality=31 Supervisor
SUBJECT: gutherford Furniture Co.i
Toxicity Testing Requirement
NPDES Permit No. NC00,05461
Rutherford County
A&74i 001W VIVA
1:3EHNR
An adminstrative letter dated February 29, 1988 required the
subject facility to begin monthly acute monitoring for outfall 002. A
subsequent administrative letter dated July 20, 1989, required that
the facility .change to quarterly chronic monitoring with a target of
41%; however, no outfall was specified. When the Permit was renewed
effective January 1, '1994, toxicity was not included since toxicity was
not deemed to be a problem as there 'had been some changes in the
components of the wastewater discharges. The administrative letter
remained in effect.
By this memo, this Office is requesting that the administrative
letter requiring chronic toxicity monitoring be rescinded.
If you have any questions concerning this matter, or if you need
additional information please advise.
xc: Roger Edwards
Keith Haynes
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

9,0
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Environmental Management
59 Woodfin Place Asheville, North Carolina 28802
October 3, 1994
RICHARD H KERNS
BROYHILL FURNITURE INDUSTRIES
HIGHWAY 221 NORTH
RUTHERFORDTON NC 28139
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE.INDUSTRIES
RUTHERFORD County
Dear RICHARD H KERNS:
Review of subject
of June, 1994 revealed
parameter(s):
Pipe Parameter
001 31616 FEC COLI
self -monitoring report for the month
violation(s) of the following
Reported
Value/Unit.
326.0 #/lOOM
Limits
Value/Type/Unit
200.0 FIN #/100M
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division_of Environmental
Management may pursue enforcement actions for this and any
additional violations of State Law. ' If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality Supervisor, at 704/251-6208.
cc: Central Files
GKBDEX96/BL
Sincerely,
Roy Davis
Regional. Supervisor

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Environmental Management
59 Woodfin Place Asheville, North Carolina 28802
RICHARD H KERNS
BROYHILL FURNITURE
HIGHWAY 221 NORTH
RUTHERFORDTON NC
August 15, 1994
INDUSTRIES
28139
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE INDUSTRIES
RUTHERFORD County
Dear RICHARD H KERNS:
Review of subject self -monitoring report for the month
of June, 1994 revealed violation(s) of the following
parameter(s):
Reported Limits
Pipe Parameter Value/Unit Value/Type/Unit
001 31616 FEC COLI
323.0 #/100M 200.0 FIN #/100M
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division of Environmental
Management may pursue enforcement actions for this and any
additional violations of State Law. If you have questions or if
you need assistance, please call Forrest R. Westall, Regional Water
Quality Supervisor, at 704/251-6208.
incerely,
Roy Davi
Regional Supervisor
cc: Central Files
GKBDEX96/BL

04/28/94 15:04 pV919 733 9959 NC DEBT WQ ENVSCI ARO
U001
Per your request, below. is support information for Rutherford Furniture, NC0005461
2/12/87-1,etter to fac. from ARO transmitting Biomonitoring info.
002 LC50 28%
003 LC50 35%
2/29/88-Adm. Ltr to fac. from Div. requiring monthly acute monitoring for 002
LC50 was <5.0%
3/2/88-Ltr to fac. from ARO transmitting Biomonitoring Inspection Results
002 LC50 0 ' .
003 LC50 <5.0%
7/20/89-Adm. Ur to fac. from Div.
no pipe specified in the adm. ltr
Q Chr. Tar of 41%, Aug, Nov, Feb, and May
5/4/90-NOV from ARO for failing to submit test results
7/30/93-Warning Letter from ESB to fac. indicating that permit may be -reopened if monitoring is not
conducted according to adm. ltr. requirements
Fac. mistakenly removed from NR list -I thought they were under permit when actually they are under
adm. Itr. My notes indicate`that we, would not send NOV and ARO.would discuss. Reopening permit
and including an appropraite-limit was discussed.
All AT forms submitteed from fac. are for 003
Self mon summary has 001 listed as pipe
Permit issued 1/94 w/ no tox monitoring; staff report did not address toxicity
All "fail' test results, to date appear to suggest that chlorine (for pipe 003) is not a problem.
Concentrations for all "fail' tests, except one are < 0.05 mg/1
If you have any questions, please do not hesitate to ,contact me at 919-733-2136
Post-Ir brand fax transmittal memo t7f
# Of pages .
TO
From
Co.
Co.
Oept.
Phone #
Fax #
GF
Fax #

State of. North Carolina
Department of Environment,
Health- and_ Natural -Resources ,
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
WATER QUALITY SECTION
May 27, 1994
Mr. David,Stout
Corporate Environmental Manager
Broyhill Furniture Industries, I•nc.
One Broyhill Park
Lenoir, North Carolina 28633
Subject: Compliance Sampling Inspection
Status:. In Compliance
NPDES Permit Number NC0005461
Broyhill Furn,iture-Rutherford
Plant,
Rutherford County
Dear Mr. Stout;
The above.referenced facility was,inspected May 3, 1994, by Mr.
James R. Reid and myself. The effluent results produced by the
facility are•well within NPDES Permit limits. However, these results
would not have been attainable' without the effluent polishing pond.
The operations and maintenance of the facility are found to be
undesirable.
Observations made at. the time of- the inspection were not
indicative of good plant operation and maintenance. The following is
a list of 'the facility deficiencies and recommended corrective
actions..
1) The dissolved oxygen (D. 0.) level in treatment',plant
number one was 0'mg/l.. • The time clocks operating the
blowers were set for 45.minutes.operation and 15 minutes
off. The time clocks must be adjusted so that the D. O.
does not drop below 1.0 mg/1 between blower. cycles. The
optimum operating range for D. 0. in,an aeration basin is
1.0 mg/1 to 3.0 mg/-l;' this gives the microorganisms
adequate oxygento treat.the influent wastewater.
2) The settleable solids level in treatment plant number -one -
were 95%. This high solids level in part explains•the low
D. O. level in treatment plant number one. The settleable
solids range in the,aeration basin should be 40% to 80%
The operator will have to observe the effluent of the plant
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 , Telephone 704-25,1-6208 FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

r
a
David Stout
May 27, -1994
Page Two
to determine the solids level that produces the best
quality effluent.
3) Grease should be removed before it.enters the treatment
plants. This can be accomplished with the addition of a
grease trap downstream of the kitchen facility. The grease
trap should be located so that hot water from the kitchen
does not cause the grease.to stay in solution but.allows
L it to solidify in the trap. Grease causes problems with
settling and effluent degradation.
4). The clarifier 'on each plant needs a baffle board installed
to keep floatable material confined to the inlet area of
the clarifier, The existing baffle could be improved by
placing- a board, of 2"_-x J2" material, the length of -the,
clarifier. The board can be. push down to the top of the
existing baffle and wedged from. one end to hold it in
J place. This will allow. approximately 4 to 6 inches of
freeborad. With this baffle in place the floatable
material will be easy for the operator to remove.
5 ) The sludge--return-rate from the -clari-Her should '-be slowed
down -so that settling can be accomplished in the clarifier.
When the return rate is too high the sludge is not allowed
time to settle properly before it is.removed back to the
aeration basin. Also, the skimmer depth\ should be adjusted
so that up flow currents are not caused in the clarifier
that will pull the sludge blanket up.
6) The clarifier on each plant should be scraped three (3)
timers per week. I suggest Monday, Wednesday and Friday.
This will prevent sludge from accumulating on the clarifier
side walls causing problems in the effluent.
7) All materials removed from the wastewater treatment
facility should be disposed of` in accordance with
regulations. Upon removal, material can be -put into a
plastic bucket .with holes in the sides and bottom, lime
added, and allowed to drain. back' -into the treatment plant
prior to disposal.. The addition of lime will reduce vector
attraction and occurrence of odors.
8) The return sludge air line on.treatment.plant,number one
-needs repair to prevent the air that escapes from causing a
settleability problem in.the clarifier. Also, all'
diffusers in both treatment plants should be removed,
cleaned, repaired where necessary and re -installed.

- u
' v
David Stout
May.-27., _.19.94 _ - -
Page Three -
9) The installation of a tablet chlorinator will be safer for
the operator than the present gaseous chlorine now in use.
The tablet -chlorinator Will require less maintenance and no
spare, -parts inventory. Results in fecal reduction will be
within permits limits with tablet chlorination as long as
tablets are added to the chlorinator as needed.
10) The operator needs equipment to perform operational process
testing. This will optimize the performance of the
treatment plant. The equipment necessary is a dissolved
oxygen meter, two'(2) graduated cylinders and a sludge
judge. This equipment can be purchased form any
scientific equipment distributor, i . e..._-Hach., Fisher-,
Baxter, Whatman, etc.
11) The operator must keep a log book that contains the date,
time, process control tests performed, adjustments made to
treatment plants, amount and final destination of sludge
wasted from plants, and name(s) of.the individual(s)
responsible for performing the above menti.oned items.
The log book must be signed each day by the ORC or
the back-up operator. - -
.Please respond,in writing as to how the deficiencies .in operation and
maintenance will be. .corrected by June 13, 1994. If you have
questions or comments, please give,me a call at.704-251-6208.
Respectfully,
Roger C. Edwards
Wastewater Consultant
Enclosure
xc: Dean Conner, ORC
i

United -11 —etes 'Environmental Protection Ar_'7_y I Formed Approved 1
,Q Washington, D.C. ) 1 OMB No.2040-0003 i
EPA NPDES Compliance Inspection Report I Approval Exp.7/31/851
I I
-_---Section A: :.National. -Data Data -System Coding
'ransaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type I'
lIN_1 2151 31NC0005461 Ill 12194/05/23117 181SI 191S1 20111
Remarks
'11_I_I_I_i_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_f_I' I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_I_166
Reserved Facility Evaluation Rating BI QA------------ Reserved----------- 1
11_1_1_169 70121 711_1 721_I 731_1_174 751_1_1_1_1_1_180
'I
Section B: Facility Data
I
Name and Location of Facility Inspected (Entry Time(X)am( )pmlPermit Effective Datel
Broyhill Furniture -Rutherford Plant 110:30 I Jan. 1, 1994 1
P. 0. Box 69 I I 1
Rutherfordton, NC 28139 (Exit Time/Date (Permit Expires/Date 1
I 11:30 94/05/03 I Nov. 30, 1998 1
I I I
fame(s.) .of On -Site Representatives(s) I Title(s) (Phone No(s) (-
Dean Conner I ORC 1704-287-4276 1
I
fame,Address of Responsible Official I Title 1
David Stout I Environmental Manager 1
One Broyhill Park I
Lenoir, NC 28633 I Phone,No. 704-758-3111 (Contact Yes_No_X_ I
I I
Section C: Areas Evaluated During Inspection I
(S=Satisfactory, M=Marginal;-U=Unsatisfactory,--N=Not-Evaluated) 1
_S_IPermit I _S_IFlow Measurement 1 _N_IPretreatment I=U_IOperation & Main. I
N.IRecords & Reports 1_N_ILaboratory I _S_ICompliance Sch. I _S_ISludge Disposal I
_S_IFacility Site Rev.I_S_IEff/Receiving Waters I _SISelf-Monitoring I (Other: I
I
Section D: Summary of Findings/Comments(Attach additional sheets if necessary) I
Maintain dissolved oxygen level in aeration basins between 1.0 & 3.0 mg/l. 1
Maintain 30 min. settleable in the 40 to 80 percent range. Operator to judge effluent quality 1
when adjusting percentage. Grease trap needed to reduce amount of grease entering facility..
Recommend extension of baffle board in both plants to allow 4 to 6 inches of freeboard. 1
Slow down return sludge rate to allow better settling in clarifier. 1
Adjust skimmer so that less volume of water is returned to aeration basin.
Operator should scrape clarifier on Monday, Wednesday and Friday. 1
Recommend changing form gaseous chlorine to tablet chlorinator.
Materials removed from waste stream must be disposed of according to regulations.
Repair air line leaks for return sludge line, remove and clean diffusers, put back in service.
Supply operator with Dissolved oxygen -meter, graduated cylinders (1000 ml volume) and a sludge 1
_judge. I
lames) & Signature(s) of Inspector(s) 1 Agency/Office/Telephone I Date 1
�j 2 ?�- d I NC-DEHNR/ARO/704-251.-6208 I — /_ / - I
`� Keaulatory Ottice Use Onlv I I
fiction Taken
Date I Compliance Statu
I I_INoncomp. lmp.

DIVISION OF NVIRONMENTAL MANAGEMENT WATER QUALITY FIELD -LAB FORM (DM1)
COUNTY PRIORITY
RIVER BASIN
REPORT T RO F O MRO RRO WaRO WIRO WSRO TS ❑AMBIENT ❑ QA
AT BM
MPLIANCE EJ CHAIN
Other OF CUSTODY
Shipped by: Bus Courier, taf Other ❑ EMERGENCY
COLLECTOR(•S):
Estimated BOD Range: 0- 5-65/40-130 or 100 plus STATION LOCATION:
5-25
6—f
Seed: Yes ❑ Chlorinated: Yea l No E. REMARKS: L
SAMPLE TYPE
❑ STREAM
❑ LAKE
❑ ESTUARY
EFFLUENT
❑ INFLUENT
Lab Number: p 9 r�
Date Received: _S `/ - ci Time:
Rec'd by: S From: Bus -Courier and Del
DATA ENTRY BY: CK: G
DATE REPORTED: _ i " I� — t L(
Stationf ✓
Date Begin (yy`/mm/dd)
Time Begin
Date End
Time End
Depth MIDB DBM
Depth(
Value Type
A H L
Composite
T. S B
Sample; Type
-F
C GNXX--
1
`
BOD5 310 mg/1 .
COD High 340 mg/1
3
COD Low 335 mg/!
4
Coliform: MF Fecal 31616 /100m1
5
Coliform: MF Total 31504 /100ml
6
Coliform: Tube Fecal 31615 /100ml
7
Coliform: Fecal Strep 31673 /100ml
8
Residue: Total 500 mg/I
9
Volatile 505 mg/I
10
Fixed 510 mg/1
11
Residue: Suspended 530 mg/1
12
Volatile 535 mg/1
13
Fixed 540 mg/I
14
PH 403 units
15
Acidity to pH 4.5 436 mg/1
6
Acidity to pH 8.3 435 mg/I
_• 7
Alkalinity to pH 8.3 415 mg/!
18
Alkalinity to pH 4.5 410 mg/1
19
TOC 680 mgA
20
Turbidity 76 NTU
Chloride 940 mg/l
Chi a: TO 32217 ug/I
Chi a: Corr 32209 ug/1
Pheophytin a 32213 ug/1
Color: True 80 Pt -Co
Color:(pH ) 83 ADMI
Color: pH 7.6 82 ADMI
Cyanide 720 mg/1
Fluoride 951 - mg/I
Formaldehyde 71880 mg/l
Grease and Oils 556 mg/I
Hardness Total900 mg/!
Specific Cond. 95 uMhos/cm2
MBAS 38260 mg/1
Phenols 32730 ug/I
Sulfate 945 mg/1
Sulfide 745 mg/1
NH3 as N 610 mg/l
TKN as N 625 mg/I
NO2 plus NO3 as N 630 mg/I
P: Total as P 665 mg/I
PO4 as P 70507 mg/l
P: Dissolved as P 666 mg/I
Cd-Cadmium 1027 ugA
CrChromium-Total1034 ug/l
Cu-Copper1042 ug/I
Ni-Nickel 1067 ug/l
Pb-Lead 1051 u9/I
Zn-Zinc 1092 ug/I
Ag-Silver 1077 ug/l
Al -Aluminum 1105 ug/l
Be -Beryllium 1012 ug/l
Ca -Calcium 916 mg/1
Co -Cobalt 1037 ug/I
Fc-Iron 1045 ug/I
Li -Lithium 1132 ug/1 1
Mg -Magnesium 927 mg/1
Mn-Manganese 1055 ug/1
Na-Sodium 929 mg/I
Arsenic:Total 1002 ug/l
Se -Selenium 1147 _ ug/l
Hg-Mercury 71900 ug/l
Organochlorine Pesticides
Organophosphorus Pesticides
Acid Herbicides
Base/ Neutral Extractable Organics
Acid Extractable Organics
Purgeable Organics (VOA bottle reg"d)
Phytoplankton
Sampling Point %
Conductance at 25 C
Water Temperature (C)
D.O. mgA
pH
Alkalinity
Acidity
Air Temperature (C)
PH 8.3 PH 4.5
PH 4.5 pH 8.3
2
94
10
300 1•
400 1•
82244 431
82243 182242 _
20
Salinity %
Precipition On/day)
Cloud Cover %
Wind Direction (Deg)
Stream Flow Severity
Turbidity Severity
Wind Velocity M/H
can Stream Depth ft.
Stream Width ft.
480
1 45
132
136
11351
1350
135
164 14
'DM1/Revised 10/86

l
Broyhill Furniture Industries, Inc.
One Broyhill Park, Lenoir, North Carolina 28633
BROYHILL
June 6, 1994
Mr. Roger Edwards
North Carolina Dept. of Environment,
Health, and Natural Resources
Division of Environmental Management
Water Quality Section
Interchange Building
59 Woodfin Place
Asheville, North Carolina 28801
Dear Mr. Edwards:
This letter is in response to the May 3, 1994 inspection by
you and Mr. James Reid at the Broyhill Rutherford Plant, NPDES
Permit No. NC0005461, and subsequent letter dated May 27, 1994. I
shall address each of the 11 recommendations below in the same
order as they appear in your letter:
1) According to Dean Conner, the Operator in Responsible Charge,
the setting of the blower cycles is sensitive to the weather and
seasonal conditions. Mr. Conner monitors the appearance of the
water at the plant daily and makes adjustments accordingly. In
order to help Mr. Conner make this determination, a dissolved
oxygen meter will be ordered.
2) The settleable solids level in the aeration basin should now
be at acceptable levels according to Mr. Conner. During the July
4th shutdown week, Mr. Conner has scheduled for the solids in all
sections of the facility to be pumped. This will make it easier to
keep the facility within the acceptable levels of 40 % to 80% in the
aeration basin. The proper equipment as recommended in item 10,
will be ordered.
3) We are in the process of having two grease traps installed,
one on each of the two kitchens. Presently a plumber has looked at
our plant, and is preparing to to flow test in order to size the
units. We have not been given an installation date at this time.
4) Baffle boards will be installed as recommended.
5) The sludge return rate from the clarifier and the skimmer
depth adJusted the day of the inspection(May 3rd) as,recommended.
6) A schedule has been set up for the clarifier at each plant to
be scraped 3 times a week. As recommended, this is being done on
Monday, Wednesday, and Friday.

7) Material removed from the plant will be disposed of as
recommended.
8) The air leak in the return sludge air line will be repaired
the week of July 4th, after the plant has been pumped out. The
diffusers in both treatment plants are being removed, cleaned, and
repaired as needed. Two diffusers have been removed and cleaned
this month, since your May 3rd inspection.
9) Going to a tablet chlorinator will require modification to the
plant as it will require an ,additional tank and additional
equipment. Mr. Conner is researching this type of system.
Modifying the plant to a tablet chlorinator system will be
considered as a future protect for the plant.
10) As stated in item 1 and 2, Mr. Conner is in the process of
getting the equipment that you recommended.
11) Mr. Conner was documenting this Information, and as of June 1,
1994, he is keeping all documentation in a log book as you
recommended.
Your recommendations are appreciated as we strive to operated
the plant in the most efficient and responsible manner possible.
If I can be of further assistance, please give me a call at 704-
758-3374.
Sincerely,
BROYHILL FURNITURE INDUSTRIES, INC.
David Stout
Corporate Environmental Manager
cc
Mr. Dean Conner
Mr. Bob West, Broyhill Rutherford Plant Manager
Mr. Bill Sale, Manager of Broyhill Construction and Engineering

State of North Carolina
Department of Environment,
Health_and-Nat_ural,-Resources :.
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
j F
l
[DE""Pt
WATER QUALITY SECTION
May 27, 1994
Mr. David Stout
Corporate. Environmental Manager
Broyhill Furniture Industries, Inc.
One' Broyhill, Park
Lenoir, North -Carolina 286.33
Subject: Compliance Sampling Inspection
Status:. In Compliance -
NPDES Permit Number NC0005461
Broyhill Furniture -Rutherford
Plant
Rutherford County
Dear Mr. Stout;
The above referenced facility was 'inspected May 3, 1994, by Mr.
James R. Reid and myself. The effluent results produced by the
facility are well within NPDES Permit limits. However, these results
would not -have been attainable. without the effluent polishing pond.
The operations and maintenance ofthe facility are found to be
undesirable.
Observations made at the time of the inspection were -not
indicative of good plant operation and maintenance. The following is
a list of the facility deficiencies and recommended corrective
actions.
1) The dissolved oxygen (D. 0.) level in treatment plant
number one was 0 mg/l.. The time clocks. operating the
blowers were set for 45 minutes operation and 15 minutest
off. The time clocks must be adjusted -so that the D. O.
does not drop below 1.0 mg/l between blower cycles-. The
optimum operating range for D. 0. in an aeration basin is
-1.0 -mg/l to 3.0 mg/l; this gives the microorganisms
adequate oxygen to treat the influent wastewater.
2) The settleable solids level in treatment plant number one
were 95%. This high solids level in part explains the low
D. O. level in treatment plant number one. The settleable
solids range in the aeration basin_ should be 40%,to 800
The operator will have to observe the effluent of the plant
Interchange Building, 59 Woodfin'Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer - 50%recycled/ 10%post-consumer paper

David Stout
Ma 2.7-, 19 9 4
Page -Two --.._.
�. to determine the solids level that produces the best
quality effluent.
3). Grease should be removed before it enters the treatment
plants. This can be accomplished with the addition of a
grease trap downstream of the kitchen facility. The grease
trap should be located so that hot water from the kitchen
does not cause the grease to -,stay in solution but allows
it to solidify in the trap. Grease causes problems.with
settling and effluent degradation.
4) The clarifier on each plant.needs a baffle board installed
to keep floatable material confined'to the inlet area of
the clarifier. The existing baffle could be improved by
, placing- a - board- of 2" x .12" material, the. -length of the
clarifier. The board can be -push down to the top of the
existing baffle and wedged -from one end to hold it.in.
place. 'This will allow approximately 4 to 6 inches of
freeborad•. With this baffle in place the floatable
material will be easy -for the operator to remove.
5) The sludge -_return -rate -from -the -clarifier should be slowed
down so -that settling can be -accomplished in the clarifier.
When the return -rate is.too high the sludge is not allowed
time to settle properly before it is removed back to the
aeration basin. Also, the skimmer depth should be adjusted
so that up flow currents are not caused in the clarifier
that will pull the sludge blanket up.
6) The clarifier on each plant should be scraped three (3)
timers per week. I suggest Monday, Wednesday and Friday:.
This will prevent sludge from accumulating on the clarifier
side walls causing problems in the effluent.
7) All materials removed from the wastewater treatment
facility should be disposed of in accordance with
regulations.- Upon removal, material can be put into a
plastic bucket with holes in the sides and bottom, lime-'.
added, and allowed to drain back into the treatment- plant
prior to disposal. The addition of lime will reduce vector
attraction and occurrence of'odors.
8) The return sludge air line on treatment plant number one
needs repair to prevent the air that escapes from causing a
settleability problem in -the clarifier.- Also, all
diffusers in both treatment plants should be removed,
cleaned., repaired where necessary and re -installed.

lavid Stout -
May - 2-7 , : 9-9 4 . _
Page -Three
.9) The installatiori of a tablet chlorinator will be safer for
the operator than.the present gaseous chlorine now in use.
The tablet chlorinator will require less maintenance and no
spare parts inventory.. Results.in.fecal reduction will be
within permits limits with tablet chlorination as long as
tablets are added to the chlorinator as needed.
10) ."The operator.needs equipment to•perform operational process
testing.' This will optimize the -performance of the
treatment plant. The equipment necessary is a dissolved
-oxygen meter, two (2) graduated cylinders and a sludge
judge. This equipment can be purchased form any
scientific equipment distributor, i.e. Hach, Fisher.,
Baxter,:Whatman, etc.
1.1). The operator must keep a log book that contains the'date,
time, process control tests performed, adjustments made to
treatment plants,.amount and final destination of sludge
wasted from plants,: and name(s) of the individual(s)
responsible for performing the above mentioned -items.
The log book must be signed each day by the,ORC or
the back-up operator.
Please respond in writing,as.to how the deficiencies in operation and
maintenance will be corrected by June 13, 1994. -If you have
questions or comments, please give me a call at 704-251-6208.
Respectfully,
c,
Roger C: Edwards
-Wastewater Consultant
Enclosure
xc: Dean Conner, ORC

United .es'Environmental Protection A� cy I Formed Approved 1
Washington, D.C. I OMB No.2040-0003 J
NPDES Compliance Inspection Report I Approval Exp.7/31/851
__.-Section- A:-_- .National - Data ,.Data -System Coding i
'ransaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type [
11N_1 215.1 31NC0005461 111 12194/05/23117 181SI 191SI 20111
Remarks
Reserved Facility Evaluation Rating BI QA------------ Reserved-----------
1_1_1_169 .70121 . 711_1' 721_1 731_1_174 751_1_1_1_1_1_180
Section B: Facility Data
Name and Location of Facility Inspected
Broyhill Furniture -Rutherford Plant
P. 0. Box 69
Rutherfordton, NC 28139
1Entry Time(X)am( )pmlPermit Effective Date[
i 10:30 1 Jan. 1, 1994 [
I i I
(Exit Time/Date (Permit Expires/Date J
11:30 94/05/03 I Nov. 30, 1998 [
I I I
fame(s) of On -Site Representatives(s) I Title(s) 1Phone No(s) [
Dean Conner I ORC 1 704-287-4276 [
I I•
fame,Address of Responsible Official 1 Title [
David Stout I Environmental Manager [
One Broyhill Park I J
Lenoir, NC 28633 I Phone No. 704-758-3111 lContact Yes_No_X_ I
I I
Section C: Areas Evaluated During'Inspection [-
(S=Satisfactory, M=Marginal, U=Unsatisfactory, N=Not-Evaluated) [
S_IPermit I_S_1Flow
Measurement 1
1 & Main.
N_1Records & Reports 1_N_1Laboratory
I_S_1Compliance
_N_1Pretreatment
Sch.
_U_10peration
I Disposal
.S_1Facility Site Rev.I_S_lEff/Receiving
Waters I_S1Self-Monitoring
_S_lSludge
l 10ther:
Section D: Summary of Findings/Comments(Attach additional sheets if necessary)
1
Maintain dissolved oxygen level in aeration basins between 1.0 & 3.0 mg/l.
Maintain 30 min. settleable in the 40 to 80 percent range. Operator to judge effluent quality
when adjusting percentage. Grease trap needed to reduce amount of grease entering facility.
Recommend extension of baffle board in both plants to allow 4 to 6 inches of freeboard.
Slow down return sludge rate to allow better settling in clarifier.
Adjust skimmer so that less volume of water is returned to aeration basin.
Operator should scrape clarifier on Monday, Wednesday and Friday.
Recommend changing form gaseous chlorine to tablet chlorinator.'
Materials removed from waste stream must be disposed of according to regulations.
Repair air line leaks for return sludge line, remove and clean diffusers, put back in service.
Supply operator with Dissolved oxygen meter, graduated cylinders (1000 ml volume) and a sludge
judge.
lame(s) & Signature(s) of Inspector(s) l Agency/Office/Telephone 1 Date
' `� Regulatory Office Use Onlv I
lction Taken I Date
. I
I
Compliance Statu
1_INoncomp. Imp

State of North Carolina „
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
Nann B. Guthrie, Regional Manager
Asheville Regional Office
H.1\
:$ o WATER QUP,;ITY SECTION
'November 2, 1993
MEMORANDUM
TO: Susan Robson
Permits & Engineering Unit
FROM: Jim Reid.
Ashevi],1�%' egional office
SUBJECT: Rutherford Furniture Company (Broyhill)
NPDES-Perm.it No. NC0005461
Rutherford Co, NC
F1
a�q
In accordance with our discussion- of this date, I spoke with Mr. Dean
Conner of Rutherford Furniture Company.- The wastewater discharge pipes
in operation at the facility are as follows; 001 package type treatment
facilities, 002 14,on-contact cooling waters, and 003 kiln condensate.
Mr. Conner stated thatPipe002's discharge, non�-ontact cooling
waters, consists entirely of City of Rutherfordton p.�abl,e water which
has been run through the cooling coils of a� compre`ssors. No .
additives, biocides, or water conditioning chemicals are added, by
Rutherford Furniture Company, to the stream co
mpr.isinq discharge 002.
Your assistance with- this matter is appreciated.;, If there are
questions or a need for additional information please cont ct me.
- i
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 Telephone [phone] FAX [phone]
-An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

Permit No. NC0005461
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
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,
Broyhill Furniture Industries
is hereby authorized to discharge wastewater from a facility located at
NCSR 1535
north of Rutherfordton
Rutherford County
to receiving watersdesignated as an unnamed tributary to Cathey's Creek for outfall 001, and a dry
ditch to Hollands Creek for outfall 002 in theBroadRiver Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, and III hereof.
This permit shall become effective
This permit and authorization to discharge shall expire at midnight on November 30,1998
Signed this day
A. Presto '• vi+. • , Jr., Director
Division o nvironmental Management
By Authority of the Environmental Management Commission

j
Permit No. NCO005461
SUPPLEMENT TO PERMIT COVER SHEET
Broyhill Furniture Industries
is hereby authorized to:
1. Continue to operate two extended aeration wastewater treatment units in parallel followed by
effluent polishing and chlorination for outfall 001, and continue to discharge kiln condensate
from outfall 002 from a facility located on NCSR 1535, North of Rutherfordton, Rutherford
County (See Part III of this Permit), and
2. Discharge from said, treatment works at the location specified on the attached map into
an unnamed tributary to Cathey's Creek for outfall 001 which is classified as WS V, and
into a dry ditch to Holland's Creek which is classified as WS IV'for outfall 002 in the Broad
River Basin.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NC0005461
During the period beginning on the effective date of the permit and lasting until, expiration; the Permittee is authorized to discharge from
outfall(s) serial number 001-DOMESTIC WASTEWATER. Such discharges shall be limited and monitored by the permittee as specified below:
Effi.uent . Characteristics
Flow
BOD, 5 day, 200C
Total Suspended Residue
IVH3 as N
Fecal Coliform (geometric mean)
Total Residual Chlorine
Temperature
Discharge Limitation
Monthly Avg Weekly Avg... Dally Max
0.026 MGD
30.0 mg/I 45.0 mg/I
30.0 mg/I 45.0 mg/I
200.0 /100 ml
* Sample locations: E - Effluent, I - Influent
400.0 /100 ml
Monitoring
Requirements
Measurement
Sample
*Sample
Frequency
Tvoe
Location
Weekly
Instantaneous
I or E
Weekly --
Grab
E
Weekly
Grab
E
Weekly
iGrab
E
Weekly
Grab
E.
2/Week
Grab
E
Daily
Grab
E
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored,2/month at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A. (). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC0005461
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 002-KILN CONDENSATE. Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characterls.tics Discharge Limitations Monitoring Requirements
Lbs/day Units (specify) Measurement SaMP12
Mon. An, Daily Max Mon, Ava. Daily Max. Frequency Tvpe
Flow
Temperature
Monthly Instantaneous
Monthly Grab
*Sample
Location
E
E,U,D
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS (See Part III of this permit).
* Sample Locations: E - Effluent, U - Upstream, D - Downstream
The permittee shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See
Part III of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored monthly at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
s

r
Part III Permit No. NC0005461
E. The Permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water. The Permittee shall notify the Director in writing not
later than -ninety (90) days prior to instituting use of any additional biocide.used in -the treatment
system. which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map indicating the discharge point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream, as determined by calculations from the Biocide Worksheet
Form 101 with Supplemental Metals Analysis Worksheet.
F.- The facility discharges into a stream with 7Q10/30Q2=0 cfs. Removal of discharge is
recommended if a more environmentally sound alternative is available at an economically
reasonable, cost. An engineering report evaluating alternatives to discharge is due 180 days prior to
permit expiration along with the permit renewal application. As part of the report, the cost of
constructing a treatment plant at the discharge point to meet limits of 5 mg/l BOD5, 2 mg/l NH3 as
N, 6.0 mg/l DO, and 17.0 µgll chlorine should also be included if there are no feasible alternatives
to a surface"discharge. Upon review of the results of the engineering report, the Division retains
the right to:reopen and modify this NPDES. permit to require removal of the discharge or to revise
the permit limitations within a specified time schedule.

771
PERMIT NO.: NC0005461
PERMPI'IIrE NAB: Broyhill Furniture Industries
FACILITY NAME: Rutherford Plant
Facility Status: Existing
Permit Status: Renewal
Major Minor _4
Pipe No.: 001
Design Capacity: 0.026 MGD
Domestic (% of Flow):
Industrial (% of Flow):
Comments:
100 %
NPDES WASTE LOAD ALLOCATION
RECEIVING STREAM: UT to Cadiaya Cke i and a ditch to Hollands Creek
Class: WS V and WS IV
Sub -Basin: 03-08-02
Reference USGS Quad. F11NW (please attach)
County: Rutherford
Regional Office: Asheville Regional Office
Previous Exp. Date: 6/30/93 Treatment Plant Class: II
Classification changes within three miles:
Requested by: Susan Robson Date: 2/22/93
Prepared by: , q -Date:-,V/S/93
Reviewed Date: a
/ 3 r'-
z 3
;;:
Modeler
Date Rec.
�nnA
3
Ell
Drainage Area (miZ) 0. `f Avg. Streamflow (cfs): C,3
7Q10 (cfs) 4.6_Winter 7Q10 (cfs) O o 30Q2 (cfs) o. o
Toxicity Limits: IWC _ % Acute/Chronic
Instream Monitoring:
Parameters
Upstream Location
Downstream . Location
Effluent
Characteristics
Summer
Winter
BODS m
30 EL
�NH3-N (mg/1)
D.O. (mg/1) '
tir
TSS (mg/1)
30 F�
F. Col. (/100 ml)
zoo
pH (SU)
The facility discharges into a stream with 7Q10/30Q2=0 cfs. Removal of the
discharge will be required if a more environmentally sound alternative is
available. An engineering report evaluating alternatives to discharge is due
180 days prior to permit expiration along with the permit renewal
application. As part of the report, the cost of constructing a treatment facility
to meet limits of 5 mg/l BOD5, 2. mg/l NH3, 6 mg/1 dissolved oxygen, and
17 ug/l chlorine must also be included if there are no alternatives to a surface
discharge. Upon review of the results of the engineering report, the Division
may reopen and modify this NPDES permit to require removal of the
discharge, modified treatment designs, and/or revised effluent limitations
within a specified time schedule.

Facility Name:
NPDES No.:
Type of Waste:
Facility Status:
Permit Status:
Receiving Stream:
Stream Classification:
Subbasin:
County:
Regional Office:
Requestor:
Date of Request:
Topo Quad:
FACT SHEET FOR WASTELOAD ALLOCATION
Request # . 7349�A9
!Broyhill Furniture Industries -Rutherford Plant
NC0005461
Domestic -100% .,f?1PE Q0
Existing
Renewal
UT Catheys Creek
WS-V -
030802
Rutherford Stream Characteristic:
Asheville USGS #
Robson Date:
3/2/93 Drainage Area_(mi2):
F11NW Summer 7Q10 (cfs):
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
Winter 7Q10 (cfs):
Average Flow (cfs):
30Q2 (cfs):
IWC (%):
0.4 (Estimated)
0.0 (Estimated] . - -
0.0 (Estimated)
0.3 (Estimated)
0.0 (Estimated) -
The facility discharges into a receiving stream which has a 7Q10/30Q2=0 cfs. Removal of the
discharge will be required if a more environmentally sound alternative is available. An engineering
report evaluating alternatives to discharge is due 180 days prior to permit expiration along with the
permit renewal application. As part of the report, the cost of constructing a treatment plant at the
discharge point to meet limits of 5 mg/1 BOD5, 2 mg/l NH3, 6 mg/1 DO, and 17 µg/l chlorine must
also be included if there are no alternatives toa. surface water discharge. Upon review of the
results of the engineering report, the Division may reopen and modify this NPDES permit to
require removal of the discharge, modified treatment designs, and/or revised effluent limitations
within a specified time schedule.
Special Schedule Requirements and additional comments from Reviewers:
Recommended by: A
Reviewed
Instream
Regional
Permits
RETURN TO TECHNICAL SERVICES $Y
Date: 4/8/93
Date:
Date-41 ' �- 93

Existine Limi
Monthly Average
Summer Winter WQ or EL
Wasteflow (MGD):
0.026
BOD5 (mg/1):
30 -
NH3N (mg/1):
monitor
DO (mg/1):
nr
TSS (mg/1):
30
Fecal Col. (1100 ml):
1000
pH (SU):
6-9
Residual Chlorine (µg/1):
monitor
Temperature (C):
monitor
Recommended Limits:
Monthly Average
Summer Winter WQ or EL
Wasteflow (MGD):
0.026
BOD5 (mg/1):
30 EL
NH3N (mg/1):
monitor
DO (mg/1):
nr
TSS (mg/1):
30 EL
Fecal Col. (/100 ml):
200
pH (SU):
6-9
Residual Chlorine (µg/1):
monitor
Temperature (C):
monitor
Limits -Changes Due To: Parameter(s) Affected
Change in 7Q10 data
New regulations/standards . Fecal Coliform
New procedures
New facility information
'Change in stream classification
Other
Parameter(s) are water quality limited. 'For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
X_ No parameters are water quality limited, but this discharge may affect future allocations.

INSTREAM MONITORING REQUIREMENTS
Upstream Location: J
Downstream Location:
Parameters:
Special instream monitoring locations or monitoring fiequencies:
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
Ad�uacy of Existing Treatment
Has the facility d onstrated the ability to meet the proposed new limits with existing treatment
facilities? Yes No
If no, which parameters cannot be met?
Would a "phasing in" of the new limits be appropriate? Yes No
If yes, please provide a schedule (and basis for that schedule) with the regional
office recommendations:
If no, 'why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) (Y or N)
(If yes, then attach schematic, toxics spreadsheet, copy of model, or, if not modeled, then old
assumptions that were made, and description of how it fits into basinwide plan)
Additional Information attached? (Y or N) If yes, explain with attachments.

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0005461
PERMr= NAME: Broyhill Furniture Industries
FACILITY NAME: Rutherford Plant
Facility Status: Existing
Permit Status: Renewal
Major Minor
Pipe No.:
Design Capacity: 0.026 MGD
Domestic (% of Flow): 100 %
Industrial (% of Flow):
Comments:
piM 001-extended aeration package plants in jarallel
002: ft kiln condensate p
RECEIVING STREAM: UT to Catheys Creek and a ditch to Hon; Creek
Class: WS V and WS IV
Sub -Basin: 03-08-02
Reference USGS Quad: F11NW (please attach)
County; Rutherford
Regional Office: Asheville Regional Office
Previous Exp. Date: 6/30/93 Treatment Plant Class: 11
Classification changes within three miles:
Requested by: n Susan Robson
Prepared by: iAe- A
Reviewed b
Date: W22193
Date:
Date: a
� �a,/193
Modeler
Date Rec.
#
Drainage Al Area (mi) 0, / Avg. Streamflow (cfs): 6.0
7Q10 (cfs) 0.6 Winter 7Q10 (cfs) 0.0 30Q2 (cfs) 0.0
Toxicity Limits: IWC % Acute/Chronic
Instream Monitoring:
Parameters
Upstream Location
Downstream_
Location
Effluent
Characteristics
Summer
Winter
BODS m
NH3-N (mg/1)
D.O. (mg/1)
TSS (mg/1)
F. Col. (/100 ml)
PH (SU)
Comments:

Facility Name:
NPDES No.:.
Type of Waste:
Facility Status:
Permit Status:
Receiving Stream:
Stream Classification:
Subbasin:.
County:
Regional Office:
Requestor:
Date of. Request: -
Topo Quad:
FACT SHEET FOR WASTELOAD ALLOCATION
Request # 7349 (B)
-,Broyhill Furniture Industries -Rutherford Plant
NC0005461
100% Industrial (Kiln Condensate) (Pipe 002)
Existing
Renewal
UT Hollands Creek (dry ditch)
WS-1V
030802
Rutherford Stream Characteristic:
Asheville USGS #
Robson Date:
3/2/93 Drainage Area (mi2): 0.1(Estimated)
F11NW Summer 7Q10 (cfs): 0.0 (Estimated)
Winter 7Q10 (cfs): 0.0 (Estimated)
Average Flow (cfs): 0.6 (Estimated)
30Q2 (cfs): 0.0 (Estimated)
IWC (%):
Wasteload Allocation Summary '1
(approach taken, correspondence with -region, EPA, etc.)
Facility requesting, renewal of NPDES permit. Plant outfall #001 contains domestic waste and
discharges into stream with 7Q10/30Q2= 0 cfs. This outfall #002 discharges kiln condensate.Will_.;
renew #002 limits with QW, temperature,. and pH.
Special Schedule Requirements and additional comments from Reviewers:
Recommended b ; °{ � h
Reviewed by "
Instream Assess nt•
Regional r:
Permits ngineering:
RETURN TO TECHNICAL SERVICES BY:
Date:_4/8/93
Date: 3
Date a 7 ai
_ Date:
MAY 1 1993
�� APR 14.

/ 2 i
PARAMETERS
Existine Limi
Monthly Average
Summer Winter WQ or EL
Wasteflow (MGD): 0.026
pH (SU): 6-9
Temperature (C): monitor
Recommended Limi
Monthly Average
Summer Winter WQ or EL
Wasteflow (MGD): 0.026
pH (SU): 6-9
Temperature (C): monitor
Limits Chan Les Due To: Parameter(s)'Aff
Change in 7Q10 data
New regulations/standards Fecal Coliform
New procedures
New facility information
Change in stream classification
Other
Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
X_ No parameters are water quality limited, but this discharge may affect future allocations.

3
INSTREAM MONITORING REQUIREMENTS
Upstream Location:
Downstream Location:
Parameters:
Special instream monitoring locations or monitoring frequencies:
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
• m
Has the facility !7.No
ted the ability to meet the proposed new limits with existing treatment
facilities? Yes
If no, which parameters cannot be met?
Would a "phasing in" of the new limits be appropriate? Yes No
If yes; please provide a schedule (and basis for that schedule) with the regional
office recommendations:.
If no, why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) (Y or N)
(If yes, then attach schematic, toxics spreadsheet, copy of model, .or, if not modeled, then old
assumptions that were made, and description of how it fits into basinwide plan)
Additional Information attached?
(Y or N) If yes, explain with attachments.
M
I

Broyhill Furniture Industries, Inc.
One Broyhill Park, Lenoir, North Carolina 28633
'Mr. Michael R. Parker
North Carolina Dept. of Environment,
Health, and Natural Resources
Division of Environmental Management
Water Quality Section
Interchange Building
59 Woodfin Place
Asheville, North Carolina 2.8801
Dear Michael:
SUBJECT: Broyhill Rutherford Plant
NPDES Permit NC0005461
Rutherford County
�.� APR 3 0 1993
BROYHILL
April 29, 1993
Zo t e 7`a re
This letter is in response to our phone conversation of April
29, 1993 regarding the Bioassay testing at the Broyhill Rutherford
Plant. Samples for the Bioassay testing were originally scheduled
to be collected April 5 - 6, and 8 - 9. Samples were collected and
sent. I have enclosed a copy of the letter from Burlington
Research that explains why the second sample could not be used. As
explained in the letter, the,second sample arrived at the lab late.
As soon as the Burlington Research called to notify us that a
retest would be required, the test was rescheduled. Sample
collection is scheduled for April 26 - 27, and April 29 - '30, which
is this week. I did not notify you because sample collection was
to take place in April, and our quarterly schedule was not
interrupted. Test results of our April test will be forwarded to
you when we receive them.
Thank you for you assistance in this matter and call me if I
can be of further help.
Sincerely,
BROYHILL FURNITURE INDUSTRIES, INC.
David Stout
Corporate Environmental Manager
cc
Dean Powell, Plant Manager of Broyhill Rutherford Plant
Bill Sale, Manager of Broyhill Engineering and Construction
Enclosure

Analytical Services • Aquatic Bioassay Testing Aquatic Toxicity Reduction Evaluations
AATCC Testing Services • NPDES Testing • Reporting 8` Data Handling Services
PMN Aquatic Bioassay Evaluations
Burlington
Research Post Office Box 2481 •615 Huffman Mill Road • [phone] • Burlington, NC 27216-2481
April 14, 1993
Broyhill Furniture Industries
-1 Broyhill .Park
Lenoir, NC 28633
Attention: Mr. David Stout
Enclosed find -report(s) for your-sample'(s) received 04/07/93,
BRI Work Order # 93-04-098. Please call if you'have any
questions.
Thank you.
Sincerely;
URLINGTON RESEARCH, INC.
Joni M: Barnhardt
Manager, Riomonitoring Department

Analytical Services • Aquatic Bioassay Testing • Aquatic Toxicity Reduction Evaluations
AATCC Testing Services • NPDES Testing • Reporting & Data Handling -Services
PMN Aquatic Bioassay Evaluations
Burlington
Research Post Office, Box 2481 0615 Huffman Mill Road • [phone] • Burlington, NC 27216-2481
ANALYTICAL REPORT
J
CUSTOMER:
BROYHILL FURNITURE INDUSTRIES
WORK ORDER
#: 93-04-098-01
FACILITY:
Rutherfordton, NC
REPORT TO:
Mr. David Stout
COLLECTED:
04/06/93
RECEIVED:
04/07/93
SAMPLE:
April Tox. Monitoring
REPORTED:
04/14/93
Effluent Comp. 4/5-6/93
PARAMETER
METHOD STARTED
ANALYZED
RESULT
Ceriodaphnia
Mini -chronic NCDEM 9/89 04/07/93
04/12/93
Retest
Second sample arrived on Monday 4/-12/93, after hold time had
been exceeded., Therefore, the second sample was not able.to
be used and the test was terminated on Day 5.

i
State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary H
A. Preston Howard, Jr., P.E., Director
July 30, 1993
CERTIFIED MAII 0 U .
RETURN RECEIPT REQUESTED
Mr. Richard H. Kerns AUG `,— 4 M
Broyhill Furniture Industries Rutherford Facility
Highway 221 N. UALI'i;' SECTION
WATER Rutherfordton, North Carolina 28139 ASNE ER 2 REGIONAL OFFICE
Subject: Effluent Toxicity Testing
Broyhill Furniture Industries - Rutherford Facility
NPDF,S Permit NC0005461
Rutherford County
Dear Mr. Kerns:
By administrative letter from the Division of Environmental Management dated July 20, 1989,
Rutherford Furniture Company's monitoring requirement for toxicity testing was altered to an acute
pass/fail test with a target effluent dilution of 41%. A review of the past twelve months of toxicity self -
monitoring data reveals four violations of the administrative letter requirement to conduct testing during the
required monitoring months of Au2ust November, February and May. Language present in the
administrative letter states, "Should any single quarterly monitoring indicate a failure to meet the specified
target level, then monthly monitoring will begin immediately until such time that a single test is passed.
Upon passing, this monthly requirement will revert to quarterly in the months specified above." The
facility failed. to conduct testing after experiencing test failures during- the months of September and
November, 1992. Likewise, beginning in January 1993, the facility appears, to have performed testing
during months which are not specified by the administrative letter.
Please be advised that any future instances of failing to conduct toxicity testing or to timely submit
the test results will result in a recommendation to reopen NPDES Permit No. NC0005461 and include a
toxicity testing requirement with an accompanying limit.
Should there be,no discharge of flow from the facility for the required.testing month, you should
complete the information block located at the top of the AT form indicating the facility name, permit
number, pipe number, county and the month/year of the subject report. You should also write "No Flow"
on the AT form and submit following normal procedures. You will be considered noncompliant with the
reporting requirements contained in your administrative fetter until the completed report hiss been -submitted -
and reviewed by the Aquatic Toxicology Unit.
You may wish to consider submitting future toxicity test results via certified mail to the address
located at the bottom of this page to assist you in determining whether your toxicity test results were
received timely by the Environmental Sciences Branch.
If you have any questions concerning this correspondence, please contact �den at (919)
733-2136.
Section Chief
cc: EForree Westall A-s-hexilleRegional-Offce-
Permits and Engineering
Central Files
EnAronmental Sciences Branch • 4401 Reedy Creek Road Ralelgh, North Carolina 27607
Telephone [phone] FAX # [phone]
An Equal Opportunity Attkmattve Acton Employer W% recycled/10% post consumer paper

FACT SHEET FOR WASTELOAD ALLOCATION
Request # 7349 (B)
Facility Name:
Broyhill Furniture Industries -Rutherford Plant
NPDES No.:
NC00054461
Type of Waste:
100% Industrial
(Kiln Condensate) (Pipe 002)
Facility Status:
Existing
Permit Status:
Renewal
Receiving Stream:
UT Hollands Creek (dry ditch)
Stream Classification:
WS-IV
Subbasin:
030802
County:
Rutherford
Stream Characteristic:
Regional Office:
Asheville
USGS. #
Requestor:
Robson
Date:
Date of Request:
3/2/93
Drainage Area (mi2):
0. 1 (Estimated)
Topo Quad:
F11NW
Summer 7Q10 (cfs):
0.0 (Estimated)
Winter 7Q10 (cfs):
0.0 (Estimated)
Average Flow (cfs):
0.0 (Estimated)
30Q2 (cfs):
0.0 (Estimated)
IWC M:
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
Facility requesting renewal of NPDES permit. Plant outfall #001 contains domestic waste and
discharges into stream with 7Q10/30Q2= 0 cfs. This outfall #002 discharges kiln condensate.Will
renew #002 limits with QW, temperature, and pH.
Special Schedule Requirements and additional comments from Reviewers:
Recommended
Reviewed by
Instream A;
Regional
Permits
ac.
Date: 4/8/93,
Date:--�3
Date: 7 ��
Date:
RETURN TO TECHNICAL SERVICES BY: MAY 11 1993
s APR 14 M
VfiNTE.R. 0UALiTY SECTi0

2
Existing Limits:
Wasteflow (MGD):
pH (SU):
Temperature (C):
PARAMETERS
Monthly Average
Summer Winter WQ or EL
0.026
6-9
monitor
Recommended Limits:
Monthly Average
'
Summer Winter WQ or EL
Wasteflow (MGD):
0.026
pH (SU):
6-9
Temperature (C):
monitor
Limits Chanaes Due To: Parameter(s)'Affe
Change in 7Q10 data
New regulations/standards Fecal Coliform.
New procedures
New facility information
Change in stream classification
Other
Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
X_ No parameters are water quality limited, but this discharge may affect future allocations.

3
INSTREAM MONITORING REQUIREMENTS
Upstream Location:
Downstream Location:
Parameters:
Special instream monitoring locations or monitoring frequencies:
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
Adequacy of Existing Treatment
Has the facility dernoyStrated. the ability to meet the proposed new limits with existing treatment
facilities? Yes No
If no, which parameters cannot be met?
Would a "phasing in" of the new limits be appropriate? Yes No
If yes, please provide a schedule (and basis for that schedule) with the regional
office recommendations:
If no, why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) (Y or N)
(If yes, then attach schematic, toxics spreadsheet, copy of model, or, if not modeled, then old
assumptions that were made, and description of how it fits into basinwide plan)
Additional Information attached? (Y or N) If yes, explain with attachments.

FACT SHEET FOR WASTELOAD ALLOCATION
Request # 7349(,gq
Facility Name:
Broyhill Furniture Industries -Rutherford Plant
NPDES No.:
NC0005461
Type of Waste:
Domestic - 100% 01'1�
Facility Status:
Existing
Permit Status:
Renewal
Receiving Stream:
UT Catheys Creek
Stream Classification:
WS-V
Subbasin:
030802
County:
Rutherford
Stream Characteristic:
Regional Office:
Asheville
USGS #
Requestor:
Robson
Date:
Date of Request:
3/2/93
Drainage Area (mi2):
0.4 (Estimated)
Topo Quad:
F11NW
Summer 7Q10 (cfs):
0.0 (Estimated)
Winter 7Q10 (cfs):
0.0 (Estimated)
Average Flow (cfs):
0.3 (Estimated)
30Q2 (cfs):
0.0 (Estimated)
IWC (%):
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
The facility discharges into a receiving stream which has a 7Q10/30Q2--0 cfs. Removal of the
discharge will be required if a more environmentally sound alternative is available. An engineering
report evaluating alternatives to discharge is due 180 days prior to permit expiration along with the
permit renewal application. As part of the report, the cost of constructing a treatment plant at the
discharge point to meet limits of 5 mg/1 BOD5, 2 mg/1 NH3, 6 mg/1 DO, and 17 µg/1.chlorine must
also be included if there are no alternatives to a surface water discharge. Upon review of the
results of the engineering report, the Division may reopen and modify this NPDES permit to
require removal of the discharge, modified treatment designs, and/or revised effluent limitations
within a specified time schedule.
Special Schedule Requirements and additional comments from Reviewers:
Recommended by:
Date:_4/8/93
Reviewed by
Instream Assessment: Date:R�� 3
Regiona*ngineeding:
r: �. Date / 9
Permits Date:
RETURN TO TECHNICAL SERVICES BY: MAY 1 19I rn re M r
ti

�n
2
Existing Limits:
Wasteflow (MGD):
BOD5 (nig/1):
NH3N (mg/1):
DO (mg/1):
TSS (mg/1):
Fecal Col. (/100 ml):
pH (SU):
Residual Chlorine (µg/1):
Temperature (C):
Recommended Limits:
Wasteflow (MGD):
BOD5 (mg/1):
NH3N (mg/1):
DO (mg/1):
TSS (mg/1):
Fecal Col. (/100 ml):
pH (SU):
Residual Chlorine (µg/1):
Temperature (C):
Limits Changes Due To:
PARAMETERS
Monthly Average
Summer Winter
0.026
30
monitor
nr
30
1000
6-9
monitor
monitor
Monthly Average
Summer Winter
0.026
30
monitor
nr
30
200
6-9
monitor
monitor
WQ or EL
WQ or EL
1910
Parameter(s) Affected
Change in 7Q10 data
New regulations/standards Fecal Coliform
New procedures
New facility information
Change in stream classification
Other
Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
•O
X_ No parameters are water quality limited, but this discharge may affect future allocations.

INSTREAM MONITORING REQUIREMENTS
Upstream Location:
Downstream Location:
Parameters:
Special instream monitoring locations or monitoring frequencies:
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
Adequacy of Existing Treatment
Has the facility d onstrated the ability to meet the proposed new limits with existing treatment
facilities? Yes No
If no, which parameters cannot be met?
Would a "phasing in" of the new limits be appropriate? Yes No
If yes, please provide a schedule (and basis for that schedule) with the regional
office recommendations:
If no, why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) (Y or N)
(If yes, then attach schematic, toxics spreadsheet, copy of model, or, if not modeled, then old
assumptions that were made, and description of how it fits into basinwide plan)
Additional Information attached? (Y or N) If yes, explain with attachments.

SOC PRIORITY 00JECT: No4�
TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
ATTENTION: Susan Robson
DATE: February 10, 1993
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY Rutherford
PERMIT NUMBER NC0005461
PART I - GENERAL INFORMATION
1..- Facility and Address: Broyhill, Rutherford Furniture
Post Office Box 69
Rutherfordton, N. C. 28139
2. Date of Investigation: 9206.03
3. Report Prepared Bye James R. Reid
4. Persons.Contacted and Telephone Number: Dean Conner
704-287-4276 .
5. Directions to Site: From the intersection of US Highway 221 and SR
1535 in Rutherford County, travel East on SR 1535 approximately
0.1 mile.
6. Discharge Point(s), List for all discharge points:
Latitude- Longitude:
Pipe-001 35 24' 37" Pipe 001 81 57' 31"
Pipe 002 350 24' 15" Pipe 002 810 57' 35"
Attach a USGS map extract and indicate treatment facility site and
discharge point on map.
U.S.G.S. Quad Name Rutherfordton_North, N. C.
7. Site size and expansion area consistent with application? Yes
8. Topography (relationship to flood plain included): Flat terrace
above flood plain.
Page 1
uJ

9. Location of nearest dwelling: Approximately 2000 feet.
10. Receiving stream or affected surface waters: 001 - Unnamed
tributary to Catheys Creek. 002 - Dry ditch to Hollands Creek.
a. Classification: 001 - WS V. 002 - WS IV
b. River Basin and Subbasin No.: BRD 030802
c. Describe receiving stream features and pertinent downstream
uses: Agricultural support, wildlife, secondary recreation.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted 0.026 MGD (Ultimate
Design Capacity)
b. What is the current permitted capacity of the Wastewater
Treatment facility? 0.026 MGD
C. Actual -treatment capacity of the current facility (current
design capacity 0.026
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two years:
None
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: Existing, Pipe
001, consists of 2 extended aeration package ,plants in
parallel followed by .effluent polishing and chlorination.
Existing, Pipe 002, is kiln condensate.
f. Please provide a description of proposed wastewater treatment
facilities:
g. Possible toxic impacts to surface waters: None known or
anticipated.
h. Pretreatment Program (POTWs only):
in development approved
should be required not needed
2. Residuals handling and utilization/disposal scheme: Septage hauler
with disposal in the Town of Spindale's wastewater treatment
plant.
a. If residuals are being land applied, please specify DEM'.
Permit Number
Residuals Contractor
Telephone Number
b. Residuals stabilization: PSRP PFRP OTHER
Page 2

c. Landfill:
d. Other disposal/utilization scheme (Specify):
3. Treatment plant classification (attach completed rating sheet): II
4. SIC Codes(s): 2511
Wastewater Code(s) of actual wastewater, not particular'facilities
i.e., non -contact cooling water discharge from a metal plating
company would be 14, not 56.
Primary 02 Secondary 15
Main -Treatment Unit Code: 06507
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds
-or are any public monies involved. (municipals only)?
2. Special monitoring or limitations (including toxicity) requests:
3. Important SOC, JOC, or Compliance, Schedule dates: (Please
indicate) N/A
Date -
Submission of Plans and Specifications
Begin Construction
Complete Construction
4. Alternative Analysis Evaluation: Has the facility evaluated all
of the non -discharge options- available. Please provide regional
perspective for each option evaluated.
Spray Irrigation:
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
5.- 'Other Special Items: Please note; during the term of the permit
which became effective July 1, 1988, the industry eliminated pipe
002 (non -contact cooling water) and removed the boiler blowdown
waters from pipe 003.
Page 3

Pie -designations in this staff report describe the existing
wastestreams. Pipe 001 is the discharge from the package plants
receiving domestic wastes and non -contact cooling waters. (The
flow from what was formerly pipe 002 has been directed to the
package plants' influent.) Pipe 002 consists only of kiln
condensate and discharges at the location formerly designated pipe
003. (The boiler blowdown waters formerly discharged, along with
the kiln condensate, through pipe 003 have been piped to the
package plants' influent). �-_
PART IV - EVALUATION AND RECOMMENDATIONS
Renew permit noting pipe designations described in preceding
section.
z _Z /
Signature of Report Preparer
ater Quality"Regional Supervisor
A�_
Date
Page 4

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vi
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i
on
iv
42
li e s
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00,
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It
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v �
1410 tl 110000 FEET 411 412 J =,, csr CIry e M, 57'36' '"`1 ' ''r` ' % M, ' 41d ' fR11T.

wX ! II4(; ;)-CAI I -
Name of Plants 41-0�ro
FOH (:LASSIFICATION OF
In
LLS
v 2n i 7/7) ,�
Owner or Contact Person:
Mailing Address:
C
County: r�,,AerAVWJ_ Telephone:_ w -26'9- �12&
NPDES Permit No. NC000,!�NlvNondisc. Per. No.
IssueDate: J vie, I I `'rR-9 Expiration Date:-"j-(-j n e 30. I�tS 3
Existing Facility_ ,/ New Facility
Rated BY: -,,Al ki-i 1) Date:_
Reviewed (Train..,-& Cert.) Reg. Office/Q/
Reviewed (Train. & Cert.) Central Office
ORC_ CA (�0�1;y�{� Grade
Plant Class: circle one) ) oil
III IV: Total;�oints. ,,..
ITEM POINTS
(1) Industrial._ Pretreatment -Units and/or
Industrial Pretreatment Program
(see definition No. 33) 4
(2) D SI �N FLOW OF PLANT IN GPD . .
(not applicable to non -contaminated cooling waters, sludge
;,. handhng,;facilities for 'waler ptirfflcahon plants, totally
;: closed.cycleflaystems:.(def:zNo i11}; an facilities'-`
constshng.=only of=Item`Items"(4) (d) and (11) (d))
0 -- 20.000 ..
- ..........................
20.001 50.000 1
..-:50 001:,--:,.:100,000
3
100,00i - 250.000........ i�
250.001 — 500.000.... 4
500,001:;-=1,000.000 ........-. 5
<r 8
1,000,001 -- 2;000,000 :....... - 10
2,000,001 (and up) - rate 1 point additional for each
?� *- 200,000 9Pd 'capacity 'up' to a
. i��ss i41 maximum of 3p
Design Flow (gpd) ;
(3) PRELIMINARY; UNITS (see definition no. 32)
(b) .Mechanical Screens. Static .Screens or''
:Comminuting, Devices .. - .2
,c, Grit Removal ............... ................ 1
or,
(d) Mechanical or Aerated Grit Removaf 2
(e) Flow Measuring Device .......................
or
(f) Instrumented Flow Measurement .............. 2
(9) Preaeration................................ 2
(h)
Influent Flow -Equalization
W
.................... 2
Grease or Oil Separators - Gravity
.......... 2
Mechanical .......... 3
6)
Dissolved Air Flotation. 8
Prechlorinalion
.............................. 5
(4) PRIMARY TREATMENT UNITS
(a)
Septic Tank (see definition no. 43) .............. 2
(b)
Imhoff Tank ....,.................... 5
(c)
. .........
Primary Clarifiers
(d)
................ . . . . .. . ..... 5
Settling Ponds or Settling Tanks for Inorganic
Non -toxic Materials (sludge handling facilities
for %valer purification plants, sand, gravel,
stone; and other mining operations except.
recreational activities such • as gem or gold
mining) 2
(5) SECONDARY TREATMENT.UNITS.
(a) Carbonaceous Slagei<
(f)Aeration - High<Purfty Oxygen System ... • •
20
Diffused AiplSyslem
Mechanical Air System (fixed,
floating, or. rotor)
8
,.: -Separate=Sludge'Reaeialion.,-,.;. •°;
3
(ii) Trickling, -.Filter
High Rate ..:.........:; `'? 5..`.
Standard Rate
7
........:....
5
Packed Tower... ; • :_ :=; ;:...
(iii) Biological:.Aerale& Filter : -or- Aerated='';;':;
5
Biological Filter .....................
(iv) Aeraled Lagoons
10
..........
; --10
i •. .
(v) Rotating Biological. Contactors :.....' , .. ,
10
(vi) Sand Fillers-
intefmtttent biological,..
.2
recirculating %1016.61cal
3
(vii) Stabili`zaiion-Lagoons .
(viii)Clarifier ..... `
••
5
Single stage eystem for combined
�(ix)
carbonaceous removal of'80D and ''`
nilrogenouv+ -rfiov2l-".by f
.nitrificatfori.
(see def:<N0." 2) `(Points for' this item-
have to be iri''addiiit rn fo; iterris '(5)' (a)"
.(f) through-(5)'-(a) (vi�jt -!' :.:: :' .::'...
8
(x) Nutrient additions to enhance BOD '
removal.: - ...'.�... ..
5
(xi) Biological. Culture ('Super Bugs-) addition
to enhance 'organic'compo ind'removal :....
5
(b) Nitrogenous Stage
(i) Aeration - High Purfty Oxygen System '...:. '
20
Diffused Air System .. : ,
1 0
MechSanical,'Air System (fixed; '.'
-
floating. or rotor) •...... ......
8
Separate Sludge Reaeralion .....
3
(ii) Trickling Filler -
High Rate ..............
7
Standard Rate ............
5
Packed Tower........,...
5
(iii) Biological Aerated Filler or Aerated
Biological Filter ................. . .. . . . . .
(iv) Rotating Biological Contactors
10
.:....... , ..
(v) Sand Filter-
10
inlermitlenl biological . . . . . . . .
2.
recirculating biological . . . . . . ..
3
(v i) Clarifier . ..............................
5

r.
6) TC-RTIARY OR ADVANCED TREATMENT UN
(a) Activated Carbons Beds -
without carbon regeneration . .... . ........ _
with carbon regeneration .. . ................ .
(b) Powdered or Granular Activated Carbon Feed -
without carbon regeneration
with carbon regeneration ............. . .... .
(c) Air Stripping ........... . ..................
(d) Denitrificalion Process (separate process) . .. . .
(e) Electrodialysis ............................... ...........
(f) Foam Separation ...........
..................
(g) ton Exchange .........................
(h) Land Application of Treated Effluent
(see definition no. 22b) (not applicable for
sand, gravel, slone 'and other similar mining
operations)
(i) on agriculturally managed sites (See def.
No. 4) ...................................
(ii) by high rate infillralion on non -agriculturally
managed sites (includes rotary distributors
and similar fixed nozzle systems) ...........
(iii) by subsurface disposal (includes low pressure
pipe systems and gravity, systems except at,
plants consisting of..septic' tank and nitrifica-
tion lines only) .............................
(7 Microscreens...........�............
(j) Phosphorus Remo -/al by Biological Processes
T
(10) CHEMICAL ADD1i'rvN SYSTEM (S) (See definition No. 9)
5 (not applicable to chemical additions rated as item
1 5 (3) (I)• (5) (a) (xi), (6) (a). (6) (b). (7) (b). (7) (e).
(9) (a), (9) (b), or (9) (c) 5 points each: List:
5 5
15 ..... 5
5 5
10 ..... 5
5 (11) MISCELLANEOUS UNITS
5 (a) Holding Ponds, Holding Tanks or Settling Ponds
5 for Organic or Toxic Materials including wastes
c_
from mining operations ._iinlain ing nitrogen and/or
phosphorous compounds in amounts significantly
greater than is common for domestic wastewater .......... 4
(b) Effluent Flow Equalization (not applicable to storage
basins which are inherent in land application systems). 2
10 (c) Stage Discharge (not applicable to storage basins
inherent in land application systems ....................................... 5
(d) Pumps.__ ............... :............._.:._....__„......_.........„........................
(e) Stand -By Power Supply ............. _................................................... 3
(f) Thermal Pollution Control Device ............................................ 3
4 TOTAL POINTS
5
(See def_ No. 26) 20 CLASSIFICATION
(k) Polishing Ponds - without aeration ....... CZZ:::)
With aeration .......... 5
(1) Post Aeration - cascade .............. 0
diffused or mechanical ... 5
(m) Reverse Osmosis .......
(n) Sand or Mixed -Media Filters = low rate ........... 2
high rate .......... 5
(o) Treatment processes for_- removal of metal or
cyanide ........ 15
.............................
(p) Treatment processes for removal of toxic
materials other than metal or cyanide ......... 15
SLUDGE TREATMENT
(a)
Sludge Digestion Tank -.Heated ...............
10
Aerobic.......
Unheated...... ...... .
(b)
Sludge Stabilization (chemical or thermal) .......
5
(c)
Sludge Drying. Beds -.Gravity .................
2
Vacuum Assisted ,_ ...
5
(d)
Sludge Elutdation . ..:..... _.. ............
5
(e)
Sludge Conditioner (chemical or thermal) ........
5
(f)
Sludge Thickener (gravity) ... _ ..................
5
(g)
Dissolved Air.. Flotation ;Unit .
(not applicable to a_unit rates as (3) @ .........
8
(h)
Sludge Gas Utilization' (including gas storage) ....
*,'Aerated.....
2
(i)
Sludge -Holding Tank,-. . . . . . . .
5
Non -aerated ............
2
G)
Sludge Incinerator - (not including activated
carbon regeneration). .....
10
(k)
Vacuum Filler, Centrifuge or .Filter. Press or other
similar dewatering devices ....................
10
(8).. SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons .........................................
2
(b)
Land Application (surface.and subsurface)
(see definition 22a) _
-where the facility holds the land app. permit ...
10
-by contracting to a land application operator who
holds the land application permit .. . . . . . . . . . . . . <;:2�_
-land application of sludge by a contractor who does
not hold the permit for the wastewater treatment
facility where the sludge is generated .........
10
(c)
Landfilled (burial) ..... . ...... . ............. . ..
5
(9) DISINFECTION
(a)
Chlorination ......... . .............. .....
(b)
Dechlorinalion ........... . ... . . . . .....
5
(c)
Ozone ..............................
5
(d)
Radialion ..... . ....... . . ...........
5
Class I ........ ......... :.............._...._ _ _ 5 25 Points
Class II .............. „.................... _ „ __ 26- 50 Points
Class III ....... _...._............
........... ...... .„..„/ 51- 65 Points
Class IV.........„ ......................._. _ _ 66- Up Points
Facilities having a rating, of one .through loth points, - inclusive,
do not require a certified operator::,.,Classificaliori,-:of-.all, other
facilities requires a,;comparable grade operator° in' responsible
charge.
Facilities having an activated sludge process will be assigned
a minimum classification of Class 11.
Facilities having treatment processes for the- removal of metal
or cyanide will be assigned a minimum classification of Class If.
Facilities having treatment processes for the biological removal
of phosphorus will be assigned. a. minimum classification of Class
In -plant processes and related control equipment which are an
integral part of industrial production shall not be considered waste
treatment. Likewise, discharges of wastewater from residences
having a design flow of 1.000 gpd or less,- shall -!not -.be subject to
rating.
ADDITIONAL COMMENT

State of North Carolina
Department of Environment, Health and Na
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27604
James B. Hunt, Jr., Governor
David Stout
Broyhill Furniture Industries
One Broyhill Park
Lenoir, NC 28633
Dear Mr. Stout
Jonathan B. Howes, Secretary
January 20, 1993
Subject: NPDES Permit Application
NPDES Permit No.NC0005461
Rutherford Plant
Rutherford County
This is to acknowledge receipt of the following documents on January 5, 1993:
Application Form
Engineering Proposal (for proposed control facilities),
Request for permit renewal,
Application Processing Fee of $200.00,
Engineering Economics Alternatives Analysis,
Local Government Signoff,
Source Reduction and Recycling,
Interbasin Transfer,
Other ,
The items checked below are needed before review can begin:
Application Form ,
Engineering proposal (see attachment),
Application Processing Fee of
__. Delegation of Authority (see attached)
Biocide Sheet (see attached)
Engineering Economics Alternatives Analysis,
Local Government. Signoff,
Source Reduction and Recycling,
Interbasin Transfer,
;Other
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North -Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

If the application is not made complete within thirty (30) days, it will be.
returned to you and may be resubmitted when complete.
This application has been assigned to Susan Robson
(919/733-5083) of our Permits Unit for review. You will be advised of -any
comments recommendations, questions or other information nece-ssary for the
review of the application.
I am, by copy of this letter, requesting that our Regional Office
Supervisor prepare a staff report and recommendations regarding this
discharge. If you have any questions regarding this applications,
please contact the review person listed above.
Sincerely,
CC• Asheville Regional Office
J(.1.061-\ R4-0-&-rN
�
Coleen H. Sullins; P.E.

� �Ns
y5TA7go
puM
State of North Carolina
Department.of Environment, Health, and Natural Resources
Asheville. Regional Office
James G. Martin, Governor '
William W. Cobey, Jr., Secretary
DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
November 4, 1992
Mr. Max Smallwood, Plant Manager
Rutherford Furniture Company
Post Office Box 69
Rutherfordton, North Carolina 28139
Dear Mr. Smallwood:
Ann B. Orr
Regional Manager
Subject: Compliance Sampling Inspection
Status: In Compliance
Rutherford Furniture Company
Wastewater Treatment Facilities
NPDES Permit Number NC0005461
Rutherford County
An inspection of the wastewater treatment system (discharges
001, 002, and 003) serving Rutherford Furniture Company was conducted
on October 13, 1992. Based upon observations made and samples
collected,the system was judged to be in compliance with. the
requirements of its. NPDES Permit Number NC0005461. A copy of the
inspection report and lab analysis is enclosed for your records.
To help maintain a state of compliance,'the following suggestions
are offered:
(1) Maintain an appropriate Operator's log documenting
operator's visits, chlorine feed rates and residuals, flow
rates, operation and maintenance, and any unusual events at
the treatment plant.
(2) Improve maintenance and cleaning of the effluent polishing
pond would help to prevent problems that could be caused by
a high flow or plant upset. It would also-, improve plant
aesthetics by removing unsightly conditions.
Review of the monthly monitoring data from September 1991 till
August 1992, indicates no violations. The facility has two other
discharges listed in the permit, pipes 002 and 003. On -site
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 • Telephone [phone]
An Eoual Onoortunity Affirmative Action Emnlover

i2
inspection revealed a trace flow coming from pipe 003 and an estimated
flow of 1 to 2 gpm from pipe 002.- No accumulation of.foam-nor solids
was observed at any of the discharge points.
Thank you for the opportunity to visit your -facility. Mr. Dean
Conner's time and assistance in conducting the inspection is
appreciated. If there are any questions concerning this report,
please contact me at 704/251-6208.
Sincerely,
Donald R. Price
Wastewater Consultant
Enclosure
xc: Dean Conner
James R. Reid

United States Environmental Protection Agency
Washington, D. C. 20460
Form Approved
NPDES Compliance Inspection Report
OMB No. 2040-0003
Approval Expires?-31-65
Section A: National Data System Coding
nsaction Code
1(NJ 2LJ 3WIC 101010I.s'M6
NPDES yr/mo/day Inspection Type Inspector Fac Type
11 14 12 1 / I01! N 117 ,I� 1sUS 20u
IIIIIIIIIII11111111111�111111`-IIII'IIIIIIIIIIIII
Remarks
Reserved Facility Evaluation Rating BI OA -------------------Reserved------------------ 66
67uL_Lj 69 70:,� 71JEJ 721M 73W 74 .7d I I I I 1 180
Section B: Facility Data
appme and Lo��tion of Facility Inspected
f�.�l+keV 0,,? FAvmffArtC �roy �rs'�
ime
d0 ❑ AM PM
EExiiTime/Date
Permit Effective Date
Tut 1%98'S
P;�, , Box 6,9
�e (i
RHtf,er]�ore�to�►
/�, C, oZ 8'f39
0 P o (3
Permit Expiration Date
1'uHe 30j 199:3
ame(s) of On -Site Representative(s)
Title(s)
Phone No(s)
DeAIA ComjW
mai►IfPXal1ce RepIr
�l0Y)aS'7—V-?7,Q
ame, Address of Responsibl
M 4x srha /!tA/c► 17
Official
Ti
h jy! et sLaj e i-
5aw�c GtS Q�p(l�
Phone No.
'��� 7oK
Contacted
_❑
o�a /�
Yeslu rho
Section C: Areas Evaluated During Inspection
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated)
' Permit
(�(
-Flow Measurement
Al
Pretreatment
Operations & Maintenance
Records/Reports
Laboratory
Compliance Schedules
Sludge Disposal
Facility Site Review
S
Effluent/Receiving Waters
1551
Self -Monitoring Program
Other:
Section D: Summary of Findings/Comments (Attach additional sheets i/necessary)
SAMPLE R E
'ctv'awlerer
—
Su L T,s 002
Qerv►�►i+ l,'wt;ts Sarn+P/e ,Pr°sa/�s �ip� •
- 0r Sz A
`� OD
V. y /it �� Gf�
3�/yt5 `"�/1 j
,
Ts s
20/'Vs .��/� 5' , /Z-
're CA l
�v li �o
' /000 /f 00 W / 0A 00 w1 r ` o�
- IY10 �t t t
clz 4d lztvvol'-
►'�
A0� less 74k ivlc-ve-e4 s//e
4?� .�.. ft:
vtA ,t eiiCe—
ltoV /D�i Sh►�
6,0more
�j Oi7�
h o t' 1;'V' cc(
ii 93
K o i-- i wv r f eQ 5, -3 t,,j 14
i e(s) and Sigrlature(s) of inspectors)
Agency/Office/Telephone
Date
APO 70Y 2 51 6 aOe�
gnature of Reviewer
Agency/Office
Date
n
C
r
No d
Regulatory Office Use Only
;tion Taken
ate
r
Compliance Status
El
Noncompliance
Compliance

DIVISION OF ENVIRONMENTAL MANAGEMENT WATER QUAL -LAB FORM (DM1)
0
COUNTY PRIORITY SAMPLE TYPE �-
RIVER BASIN ❑AMBIENT ❑ QA ❑ L�/STREAM EFFLUENT -
REPORT TO: RO RO MRO RRO WaRO WIRO WSRO TS
AT BM EI-C--OMPLIANCEE] CHAIN ❑ LAKE ❑ INFLUENT
Other OF CUSTODY
Shipped by: Bus CgNrier, Staffher EMERGENCY ❑ESTUARY
, 0
COLLECTOR(.S):
Estimated BOD Range: 0- -25/ 5-65/40-130 or 1000 plus
Seed: Yes ElNo❑ 'Chlorinated. Yes Q No ❑ REMARKS:
%"F r M
Pn r-wh rt.. nNr V
Lab Number; //0
Date Received: /0 Time: or 3 0
Rec'd by: 51 From: Bus -Court - _and Del
DATA ENTRY BY-
DATE REPORTED: ZQ
Station/
Date Begin (yy/mm/dd)
Time Begin
Date End
Time End
Depth._DM DB DBM
Value Type'
Composite
Sample T
/-� /3
I
A H L
T' S B
C .GNXX
1
BOD5 310 C, mg/I
2
3
COD High 340 mg/I
COD Low 335 mg/I
4
Coliform: MF Fecal 31616 �to /100ml
5
6
Coliform: MF Total 31504 /100ml
Coliform: Tube Fecal 31615 /100mi
7
Coliform: Fecal Strep 31673 /100ml
8
9
Residue: Total 500 mg/I
Volatile 505 mg/I
10
Fixed 510 mg/I
11
Residue: Suspended 530 mg/I
12
Volatile 535 mg/I
13
Fixed 540 mg/I
14
pH 403 6� units
15
Acidity to pH 4.5 436 mg/1
16
Acidity to pH 8.3 435 mg/1
17
Alkalinity to pH 8.3 415 mg/1
18
19
20
Alkalinity to pH 4.5 410 mg/I
TOC 680 mg/I
Turbidity 76 NTU
Chloride 940 mg/1
Chi a: Tri 3221-7 ug/1
Chi a: Corr 32209 ug/I
Pheophytin a 32213 ug/I
Color: True 80 Pt -Co
Color:(pH ) 83 ADMI
Color: pH 7.6 82 ADM[
Cyanide 720 mg/1
Fluoride 951 mg/1
Formaldehyde 71880 mg/1
^
Grease and Oils 556 mg/l
Hardness Total 900 mg/I
Specific Cond. 95uMhos/cm2
MBAS 38260 mg/I
Phenols 32730 ug/I
Sulfate 945 mgA
Sulfide 745 mg/1
X.
NH3 as N 610 J r mg/l
TKN as N 625 In
NO2 plus NO3 as N 630 mgA
P: Total as P 665 mg/I
PO4 as P 70507 mgA-
P: Dissolved as P 666 mg/1
CdCadmium 1027 ugA
Cr-ChromiunrTotal1034 u9A
Cu-Copper 1042 ug/l •
Ni-Nickel 1067 ug/I
Pb-Lead 1051 ug/I
Zn-Zinc 1092 ug/I
A ilver 1077 ug/I
AI -Aluminum 1105 ug/I
Be -Beryllium 1012 ug/I
Ca -Calcium 916 mlln
Co -Cobalt 1037 ug/I
Fe -Iron 1045 ugA
Li -Lithium 1132 ug/1
Mg -Magnesium 927 mg/I
Mn-Manganese 1055 ug/I
Na-Sodium 929 mg/1
Arsenic:Total 1002 ug/I
Se -Selenium 1147 ug/I
Hg-Mercury 71900 ug/I
Organochlorine Pesticides
Organophosphorus Pesticides
Acid Herbicides
Base/ Neutral Extractable Organics
Acid Extractable Organics
Purgeable Organics (VOA bottle reg'd)
Phytoplankton
ampling Point %
Conductance at 25 C
Water Temperature (
D.O. mg/I
pH
Alkalinity
Acidity
Air Temperature (C)
pH 8.3 pH 4.5
pH 4.5 pH 8.3
94
10
300 .
400 Iff
82244 1431
82243 182242
20
Salinity %
Precipition (In/day)
Cloud Cover %
Wind Direction (Deg)
Stream Flow Severity
Turbidity Severity.
Wind Velocity M/H
can Stream Depth ft.
Stream Width ft.
480
45
132
136
11351
1350
135
64
14

,8/MP
i0/28/92
COMPLIANCE
EVALUATION,ANALY%I%
REPORT
PAGE i
PERMIT--NC0005461
PIPE--OOi
REPORT
PERIOD: 009-9208
LOC
--- E
FACILITY--BROYHILL
FURNITURE INDUSTRIES
DESIGN FLOW--
.0260
CLASS--2
LOCATION--RUTHERFORDTON
REGION/COUNTY--Ol
RUTHERFORD
50058
0000
'
00530
00610
31616
50060
.
000iO
0040(>
MONTH
Q/M�D
BOD
RE%/T%% NH3+NH4-
'
FEC COLI CHLORINE
TEMP
PH
LIMIT F
.0260 F
30.00
F 30.0
NOL
F 1000.0
NOL
NOL
9.0 6.0
91/09
.0090
3.00'
3.2
i.90
5.0
.300
22.00
6.7-6.5
9i/10
.0090
3.75
4.8
3.50
.4.0
.340
20.00
6.8-6.5
91/ii
.0090
2.30
8.0
.50
2.3
^300
20.00
6.8-6.5
9i/i2
.0090
` 8.8O
8.5
.iO
.3
.400
20.00
6.6-6.4
92/0i
.0090
2.60
5.5
.
1110
93.0
.
' .200
i7.00
6.8-6.5
92/02
.0872
2.55
3.5 LE%%THAN
. 2.0
'
.250
i4.0O
6.7-6.3
92/03
.0090
.85
i.5
.13
1.3
.300
15.00
6.6-6.4
92/04
.0100
i.00
3.7
1.70
i.0
.250
i6.00
6.5-6.3
92/05
.0080
.50
3.5
.i0
i.0
^
.400
19.00
6.7-6;4
92/06
.0087
1.25
2.5
.i0
13.3
.350
i9.00
°
6.516.4
92/07
.0i00
iO.5
.30
78.0
.175
18.00
6.6-6.4
92/08
.0i00
1.i0
2.0
1.50
.6
.iOO
i8.50
6.5-6.4
AVERAGE
.0089
2.5i
4.7
.99
i6.8
.280
,
18.20
...........
MAXIMUM
.0iOO
8.80
i615
3.50
93.0
.400
22.00
6.800
MINIMUM
.0072
.50
i.5 LE%%THAN
.3
.100
14.00
6.3O0
UNIT
.
MGD
MG/L
MG/L
MG/L
0006ML
MG/L
DEG.0
%U

ILL G� UR� AND
ooD�ITY �E[,orly
SEP 2 31992
ONISIDN of �k�JOEA
yDORESAUE REE �At K Off GE
,,FC;F-1VF—rJ
Water Quaint Se�fio
September 21, 1992
MAX SMALLWOOD
BROYHILL FURNITURE INDUSTRIES
BROYHILL PARK
LENOIR, NC 28633
Subject: NPDES PERMIT NO. NC0005461
RUTHERFORD COUNTY
Dear Permittee:
SFP r� 1og7
eaille Regional Grp
me, forth Carry �"
The subject permit issued on 6/23/88 expires on 6/30/93. North Carolina
General Statute (NCGS) 143-215.1(c) requires that an application for permit renewal
be filed at least 180 days prior to the expiration date. As of the date of this
letter, the Division of Environmental Management had not received an application for
renewal.
If operation of a discharge or waste treatment facility is to occur after the
permit's expiration date, or if continuation of the permit is desired, it must not be
allowed to expire. A renewal request must be submitted no later than 180 days prior
to the permit's expiration date. Operation of the waste treatment works or
continuation of a discharge after the expiration date would constitute a violation of
NCGS 143-215.1 and could result in assessment of civil penalties of up to $10,000 per
day. If continuation of the permit is desired, failure to request renewal at least
180 days prior to expiration will result in a civil assessment of at least $250.00;
larger penalties may be assessed depending upon the delinquency of the request.
A renewal application shall consist of a letter requesting permit renewal along
with the appropriate completed and signed application form (copy attached), submitted
in triplicate, referenced in Title 15 of the North Carolina Administrative Code (15
NCAC) Subchapter 2H .0105(a). Primary industries listed in Appendix A of Title 40 of
the Code of Federal Regulations, Part 122 shall also submit a priority pollutant
analysis in accordance with Part 122.21. A processing fee must be submitted with the
application. In addition to penalties referenced above, a permit renewal request
received after the expiration date will be considered as a new application and will
require the higher application fee.

Attached is a copy of the fee schedule from 15 NCAC 2B.0105(b). The application
processing fee is based on the design or permitted flow, whichever is appropriate,
listed in the first five categories of facilities. Presently, no facility is allowed
to submit a fee for the general permits listed in the schedule since the Environmental
Protection Agency has not approved the State of North Carolina's general permit. If
the facility covered by this permit contains some type of treatment works, a narrative
description of the sludge management plan must be submitted with the application for
renewal.
The Environmental Management Commission adopted revised rules on October 1, 1990
(attached), requiring the payment of an annual fee for most permitted facilities. You
will be billed separately for that fee (if applicable), after your permit is approved.
The letter requesting renewal, the completed Permit application, and appropriate
fee should be sent to:
Permits and Engineering Unit
Division of Environmental Management
Post Office Box 29535
Raleigh, North Carolina 27626-0535
The check should be made payable to the North Carolina Department of Environment,
Health, and Natural Resources which may be abbreviated as DEHNR.
If there are questions or a need for additional information regarding the permit
renewal procedure, please contact me at telephone number.[phone].
Sincerely,
OCoieenSigned BY
H. Sullins
Coleen Sullins, P.E.
Supervisor, NPDES Permits Group
cc: fAsrh N l ©Wce
Permits and Engineering Unit
Central Files

State of North Carolina
Department of Environment, Health, and Natural Resources
Asheville Regional Office .
James G. Martin, Governor -
William ... Cobg6 Jr., Secretary
DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
June 26, 1992
Mr,., -Max .Smallwood,. Plant Manager
Rutherford Furniture Company
Post Office Box 69
Rutherfordton, North Carolina 28139
Ann B: Orr
Regional Manager
Subject: Compliance.Sampling Inspection
Status: In Compliance
Rutherford Furniture Company'
Wastewater Treatment Facilities
-NPDES-Permit Number NC0005461
Rutherford County
Dear Mr. Smallwood:
An inspection of the 'wastewa.t treatment plant (discharges 001
and 003) serving Rutherford Furniture Company was performed on June 3,
1992. Observations made and samples collected indicated compliance
with the requirements of the Company's wastewater discharge permit.
Sample results and specific comments are contained' in the attached
report.
Mr. Dean Conner's time and assistance during the -inspection are
appreciated. Please contact me at telephone number 704-251-6208 if
there are questions or a need for assistance,.
Sincerely,
James R. Reid
Environmental Chemist
Enclosure
xc : Mr. .Dean POAAAK-]$uilding, 59 Woodfin Place, Asheville, N.C. 28801 • Telephone [phone]
An Equal Opportunity Affirmative Action Employer

Unite%' "tates Environmental Protection '-,ancy
Washington, D.C.
NPDES Compliance Inspection Report
Formed Approved
OMB No.2040-0003
Approval Exp.7/31/85
Section A: National Data Data System Coding
saction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
IINI 2151 3INC0005461 Ill 121920603 117 18ISI 19ISI 20121
ii Remarks
21I_I_I—I—I—I—I—I-I-I—I—I—I—I-I-I—I-I-I-I-I-I-I-i-I-I-I-I—I—I-I-I—I-I-I=I-I-I-I-I-I-I-I—I-I—I66
Reserved Facility Evaluation Rating BI QA------------ Reserved-=---------
57I-I-I-I69 70131 71INI 72INI 73I_I_I74 75I—I-I-I-I-I—I80
Section B: Facility Data
Name and Location of Facility Inspected
Broyhill Rutherford Furniture
P.O. Box.69
Rutherfordton, NC 28139
Name(s) of On -Site Representatives(s)
Dean Conner
Name,Address of Responsible Official
Max Smallwood
same as above
Entry Time(x)am( )pm
10:00
Exit Time/Date
10:50
Title(s)
Title
Plant Manager
Permit Effective Date
880701
Permit Expires/Date
930630
Phone No(s)
704-287-4276
Phone No. same as above lContact Yes_No_X_
Section C: Areas Evaluated During Inspection
(S=Satisfactory, M=Marginal, U=Unsatisfactory, N=Not Evaluated)
_S_ Permit _S_ Flow Measurement _N_ Pretreatment _S_ Operation & Main.
_N_ Records & Reports _N_ Laboratory _N_ Compliance Sch. _N_ Sludge Disposal
_S_ Facility Site Rev. _S_ Eff/Receiving Waters _S_ Self -Monitoring Other:
Section D: Summary of Findings/Comments(Attach additional sheets if necessary)
SAMPLE RESULTS
Parameter PermitLimit SampleResults
BOD
30 mg/l
1.4
mg/1
Discharge 003 was being absorbed into the
TSS
30 mg/l
2.0
mg/l
ground prior to reaching surface waters.
Fecal
Coliform 1000 counts
<10
counts
003 .flow estimated @ 1-2 gpm.
PH
6-9 Std units
5.4
Std units
C12 >2.2 mg/l (The operator adjusted cl2 feed downward during insp)
Dissolved 0 2 5.1 mg/1
Temp 18° C
Dissolved 02 in aeration basins was 3.7 mg/1 and 1.0 mg/]. respectively.
Name(s)
James R.
(s) of Inspec�;pr(s)
Agency/Office/Telephone
NC-DEHNR/ARO/704-251-6208
S' atur-,6f Reviewer Agency/Office/Telephone
7dZa`/-Gdycf
Regulatory Office Use Only
Date
Date
eczion iaxen
Date
Compliance Status
—INoncomp. I&'IComp.

For Lab Use ONLY
DIVISION 97VIRONMENTAL MANAGEMENT., WATER QUAL,�y FIELD -LAB FORM (DM1)
COUNTY ti . PRIORITY' ', �)+ SAMPLE TYPE
RIVER BAST
REPOR O: ARO F O,MRO RRO WaRO WiRO �WSRO �T .�f 00 Faa�*' ❑ QA ❑ STREAM EFFLUENT
1.AT B COMPLIANCE ❑ CHAIN ❑LAKE ❑`INFLUENT
Other ( OF CUSTODY
Shipped by: B ..,Staff' ther ❑EMERGENCY ❑ STUARY .
COLLECTOR(S): "I 'STATION LOCATION:
Estimated BOD�Rann6e- 0-5/5 25/25-65/40-130 or 100 plus „ �7
Seed: Yey'C7—No❑ Chlorinated: No REMARKS oC
Station "''' :' is>; D Begin (yy/mm/dd) Time Begin Date End Time End Dept D B
1 135 310.;;, - mg/(
2 COD High 340 mg/I
6
7
10
12
13
15
l6
17
18
19
20
COD Lotii`v335,, ,: mg/1
liform :MF Feca1.S1616 O /loom!
Coliform-'MF Total 31504` z, :`.w'; "' /loom!
Collform �++Tube Feca1;'31615-•:,`'4. /loom! '
Coliform:;F -6 Strej"311 73 ;' /100ml
Residue:;Total'500 r > -•
j =+Volatile 505- — - mg/I
'ar;;� ki3d.510i mg/I
esidue`^.Suspended.530 mg/I
mg/I
Fixed 546 , .• mg/1
units
Acidity;to pH 4.5 436 ` *' mg/I
Acidity to pH 8.3 435 mg/1
Alkalinity to pH 8.3,415'` .mgA
Alkalinity to pH 4.5 410' mg/I
TOC 680 = mgA
Turbidity,76 u ; NTU
Chloride 940
mg/1
Lab Number: ��
3
Date Received:
—��•— 4,2. Time: t/-G-
Rec'd by: ��
nC)
From: Bus-Courierd Del
DATA ENTRY BY:
� u G—P CK: /F
DATE REPORTED:
i f 0
DBM I Value Tytpie L I Composite B I Sampl
NH3 as N 610 mg/I
TKN as N 625 mg/1
NO2 plus NO3 as N 630 mg/I
P: Total as P 665 mg/I
PO4 as P 70507 mgA
P: Dissolved as P 666 mg/1
Cd-Cadmium 1027 ug/I
CrChromium:Tota11034 ug/I
Cu-Copper 1042 ug/I
Ni-Nickel 1067 ug/I
Pb-Lead 1051 ug/I
Zn-Zinc 1092 ug/I
Ag-Silver 1077 ug/I
Al -Aluminum 1105 ug/I
Be -Beryllium 1012 ug/I
Ca -Calcium 916 mg/I
Co -Cobalt 1037 ug/l
Fe -Iron 1045 ug/I
Li -Lithium 1132 ug/l
Mg -Magnesium 927 mg/I
Mn-Manganese 1055 ug/l
Na-Sodium 929 mg/I
Arsenic:Total 1002 ug/l
Se -Selenium 1147 ug/l
Hg-Mercury 71900 ug/l
Organochlorine Pesticides
Organophosphorus Pesticides
Acid Herbicides
Base/ Neutral Extractable Organics
Acid Extractable Organics
Purgeable Organics (VOA bottle reg'd)
Phytoplankton
ampling Point %
Conductance at C
'�
Water Temperature
D O' mgA -
pH
Alkalinity
Acidity
y
Air Temperature (C)
Pe
s-.
pH 8.3 pH 4.5
pH 4.5 pH 8.3
*{
1
94
)
lo., . '
300;` .. •.'' ' : "
400:
82244 431
82243 182242
20
Salinity %
Precipition 0n/day)
Cloud Cover %
Wind Direction (Deg)
Stream Flow Severity
Turbidity Severity
Wind Velocity M/H
can Stream Depth ft.
Stream Width ft.
480
145
32.-
136
11351
1350
135
64 14

State of North Carolina
Department of Environment, Health, and Natural Resources
Asheville Regional Office
James G. Martin, Governor Ann B. Orr
William W. Cobey, Jr., Secretary Regional Manager
DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
August 7, 1997-
Mr. Max Smallwood, Plant Manager
Rutherford Furniture Company
Post Office Box 69
Rutherfordton, North Carolina 28139
19
Subject: Compliance Sampling Inspection
Status: In Compliance
Wastewater Treatment Facilities
Rutherford Furniture Company
PDES Permit Number NC0005461
utherford County
Dear Mr. Smallwood:
An inspection of the wastewater t eatment plant (discharges 001
and 002) serving Rutherford Furniture Company was performed on June 27,
1991. Observations made and samples collected indicated compliance
with the requirements of your wastewater discharge permit. Sample
results and specific comments are contained in the attached report.
Mr. Dean Conner's time and assistance during the inspection are
appreciated. Please contact me at telephone number 704-251-6208 if
there are questions or a need for assistance.
Sincerely,
James R. Reid
Environmental. Chemist
Enclosure
xc: Dan Ahern, EPA
Mr. Dean Conner
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 9 Telephone [phone]

United,5- .ttes Environmental. Protection
Washington, D.C.
NPDES Compliance Inspection Report
.icyFormed Approved
OMB No.2040-0003
Approval Exp.7/31/85
Section A: National Data Data System Coding
_ansaction Code NPDES yr/mo/day Inspect -Jon Type Inspector Fac Type
11NI 2151 3INC0005461 Ill 121910627 117 1.8ISI 19ISI 20121
Remarks
21I---------------------------------------------�-I66
Reserved Facility Evaluation Rating BI QA------------ Reserved---.--------
7I-I-I-I69 70131 71INI 72INI 73I_I_I74 75I_I-I-I-I-1-I80
Section B: Facility Data
Name and Location of Facility Inspected
Broyhill Rutherford Furniture
P.O. Box 69
Rutherfordton, NC 28139
Name(s).of On -Site Representatives(s)
Dean Conner
Name,Address of Responsible Official
Max Smallwood
same as above
Entry Time( )am(X)pm
1.: 30
Exit Time/Date
2:15 910627
Title(s)
Title
Plant ManagFr.
Permit Effective Date
880701
Permit Expires/Date
930630
Phone No(s)
704-287-4276
Phone No. same as above lContact Yes_No_X_
Section C: Area; Evaluated During Inspection
(S=Satisfactory, M=Marginal, U=Unsatisfactory, N=Not Evaluated)
_S Permit _S_
_S_ Records & Reports _N_
_S_ Facility Site Rev. _S_
Flow Measurement
Laboratory
Eff/Receiving Waters
_N_ P.r.etreatment
_N_ Compliance Sch.
_S_ Self -Monitoring
_S_IOperation & Main.
_N_ISludge Disposal
Other:
Section D: Summary
of Findings/Comments(Attach additional sheets
if necessary)
SAMPLE RESULTS
Parameter PermitLimit
SampleResults
BOD 30 mg/1
1.6 mg/1
l
TSS 30 mg/1
3.0 mg/1
Fecal Coliform 1000 counts
150 counts
PH 6-9 Std units
6.8 Std units
Temp. 2.80 change
2.00 change (between
up and downstream sampling points)
Dissolved 0 in aeration basins
was 4.5 mg/1 and
2.7 mg/1 respectively.
Maintain careful
oversight of dissolved 02
levels to insure that excessive. solids do not
escape to the
polishing pond as a result
of the high 02 levels.
Operat._ion and maintenance appeared good.
Va s) & Signature(s) Inspectors) Agency/Of fi_ce/'T'eIephone
JXmej R. Reid
c- _26�1-2s1-(QZg
i ure of Rev' Agency/Offi.ce/7'eleph0
Regulatory Off i-ce. Use Oi -.y
Date
Date
q lql, I
U/ /
Action Taken
Date. --
Compliance
-INoncomp
Sta us
Comp.

DIVISION OF ENVIRONMENTAL MANAGEM$ T' W 1 For Lab Use ONLY
COUNTY'
,. ATER QUALITY FIELD -LAB FORM (DM1)
J. .,.. ..
PRIORITY SAMPLE TYPE
RIVER 8AS1N
: REPORT T ARO F O MRO RBO'WaRO W1R0 WSRO TS ❑AMBIENT ❑ QA
❑STREAM
DENT
Other AT
Ot-
- OMPLIANCE ElCHAIN
❑ LAKE
❑ INFLUENT
\ OF CUSTODY
❑ EMERGENCY
.:
❑ ESTUARY
Shipped by: Bus Course �Staffi`they
COLLECTOR( )•
'
Lab Number:
Date Received: -
7- f;/
'Time:
Rec'd by: f
I From: Bus -Courier- el
DATA ENTRY BY:
C W r
CK:
DATE REPORTED:
/- J/-
G/ V
• - -
Estimated BOD.Range: 0-5/5-25/25-65/40-130 or 100 plus
STATION LOCATION:
Seed: Yes No ❑ Chlorinated: Yes No ElREMARKS:
Statio # r Date Begin (yy/mm/dd) Time Begin Date End Time End De th DM B DBM Value Type Compo
C/D L A H L T S 8 C
C1
2
3
4
.5
6
7
8
9
10
11
12
13
14
15
} 16
17
18
1.9
20
OD5 310 mg/I
COD High 340 mg/l
COD Low 335 mg/I
Coliform: MF Fecal 31616 0 /100m1
Coliform: MF TotaI 31504 /100m1
Coliform: Tube Fecal 31615. /100m1 '
Coliform:,Fecal-Strep 31673 /100ml
Residue: Total 500 • ' mg/1
Volatile•505' mg/1",
' Fixed 510 mg/l,
esidue: Suspended 530 ,,' ,oz mg/1
Volatile 535 mg/I
Fixed 540 mg/1
H 403 :units
Acidity to pH 4.5 436 mg/l
Acidity'to pH 8.3 435 " mg/I
Alkalinity to. pH 8.3415, mgA'
Alkalinity to- pH 4.5';410• •-' , mg/l, '
TOC 680
Turbidity 76 j NTU '
Chloride 940 mg/I
Chi a: Tri 32217 ug/I
Chi a: Corr 32209. ug/l
Pheophytin a_32213 ug/I
Color: True 80 Pt -Co
Color:(pH ) 83, ADMI
Color: 'pH 7.6 82 ADMI
Cyanide 7,20 .;'�.'` '';. =, mgA
'Fluoride.951 mg/l,` .
Formaldehyde. 71880-:.: , - ''mg/l.
Grease :and Oils 556 mg/1:
Hardness Total900' m9/f
Specific pond 95 2
uMhos/cm.
MBAS 38260
Phenols '32730 ug/I
Sulfate 945 mg/l
Sulfide Z45 mg/1 ,
NH3 as N 610 mgA
TKN as N 625, mg/1
NO2 plus NO3 as N 630 mg/1
P: Total as P 665 mg/I
PO4 as P 70507 mgA
P. Dissolved as P 666 mgA
,CdCadmium 102.7 ugA
CrChiomiumeTotal 1034- • 410
Cu•Copper 1042 ug/I
Ni-NickeI1067., ug/1
Pb-Lead 1051: ug/i
Zn-Zinc 1092 ugA
A9 fiver 1077 u9A
AI Aluminum 1105 ug/I
Be -Beryllium 1012 . ' ug/I
Ca -Calcium 916 mg/1
Co -Cobalt 1037 ugA
Fe -Iron ,1045, • ' u9/1
Li -Lithium 1132 ug/l
Mg -Magnesium 927. mg/l
Mn-Manganese 1055 ug/l
Na-Sodium 929 mg/1
Arsenic:Total 1002 ug/I
Se -Selenium 1147 ug/l
Hg-Mercury 71900 ug/l
Organochlorine Pesticides
Organophoedarus Pesticides
Acid
I Base/ Neutral Extractable Organics I
Furgeable Organics (VOA bottle reg'd)
Phytoplankton
nt %
Conductance at 25 C
stet Temperature ,
D.O: mg/l.
pH„
'Alkalinity
Acidity'
Air Temperature (C)
pH 8.3 pH,4.5
pH 4.5 pH 8.3
IL
94
10
300" i`r-
400 .
82244 431
82243 82242
20
Salinity %-
Preclpitiou an/day)'Cloud
Cover %
Wind Direction (Deg)
Stream Flow Severity
Turbidity Severity
Wind VelocityM/H
can Stream Depth &
Stream Width ft.
480
145
32
36` f
1351 , .,. ^,
1350
35
64 14

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
Division of Environmental Management
59 Woodfin Place Asheville, North Carolina 28802
February 25, 1991
MAX SMALLWOOD
BROYHILL PARK
LENOIR NC 28633
SUBJECT: Notice of Violation - Effluent Limitations
NPDES No. NC0005461
BROYHILL FURNITURE INDUSTRIES
RUTHERFORD County
Dear MAX SMALLWOOD:
Review of subject self -monitoring report for the month
of December, 1990 revealed violation(s) of the following
parameter(s):
Pipe Parameter
001 31616 FEC COLI
Reported
Value/Unit
10100.0 #/loom
Limits
Value/Type/Unit
1000.0 FIN #/loom
Remedial actions, if not already implemented, should be
taken to correct the problem(s). The Division of Environmental
Management may pursue enforcement actions for this and any
additional violations of State Law. If there are questions or
a need for assistance, please call this office at 704/251-6208.
Sincere9_jw_�
ly,
M.O."
Roy Davis
Regional Supervisor
CC: Central Files
GKBDEX96/BL

na. SrATE' o-
State of North Carolina
Department of Natural Resources and Community Development
Asheville Regional Office
James G. Martin, Governor Ann B. Orr
William W. Cobey, Jr., Secretary Regional Manager
DIVISION OF ENVIRONMENTAL MANAGEMENT
WATER QUALITY SECTION
May 4, 1990
Mr. Max Smallwood, Plant Manager
Rutherford Furniture Company
Post Office Box 69
Rutherfordton, North Carolina 28139
Subject: Notice of Violation
Failure to Submit Toxicity
Monitoring Data
Rutherford Furniture Company
Wastewater Treatment Facilities
NPDES Permit No. NC0005461
Rutherford County
Dear Mr. Smallwood:
A review of our files indicates that Rutherford Furniture Company
has not submitted the results of toxicity test as required by
Administrative Letter dated July 20, 1989. -The test results are required
to be reported to this Division by completing the AT-1 form and mailing
it to the address listed below within 30 days following the month in
which the test was performed:
Mr. Ken Eagleson
Environmental Sciences Branch
N. C. Division of Environmental Management
P. 0. Box 27687
Raleigh, North Carolina 27611
Additionally, the test results are to be recorded on the State
Discharge Monitoring Report Form (MR.-1). TGP3B should be entered at the
top of the page as the parameter code and bioassay entered in one of the
blank columns identifying the test procedure.
Interchange Building, 59 Woodfin Place, Asheville, N.C. 28801 • Telephone [phone]
An Equal Opportunity Affirmative Action Employer

r
Max Smallwood
ay 4, 1990
Page Two
Failure to submit the data in accordance with administrative
requirements may result in enforcement action being taken against
Rutherford Furniture Company. The test results for the month of
February, 1990 should.be submitted as soon as possible.
Should you have questions concerning -this matter, please contact
Mr. Mike Parker at 704/251-6208.
Sincerely,
Roy M. Davis, Regional Supervisor
Division of Environmental Management
xc: Ken Eagleson
C . W . Meadcis
Jim Reid
Mike Parker
Rutherford County Health Department