NCG500618_Regional Office Historical File Pre 2018

ROY C01vP
r;
�' = :fivvernor.
MICHAEL S: REGAN
Secrerary
Water Resources LINDA CULPEPPER
Environmental Quality
Interim 1)irecror
January 3, 2018
i
Mr. Frankie Bumgarner, Facilities Manager
Mack Molding Company
149 Water Tank Road
Statesville, North Carolina 28677
Subject: Compliance Evaluation Inspection
Mack Molding Company
NPDES General Permit No. NCG500618
Iredell County
Dear Mr. Bumgarner:
Enclosed is a copy of the Compliance Evaluation Inspection Report for the.. inspection conducted
at the subject facility on. December 21, 2017, by Mr. Wes Bell of this Office.
Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell
at [phone], or via email at [e-mail].
Sincerely,
W. Corey Basinger, Regional Supervisor
Water Quality Regional Operations Section
Division of Water Resources, NCDEQ
Enclosure:
Inspection Report
cc: Iredell County Health Department
MSC-1617 Central -Basement
M.
State of North Carolina I Environmental Quality) Water Resources I Water Quality Regional Operations
Mooresville Regional Office 1610 East Center Avenue, Suite 3101 Mooresville, North Carolina 28115
704-663-1699

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Water Compliance Irispection Report
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fee Type
1 iti i 2 3 I NCG500618 I11 12 17/1y21 17 18 Li. I. 19 I c I 20L
211 1 1 t I I I I I I I.I I I 11 I I I I I I I I I I I I I 1 I I l l l l 11 l l l l l 166
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---Reserved----
67
1.0 701d I 71 itIti I 72 i u i 731 I 174 75
LJ L1 I t t
80
Section 13: Facility -Data
Name and Location of Facility. Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
09:15AM 17/12/21 '
16/03/22
Mack Molding Company
149 Water Tank Rd
Exit Time/Date
Permit Expiration Date
Statesville NC 28677
10:35AM 17/12/21
20/07/31
Name(s) of Onsite Representative(s)Ttles(s)/Phone and Fax Number(s)
Other Facility Data
Frankie Bumgamer/Facilities Manager/704-878-4433 t7048731966
Name, Address of Responsible OMciai title/Phone and Fax Number
Contacted
Frankie Bumgamer,149 Water Tank Rd Statesville NC 2867.7/Facilities
Manager/704-878-4433/7048731966 Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement' Operations & Maintenance N Records/Reports
Self -Monitoring Program Facility Site Review E,Effluent/Receiving Waters 0 Laboratory
Section D: Stimmary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of I spector(s) Agency/Office/Phone and Fax Numbers Date
MRO W0//704-663-1699 Ext.2192/
Wes Bell (14Z/JYj�ff
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
W. Corey Basinger MRO WQ//704-235-2194/
EPA
AAForm
�,�3560-3 (Rev 9-94) Previous editions are obsolete.
� obsolete. � - A �, �� e
��CPT
Page#.

Permit: NCG500618 Owner - Facllfty: Mack Molding Company
Inspection Date: 12/21/2017 Inspection Type: Compliance Evaluation
Permit
Yes Nb NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted anew
❑
❑
❑
application?
Is the facility as described. in the'permit?
❑
❑
❑
# Are there any special conditions for the permit?
❑
❑
N
❑
Is access to the plant site restricted to the general public?
❑
❑
❑
Is the Iinspector granted access to all areas for inspection?
❑
❑
❑
Comment: The subject permit expires on 7/31/20. The facility continues to discharge non -contact
coolina water (primary discharge) and air compressor condensate (very small discharge).
The.last compliance evaluation inspection was performed at the facility on 7/21/16 by DWR
staff.
Record Keepina
Are records kept and maintained as required by the permit?
Is all required information readily available, complete and current?
Are all records maintained for 3 years (lab. reg. required 5 years)?
Are analytical results'consistentwith data reported on DMRs?
Is the chain -of -custody complete?
Dates, times and location of sampling
Name of individual performing .the sampling
,Results of analysis and calibration
Dates of analysis
Name of person performing analyses
Transported COCs
Are DMRs complete: do they include all permit parameters?
Has the facility submitted its annual compliance report to users and DWQ?
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator
on each shift?
Is the ORC visitation log available and current?
Is the ORC certified at grade equal to or higher than the facility classification?
Is the backup operator certified at one grade less or greater than the facility classification?
is a copy of the current NPDES permit available on site?
Facility has copy of previous year's Annual Report on file for review?
Yes No NA NE
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01
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Page# 3

Permit:. NCG500618 Owner - Facility: Mack Molding Company
Inspection Date: 12/21/2017 Inspection Type: Compliance Evaluation
Upstream / Downstream Sampling Yes No NA NE
Comment: The facility discharges into a stormwater ditch: therefore. no upstream/downstream
temperature monitoring is required.
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ 0 ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: No biocides are added to the non -contact coolina water system. Microbial growth is
controlled by an ozone treatment system. The ozone treatment system was operational
and in service.
The coolina water system is fed by an on -site well (not chlorinated) and the facility continues
to use Dica 66 as a corrosion inhibitor.
The air compressor condensate is treated by an oil/water separator Drior'to discharge. The
spent oil filters are disposed at the Iredell County Landfill. The air compressor condensate
discharges and absorbs into the around directly adjacent to the building structure.
Flow Measurement - Effluent Yes No NA NE
# Is flow meter used for reporting? ❑ ❑ M. ❑
Is flow meter calibrated annually? ❑ ❑ ❑
Is the flow meter operational? ❑ ❑ M ❑
(If units are -separated) Does the chart recorder match the flow meter? ❑ ' ❑ M ❑
Comment: The facility staff must ensure that all future flow measurements/values on the non -contact
coolina water discharge are based on a daily discharge event.
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? ❑ ❑ ❑
Are the receiving water free of foam other than trace amounts and other debris? ❑ ❑ E ❑
If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ ❑
Comment: The facility was not dischar-ging non -contact coolinq water at the time of the inspection:
however, the water in the coolina system appeared.clear with no floatable solids or foam.
,The air compressor condensate discharge appeared clear with no oil sheens or foam.
Page# 5

WaterResources:y
ENVIRONMENTAL QUALITY.
Mr. Frankie Bumgarner, Facilities Manager
Mack Molding Company
149 Water Tank Road
Statesville, North Carolina 28677
A( M CRORY
6.� ' k Governor
j `f
DONALD R. VAN PER VAART
Secretary
S. JAY ZIMMERMAN
Director
August 2, 2016
Subject: Compliance Evaluation Inspection
Mack Molding. Company
NPDES Permit No. NCG500618
Iredell County.
i
Dear Mr. Bumgarner:
..Enclosed is a copy.ofthe Compliance Evaluation Inspection.Report.for.the inspection conducted ..
at the subject facility on July 21, 2016 by Mr. Wes Bell of this Office.
Should you; have any questions concerning this report, please do -not hesitate to contact Mr. Bell .
at [phone], or via email at [e-mail].
Sincerely,
W. Corey Basinger, Regional'Supervisor
Water Quality_ Regional Operations. Section..
Division of Water Resources, NCDEQ
Enclosure:
Inspection Report. -
cc: Redell County Health Department
MSC-1617 Central -Basement
WB
State of North Carolina I Environmental Quality I Water Resources I Water Quality Regional Operations .
Mooresville Regional Office 1 610 East Center Avenue, Suite 301 Mooresville, North Carolina 28115
704 663 1699 .

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C.20460
OMB No. 204b-0057
Water Compliance Inspection Report : "
Approval expires 8-31-98
Section A: National Data System Cod'ing`(i.e., PCs)
Transaction Code NPDES yNmo/day Inspection Type Inspector Fac Type
1 IN i 2 15 I 3 I. NCG500618 I11 12 16/07i21 17 18 I C I 19 I c I 20I I
Inspection
Work Days Facility Self -Monitoring Evaluation Rating 131 CIA Reserved
67.
1.0 70 id ( 71 iti Ji 72 i �, i 731 I 174 75
tJ
�.
80
Section B: FacilityDataL
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Data
POTW name and NPDES oermit Number)
11:40AM 16/07/21
16/03/22 ,
Mack Molding Company
Exit Time/Date
Permit Expiration Date
149 Water Tank Rd.
12:55PM 16/07/21
20/07/31
Statesville NC 28677
Name(s) of Onsite Representative(s)mties(s)/Phone and Fax Number(s)
Other Facility Data
Frankie Bumgamer/Facilities Manager/704-878-9641 /7048731966.
Name, Address of Responsible OFficiaUTitle/Phone and Fax Number
Contacted
Frankie Bdmgamer,149 Water Tank Rd Statesville NC 28677/Facilities
Yes
Manager/704-878-4433/7o48731966
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenance Records/Reports
Self -Monitoring Program " Facility Site Review Effluent/Receiving Waters Laboratory .
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment.summary)
Name(s) and Signature(s) of pector(s) Agency/Office/Phone and Fax Numbers Date
%
Wes Bell < MRO WQ/1104-663-1699 Ext.2192/iv-
-X
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
W. Corey Basinger MRO M/704435-2194/ "
EPA Form 3 0-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

Permit: NCG500618 Owner - Facility: Mack Molding Company
Inspection Date: 07/21/2016 Inspection Type: Compliance Evaluation
Permit
Yes No NA NE
(If the present permit expires in 6 months or less): Has the permitted submitted a new
❑ :
❑
0
❑
application?
Is the facility as described In the:permit?
70
❑
❑
# Are there any special conditions for the -permit? .
❑
❑
❑
Is access to the plant site restricted to the. general public?
0,
: 0
❑
❑
Is the inspector granted access to all areas for inspection?
N
❑
❑
❑ .
Comment;
The last compliance evaluation inspection was performed at the facility on 9/4/14 by DWR
staff:
Record Keepina
Are'records kept and maintained as required by the.permit?
Is all required information readily available, complete and current?
Are all records maintained for 3 years. (lab. reo: required, 5 years)?;
Are analytical results consistent'with data reported on D.M.W. -
Is the chain -of -custody complete?
Dates, times and location of.sampling
Name of individual performing the 'Sampling
Results of analysis and calibration
Dates of analysis .
Name of person. performing analyses
Transported COCs
Are DMRs complete: do they include. all permit parameters?
Yes No NA NE
❑'❑
0:.0
❑
❑.
19
❑
❑
❑
Has the facility submitted its annual compliance report to users and DWQ?
0
❑ .
,E
0
(If the facility is = or > 5 MGD permitted flow) Do.they operate 24/7 with a certified operator
0
❑ .,
'W
❑
on'each shift?
Is the ORC visitation log available and current?
❑
❑
Is the ORC certified. at grade equal to or higher than the facility classification?
❑
El❑
Is the backup operator certified at one grade less or greater than the facility. classification?
❑
❑,
.
❑.
Is a copy of the current NPDES permit available on site?
❑
❑
- ❑
Facility has copy of previous year's Annual Report on file for review?.
0
❑
N
El
Page# 3

Permit: NCG500618 Owner - Facility: Mack Molding Company
Inspection. Date: 07/21/2016 Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Comment: The records reviewed during the inspection were or and well maintained.
Self -monitoring data was reviewed for 20'14J015. and 201'& The facility did not exceed anv
permit limits for the non -contact cooling water discharges during the review period. The
facilb did exceed the oil & -grease permit limit (daily maximum and monthly average) for the
air compressor condensate discharge in January 2016: however, the February 2016
(follow-up) and July 2016 sampling events were in compliance with the permit limits.
All monitoring frequencies were performed in accordance with the permit.
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory..,. ❑ ❑ ❑
Are all other parameters(excluding field parameters) performed by a certified lab? ,0 ❑ ❑ ❑
# Is the facility using a contract'lab? �;, ❑ ❑ ❑
# Is proper temperature set for• sample storage (kept at less than or equal to 6.0 degrees W❑ 0 ❑
Celsius)?
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ❑ , .
Incubator (BOD) set to 20.0 degrees Celsius +/-1.0 degrees? ❑ ❑ ❑. .
Comment: Statesville Analytical (Laboratory Certification #440) has been contracted to perform COD -
company.
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
1:1
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0
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Is sample collected below all treatment units?
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❑ .
Is proper volume collected?
❑
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�.
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Is the tubing clean?.,
❑
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M
11.
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees ..
❑
. ❑
M,
❑
Celsius)?
Is the facility sampling performed as required by the permit (frequency,\ sampling type '
❑
❑
❑
representative)?
Comment: The subject permit requires effluent grab samples.
Upstream /Downstream Sampling
Yes No NA NE
Is the facility sampling performed as required by the permif(frequency, sampiingtype, and
❑
❑
0
❑
sampling location)?
Comment:. ,The facility discharges into'a stormwater drainage system: therefore, no upstream and
downstream monitoring is required.
Page# 4

Permit:.NCG500618 Owner - Facility: Mack Molding Company
Inspection Date: 07/21/2016 Inspection Type: Compliance Evaluation
Operations & Maintenance') Yes No NA .NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ N ❑
Solids, pH, DO, Sludge Judge, and other that, are applicable?
Comment: No biocides are added to the cooling water system. Microbial -growth is controlled by an
ozone treatment system. The cooling water system is fed by an on -site well (not
chlorinated).- The facility continues -to use Dica 66 as a corrosion inhibitor. The air
compressor condensate is treated by an oil/water separator prior to discharge on the
-ground The oil filters from the oil/water separator are transported to the.lredell County
Landfill -for final disposal.
No surface waters and%or stormwater drains are within close proximity to the air compressor
condensate discharge.
Flow Measurement = Effluent Yes No NA -NE.
# Is flow meter used for reporting? ❑ ❑ ❑
Is flow meter calibrated annually? ❑ - ❑ ❑
Is the flow meter operational? . ❑ ❑ ❑
(If units are separated) Does the chart recorder match the flow meter? : ❑ ❑0 ❑
Comment: The discharge (non -contact cooling water) is measured by an in -line totalizer. The facility
staff must ensure that the totalized flow measured/reported during'each semi-annual
sambling event is based on the daily flow and not a 6-month totalized flow.
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? ❑ ❑ 0- ❑ '
Are the receiving water free of foam other than trace amounts and other debris? ❑ ❑ N ❑
If effluent (diffuser pipes are required) are they operating "properly? ❑• ❑ E ❑
Comment: No non -contact cooling water was being discharged at the time of the inspection: however,
the treated water being used in the cooling system appeared clear with no floatable solids or
foam. The air compressor condensate discharge appeared 'clear with no oil sheens or
foam.
Page# 5

a

NCDENR
North Carolina Department of Environment and
Pat McCrory
Governor
April 16, 2014
Mr. Frank Bumgarner, EHS Manager
Mack Molding Company
149 Water Tank Road
Statesville, North Carolina 28677
Natural Resources
Subject: Notice of Deficiency
Compliance Evaluation Inspection
Mack Molding Company
NPDES Permit No. NCG500618
Iredell County
Tracking #:NOD-2014-PC-0090 .
Dear Mr. Bumgarner:
John E. Skvarla, III
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the
subject facility on April 9, 2014 by Mr. Wes Bell of this Office.
It is requested that a written response be submitted to this Office by May 7, 2014, addressing the
deficiencies noted in the Effluent Sampling Section of the attached report. In responding, please address your
comments to the attention of Mrs. Marcia Allocco.
The report should be self-explanatory; however, should you have any questions concerning this report, please
do not hesitate to contact Mr. Bell at [phone] or at wes.bellt'a)ncdenl.gov.
Sincerely, I
-�" Michael L. Parker, Regional Supervisor
Mooresville Regional Office
Water Quality Regional Operations Section
Division of Water Resources, NCDENR
Enclosure:
Inspection Report
Technical Guidance Documents -
cc: Iredell County Health Department
Mooresville Regional Office
Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115
Phone: [phone] Fax: [phone] Customer Service: 1-877-623-6748
Internet www,ncwaterqualiV.org
An Equal Opportunity l Affirmative Action Employer— 30% Recycledl10% Post Consumer paper

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCs)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 INI 2 15 I 31 NCG500618 111 121 14/04/09 117 18I C I 19I S I 20I II
Remarks
21I1II IIIIII11IIII IIII I I I I I I I I I I I I I I I I IIIIIIIIII16
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 CIA — — — — — -Reserved----
67 I 1.0 169 70131 711 NJ 721 N I 73 LJJ 74 751 I I I I I I 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
09:20 AM 14/04/09
12/08/01
Mack Molding Company
Exit Time/Date
Permit Expiration Date
149 Water Tank Rd
Statesville NC 28677
11:10 AM 14/04/09
15/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
///
Frank Bumgarner/EHS Manager/704-878-9641 [7048731966
Name, Address of Responsible Official/Title/Phone and Fax Number
Frank Bumgarner,149 Water Tank Rd Statesville NC 28677/EHS Contacted
Manager/704-878-9641/7048731966 Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit ■ Flow Measurement Operations & Maintenance Records/Reports
Self -Monitoring Program Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters
Laboratory
Section D: Summary of Finding/Comments Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s))y Agency/Office/Phone and Fax Numbers Date
Wes Bell �%// MRO WQ//704-663-1699 Ext.2192/
r
Signature of Management Q A vie er Agency/Office/Phone and Fax Numbers Date
MarciSAho cco MRO WQ//704-663-1699 Ext.2204/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type
3I NCG500618 I11 12, 14/04/09 17 18ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Page # 2

Permit: NCG500618
Inspection Date: 04/09/2014
i
Permit
Owner - Facility: Mack Molding Company
Inspection Type: Compliance Evaluation
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Is the facility as described in the permit?
# Are there any special conditions for the permit?
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment: The facility discharges non -contact cooling water (main effluent
constituent) and air compressor condensate (very small discharge) to a stormwater
drainage system. The receiving stream (unnamed tributary to Broad Meadow Creek) is
not within the immediate vicinity of the industrial facility.
The last compliance evaluation inspection was performed on 9/17/2009.
Record Keeping
Are records kept and maintained as required by the permit?
Is all required information readily available, complete and current?
Are all records maintained for 3 years (lab. reg. required 5 years)?
Are analytical results consistent with data reported on DMRs?
Is the chain -of -custody complete?
Dates, times and location of sampling
Name of individual performing the sampling
Results of analysis and calibration
Dates of analysis
Name of person performing analyses
Transported COCs
Are DMRs complete: do they include all permit parameters?
Has the facility submitted its annual compliance report to users and DWQ?
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift?
Is the ORC visitation log available and current?
Is the ORC certified at grade equal to or higher than the facility classification?
Is the backup operator certified at one grade less or greater than the facility classification?
Is a copy of the current NPDES permit available on site?
Facility has copy of previous year's Annual Report on file for review?
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Page # 3

C
Permit: NCG500618
Inspection Date: 0410912014
Record Keeping .
Owner - Facility: Mack Molding Company
Inspection Type: Compliance Evaluation
Comment: The records reviewed during the inspection were organized and well
maintained. The facility did not exceed any effluent limitations in 2013 and the first
sampling event in 2014.
Laboratory
Are field parameters performed by certified personnel or laboratory?
Are all other parameters(excluding field parameters) performed by a certified lab?
# Is the facility using a contract lab?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
Comment: Statesville Analytical, Inc. (Laboratory Certification #440) has been
contracted to analyze the effluent oil & grease samples.
The facility is equipped with in -line pH and temperature monitoring systems. The pH
measuring device is calibrated with two standards. The facility staff must ensure that
the pH. measuring device is calibrated according to Standard Methods, 4500-H B -
2000. Note: The technical guidance documents for pH and temperature
calibration/analysis have been attached to this report.
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment: The subject permit requires effluent grab sampling. The facility did not
collect the semi-annual effluent COD samples and report the discharge flow in 2013.
The facility staff must ensure to monitor all permit -required parameters during future
sampling events.
V-- K1— \IA •IC
Yes No NA NE
nn■n
■nnn
■nnn
■nnn
nn■n
nn■o
Ve K1— \IA 11IC
Upstream/ Downstream Sampling - Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? n n ■ n
Comment: The effluent is discharged into a stormwater ditch; therefore, no upstream
and downstream monitoring is required as noted in the subject permit.
Operations & Maintenance
V-- K1— NIA \IC
Page # 4

f,
Permit: NCG500618
Inspection Date: 04/09/2014
Owner - Facility: Mack Molding Company
Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ■ ❑ n 0
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ❑ n E [l
Judge, and other that are applicable?
Comment: The facility appeared to be properly operated and well maintained. The air
compressor condensate passes through an oil/water separator prior to discharge.
The non -contact cooling water system is fed by an on -site well (no chlorine added). No
biocides are added; however, microbical growth is controlled by an ozone treatment
system. A corrosion inhibitor (DICA 66) is also added to the cooling water process.
Effluent Pipe Yes No NA NE
Is right,of way to the outfall properly maintained? ■ Q DI 0
Are the receiving water free of foam other than trace amounts and other debris? Q 0 ■ f>
If effluent (diffuser pipes are required) are they operating properly? ❑ 0 E 0
Comment: The effluent appeared clear with no floatable solids or foam.
Page # 5

Weaver, Charles
,From: Weaver, Charles RECEIVED/NCDENR/DWR
Sent: Tuesday, March 22, 2016 10:19 AM MAR 3 0 2016
To: '[e-mail]'
Subject: renewal of NCG500618 - Mack Molding Company �pp WQROS
Attachments: NCG50 Final 093015.pdf, Technical Bulletin - NCG500000 2015.MMdocREsv►LLE REGIONAL OFFICE
Importance: High
Attached you will find the updated version of NPDES General Permit NCG500000, effective 10/1/2015. Discard any
previous versions of the General Permit and use this version until further notice.
u do not need a reprinted Certificate of Coverage, as the one issued to you in 2007 is still applicable.
nk you for your patience during the longer -than -expected renewal period.
you have any questions about this matter, simply reply to this message.
harles H. Weaver
nvironmental Specialist
.C. Division of Water Resources
.C. Department of Environmental Quality
9-807-6391
:al address) 512 North Salisbury Street, Raleigh, NC 27604
g address) 1617 Mail Service Center, Raleigh, NC 27699-1617
---:'='"Nothing Compares. %-.-
nail correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed
third parties.
1

Weaver, Charles
From: Frank Bumgarner <[e-mail]>
To: Weaver, Charles
Sent: Tuesday, March 22, 201610:23 AM
Subject: Read: renewal of NCG500618 - Mack Molding Company
Your message
To:
Subject: renewal of NCG500618 - Mack Molding Company
Sent: Tuesday, March 22, 2016 2:23:20 PM (UTC) Monrovia, Reykjavik
was read on Tuesday, March 22, 2016 2:23:13 PM (UTC) Monrovia, Reykjavik.

April 28, 2014
NCDENR
Mooresville Regional Office
610 East Center Avenue
Suite 301
Mooresville, N.C. 28115
Attention: Mrs. Marcia Allocco
RECW 21VED
DIVISION OF `jc1 TEE QUALITY
APR 3 0 2014
MOO1 ESVv LLL i:L.�GiONAL OFFICE
Reference: Response to notice of deficiency.
Compliance Evaluation Inspection by Mr. Wes Bell on April 09, 2014.
Tracking #: NOD-2014-PC-0090
Dear Mrs. Allocco,
Enclosed please find information concerning the notice of deficiency found during the
April 9, 2014 Compliance Evaluation Inspection by Mr. Wes Bell. Items are as follows.
15L Item:
A copy of the analytical results from the grab sample taken on 04-09-2014.
2"d Item:
Created a new form to include time, COD, comments and PM of Cooling Tower.
3`d Item:
Installing a Seametrics %" water flowmeter/totalizer to capture discharge gallons of
water.
All semi-annual inspections of Cooling Tower will be scheduled with Dubois Chemical Company. They
will assist in the calibration of the PH meter using buffer 4-7-10; temperature reading and flow. Please
note Dubois will still service Mack Molding on a monthly basis for calibration the PH meter per ISO-
14001.
Should you have any questions regarding this letter, please feel free to call me at 704-878-4433
SincerelyeBumgarZner
Pl
EHS Manager
Mack Molding Company ■ 149 Water Tank Road ■ Statesville, North Carolina 28677
[phone] ■ [phone] Fax
FULL -SERVICE PLASTIC MOLDING AND MANUFACTURING
COMPANY CONFIDENTIAL
IYgH V
IS09002
xsc�srtnso co¢vaxr
W 9002: 1967 CUOfxaie No. 5214

Analytical Results
Mack Molding
149 Water Tank Road
Statesville NC 28677
Entered 4/9/2014
Reported: 4/24/2014
For:
P87379
Sample ID
Parameter
Cust ID
Result
, Units
Method
Date Analyzed
Analyst
140409-28
COD
P87379
<25
mg/L
HACH8000
4/16/14
CL
Respectfully submitted,
Dena Myers
NC Cert #440,
NCDW Cert #37755,
EPA NCO0909
P.O. Box 228 * Statesville, North Carolina 28687 * 704/872/4697

Alum
Cooling Tower Semi Annual Inspection
DATE Time Flow Temperture © pHChemical Oxygen Comments & PM of3 (6.0 - 9.0) Demand (COD) Cooling Tower Signature
FORWARD COMPLETED FORM TO EHS MANAGER

Z�1
r. ���+y111ryyy, apt i(
t .
Creating the Right Solutions Together
April 14, 2010
Mr. Jim McKay
NC DENR Division of Water Quality.
Surface Water Protection Section
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
Pro
APR 192010 !
Re: Mack Molding Notification of New Discharge to be Covered by the
NPDES General Permit # NCG500000 for Non -contact Cooling Water,
Boiler Blowdown, Cooling Tower, Condensate and Hydroelectric
Dams. HRP Job # MAC1047.WM
Dear Mr. McKay:
Pursuant to your request on March 5, 2010, this letter is being submitted to the
NCDENR Division of Water Quality on behalf of Mack Molding Company, located at
149 Water Tank Road in Statesville, NC, in order to notify the, division that the facility
has installed a new air nomnressor which will rli.qrrharnP rnndznQntP to thA nrni inrl
CONNECTICUT
197 Scott Swamp Road
Farmington, CT 06032
800-246-9021
860-674-9570
FAX [phone]
501 Kings Highway East
Fairfield, CT 06825
203-610-8212
FAX [phone]
FLORIDA
2435 US Highway 19
Suite 550
Holiday, FL 34691
727-942-2115
FAX [phone]
INDIANA
7965 East 106th Street
Suite 116
Fishers, IN 46038
317-570-4851
FAX [phone]

Mr. Jim McKay.
NC DENR DWQ
April 14, 2010
Page 2
Should you have any questions or concerns regarding this submittal, please do not hesitate to
contact Mr. Frank Bumgarner of Mack Molding Company at [phone] or myself at (864)
289-0311.
Sincerely,
HRP Associates, Inc.
Shannon M. Cohen
Project Scientist
cc: Frank Bumgarner/Mack Molding
Attachment

The Ingersoll-Rand PS Polysep Oil/Water Seperator product offering is the
most comprehensive environmental solution in the air
compressor industry.
The Problem with Other Oil titer
Separators
Compressor oils that do not have good separation
characteristics, known as emulsions, tend to foul up the
carbon filters as well as the pre -adsorption and
coalescing medias that are commonly installed in front of
the carbon filters.Those filters have to be replaced before
their capacity is fully used.Th s is a result of oil binding off
the pore area of the carbon where the condensate first
comes in contact with the G1tec1he jelled oil clogs the
filter, —which then prevents the -volume of condensate from
properly flowing through the filter.This premature failure
of the carbon filters most often results in the system
backing up on the floor.
ThP 1R Fniiirnnmi ntal Cnlritinr-i
00)
Ingersollfland

s
Operation
The condensate enters the diffuser chamber (1)
when it is depressurized. The oily condensate then
enters a main reservoir (2) where gravity separation
occurs. Any oil that floats to the surface is skimmed
off through an adjustable oil weir (3). The conden-
sate then moves to a separate chamber through a
pick-up tube (4). As the condensate accumulates in
the next chamber, a float (.i) rises with the level of
condensate. The float is connected to a ball
valve (6) by a. lever arm. The increased level of
condensate causes the float to rise and open
the ball valve. As the valve opens, the air -operated
pump (7) is allowed to push the condensate out to
the filter module (8). if the level of condensate con-
tinues to rise, the -float also rises and further opens .
the ball valve. Cleaned water discharged (9) from the,
filter module can be disposed of directly into the
facility's sanitary sewer. This system assures
maximum contact time for the filter module.

:.
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
July 23, 2007
Don Kendall
Mack Molding Company
149 Water Tank Rd
Statesville, NC 28677
Subject:
Dear Permittee:
William G. Ross, Jr., Secretary
Coleen H: Sullins, Director -
Renewal of coverage / General Permit.NCG500000
Mack Molding Company
Certificate of Coverage NCG500618
Iredell County
In accordance with your renewal application [received on December 8; 20061, the Division is renewing
Certificate of Coverage (CoC) NCG500618 to discharge' under. CG500000. This CoC is issued pursuant to the
requirements of North Carolina General Statue 143-215.1 and Nthe Memorandum of Agreement between 'North
Carolina and the US Environmental Protection agency dated May 9, 1994 [or as subsequently amended]. .
If any parts, measurement frequencies' or samplingrequirements contained in this General Permit are
unacceptable to you, you have the right to'request anindividual permit by submitting an -individual -permit
application. Unless such demand is made, the certificate of.coverage shall be final and binding.
Please take notice that this Certificate of Coverage is not transferable except after notice to the
Division. The Division may require modification or revocation and reissuance of the certificate of coverage.
Contact the Mooresville Regional Office prior to any sale or transfer of the permitted facility:
Regional Office staff will assist you in documenting the transfer of this. CoC.
This permit does not affect the legal requirements to obtain other permits which may be required. by
the Division of Water Quality or permits required by the Division of Land Resources, Coastal Area.
Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning the requirements of the General_ Permit, please court i
McKay [919 733-5083, extension 595 or [e-mail].
AM HATURX
Sincerely,
NOOFESVILL E RtQMOFF- E
®�!C!7C'�
t
JUL
for Coleen H. Sullins'=+.=
.
cc: Central Files
ooresvi4�le Re 'oval Off ce /Surface Water Protectio
\. t4,
"`
NPDES file
PAR QU
A
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 one 7
512 North Salisbury Street, Raleigh, North Carolina 27604 NOl'ChC�TO1111a
Phone: [phone] / FAX [phone] / Internet: www.ncwaterquality.org
Nahmall
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper y.

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NCG500000
CERTIFICATE OF COVERAGE NCG500618
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE AND SIMILAR WASTEWATERS 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,
Mack Molding Company
is hereby authorized to discharge Cooling Tower Blowdown from a facility located at
Mack Molding Company
149 Water Tank Road
Statesville
Iredell County
to receiving waters designated as an unnamed tributary to Broad Meadow Creek in
subbasin 30832 of the Catawba River Basin in accordance with the, effluent limitations,
monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof..
This certificate of coverage shall become effective August 1, 2007.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 23, 2007.
for Coleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

l
NCDENR
North Carolina Department of Environment and Natural Resources_
Division of Water Quality
Michael F. Easley, Governor
Frank Bumgarner..
Mack Molding Company
149 Water Tank Rd
Statesville, NC 28677
November 15, 2006
William G. Ross, Jr., Secretary
Alan W. Klimek,.P.E., Director
Subject:. NPDES Permit NCG500000 renewal
Certificate :of Coverage (CoC) NCG500618
Mack Molding Company
Iredell County
Dear Permittee:
The facility listed above is covered -under NPDES General Permit NCG500000. NCG500000 expires
on July 31, 2001. Federal (46 CFR 122.'41).and North,Carolina:(15A NCAC 2H.0105(e)) regulations require
that: perm it renewal applications- must. be filed at least 180 days prior to expiration of the. current permit.. If
you have already mailed a renewal request, you may.disregard this notice.
To satisfy this requirement, the Division must 'receive a renewal request postmarked.no later thane
February 1, 2007. Failure to request renewal by this date may result in a civil penalty assessment: Larger
penalties may be assessed depending upon,the delinquency of,the request: This renewal notice. is. being sent.
well in advance of the due date so that you have adequate time to prepare your application.
If any discharge previously. covered under NCG500000 will occur after July 31, 2007, .the
CoC.-must be renewed. Discharge of wastewater without a valid permit would. violate. North Carolina -
General Statute 143-215.1; unpermitted discharges of wastewater may be assessed civil penalties of up to
$2500 per day.
If all discharge has ceased at. your, facility and you wish to rescind this CoC [or if you have other
questions], contact me at the telephone number or e-mail address listed below. .
. _ .��r s . iJr i;..i'W�lltizJt�� ���n,d -•
Ai
Sincere l
y, I'e�C1G13CF�t a r ":h I? OFFICE
NOV 1 6 200E
Charles H. Weaver, Jr.. ,
NPDES Unit
ec: Central Files
NPDES File. l�1ua^o y'a�I �Itr
16.17 Mail Service Center, Raleigh, North Carolina 27699-1617 One �T
512 North Salisbury Street; Raleigh, North, Carolina 27604. 1V offfiCarohna
Phone: [phone], extension 511. /FAX [phone] / charles.weaver@ ncmail.net
Natza
�� //, /
An Equal Opportunity/Affirmative Action Employer - 56% Recycled/10% Post Consumer Paper ally

Mr. Frank Bumgarner
Mack Molding Company
149 Water Tank Road
Statesville, NC 28677
Dear Mr. Bumgarner:
Michael F. Easley, Governor
o� 11'a�Ross Jr., Secretary
North CaiottNj'que`j��rt�riYnt'�oiE�nVi�rdti dNatural Resources
MOORESVILLE 6 EGtOr3AL OFF101'
-AIWI . Klimek, P.E. Director
division of Water Quality
September 8, 2006 SEP 12 2006
WATER QUAUTY SECTID�
Subject: General Permit No. NC6050000
Mack Molding Company
COC No. NCG050348
Iredell County
In accordance with your application for a discharge permit received on April 24, 2006 we
are forwarding herewith the subject certificate of coverage (COC) to discharge under the subject
state — NPDES general permit. This permit is issued pursuant to the requirements of North
Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina
and the US Environmental Protection Agency dated May 9, 1994 (or as subsequently amended).
If any parts, measurement frequencies, or sampling requirements contained in this permit
are unacceptable to you, you have the right to request -an individual permit by submitting an
individual permit application. Unless such demand is made, this certificate of coverage shall be
final and binding.
Please take notice that this certificate of coverage is not transferable except after notice to
the Division of Water Quality. The Division of Water Quality may require modification or
revocation and reissuance of the certificate of coverage. This permit does not affect the legal
requirements to obtain other permits which may be required by the Division of Water Quality or
permits required by the Division of Land Resources, Coastal Area Management Act or any other
federal or local governmental permit that may be required.
If you have any questions concerning this permit please contact Aisha Lau at telephone
number [phone] ext. 578.
Sincerel
21GINAL SIGNED SY
KEN PICKLE
Alan W. Klimek, P.E.
cc: LVlooresvilTe_Regional::Gffi_c`o
Central Files
Stormwater Permitting Unit Files
Attachments
onr NthCarolina
Natura!!J
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh; NC 27699-1617 Phone [phone] Customer Service
Internet: h2o.enr.state.nc.us 512 N. Salisbury St.. Raleigh, NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

i
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG050000
CERTIFICATE OF COVERAGE No. NCG050348
STORMWATER DISCHARGES
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the
Federal Water Pollution Control Act, as amended,
Mack Molding Company
Is hereby authorized to discharge stormwater from a facility located at
Mack Molding Company
149 Water Tank Road
Statesville
Iredell County
to receiving waters designated as an unnamed tributary to Broad Meadow Creek, Class WS-IV waters in the
Catawba River Basin in accordance with the effluent limitations, monitoring requirements, and other conditions set
forth in Parts 1,1I, III, IV, V, and VI of General Permit No. NCG050000 as attached.
This certificate of coverage shall become effective September 8, 2006.
i
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day September 8, 2006. ORIGINAL SIGNED. BY
'<E,kl P!CKI P
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

www.mack.com
"`'` ANABP....
.
Frank Bumgarner
Facilities Manager
Mack Molding Company
149 Water Tank Road
Statesville, NC 28677
phone [phone]
fax [phone]
email [e-mail]

Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department or Etivirunruenl and Natural Resources
Division of Water Quality
March 7, 2007
MEMORANDUM
To: Susan Wilson
Western NPDES Program
From: Cindy Moore
Aquatic Toxicity Unit
Alan W. Klimek, P.E'.; Director
Division of Water Quality
Subject: Biocide Use Review
Mack Molding Company
NPDES # NCG500618
Iredell County
Mack Molding Company has -requested approval of a corrosion inhibitor Dica 66 in their water treatment system.
They use [this product to modify their pH in order to -prevent scale accumulations. They are required by their
permit to monitor for pH. Since the product is used for pH modification, and they are required to monitor for pH,
the biocide 101 form is not required.
cc: Mr. Frank Bumgarrner
Mack Molding Company
149 Water Tank Road
Statesville, NC 28677
Central Files
Noae
�rhCarolina
rtrrra!!�
North Carolina Division of Water Quality- 1621 Mail Service Center Raleigh, NC 27699-1621 Phone [phone] Customer Service
Internet: www.esb.enr.state.nc.us 4401 Reedy Creek Rd.. Raleigh, NC 27607 FAX [phone]
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/109% Post Consumer Paper

Environmental/Civil` Engineering and Hydrogeology
www.hipassociates.com
To: Ms. Chidy Moore
From: Ms. Toni Massey
Company: NCDENR
# of pages Inc. cover:
Fax#: [phone]
Fax# [phone]
Date: 3-6-07
Phone#: [phone]
Subject: Cooling Water Discharge Report
Job #:
Ms. Moore:
In response to our telephone conversation on 3/l/07, I am providing the following information
concerning Mack Molding.'s Statesville, North Carolina facility. Mack Molding is required by
their General Permit NCG500000 to monitor pII senni-annually. Therefore, a Biocide 101 form
has not been completed for the use of Dica 66. For clarification, Dica 66 is used in Mack's
cooling water at a rate of 2.78 lb/day to maintain a balanced pH to inhibit scale accumulation.
In a letter dated December 5, 2003 from Todd Christenson of the Division of Water.Quality, it
was stated, "neither Dica 66 nor Omni Guard contain biocidal ingredients, therefore approval of
this office is not necessary." Please note that the facility does not use Ultrex LIVI PB.
The facility has determined it's maximum cooling water discharge to be 500 gpd. The maximum
capacity of the cooling water system is the 1,000-gallon holding tank plus approximately 400
feet of 6" piping (588 gallons), for a total capacity of 1,588 gallons within the cooling water
system.
If you need any additional information, please do not hesitate to contact us at 864-289-0311.
Sincerely,
74. 1 mll-"l
Toni M. Massey
Project Engineer
• Hazardous/Solid Waste Management
• Air Compliance and Permitting
• OSHA Health & Safety Compliance
• Underground/Aboveground Tank Management
• Wastewater and Stormwater Management
• Soil and Groundwater Investigations
• Due Diligence Site Assessments
• Multimedia Compliance Training
• Asbestos, bead Paint, Mold Investigations
• Environmental Management Systems
• Brownfields Redevelopment
• Indoor Air Quality
Vie preceding fax message contains information that is confidential, may be protected by the attorney/client or
other applicable privileges, and ma-y cianstitute non public n forma-tioit. It is intended to be conveyed only-
nly to the
designated recipient(s). If you are not an intended recipient of this message, please notify the sender at (800) 752-
3922. Unauthorized use, dissemination, distribution, or reproduction of this message is strictly prohibited and may
be unlawful.
1327-D Miller Road • Greenville, SC 29607 e [phone] ® Fax: [phone]
Office Locations: Connecticut, New York, Massachusetts, Pennsylvania, South Carolina
Creating the Right Solutions 'together

SOC PRIORITY PROJECT: No
To: NPDES Unit
Water Quality Section
Attention: Ken Pickle
Date: June 23, 2004
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Iredell
NPDES-Permit No.: NCG500618
MRO No.: 04-35A
PART I - GENERAL INFORMATION
1. Facility and address: Mack Molding Company
149 Water Plant Road _
Statesville, NC 28144
2. Date of investigation: June 11, 2004
3. Report prepared by: Michael L. Parker, Environmental Engineer II
4. Person contacted and telephone number: Frank Bumgarner, [phone]
5. Directions to site: From the jct. of Old Mountain Road (SR 1005) and I-40 west of
Statesville, travel southeast on Old Mountain Rd. = 50 yards and turn onto Water Tank
Road. The Mack Molding Company is located at the end of Water Tank Rd.
6. Discharge point(s), List for all discharge points: -
Latitude: 350 46' 15"
Longitude: 80' 59' S8"
Attach a USGS Map Extract and indicate treatment plant site and discharge point on map.
USGS Quad No.: D 15 SW
7. Site size and expansion area consistent with application: Yes.
8. Topography (relationship to flood plain included): Gently rolling, 2-.4% slopes. The site
is well removed from any flood plain.
9. Location of nearest dwelling: Approx. 500+ feet from the manufacturing site.

Page Two
10. Receiving stream or affected surface waters: U. T. To Broad Meadow Creek
a. IClassification: WS-IV
b. River Basin and Subbasin No.: Catawba 030832
C. Describe receiving stream features and pertinent downstream uses: The receiving
stream is actually several hundred feet south of the plant site. Under normal
conditions, it is unlikely that the effluent will reach the UT, except during periods
of wet weather. The area is generally rural with agriculture being the primary use.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater: = 500 gpd (Design Capacity)
b. What is the current permitted capacity: N/A (new permit)
C. Actual treatment capacity of current facility (current design capacity): N/A
d. Date(s) and construction activities allowed by previous ATCs issued in the
previous two years: N/A
e. Description of existing or substantially constructed WWT facilities: There are no
existing WWT facilities. The discharge consists of cooling tower blowdown.
f. Description of proposed WWT facilities: There are no proposed WWT facilities.
g. Possible toxic impacts to surface waters: Toxic impacts are not expected since it
is unlikely that the discharge will reach surface waters except during extended wet
periods. Biocidal additives are proposed for use in the cooling towers, and have
been approved for use by the Division's Aquatic Toxicology Unit.
h. Pretreatment Program (POTWs only): Not Needed.
2. Residual handling and utilization/disposal scheme: Residuals generation is not expected.
3. Treatment plant classification: Does not meet minimum criteria for a Class I rating.
4. SIC Code(s): 3780 Wastewater Code(s): 14 MTU Code(s): N/A
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? No public monies were used in the construction of this
facility.
2. Special monitoring or limitations (including toxicity) requests: None at this time.
3. Important SOC/JOC or Compliance Schedule dates: N/A

Page Three
4. Alternative analysis evaluation
a. Spray Irrigation: This option may be available, however, it would be economically
impractical given the small quantity of wastewater generated.
b. Connect to regional sewer system: The nearest municipal collection system is
4.6 miles from the site.
C. Subsurface: This option may be available, however, it would be economically
impractical given the small quantity of wastewater generated.
d. Other disposal options: None that we are aware of.
PART IV - EVALUATION AND RECOMMENDATIONS
The applicant, Mack Molding Company, has applied fora GP for the discharge of up to
500 gpd of non -contact cooling water from a cooling tower. This cooling tower has been in
existence since 1989, however, as a result of excessive scaling within the cooling tower, biocidal
additives have been selected that will assist in dissolving and eliminating the scale deposits.
Approval of the biocidal additives has been obtained from the Division's Aquatic Toxicology
Unit.
The discharge will be released at the southeast corner of the facility, and travel overland
for several hundred feet before it contacting the receiving stream. It is likely that the discharge
will soak into the ground before reaching the receiving stream, except during extended wet
periods.
It is recommended that a GP be issued as requested to Mack Molding Company.
Water
h:\dsr\dsc04\mack.dsr
f26
tal Supervisor
6�d
D to

NCS Stormwater Questions for Facilities in BIMS
Stormwater Pollution Prevention Plan -
Yes
No
NA
NE
Does the site have a Stormwater Pollution Prevention Plan?
❑
❑
❑
❑
Site Plan
1. Does the Plan include a General Location (USGS) map?
❑
❑
❑
❑
Facility location in relation to roads and surface waters. Includes: name of receiving stream or name of municipal
storm sewer system, and accurate lat. and long. of point of discharge. This helps the permittee to understand their
location with respect to receiving waters.
2. Does the Plan include a "Narrative Description of Practices"?
❑
❑
❑
❑
Should cover storage practices, loading and unloading areas, outdoor process areas, dust or particulate generating
or control processes, and waste disposal practices, etc.
3. Does the Plan include a detailed site map including outfall locations and
❑
❑
❑
❑
drainage area's?
Should show
• Location of industrial activities (storage areas, disposal areas, process areas, unloading and loading areas)
• The drainage structures
• Drainage areas for each outfall and activities occurring in the drainage area
• Building locations
• Existing BMPs and impervious surfaces and the % of each drainage area that is impervious
• For each outfall, a narrative description of the potential pollutants which could be expected to be present in the
stormwater discharge.
This forces permittee to analyze the site with relation to stormwater discharges. It is also a tool for the inspector to
understand if the site has changed over time, i.e. if site map does not match facility they must update their plan.
4. Does the Plan include a list of significant spills occurring during the past 3
❑
❑
❑
❑
years?
Needs to include corrective actions that were taken. The permittee needs to know what the reportable quantities are
for wastewater, oil pollution, and SARA Title III.
5. Have stormwater outfalls been evaluated for the presence of non-stormwater
ElEl❑
Eldischarges?
Signature required:
• Corporation - signed by Responsible Corporate Officer or assigned manager
• Partnership or Sole Proprietorship — General Partner or the Proprietor
• Municipality, State, Federal, or other public agency — either principal executive officer or ranking elected official
Comments:

NCS Stormwater Questions for Facilities in BIMS
Stormwater Management Plan
Yes
No
NA
I NE
1. Has the facility evaluated feasible alternatives to current practices?
❑
❑
❑
❑
• Provide a review of the technical and economic feasibility of changing the methods of operations and/or
storage practices to eliminate or reduce exposure of materials and processes to stormwater.
• In areas where elimination of exposure is not practical, the stormwater management plan shall document the
feasibility of diverting the stormwater runoff away from areas of potential contamination.
2. Does the facility provide all necessary secondary containment?
❑
I ❑
❑
❑
• Applies to liquid raw materials, manufactured products, waste materials, or by-products
• Single AST capacity > 660 gallons
• Multiple AS containers in close proximity to each other with a total combined capacity of > 1,320
• If connected to SW conveyance; controlled by manually activated valves or other similar devices? (Closed?)
• Collected water observed for color, foam, outfall staining, visible sheens, and dry weather flow prior to release
• Document individual making observation, description of water, date, and time of release (RR=5 yrs)
3. Does the Plan include a BMP summary?
❑
❑
I ❑
❑
Narrative description of BMPs to be considered including oil and grease separation, debris control, vegetative filter
strips, infiltration and stormwater detention or retention, where necessary.
• The need for structural BMPs shall be based on the assessment of potential sources to contribute significant
quantities of pollutants to stormwater discharges and data collected through monitoring of stormwater
discharges.
4. , Does the Plan include a Spill Prevention and Response Plan (SPRP)?
❑
I ❑
❑
I ❑
• Assessment of potential pollutant sources based on materials inventory of the facility
+ Facility personnel responsible for implementing the SPRP shall be identified
• Responsible person shall be on -site at all times during facility operations that have the potential to
contaminate stormwater runoff through spills or exposure of materials associated with the facility operations.
5. , Does the Plan include a Preventative Maintenance and Good Housekeeping
❑
❑
❑
❑
Plan?
Document schedules of inspections and maintenance activities of stormwater control systems, plant
equipment and systems
• Inspect material handling areas
• Regular cleaning schedules of these areas
6. Does the facility provide and document Employee Training?
❑ 1
❑ I
❑ I
❑
• Provide at a minimum, annual training for all personnel including: proper spill response, cleanup procedures,
preventative maintenance activities for all personnel involved in any of the facility's operations that have
the potential to contaminate stormwater runoff
• Develop training schedule and identify facility personnel responsible for implementing the training

NCS Stormwater Questions for Facilities in BIMS
Yes
No
NA
NE
7. Does the Plan include a list of Responsible Parties?
❑
❑
❑
❑
Identify position responsible for the overall coordination, development, implementation, and revision of the SPPP
8. Is the Plan reviewed and updated annually?
❑ I
❑
I ❑ I
❑
Have there been any changes to the design, construction, operation, or maintenance of the facility, which would have
a significant effect on the potential for the discharge of pollutants to surface waters? Does plan include changes?
9. Does the Plan include a Stormwater Facility Inspection Program?
❑
❑
1 ❑
I ❑
• Inspect at a minimum semiannually once in Fall (Sept. -Nov) and once in Spring (Apr -June)
• Inspection and subsequent maintenance activities performed shall be documented
o Record date and time
o Individual performing inspection
o Narrative description of the stormwater outfall and plant equipment and systems
• Records should be incorporated into the SPPP
10. Has the Stormwater Pollution Prevention Plan been implemented?
❑
1 ❑
1 ❑
❑
Have they done what they said they were going to do and have they documented it. Examples include:
• Monitoring and measurements including sampling data
• Inspections
• Maintenance activities
• Training provided to employees
• Activities to implement BMPs associated with industrial activities including vehicle maintenance. (RR=5 yrs)
Comments:
Qualitative Monitoring
Yes
No
NA
NE
1. Has the facility conducted its Qualitative Monitoring semi-annually?
❑
❑
❑
❑
Sampling in Spring (April -June) and Fall (September -November)
Color Odor Clarity Floating Solids
Suspended solids Foam Oil Sheen Other indicators
Comment:

NCS Stormwater Questions for Facilities in BIMS
Analytical Monitoring
Yes
No
NA
NE
1. Has the facility conducted its Analytical monitoring?
❑
❑
❑
❑
2. Has the facility conducted its Analytical monitoring from Vehicle Maintenance
❑
El
Elareas?
Comment:
I
Permit and Outfalls
Yes
No
NA
NE
I., Is a copy of the Permit and the Certificate of Coverage available at the site?
❑
❑
❑
❑
2. , Were all outfalls observed during the inspection?
❑
❑
❑
❑
If the facility D has representative outfall status; has it been documented by the
❑
❑
El
ElDivision?
4. i Has the facility evaluated all illicit (non stormwater) discharges?
❑
❑
❑
❑
Comment:

NCG Stormwater Questions for Facilities in BIMS
Yes
No
NA
NE
Stormwater Pollution Prevention Plan
❑
❑
❑
❑
Does the site have a Stormwater Pollution Prevention Plan?
❑
❑
❑
❑
Does the Plan include a General Location (USGS) map?
❑
❑
❑
❑
Does the Plan include a "Narrative Description of Practices"?
❑
❑
❑
❑
Does the Plan include a detailed site map including outfall locations and drainage areas?
❑
❑
❑
❑
Does the Plan include a list of significant spills occurring during the past 3 years?
❑
❑
❑
❑
Has the facility evaluated feasible alternatives to current practices?
❑
❑
❑
❑
Does the facility provide all necessary secondary containment?
❑
❑
❑
❑
Does the Plan include a BMP summary?
❑
❑
❑
❑
Does the Plan include a Spill Prevention and Response Plan (SPRP)?
❑
❑
❑
❑
Does the Plan include a Preventative Maintenance and Good Housekeeping Plan?
❑
❑
❑
❑
Does the facility provide and document Employee Training?
❑
❑
❑
❑
Does the Plan include a list of Responsible Party(s)_?
❑
❑
❑
❑
Is the Plan reviewed and updated annually?
❑
❑
❑
❑
Does the Plan include a Stormwater Facility Inspection Program?
❑
❑
❑
❑
Has the Stormwater Pollution Prevention Plan been implemented?
❑
❑
❑
❑
Comment:
Yes No NA NE
Qualitative Monitoring ❑ ❑ ❑ ❑
Has the facility conducted its Qualitative Monitoring semi-annually? ❑ ❑ ❑ ❑
Comment:
Yes
No
NA
NE
Analytical Monitoring
❑
❑
❑
❑
Has the facility conducted its Analytical monitoring?
❑
❑
❑
❑
Has the facility conducted its Analytical "monitoring from Vehicle Maintenance areas?
❑
❑
❑
❑
Comment:
Yes
No
NA
NE
Permit and Outfalls
❑
❑
❑
❑
Is a copy of the Permit and the Certificate of Coverage available at the site?
❑
❑
❑
❑
Were all outfalls observed during the inspection?
❑
❑
❑
❑
If the facility has representative outfall status; has it been documented by the Division?
❑
❑
❑
❑
Has the facility evaluated all illicit (non stormwater) discharges?
❑
❑
❑
❑
Comment:

NCS Stormwater Questions for Facilities in BIMS
Stormwater Pollution Prevention Plan
Yes
No
NA
NE
Does the site have a Stormwater Pollution Prevention Plan?
❑
❑
❑
❑
Site Plan
1. Does the Plan include a General Location (USGS) map?
❑
1 ❑
❑
❑
Facility location in relation to roads and surface waters. Includes: name of receiving stream or name of municipal
storm sewer system, and accurate lat. and long. of point of discharge. This helps the permittee to understand their
location with respect to receiving waters.
2. Does the Plan include a "Narrative Description of Practices"?
❑
❑
❑
I ❑
Should cover storage practices, loading and unloading areas, outdoor process areas, dust or particulate generating
or control processes, and waste disposal practices, etc.
3. Does the Plan include a detailed site map including outfall locations and
❑
❑
❑
❑
drainage areas?
Should show
• Location of industrial activities (storage areas, disposal areas, process areas, unloading and loading areas)
• The drainage structures
• Drainage areas for each outfall and activities occurring in the drainage area
• Building locations
• Existing BMPs and impervious surfaces and the % of each drainage area that is impervious
• For each outfall, a narrative description of the potential pollutants which could be expected to be present in the
stormwater discharge.
This forces permittee to analyze the site with relation to stormwater discharges. It is also a tool for the inspector to
understand if the site has changed over time, i.e. if site map does not match facility they must update their plan.
4. Does the Plan include a list of significant spills occurring during the past 3
El❑
ElElyears?
Needs to include corrective actions that were taken. The permittee needs to know what the reportable quantities are
for wastewater, oil pollution, and SARA Title I II.
5. Have stormwater outfalls been evaluated for the presence of non-stormwater
❑
❑
❑
❑
discharges?
Signature required:
• Corporation - signed by Responsible Corporate Officer or assigned manager
• Partnership or Sole Proprietorship — General Partner or the Proprietor
• Municipality, State, Federal, or other public agency — either principal executive officer or ranking elected official
Comments:

NCS Stormwater Questions for Facilities in BIMS
Stormwater Management Plan
Yes
No
NA
NE
1. Has the facility evaluated feasible alternatives to current practices?
❑
❑
❑
❑
• Provide a review of the technical and economic feasibility of changing the methods of operations and/or
storage practices to eliminate or reduce exposure of materials and processes to stormwater.
• In areas where elimination of exposure is not practical, the stormwater management plan shall document the
feasibility of diverting the stormwater runoff away from areas of potential contamination.
2. Does the facility provide all necessary secondary containment?
❑
1 ❑
❑
❑
ip Applies to liquid raw materials, manufactured products, waste materials, or by-products
• Single AST capacity > 660 gallons
• Multiple AS containers in close proximity to.each other with a total combined capacity of > 1,320
• If connected to SW conveyance; controlled by manually activated valves or other similar devices? (Closed?)
• Collected water observed for color, foam, outfall staining, visible sheens, and dry weather flow prior to release
+ Document individual making observation, description of water, date, and time of release (RR=5 yrs)
3. Does the Plan include a BMP summary?
❑
j ❑
1 ❑
1 ❑
Narrative description of BMPs to be considered including oil and grease separation, debris control, vegetative filter
strips, infiltration and stormwater detention or retention, where necessary.
41 The need for structural BMPs shall be based on the assessment of potential sources to contribute significant
quantities of pollutants to stormwater discharges and data collected through monitoring of stormwater
discharges.
4. Does the Plan include a Spill Prevention and Response Plan (SPRP)?
❑
1 ❑
1 ❑
I ❑
• Assessment of potential pollutant sources based on materials inventory of the facility
Facility personnel responsible for implementing the SPRP shall be identified
• Responsible person shall be on -site at all times during facility operations that have the potential to
contaminate stormwater runoff through spills or exposure of materials associated with the facility operations.
5. Does the Plan include a Preventative Maintenance and Good Housekeeping
❑
❑
❑
❑
Plan?
• Document schedules of inspections and maintenance activities of stormwater control systems, plant
equipment and systems
• Inspect material handling areas
• Regular cleaning schedules of these areas
6. Does the facility provide and document Employee Training?
❑
❑ 1
❑
❑
• Provide at a minimum, annual training for all personnel including: proper spill response, cleanup procedures,
preventative maintenance activities for all personnel involved in any of the facility's operations that have
the potential to contaminate stormwater runoff
• Develop training schedule and identify facility personnel responsible for implementing the training

NCS Stormwater Questions for Facilities in BIMS
Yes
No
NA
I NE
7. Does the Plan include a list of Responsible Parties?
❑
❑
❑
❑
Identify position responsible for the overall coordination, development, implementation, and revision of the SPPP
8. Is the Plan reviewed and updated annually?
❑
❑
I ❑
I ❑
Have there been any changes to the design, construction, operation, or maintenance of the facility, which would have
a significant effect on the potential for the discharge of pollutants to surface waters? Does plan include changes?
9. Does the Plan include a Stormwater Facility Inspection Program?
❑
1 ❑
❑
❑
• Inspect at a minimum semiannually once in Fall (Sept. -Nov) and once in Spring (Apr -June)
• Inspection and subsequent maintenance activities performed shall be documented
o Record date and time
o . Individual performing inspection
o Narrative description of the stormwater outfall and plant equipment and systems
• Records should be incorporated into the SPPP
10. Has the Stormwater Pollution Prevention Plan been implemented?
❑
I ❑
❑
❑
Have they done what they said they were going to do and have they documented it. Examples include:
• Monitoring and measurements including sampling data
• Inspections
• Maintenance activities
• Training provided to employees
• Activities to implement BMPs associated with industrial activities including vehicle maintenance. (RR=5 yrs)
Comments:
Qualitative Monitoring
Yes
No
NA
NE
1. Has the facility conducted its Qualitative Monitoring semi-annually?
❑
❑
❑
❑
Sampling in Spring (April -June) and Fall (September -November)
Color Odor Clarity Floating Solids
Suspended solids Foam Oil Sheen Other indicators
Comment:

NCS Stormwater Questions for Facilities in BIMS
Analytical, Monitoring
Yes
No
NA
NE
1. Has the facility conducted its Analytical monitoring?
❑
❑
❑
❑
2. Has the facility conducted its Analytical monitoring from Vehicle Maintenance
El
El
El
Elareas?
Comment:
Permit and Outfalls
Yes
No
NA
NE
1. Is a copy of the Permit and the Certificate of Coverage available at the site?
❑
❑
❑
❑
2. Were all outfalls observed during the inspection?
❑
❑
❑
❑
3..If the facility has representative outfall status; has it been documented by the
Division?
❑
❑
❑
❑
4. Has the facility evaluated all illicit (non stormwater) discharges?
❑
❑
❑
❑
Comment:

OF W A
MEMO
May 10, 2004
To: Mike Parker, MRO
From: Ken Pickle, SGPU
Subject: Request for a staff report
Discussion
Mike,
Michael F. Easley
Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
l%00k:`s1�+', + " '�iONA!_ OFFICE
yr1
MAY 1 2 2004
=s
TV,
I am requesting a staff report for the Mack Molding Company site at 149 Water Tank Road
in Statesville. They have applied for a general permit to discharge cooling tower blowdown
into a UT to Broad Meadow Creek, WS-IV. After a second submittal their NOI and
supporting information is in order, and I intend to issue them general permit NCG500618,
pending your staff report and ok. The second, amended submittal is attached for your
information.
Thanks,
Ken
0A
NCDENR
Customer Service
1 800 623-7748
Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 [phone]

__ vas<,.�,ti
�. .�. as .-�.. .--5t�s:V�•`��
MACK MOLDING C
149 WATER TANK
STATESVILLE, NC
U
SUBMITTED JAN
REVISED APRIL
PREPARED FOR:
MR. FRANK BUMGARNER
MACK MOLDING COMPANY
149 WATER TANK ROAD
STATESVILLE, NC 28677
[phone]
H.•LIASONIMackMoldinglMac1002IRevised 042704IRevised CoverTOCI.doc
Udm+�lHJizaa�'�au':�yi
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM (NPDES)
APPLICATION FOR COVERAGE UNDER GENERAL PERMIT NCG500000: NON —
CONTACT COOLING WATER, BOILER BLOWDOWN, COOLING TOWER
BLOWDOWN, CONDENSATE, AND SIMILAR POINT SURFACE DISCHARGES
PREPARED FOR:
OMPANY [ J
ROAD
28677
ARY 2004
2004
PREPARED BY:
HRP
MAY 3 2004
�U;
ENVIRONMENTAUCIVIL ENGINEERING &
HYDROGEOLOGY
7001-J PELHAM ROAD
GREENVILLE, SC 29615
[phone]
"Creating the Right Solutions Together" HR1C G�1�Oc�-, �•

SECTION
1.0
2.0
3.0
4.0
5.0
6.0
TABLE OF CONTENTS
NOTICE OF INTENT
PHYSICAL LOCATION INFORMATION
ENGINEERING ALTERNATIVES ANALYSIS
BIOCIDE / CHEMICAL TREATMENT INFORMATION
CHEMICAL TREATMENT PRODUCT INFORMATION AND MSDS
SPRAY FIELD IRRIGATION COST ANALYSIS AND SUPPORTING DATA
H.-UASONWackMoldingWac]0021Revised 0427041Revised CoverTOC.doc
"Creating the Right Solutions Together" HRP (/Ly voie4 , ��-

SECTION 1.0
NOTICE OF INTENT
KVASON1MackMoldinglMac10021Revised 0427041Revised CoverTOCI.doc
"Creating the Right Solutions Together- HRP�(•

rorz 4c.r.�c Y iish unl.v
Hate Re(ei,rd _.
� I Year !,4nnih T nay.
Division of -N ater Quality / Water Quality Section
CC uriicItc of C�vcrtsc�
NCDENR National Pollutant Discharge Elimination System ---
! Check a i Amount
NOrJrn C.�NOVM1� DEY�r.1 rEMl pr �_ -_
[.vino.. _ -E-CES Permit Assi „ted to
NCG500000
NOTICE OF INTENT
National Pollutant Discharge Elimination System application for coverage under General Permit
NCG500000: Non -contact cooling water, cooling tower and boiler blowdown, condensate, exempt
stormwater, cooling waters associated with hydroelectric operations and similar wastewaters
(Please print or type)
1) Ownerloperator:
Company Name: Mack Moldin___Co _------
Contact Person: Don Kendall
Street Address: 149 Water Tank Rd.
------------------------
City: Statesville
Telephone No.: 704-88878-9641
2) Location of facility producing discharge:
Facility Name: Mack Molding Co ____
Contact Person- F`ranTc�umgarner
Stater_—_ ZIP Code:28g77___--
Fax: 704=$Z3—12fz6
--------------------------------------------------
Street Address: 1 9 Wat<_er_Sa.nk__Rd-----__—___--_—_____—_____--__—_—___
City: t u}l�------------------- State: NC -__ ZIP Code:2fa'ZZ_____
County: Iredell
----------------------
------------------------------
Telephone No.: 704_ 878-9641 Fax:7D�3.73-1966------------
3) Permit Contact (complete this section if permit contact is different from facility contact) :
Contact Person
Street Address:
City:
County:
Telephone No.:
faayuW __Dayis_--------------------------------------
7001-J Pelham Rd
864=289-0311
4) Physical location information:
State:_ZIP Code: 29,&l 5 --
Fax: 864-2
A copy of an USGS quad map or county map with the facility clearly located on the map IS REQUIRED to
be submitted with this application.
Please provide a narrative description of how to get to the facility (use street names, state road numbers,
and distance and direction from a roadway intersection): From I­roTW
Mountain -Rd (limit 1:4_4) ,_ Right on Water Tank Rd.__—_ --_-
5) This NPDES permit application applies to which of the following:
New or Proposed ❑ Modification
Please describe the modification:
❑ Renewal —
Please specify existing permit number and original issue date:
Page 1 of 4
SWU-212-080102

NCG500000 N.O.I.
6) Does this facility have any other NPDES permits, including stormwater general permits?
No ❑Yes
If yes, list the permit numbers for this facility: ----________ _____________------_-
------------7) What is the nature of the business applying for this permit? ___ ________________-_--__----
Injection Molded Plastic Parts (SIC Code 3780)
8) Description of Discharge:
a) Total number of discharge points that convey wastewater from the property, including ditches, pipes,
channels, etc.: 1. _ .
---------------------------------------------------------
b) What type of wastewater is discharged and from which discharge points?
❑ Non -contact cooling water Discharge point(s) # : _--___--___—__
❑ Boiler Blowdown Discharge point(s) # : ______--____
9 Cooling Tower Blowdown Discharge point(s) # : ---1 _----_ ____
❑ Condensate Discharge point(s) # : -----------
El Other Other Discharge point(s) # : ___------- —_____
(Please describe "Other") :____________—____--________—---------
c) Approximate volume of discharge for each discharge point (in GPD):
41: _ 500 ------ #2:------------- #3:------------- #4 -----------
9) Please check the type of chemical added to the wastewater for treatment for each separate discharge
point (if applicable, use separate sheet):
❑ Biocides
Name:
— Manuf.:
M Corrosion inhibitors
Name: —Reference _EAA
Manuf.:
❑ Chlorine
Name:
Manuf.:
❑ Algaecide
Name:
Manuf.:
❑ Other
Name:
Manuf.:
❑ None
If any box above, other than none, was checked, a completed Biocide 101 Form and manufacturers
information, including MS/DS sheets on the additive IS REQUIRED to be submitted with the application
for the Division's review.
10) Discharge Frequency:
a) The discharge is: CT Continuous ❑ Intermittent
i) If the discharge is intermittent, describe when the discharge will occur:
❑ Seasonal•
ii) If seasonal check the month(s) the discharge occurs: ❑ Jan. ❑ Feb. ❑ Mar. ❑ Apr.
❑ May ❑ Jun. ❑ Jul. ❑ Aug. ❑ Sept. ❑ Oct. ❑ Nov. ❑ Dec.
b) How many days per week is there a discharge?
11) Receiving waters:
a) What is the name of the body or bodies of water (creek, stream, river, lake, etc.) that the facility
wastewater discharges end up in? If the site wastewater discharges to a separate storm sewer
system (4S), name the operator of the 4S (e.g. City of Raleigh) : B , %'�.E4 bout GRE6
b) Stream Classification (WS-IV, NSW, etc.) : _ WS—T _
Page 2 of 4
SWU 212-080102

NCG500000 N.O.I.
c) Is the discharge directly to the receiving water? ❑ Yes 7 No
If no, a site map with the pathway to the potential receiving waters clearly marked IS REQUIRED to
be submitted with the application. This includes tracing the pathway of the storm sewer to the
discharge point, if the storm sewer is the only viable means of discharge.
12) Is there any type of treatment being provided to the wastewater before discharge (i.e., retention ponds,
settling ponds, etc.)? ❑ Yes ET No
If yes, please include design specifics (i.e., design volume, retention time, surface area, etc.) with
submittal package. Existing treatment facilities should be described in detail. Design criteria and
operational data (including calculations) should be provided to ensure that the facility could comply with
the requirements of the General Permit. The treatment shall be sufficient to meet the limits set by the
general permits.
Note: Construction of any wastewater treatment facilities requires submission of three (3) sets of plans
and specifications along with the application. Design of treatment facilities must comply with the
requirements of 15A NCAC 2H .0138. If construction applies to this discharge, include the three
sets of plans and specifications with this application.
13) Pollutants:
Please list any known pollutants that are present in the discharge, per each separate discharge point (if
applicable, use separate sheet) : Reference EAA__----------------
14) Alternatives to Direct Discharge:
Address the feasibility of implementing each of the following non -discharge alternatives
a) Connection to a Regional Sewer Collection System
b) Subsurface disposal (including nitrification field, infiltration gallery, injection wells, etc.)
c) Spray irrigation
The alternatives to discharge analysis should include boring logs and/or other information indicating that a
subsurface system is neither feasible nor practical as well as written confirmation indicating that
connection to a POTW is not an option. It should also include a present value of costs analysis as
outlined in the Division's "Guidance For the Evaluation of Wastewater Disposal Alternatives".
15) Additional Application Requirements:
For new or proposed discharges, the following information MUST BE INCLUDED in triplicate with this
application or it will be returned as incomplete.
a) 7.5 minute series USGS topographic (quad) map (or a photocopied portion thereof) with discharge
location clearly indicated.
b) Site map. If the discharge is not directly to a stream, the pathway to the receiving stream must be
clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
c) If this application is being submitted by a consulting engineer (or engineering firm), include
documentation from the applicant showing that the engineer (Or firm) submitting the application has
been designated an authorized Representative of the applicant.
i.� d) Final plans for the treatment system (if applicable). The plans must be signed and sealed by a North
Carolina registered Professional Engineer and stamped -"Final Design -Not released for construction".
Page 3 of 4
SWU-212-080102

NCG500000 N.O.I.
e) Final specifications for all major treatment components (if applicable). The specifications must be
signed and sealed by a North Carolina registered Professional Engineer and shall include a narrative
description of the treatment system to be constructed.
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing: --------------------------- -------------
Title:
-------------------------------------------------------------------
(Signature of Applicant) (Date Signed)
North Carolina General Statute 143-215.6 b (i) provides that:
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan
or other document filed or required to be maintained under Article 21 or regulations of the Environmental Management
Commission implementing that Article, or who falsifies, tampers with or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the Environmental
Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed
$10,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine
of not more than $10,000 or imprisonment not more than 5 years, or both, for a similar offense.)
Notice of Intent must be accompanied by a check or money order for $80.00 made payable to:
NCDENR
Mail three (3) copies of the entire package to:
Stormwater and General Permits Unit
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Final Checklist
This application will be returned as incomplete unless all of the following items have been
included:
l Check for $80 made payable to NCDENR
3 copies of county map or USGS quad sheet with location of facility clearly marked on map
1 3 copies of this completed application and all supporting documents
❑ 3 sets of plans and specifications signed and sealed by a North Carolina P.E. (No Treatment Sys. Design
iN Alternatives analysis including present value of costs for all alternatives
Note
The submission of this document does not guarantee the issuance of an NPDE.S permit
Page 4 of 4
SWU-212-080102

SECTION 2.0
PHYSICAL LOCATION INFORMATION
"Creating the Right Solutions Together" HR aaa....�, ( •

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Name: STATESVILLE WEST Location: 035° 45' 43.7" N 081 ° 00' 02.6" W
Date: 4/27/104 Caption: Site Location -Mack Molding
Scale: 1 inch equals 1000 feet
Copyright (C) 1997, Maptech, Inc.

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81 b 00'
0.0b" I I 1 0804 58'
0.0 " W 1 080 56' 0.0 " VV 80° 54'
0.00'
Name: STATESVILLE WEST Location: 035' 46' 44.8" N 080' 57' 12.9" W
Date: 4/27/104 Caption: Distance to Nearest Sewer Connection
Scale: 1 inch equals 4000 feet
Copyright (C) 1997, Maptech, Inc.

SECTION 3.0
ENGINEERING ALTERNATIVES ANALYSIS
"Creating the Right Solutions Together" HRP� In G.

ENGINEERING ALTERNATIVES ANALYSIS (EAA)
MACK MOLDING COMPANY
149 WATER TANK ROAD
STATESvILLE, NC 28677
RE: NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM (NPDES) APPLICATION
FOR COVERAGE UNDER GENERAL PERMIT NCG500000: NON -CONTACT COOLING
WATER, BOILER BLOWDOWN, COOLING TOWER BLOWDOWN, CONDENSATE, AND
SIMILAR POINT SURFACE DISCHARGES
I. GENERAL INFORMATION
A. Basic Identification of the Project
■ Facility Name: Mack Molding
■ County: Iredell
■ Facility Address: 149 Water Tank Road, Statesville, NC 28677
■ Facility Phone #: [phone]
■ EAA Preparer's Name: Jason W. Davis, PE, HRP Associates, Inc.
■ EAA Preparer's Address: 7001-J Pelham Road, Greenville, SC 29615
■ EAA Preparer's Phone #: [phone]
B. Project Description
Mack Molding Company currently maintains a 916 gallon, double cell Thermal
Care, non -contact cooling tower for the sole purpose of cooling machinery and
other equipment. Each cell (Model FC620, Model FC 640) has a 115 and 140 ton
cooling capacity, respectively. Water for the cooling tower is derived from an on -
site groundwater production well. The cooling tower has been in operation since
1989, and has subsequently developed silica (scale) deposits, primarily in the heat
exchanger, resulting in reduced operating efficiency. In order to restore
operational efficiency, Mack Molding Company is proposing the use of two
chemical additives to slowly dissolve and flush the system of scale deposits,
promote a more adherent protective film for corrosion inhibition, and maintain a
balanced coolant water pH to inhibit future scale accumulation. The chemical
additives to be employed consist of Dica 66, and OmniGuard.
Dica 66 is a concentrated sulfiuic acid used for in-service descaling of cooling
systems. Dica 66 shall be an initial, non -continuous application. The initial
application will take course over approximately 30-days and will involve a total
1
H.•VASOMMackMoldinglMacI0021Revised 0427041EngineeringAlternatives Analysis.doc
"Creating the Right Solutions Together" HRP ( ..

usage of approximately 10-gallons of Dica 66. The purpose of the Dica 66
additive is to lower the system water pH to 6.0 to 6.5. The low pH will cause
some scale to dissolve and the rest to disintegrate. During the initial Dica 66
application, Mack Molding is proposing to slowly and continuously discharge
cooling tower waters (approximately 500 gallons/day) in order to aid in the
flushing of silica scale deposits as well as to maintain pH levels at approximately
6.5. Based on a daily discharge rate 500 gallons, a continuous discharge rate of
approximately 0.34 gallons/minute will be realized. The proposed discharge shall
be released at the southeast corner of the manufacturing facility and, assuming no
evaporation or infiltration, travel overland via gravity flow, ultimately discharging
to a tributary of Broad Meadow Creek located approximately 1850 feet southeast
of the facility.
Following the initial Dica 66 application, Omni Guard will be employed as a
continuous additive to maintain optimal water quality. Omni Guard is a
molybdenum containing additive and corrosion inhibitor. Omni Guard is typically
maintained at 400-500 ppm, resulting in a molybdenum concentration of 10-12
ppm.
Preliminary communications (Nov. 2003-Dec. 2003) with Todd Christensen of
the NC-DENR Environmental Sciences Branch, and Ken Pickle of the NC-DENR
Stormwater Unit, requested an evaluation of the proposed additives Dica 66 and
Omni Guard, as well as a third additive, Ultrex LM PPB. Based on these initial
evaluations, Dica 66 and Omni Guard were approved for potential discharge,
while Ultrex LM PPB was deemed unacceptable due to the biocidal compounds
sodium bromide and sodium tolytriazole. Copies of the Division of Water
Quality's evaluation are included in Section 4.0, Biocide/Chemical Treatment
Information. Further communication with Al McCormick of Dubois Chemicals,
the supplier of the proposed additives, indicated that Mack Molding could
successfully achieve the necessary water quality objectives without the use of
Ultrex LM PPB. Therefore, Mack Molding is proposing the use of Dica 66 and
Omni Guard only.
The use of these additives will subsequently require limited discharge of non -
contact cooling water. Mack Molding anticipates that this discharge volume will
be approximately 500 gallons/day during the fall and winter months, 300 gallons
per day during the spring and summer months. Based on a daily discharge rate of
500 gallons, a continuous discharge rate of approximately 0.34 gallons/minute
will be realized. The proposed discharge shall be released at the southeast corner
of the manufacturing facility and, assuming no evaporation or infiltration, travel
overland via gravity flow, ultimately discharging to a tributary of Broad Meadow
Creek located approximately 1850 feet southeast of the facility.
2
Engineering Alternatives Analysis
"Creating the Right Solutions Together" HRP l/ j".. — , � .ri.

"Creating the Right Solutions Together" HR1 AEG �, .-

H. EVALUATE DISPOSAL ALTERNATIVES
A. Connection to a Regional Sewer Collection System
According to Carol Murphy, City of Statesville Commission of Public Works, the
nearest sewer connection is located at the intersection of Garner -Wagner Blvd.
and US 70 in Statesville, NC, approximately 4.6 miles from the Mack Molding
facility (see Figure 2). The cost of installing a sewer connection line is cost
prohibitive for this project due to the distance involved.
B. Subsurface/Spray Irrigation Disposal
Mack Molding owns and maintains an undeveloped tract of land, encompassing
approximately 1.5 acres, located west of the manufacturing facility. To date, no
geotechnical investigations have been performed for soils in this area to determine
the feasibility of land application, drip irrigation, or subsurface injection (i.e
infiltration gallery).
In the event that NC DENR will not permit the proposed discharges under
NCG500000, and that site soils are suitable for a subsurface disposal system, a
Present -Value -of Costs Analysis indicates that installation and operation of a
subsurface disposal system is approximately $24,110, while Present -Value -of
Costs Analysis indicates installation and operation of spray irrigation system is
$30, 664 (reference Section 6.0 for sprayfield irrigation cost analysis).
C. Wastewater Reuse
There are currently no wastewater reuse applications available for cooling tower
discharge.
D. Surface Water Discharge
Direct Surface Water Discharges are typically considered in conjunction with
treatment plant design. Mack Molding's proposed discharge shall be released at
the southeast corner of the manufacturing facility and, assuming no evaporation or
infiltration, travel overland via gravity flow, ultimately discharging to a tributary
of Broad Meadow Creek located approximately 1850 feet southeast of the facility.
E. Disposal Combinations
Disposal Combinations consist of Subsurface/Spray Irrigation Disposal
(addressed in B) in conjunction with off -site transport of collected discharge for
disposal at a licensed wastewater disposal facility. Mack Molding currently
Engineering Alternatives Analysis
"Creating the Right Solutions Together" HRP Ai"G-' �'

maintains a contract with US Waste for transport and disposal of non -hazardous
wastewaters. The contract price for non -hazardous waste water disposal is
$0.75/gallon. Assuming a daily discharge rate of 500 gallon/day, six days/week,
52 weeks/year, the annual cost incurred is $117,000.
5
Engineering Alternatives Analysis
"Creating the Right Solutions Together- HRP

SECTION 4.0
BIOCIDE / CHEMICAL TREATMENT INFORMATION
f "Creating the Right Solutions Together" HRP G.,.".�, � •

.DIVISION OF WA' EP', QUALN-Y
rDcccinber S, 2003
Mf�.MORANDL[M
Ken Piclac — Stormwater l lnit
Throlluh: Malt M;iuhew•s
Broil: Todd Cltristc.rtsol►
Suhjccl: Mack Melding Company
Nr,l')T:S No. NCG500000 (blew Pern-iit)
Ircdcll County
Mack 11.'iuldin; Company 11as suhrltillcd thcirreclucst iOr 1pprc)v;11 of 1hC 1011otvinf;
wn(cr lival 11ent compounds for use nt its Iredell County facility.
Dubois Chemicals TNca GG— A concentrated sulruric mid do -scaling agent to be
Cuticcl 17or an iPiitial treatment PQ.riocl OF til)hrc \irrtatcly thirty days.
g&jhusouDivei-scy Omni Cutocl — A ccll-rc)sim inhibitor.
job Ulirex LM PIT — A biocide containing sodium bromide, and
fo sodium tolytri;azole.
Data submitted by the facility concerning the dosage rate, degradation, system
volume, average daily discharge, toxicity or the ,Iclive ingredient(s) and/or breakdown
pi-oducts, and minimum stream flow have been re.viewed and evaluated.
Basr..cl Ofl the calculations, the use of JohnswiDivercey Ullre_L LAI PPR al the;
slateel elosa e races and discharge c•oncliliuns will result in toxic impact to aquatic life
in thcc recei vine, mream and, thcre:fore:, is dco med unacceptable.
The docurncnts submitted on the facili-ties behalf suggest that Lhe primary conecril
is corrosion inhibition rather than biofouling. if so, a product containing biocidai
rotMpouncls such as soclium bromide: and sodium tolytriazole may be inappropriate for
this application.
Plewu e now that neither Dira GG nor Oath Guard contain biocidal itigredicnls,
thcrcforc.:ipproval of* this office is not necessary.
If thcro arc questions regarding this review please call me at [phone].
AlUichrrtcnis
cc: Central Files

% Mack Molding SIOCIDE W019KSHEEF
PERMITM NCG500000
RECEIVING STREAM: Roadorc.roc:k
7010.(cfs): 0.03 (given as 0.0-0.03 on 101 loan)
I.W.C.%: 2.52
PRODUCT: Ullrex LM PPB
ACTIVE INGREDIENT: NaBr (5.15%)
Sodium Tolylriazole (5-115%)
HALF LIFE (DAYS): 0.002 STEADY STATE DISC CONr 8.108335563
LC 0 01= SPLC-CI ED TOX DATA (MC 0.49 DWfIAnATION FACTOR: 410.882
DUGAY RATE: 4 05.824 APPLICATION FACTOR: 0.050
DO' IIATE (GRAMS/DAY): 1261
AVG DAILY DISCHARGE (MGD): 0.0005 INSTREAM BIOCIDE CONC 0.204
VOLUME OF SYSTf M (MIL. GAI: S): 0.0001 REGULATED LIATION:
�PA6S!FAIL: _ M11-0.025
FAIL
LC50 derived from previously submilted data for Nalco 73-12 (42.8% NaBr. LC50-0.17); Curren[
1,050 � 0.17x(42 8VI5'7.)-0.49
" Hall lilo = 2.4 minules based on calculaliens by New Hanover Refuse Plaill (1997) - NC000158971

SECTION 5.0
CHEMICAL TREATMENT PRODUCT INFORMATION AND MSDS
i
"Creating the Right Solutions Together" HRP ��► �

GENERAL DESCRIPTION:
Dica 66 is highly concentrated sulfuric acid and used to
reduce alkalinity and pH of cooling waters and other water
treatment applications. When used in conjunction with scale
inhibiting treatments, It helps to prevent the formation of scale
in cooling waters of a high alkaline nature.
TYPICAL PROPERTIES:
Appearance ......... . ............ . Heavy, clear liquid
Density ....... ........... . ... . .... 15.3 lbs./gal.
pH (1 % Solution) ................................ 1.5
Solubility .......................... Complete in water
USING PROCEDURES:
Dica 66 should be considered for use In cooling tower water
when the M alkalinity (total) of the make up water exceeds
250 ppm, in systems with high scale potential without
alkalinity reduction, and to allow higher cycles 'of
concentration in some situations.
' Sufficient Dica 66 should be added to maintain system M
alkalinity at 200 to 250 ppm or at a level established by the
DuBois Representative based on system conditions and
needs. The amount of the Dica 66 product required to
achieve these readings will be determined by the M alkalinity
of the make up water and the cycles of concentration that
�`— can be maintained.
Your DuBois Representative will recommend operating
parameters such as the proper cycles of concentration in
cooling systems, and the proper Dica 66 dosage, or pH for
such applications as waste treatment. One pound of Dica 66
product per 1000 gallons of water reduces its M alkalinity by
about 120 ppm.
Dica 66 acid can also be used for In-service descaling of
cooling systems. For this purpose, sufficient Dica 66 product
should be added to drop the system water pH to 6.0 to 6.5
until the scale is removed (usually 8 to 48 hours). The low pH
will cause some scale to dissolve and the rest to disintegrate.
Flush out any sludge accumulation and resume normal
treatment when descaling Is complete. Corrosion potential on
clean metal surfaces will increase during this period, so It is
critical that operating time under these depressed pH
conditions be limited.
# NOTE: Before opening the container, place it in the spot
where it will be used. Close container before moving it to
another location. DO NOT ADD WATER TO THE
CONTAINER.
DISPENSING:
Dica 66 should be discharged from the container with a
DuMETER Pulse pump or other acid -resistant pump.
TITRATION:
Testing for Dica 66 is performed (based on alkalinity
target)with either 11901, or W.T. 2001 Test Kits. A pH Test Kit
such as 42240 or a meter #033538 should be used if control
is based on pH.
MATERIAL SAFETY:
Dica 66 when properly diluted and used as recommended is
safe on all metals normally used in cooling system
construction. Excessive feed will be highly corrosive to most
metals.
STORAGE:
Acid liquid - avoid contact with alkaline materials_ Protect
from freezing and extreme heat. Keep container closed when
not in use.
May cause irritation or damage to eyes, skin and mucous
membranes. DO NOT TAKE INTERNALLY. Avoid contact
with eyes and skin. Wear appropriate personal protective
equipment to enable safe handling of an acidic liquid.
PRECAUTIONS:
KEEP OUT OF REACH OF CHILDREN.
Please refer to the label and Material Safety Data information
for all warnings, recommendations for safety equipment, and
other regulatory information. Copies of the Material Safety
Data information can be ordered by calling 800 438 2641.
ACCEPTABILITY:
Dica 66 Is authorized as G5 and G7.
DbB07S
ISO • C4-0000 Repletared Cuatltr System•
DuBois Chemicals - 12D0 Chemed Center - 255 E 51h 51 - Cmctinnaii OH 452024799 - 24-Hour Customer Service 600 438 2647 - Fax 800 433 S508
-the information contained In this bulletin is to our best knowledge. true and accurate, but ill recommendations or suggestions are made without guarantee. since the
conditions of use are beyond our control. DuBois Chemicats discioims any Gabdily tncutred to connection with the use or these data or suggestions.
Reorderr 1318616 (0597) - Tech Data

----- -- MATERIAL.-SP_EEIY DOM SHE -El Page I of 3
Revised 6/26/02
DICA 66 Replaces 6/25/02
Printed 9/25/02
MSDS ID- 01066
I CHEMICAL PRODUCT AM COMPANY IDENTIFICATION
LF,RODUCT.: NRWEd D I CA GG
PRODUCT DESCRIPTOR: INORGANIC ACID
ANUFACTURER: JOHNSONDIVERSEY, INC_
3630 E. KEMPER ROAD
CINCINNATI, OH. 45241
MERGENCY PHONE NUMBERS: MEDICAL (COLLECT): [phone]
CHEMTREC: [phone]
JOHNSONDIVERSEY: [phone]
INGREDIENT NAME(CAS NUMBER) % EXPOSURE LIMITS UNITS
------------------------------ --- - - ------------------------- -------
SULFURIC ACID (7664-93-9) 93 TLV 1; PEL 1 MG/M3
ROUTES OF ENTRY: INHALATION: YES
SKIN: NO
INGESTION: YES
SIGNS AND SYMPTOMS OF EXPOSURE:
ACUTE: DANGER - CAUSES BURNS TO EYES AND SKIN WITH PAIN, REDNESS AND
SWELLING. INHALATION MAY CAUSE IRRITATION OR BURNS TO
RESPIRATORY TISSUE WITH COUGHING OR CHOKING. SWALLOWING
CAUSES PAIN, NAUSEA AND POSSIBLE TISSUE DAMAGE.
CHRONIC: NO KNOWN HAZARDS
DICAL CONDITIONS GENERALLY AGGRAVATED BY EXPOSURE:
SENSITIVE SKIN; DUST OR MIST MAY AGGRAVATE RESPIRATORY
DISEASE.
EYES: IMMEDIATELY FLUSH THOROUGHLY WITH FRESH WATER FOR AT LEAST 15
MINUTES. GET MEDICAL ATTENTION IF EYES ARE INJURED OR IRRITATION
PERSISTS.
SKIN: IMMEDIATELY FLUSH WITH FRESH WATER. REMOVE CONTAMINATED CLOTHES
AND SHOES_
INGESTION: GIVE SEVERAL GLASSES OF WATER- DO NOT INDUCE VOMITING. GET MEDICAL
ATTENTION. NEVER GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON.
INHALATION: REMOVE TO FRESH AIR. GET MEDICAL ATTENTION.
FLASH POINT: NONE DEG F
FLAMMABLE LIMITS IN AIR BY VOLUME:
UNUSUAL FIRE OR EXPLOSION HAZARDS:
A
EXTINGUISHING MEDIA:
FIRE FIGHTING INSTRUCTIONS:
FLAME EXTENSION: N/A IN.
LEL:\NONE UEL: NONE.
LIQUID CORROSIVE MATERIAL CONTACT WITH
METALS WILL PRODUCE HYDROGEN WHICH IS
FLAMMABLE.
WATER SPRAY, CO2, DRY CHEMICAL
WEAR FULL PROTECTIVE GEAR AND

MAI R_i fly. _Sflf EI Y_ .pAIFL-5HU-1 Page 2 of 3
Revised 6/2G/02
DICA 66 Replaces 6/25/02
Printed 9/25/02
n� ID 0106E
V FIRE FIGHTING MEASURES (Cant.)
SELF-CONTAINED BREATHING APPARATUS (SCBA)
IN FIRE AREA.
i
VI RCCID`ENTRL RELEASE MERSUR S
IF MATERIAL IS RELEASED OR SPILLED: CONTAIN SPILL. ABSORB SMALL AMOUNTS ON
AND OR CLAY. PLACE IN COMPATIBLE CONTAINER. NEUTRALIZE RESIDUE WITH DILUTE
ALKALI AND FLUSH TO SANITARY SEWER. WASH AREA THOROUGHLY WITH WATER. CERCLA
PRODUCT R.Q_: 1,000 LBS.'OR GS GALLONS.
I
VII HANDLING AND STORRGF
HANDLING AND STORAGE PRECAUTIONS: STORE IN R COOL, DRY PLACE. KEEP CONTAINER
CLOSED WHEN MOVING OR NOT IN USE. KEEP OUT OF THE REACH OF CHILDREN. WHEN
DILUTING, ADD SLOWLY WITH STIRRING TO AVOID VIOLENT SPATTERING AND HEAT
GENERATION.
VIII EXPOSURE CONTROLS/P RSONAL PROTECTION
EYE/FACE PROTECTION: CHEMICAL GOGGLES, SIDE SHIELDED SAFETY GLASSES, OR
FACE SHIELD.
PROTECTIVE GLOVES: RUBBER/CHEMICAL RESISTANT.
RESPIRATORY PROTECTION: WEAR APPROVED CARTRIDGE RESPIRATOR TO MAINTAIN PEL/TLV
IN MIST, SPRAY, ON DUSTY CONDITIONS.
OTHER PROTECTIVE CLOTHING/EQUIPMENT: WEAR APRON, PROTECTIVE CLOTHING AND
FOOTWEAR_ LAUNDER CLOTHES BEFORE REUSE-
{ ` SAFETY SHOWER/EYE WASH.
EXPOSURE GUIDELINES: SEE SECTION II FOR DETAILED INFORMATION.
BOILIING POINT (F): 535 SPECIFIC GRAVITY: 1.8350
VOLATILE BY VOLUME: 7 SOLUBILITY IN WATER: 100
VAPOR PRESSURE (MMHG): N/A AT 20 C
APPEARANCE AND ODOR: CLEAR TO SLIGHTLY CLOUDY VISCOUS LIQUID, SLIGHT PUNGENT
ODOR.
CHEMICAL STABILITY:
INCOMPATIBILITY WITH OTHER MATERIALS:
HAZARDOUS DECOMPOSITION PRODUCTS
HAZARDOUS POLYMERIZATION:
STABLE
WATER, ALKALIS, ORGANIC MATERIALS, MOST
METALS.
OXIDES OF SULFUR
NONE

MATERIAL-SAFEIY DATE-5HEE7 Page 9 of 9
Revised 6/2G/02
DICA 66 Replaces 6/25/02
Printed 9/25/02
"S^c ID- 01066
XI TOXICOLOGICAL INFORMATION
NO DATA AVAILABLE
XII ECOLOGICAL INFORMATION
NO DATA AVAILABLE
L XIII DISPOSAL CONSIDERATIONS
WASTE DISPOSAL METHOD: DISPOSE OF IN ACCORDANCE WITH LOCAL, STATE, OR FEDERAL
REGULATIONS. TRIPLE RINSE EMPTY CONTAINER AND ADD RINSRTE TO OPERATION.
REMOVE OR DEFACE LABEL BEFORE SELLING, RECYCLING, OR DISPOSAL OF CONTAINER.
XIV TRANSPORT INFORMATION
HAZARDOUS MATERIALS DESCRIPTION/PROPER SHIPPING NAME:
DOT CLASS: SULFURIC ACID, 8, UN1830, PG II, ERG NO. 39 NAERG #137
XV REGULATORY INFORMATION
U_S_ FEDERAL REGULATIONS:
CERCLA/EPCRA:SECTION 313 TOXIC CHEMICALS:
THIS PRODUCT CONTAINS SULFURIC ACID (7664-93-9) AT 93%. FUMES AND MISTS
OF THIS ACID ARE REPORTABLE UNDER SARA TITLE III, SECTION 313.
LISTED CARCINOGEN: NONE
NTP: NO IARC: NO OSHA: NO
P14IS RATINGS: HEALTH: 3 FIRE: 0 REACTIVITY: 2
PERSONAL PROTECTIVE EQUIPMENT: D
5-iATE RIGHT -TO -KNOW INFORMATION:
SULFURIC ACID - CAS 47664-93=9
-WATER - CAS #7732-18-5
THE INFORMATION IN THIS MSDS RELATES TO THIS SPECIFIC MATERIAL. IT MAY NOT .BE
VALID FOR THIS MATERIAL IF USED OTHER THAN AS RECOMMENDED BY DIVERSEY LEVER
OR IN COMBINATION WITH OTHER MATERIALS. IT IS THE USER'S RESPONSIBILITY TO
EVALUATE THE APPLICABILITY OF THIS INFORMATION FOR HIS PARTICULAR CONDITIONS
OF STORAGE, HANDLING AND USE_

Omni -Gard - Treatment for Large Closed Loop Cooling Water Systems
GENERAL DESCRIPTION:
OMNI-GARD treatment for large closed loop
cooling water systems Is a balanced blend of
inhibitors formulated to promote a more
adherent protective film for corrosion
Inhibition. OMNI-GARD is designed for
corrosion protection of mild steel, copper
and copper alloys inclosed cooling systems.
USDA Authorized, Code G5, G7.
PROPERTIES:
Appearance .......................... A clear, light
yellow liquid
Density ................................. 9.25 lb./gal.
Odor ..................................... Sweet, Musty
pH(Concentrate) ................... 12.9
Specific Gravity .................... 1.110
USING PROCEDURES:
OMNI-GARD treatment is best utilized in
closed chilled water systems at a
concentration of 400 to 500 ppm, or greater,
depending on severity of conditions. (About
3.2 to 4 pints per 1000 gallons of system
volume.) Initial charge to new or poorly
treated systems will usually result in loss of
molybdenum, as it is used to passivate the
metal and adsorb onto particulate Iron. It
may require additional feed during the first
several days in order to establish the 10-12
ppm molybdenum value. OMNI-GARD
treatment contains no chromate or hydrazine.
If system water maximum temperature
exceeds 1300-140°F, contact Water
Management Department.
DISPENSING:
The OMNI-GARD product can be slug fed
into a bypass feeder for use In closed
systems.
See your DuBois Representative for detailed
recommendations.
TITRATION:
The concentration of the OMNI-GARD
product in a system can be determined by
use of a #K-1805P Molybdate Test Kit or
W.T. 2000 Test Kit. The following table
Illustrates the relationship between
molybdenum concentration determined by
the Kit, and the OMNI-GARD concentration.
Molybdenum (Mo) conc.
8 ppm 10 ppm 12 ppm 15 ppm
OMNI-GARD
320 ppm 400 ppm 480 ppm 600 ppm
MATERIAL SAFETY:
OMNI-GARD product is safe on all metals
and seals normally used in cooling system
construction.
STORAGE:
Keep from freezing. If frozen, thaw and
remlx to a uniform solution after warming to
above 55°F.(12.8oC.).
PRECAUTIONS:
KEEP OUTOFTHE REACH OFCHiLDREN.
Please refer to the label and Material Safety
Data Sheet for ail warnings,
recommendations for safety equipment, and
other regulatory information. Copies of labels
and Material Safety Data Sheets can be
ordered by calling 1-800-354-2549.
Divorssy Corp. • DuBois Division - 255 E FMth St - Cincinnati OH 45202-4799
7h. WommIL— oo. Wra d in tN. erddek, is to our b a bwaudgr, trm and a Atz. W 84 nooaTrw dd►" or tum-w1cm ar. n,ad. - Ah ui Duwanr.. drn. *- o rdh6m of
uft sm beyond orrr oonlroL Dt-. y Corp. didsimn"i Ubw kwirt.d to ocnh. *&c ..Wt, Ow u� of tt. data or argp.Afona
aPrl.t-da R.aydW Paprr - C-APk. Padort.umr Fl ..

MATERIAL SAFETY DATA SHEET Page 1 of 3
Revised 6/26/02
OWNI GARD Replaces 6/2S/02
Printed 9/2S/02
MSDS ID- 02290
A I CHEMICAL PRODUCT AND -COMPANY IDENTIFICATION
,;PRODUCT- NAME : OMNI GARD
PRODUCT' DESCRIPTOR: TREATMENT FOR COOLING WATER SYSTEMS.
MANUFACTURER: JOHNSONDIVERSEY, INC.
3630 E. KEMPER ROAD
CINCINNATI, OH. 45241
EMERGENCY PHONE NUMBERS: MEDICAL (COLLECT): [phone]
CHEMTREC: [phone]
JOHNSONDIVERSEY: [phone]
INGREDIENT NAME(CAS NUMBER) % EXPOSURE LIMITS
------------------------------ ----- -------------------------
SODIUM NITRITE (7632-00-0) <7 85 LD50
SODIUM MOLYBDATE (7631-95-0) <7 TLV 5; PEL S
(AS MOLYBDENUM)
POTASSIUM HYDROXIDE (1310-58-3) <2 TLV C 2, PEL C 2
ROUTES OF ENTRY: INHALATION: YES
SKIN: NO
INGESTION: YES
SIGNS AND SYMPTOMS OF EXPOSURE:
ACUTE: CAUSES EYE IRRITATION
CHRONIC: SAME AS ACUTE
F DICAL CONDITIONS GENERALLY AGGRAVATED BY EXPOSURE:
SENSITIVE SKIN AND EYES.
UNITS
MG/KG
MG/M3
MG/M3
EYES: FLUSH THOROUGHLY WITH FRESH WATER FOR AT LEAST 15 MINUTES, GET
MEDICAL ATTENTION.
SKIN: FLUSH WITH FRESH WATER, WASH WITH SOAP AND WATER. REMOVE
CONTAMINATED CLOTHES AND SHOES. GET MEDICAL ATTENTION.
INGESTION: GIVE WATER. DO NOT INDUCE VOMITING, GET MEDICAL ATTENTION.
INHALATION: N/A IN NORMAL OPERATION
FLASH POINT: NONE DEG F FLAME EXTENSION: N/R IN.
FLAMMABLE LIMITS IN AIR BY VOLUME: LEL: NONE UEL: NONE
UNUSUAL FIRE OR EXPLOSION HAZARDS: NONE KNOWN
EXTINGUISHING MEDIA: CO2, FOAM, DRY CHEMICALS
FIRE FIGHTING INSTRUCTIONS: WEAR PROTECTIVE GEAR AND SELF-CONTAINED
BREATHING APPARATION IN FIRE AREA.

AF TERIAL_._SAFE-1__Y.-DID19-SHEET Page 2 of 9
Revised G/26/02
OWNI GARD Replaces 6/25/02
Printed 9/25/02
MSSDS I D . 02290
— VI ACCIDENTAL RELEASE MEASURES
IF ►MATERIAL IS RELEASED OR SPILLED: FLUSH SMALL AMOUNTS TO DRAIN COLLECT PIND
RETURN LARGE AMOUNTS TO CONTAINER REPORTABLE QUANTITY (R.Q.) OF PRODUCT: 1600
LBS. OR 173 GAL.
VIL HANDLING AND STORAGE
HANDLING AND STORAGE PRECAUTIONS: DO NOT PRESSURE CONTAINER TO EMPTY KEEP
CONTAINER CLOSED WHEN NOT IN USE KEEP FROM FREEZING. IF FROZEN THAW AND MIX
TO MAKE USABLE. WASH HANDS THOROUGHLY AFTER HANDLING PRODUCT.
VIII. EXPOSURE CONTROLS/PE.RSONRL PROTECTION
EYE/FACE PROTECTION: FACE SHIELD
PROTECTIVE GLOVES: NON -ABSORBENT
RESPIRATORY PROTECTION: NONE
OTHER PROTECTIVE CLOTHING/EQUIPMENT: CLOTHING TO PREVENT PROLONGED SKIN
CONTACT.
EXPOSURE GUIDELINES: SEE SECTION II FOR DETAILED INFORMATION.
BOILIING POINT (F): 212 SPECIFIC GRAVITY: 1.1100
VOLATILE BY VOLUME: 90 SOLUBILITY IN WATER: 100
VAPOR PRESSURE (MMHG): 17.5 AT 20 C
APPEARANCE AND ODOR: STRAW COLORED LIQUID; MILD ODOR
CHEMICAL STABILITY:
INCOMPATIBILITY WITH OTHER MATERIALS
HAZARDOUS DECOMPOSITION PRODUCTS
HAZARDOUS POLYMERIZATION:
NO DATA AVAILABLE
NO DATA AVAILABLE
STABLE
CONCENTRATED MINERAL ACIDS, ORGANIC
MATERIALS
OXIDES OF NITROGEN
COMBUSTION
NONE
WITH INCOMPLETE
WASTE DISPOSAL METHOD: USE UNTIL LESS THAN 1 INCH REMAINS IN CONTAINER, EMPTY
CONTAINER TRIPLE RINSE WITH WATER, ADD TO OPERATION REMOVE OR DEFACE LABEL
BEFORE SELLING CONTAINER OR DISPOSAL PH ADJUSTMENT; SEPARATION OF INSOLUBLES,
NO PHOSPHATES

Page 9 of 3
Revised G/26/02
Replaces 6/2S/e2
Printed 9/25/02
HAZARDOUS MATERIALS DESCRIPTION/PROPER SHIPPING NAME:
CORROSIVE LIQUID, BASIC, INORGANIC, N.O.S., (POTASSIUM HYDROXIDE,
j SODIUM NITRITE), 8, UN3266, PG III, ERG NO. 60, NAERG NO. 154
U.S. FEDERAL REGULATIONS:
CERCLA/EPCRA:SECTION 313 TOXIC CHEMICALS:
THIS PRODUCT CONTAINS SODIUM NITRITE (7632-00-0) AT 6.3% WHICH IS SARA
REPORTABLE. ALL CHEMICAL INGREDIENTS ARE LISTED ON THE TSCA INVENTORY.
LISTED CARCINOGEN: NONE
NTP: NO IARC: NO OSHA: NO
HMIS RATINGS: HEALTH: 3 FIRE: 0 REACTIVITY: 0
PERSONAL PROTECTIVE EQUIPMENT: D
STATE RIGHT -TO -KNOW INFORMATION:
SODIUM MOLYBDATE - CAS 47631=95-0
SODIUM NITRITE - CAS 47632-00-0
WATER - CAS 47732-18-5
POTASSIUM HYDROXIDE - CAS #1310-58-3
I
HE INFORMATION IN THIS MSDS RELATES TO THIS SPECIFIC MATERIAL. IT MAY NOT BE
ALID FOR THIS MATERIAL IF USED OTHER THAN AS RECOMMENDED BY DIVERSEY LEVER
R IN COMBINATION WITH OTHER -MATERIALS. IT IS THE USER'S RESPONSIBILITY TO
ALUATE THE APPLICABILITY OF THIS INFORMATION FOR HIS PARTICULAR CONDITIONS
r STORAGE, HANDLING AND USE.

SECTION 6.0
SPRAY FIELD IRRIGATION COST ANALYSIS AND SUPPORTING DATA
"Creating the Right Solutions Together" HRP a:�,"c/ ' ( '

�f�810001 - `IVU-NTY _ 80°551 •
i�'jl'/ 115 —I� — _ _L _ 80050/ YADKIN 80°45r
1 _ _ _ _ _ I COUN�T—Y�I{I—
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Moor eville
OU \n 57 B
58 ^Mourne
60 !NECK NBURG 61 I COUP TTY -�
CAB
r \ ,
Scale 1:190,080
1 P 1 2 3 4 Miles
r r r r r r r

U. S. DEPARTMENT OF AGRICULTURE
SOIL CONSERVATION SERVICE
NORTH CAROLINA AGRICULTURAL EXPERIMENT STATION
GENERAL SOIL MAP
IREDELL COUNTY, NORTH CAROLINA
7
35°55'
81000' COUNTY 80055' I
S i ii,;:; ,, LY.'q�^- .�• Via —I i 80°50' 80045'
is 1 �. YADKIN
'
Cecil -Wilkes association: Deep to shallow steep, stony ^ '// "�.' ' //�N
�
soils of foothills, on mixed acidic and bash rocks or �MECII / acidic rocks URG <�
February 1963 IlNTY
Scale 1:190,080
1 0 1 2 3 4 Miles
CO
0
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I�
A

US Plastic Corp.
Page 1 of 1
states plr� t
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dTanks Rubbermaid® Buckets & Barrels Labware Tubing Packaging 1?� Clearance 80,
Home «Tanks an
Horizontal Leg Tanks Cross Linked Hil
s Polyethylene
For maximum stress crack and impact resistance.
y- flammable chemistry. Maximum specific gravity 1.5.
boiler treatment chemicals,wetting a ents,soa s dE
acid,glycolic acid,oxalic acid,stearic acid,formaldeh
oils,most alcohols,inks,ammonia solutions, acetic a(
percent,sulphuric acid to 95 percent and hydroflour
with a maximum temperature to 150 deg.F. Accept
x pickling baths and plating brightner but only to max
deg.F. UV stabilized, not DOT approved. Transluce
no need for saddles or cradles. Optional 2 inch fittin
installed for drainage use part 8392.
Discounts Available Per Item
There are no additional discounts for this
product.
This product is available in following variations:
Item
DescriNo.ption Capacity Size of
8385
Horizontal Leg Tank
[PDF: Drawing]
8386
Horizontal Leg Tank
[PDF: Drawing]
8391
Horizontal Leg Tank
[PDF: Drawing]
8388
Horizontal Leg Tank
[PDF: Drawing]
8389
Horizontal Leg Tank
[PDF: Drawing]
8956
2" PP Bulkhead Fitting with
EPDm Gaskets
55 Gallon 29 3/4 x 33 1/4 x Each
25 1 /4
110 Gallon 331/2 x 46 1/4 x Each
29
200 Gallon 39 35 1/2 x 57 1/2 x Each
300 Gallon 46 6x 67 1/2 x 40 Each
500 Gallon 51 x 76 x 46 1/2 Each
n/a n/a
If you didn't find what you need, click here.
1390 Neubrecht Rd.
Lima, Ohio 45801-3196
1-800-809-4217 Fax[phone]
Other Info
Catalog Pe
Manufactu
PDF: Que;
In
Stock
Drop
Ship
Drop
Ship
Drop
Ship
Drop
Ship
Drop
Ship
Each Drop
Ship
I Privacy I
h4://www.usplastic.com/catalog/product.asp?catalog%5Fname=USPlastic&category%5F... 4/28/2004

FwA
027 660 ReliningExist. Pi elines
p
DAILY
LABOR-'
I999 BARE COSTS TOTAL
EQUIP. TOTAL INCL UP
CREW
O1rTWIT
HOURS
UNIT
MAT, LABOR
S64
1500
48" to 72"
C•17E
120
557
L.F.
14.90
18.95
51
34.36
47
2000
Cured in place pipe, nun-prusurn, Oexibic fdt rain, 400' runs
2100
6" diameter
LE
30
2200
8" diameter
40
2$0o
10- diameter
55
2400
12" diameter
_ ^,._
70
2500
15" diameter
95
2600
18" diameter
115
2700
21" diameter
135
'
2800
24, diameter
150
2900
30" diameter I
3000
36' diameter
250
250
3100
48" diameter
335
3200
60" diameter
420
3300
72' diameter
500
668
o010
PIPEBURSTING, 300' runs, replace with HDPE pipe
0020
Not including excavation, backiill, shoring, or dewaterrng
0100
6" to 15" diameter, minimum
LA
75
0200
Maximum
175
0300
18" to 36" diameter, minimum �M
0400
Maximum
300
'0p
'
050D
Mobilize and demobilize, minimum T
Job
2,500
0600
Maximum
i-
Site Improvements
v
' 1
on 100 1 Irrigation Systems
DAILY
!HOUR•
E CO
1999 WE
T07AL
'. }i
MAT,
LABOR
EQUIP,
TOTAL
CREW
OUTPUT
HOURS
UNIT
INCLO&P
.:
104
0010
SPRINKLER IRRIGATION SYSTEM For lawns
101
0100
Golf Course w4h fully auton-atic system
C•17
.05
1,600
9'hcles
_
75,000
45,500
120,500
154,500
`1?
s;
OZ00
24' diam, head at 15' O,C ind piping, atito oper., rninirnum
I1-20
70
.343
Head
16.50
8.35
24.85
31.50
0300
Maximum
40
,600
3$
14,60
52,60
65
} r
0500
60' diam. head at 40' O.C. incl. piping, auto oper., minimum
2$
85J
50
21
71
$8
0600
Maximum
23
1,043
140
25.50
165,50
194
4'
0800
Residential system, custom, 1" supply
2,000
.012
S,f,
.25
'29
.54
74
0900
1-1/2" supply
1,800
.013
.28
.32
.60
.82
0990
For renovation work, add to above
50%
y�
1020
Pop up spray head w/risers, hi -pop, full circle pa@ern, 4"
2 Skwk
76
.211
Ea.
3.17
5.90
9.07
12,80
1030
1/2 circle pattern r
76
.211
3.17
5.90
9.07
1040
6", fill Circle pattern
76
.211
7.45
5.90
13.35
17.50
1050
1/2 circle paftem
76
.211
7.45
5.90
13.35
17.50
,
1060
12", full circle pattern
76
211
9.25
5.90
15.15
19.50
1070
1/2 circle pattern
76
.211
9.30
5.90
15.20
19.55
1080
Pop up bubbler head w/risers, hi -pop bubbler head, 4"
76
211
13.27
5.901
9.17
12.90
z
1090
6"
76
.211
7.45
5.90
13.15
17.50
'
1100
12"
76
.2n
9.25
5.90
15.15
19.50
1110
Impact full/part circle sprinklers, 28.54' 25-60 PSI
37
.432
8.80
12.15
20,95
29
1120
Spaced 37'-49' @ 25-50 PSI
37
.432
20,50
12.15
32.65
4150
1130
Spaced 43'•61' 43 30-60 PSI
37
.432
42.50
12.15
54.65
65.50
11401
Spaced 54'•78' @ 40.80 PSI
37
.432
92.50
12.15
104.65
121
Important: See the Refei ence Section for critical supporting data - Reference Mos,, Crews, & City Cost
Ed Wdtiz:TT traaz ez '
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6
I
020 1 Site improvements 1 BARE COSTS TOTAL
028100 ` irrigation Systems
OWLY IABOfl• 999
CREW OUTFUf HOURS UNIT MAT. LABOR E UIP.
TOTAL INCL 0&P
Medium
3 Skwk 7,435 .003 L ,F.
.30
.09
04
.39
.34
.47 110
.39
110 0450
0504
Large
16,560 .001
8,100 .003
-30
.30
.08
.38
.46
6550
Rectangular area, small
30
D3
.33
.38
0600
Medium
11,264 .001
a3.264 .001
.30
.02
.32
,36
0650
Large
f353 500 016
44 .19
.63
.87
0700
Trenching and backfill
104�
0750
For vinyl tubing, 1/4, add to above
06
.05
.07
Osm
Yrttyl tubing, 1/4% material only
10
'10
.11
0850
Supply tubing, 1/2', material only, 100''coil
09
.Q9
10
0900 $00' cod
1 Stnvk 90 .089 Ea, 65
2,49
3.14
4.64
0950 Compression fittings
360 .022
,15
.62
,77
1.15
1000 Barbed fittings, 1/4
3
1100 Flush risers
60 '133
18o 044
.70
.12
.74
1.25
1,37
2.10
1150 Flush ends, figure eight
5.50
11.20
70
17.
24
•1200
eallvalve, 4-1/2°
20 .400
11.20
17.70
25
1250 43/4"
20 .400
6.50
1.75
2.49
4.24
5.85
1900 Auto flush, Spring loaded
9p .089
2.49
7.99
10
1350 Volumetric
90 .�9
45
5.50
5.90
4.99
10,39
14,35
140o Air relief valve, inl'me with compensation tee, 1/2"
.173
16,40
7.50
23.90
30
1450 J.
30 267
30 267
_25
3.25
7,50
10.75
15,40
1500 Round box for flush ends, 6"
56
59.15
92
1550 Fertilizer injector, norrproportional
4 2
17.50
18.70
36.20
49
1600 -Screen filter, 3/4" screen
12 .667
28
74
95.50
'1650 1" disk
8 1
4 2
46
110
56
166
210
1700 1-1/2" disk
3 2,667
220
75
295
360
]750 2" disk
$.F.
,70
.80
1800 Typical installation 18" O.C., small, minimum
1.30
1.50
1850 Maximum
.52
.60
1900 Large, minimum
.96
1
2000 Maximum
l0�
1096
2100 For non -pressure compensating systems, deduct
2150 For supplY piping see division 026 678
028 2W 1 Fountains
2a�
204
0010 FOUNTAINS/AERATORS
0100 Pump w/controls
102
2,127
2,375
0200 Single phase, 100' chord, 1/2 H.P. pump
Sln'�k 4.3.
Ea. 2,
104
2,379
2,675
0300 3/4 H.P. pump
4.30 0 3.721 21
2,275 75
21407
2,70D
0400 1 H.P. pump
4.20 3.810
2.300
107
2,534
2,825
0500 1-1/2 H,P. pump
4.10 3,902
2,425
2,450
109
112
2,562
2,875
0600 Z H.P. pump
4 4
5,615
7,325
07,30 Three phase, 200' chord, 5 H.P. ournp
3.90 4,103
6,500
115
7,793
8,600
03G0
7•]/2 H.P. pump
3.80
4.211
7,675
118
7,846
8,700
0900
10 H.P. pump
3,10
4.324
7,725
121
10,525
11,600
1000
15 H.P. pump
3.60
4.444
1U,400
125
56
191
238
1100
Noz les, minimum
8
2
135
302
360
1200
Maximum
9
2
246
56
25
320
365
1300
Lights w/mounting kits, 200 watt
1S
.889
295
18
.889
�30
25
355
385
400
435
300 watt
140D
1500
500 watt
18
.889
360
25
12
].333
280
37.50
317.50
365
1600
Color blender
028 300 ( Fences & GaWs
3p�
308
0010
F> 1iCE, CHAIN LINK INDUSTRIAL, schedule 40
0020
3 strands barb wire, 2" past 010' O.C., set in concrete, 6' H
1 i d J(mporfu&. see the Reference $ecfion for cri
02(
03(
D5(
061
091
14
-15
20
.,n
SS'Zb TZE 1798 : 'ON DNOHd :JTlIf1N8��J:1-WuucdJUWZ:JNU iiw . wua�
LddZz : T T b00E 8Z •.idd

32
SOIL SURVEY SERIES 1960, NO. 14
Engineering Uses of the Soils 6
This soil survey report for Iredell County, N.C., con-
tains information that can be used by engineers to—
t. Make soil and land use studies that will aid in
selecting and developing industrial, business, resi-
dential, and recreational sites.
2. Assist in planning for drainage and irrigation sys-
tems, farm ponds, diversion terraces, and other
structures for soil and water conservation.
3. Make ,preliminary evaluations of soil and ground
conditions that will aid in selecting locations for
highways and airports and in planning. detailed
surveys of the soils at the selected locations.
4. Locate sand, gravel, and rock for use in
construction.
5. Correlate the performance of engineering struc-
tures with the soil mapping units and thus develop
information that will be useful in designing and
maintaining the structures.
6. Determine the suitability of the soil mapping units
for cross-country movements of vehicles and con-
struction equipment.
7. Supelement information obtained from other pub-
lished maps, reports, and aerial photographs for
the purpose of making maps and reports that can
be used readily by engineers.
S. Develop preliminary estimates of a particular site
to determine its suitability for construction
purposes.
The mapping and the descriptive report are somewhat
g neralized and should be used only in planning more de-
tailed field surveys to determine the in -lace condition of
the soil at the site of the proposed engineering construc-
The engineer can obtain some information useful for
engineering from the soils map, but it will also be neces-
sary for him to refer to other parts of the report. By
using the information in the soils map, the profile descrip-
tions, and the tables in this section, the soils engineer can
plan a detailed survey of the soil at the site of construction.
Then, after he has tested the soils and observed their be-
havior in structures and foundations, he can estimate de-
sign requirements for the different soils shown on the map.
Some of the terms used by the soil scientist may be un-
familiar to the engineer, and some words —for example,
soil, clay, silt, and sand —may have special meanings in
soil science.. These and other special terms that are used
are defined in the Glossary at the end of the report.
Engineering classification systems
Most highway engineers classify soil material in accord-
ance with the system approved by the American Associa-
e B. F. INGRAm, civil engineer, Soil Conservation Service, assisted
with this section.
tion of State Highway Officials (1) : In this system soil
materials are classified in seven principal groups. The
groups range from A-1, which consists of gravelly soils
of high bearing capacity, to A-7, which consists of clayey
soils that have low strength when wet. Within each group
the relative engineering value of the soil material is in-
dicated by a group index number. Group index numbers
range from 0 for the best material to 20 for the poorest.
The group index number is shown in parentheses follow -
in the soil group symbol in table T.
ome eng reers prefer to use the Unified soil classifica-
tion system (14) . In this system soil materials are classi-
fied into 15 groups, 8 of which are classed as fine grained,
6 as coarse grained, and 1 as highly organic. The last
column of table 7 also gives the classification of the tested
soils of Iredell County according to the Unified system.
The classification of a soil material by either the
AASHO or the Unified system identifies that soil material
with regard to gradation and plasticity characteristics.
The classification permits the engineer to make a rapid
appraisal of the soil material by: comparing it with more
familiar soils that have the same classification.
Engineering descriptions of soils
In table 5 brief descriptions of the soils of Iredell
County and their estimated physical properties are given.
The estimates are only for the typical soils, and variations
from these values should be expected. The information in
the table is based on the results of test data shown in table
7 and on characteristics observed in the field. Data from
tests made of similar soils in other counties were also used.
The descriptions of the soil profiles in table 5 apply
only to the uneroded and moderately eroded soils in each
series. In severely eroded soils, the second layer of the
described profile is normally the surface layer.
In table 5 depth to the seasonally high water table is
shown as 10+ when the depth is more than 10 feet, be-
cause a depth greater than 10 feet cannot be estimated.
For most of the soils, the depth to bedrock varies con-
siderably. This is because the resistance of the bedrock
to weathering varies from place to place. Also, some
slopes are younger geologically or geomorphologically
than others. On these relatively young slopes, the hard
rock is closer to the surface than on older slopes that are
underlain by similar rocks. The range given in the column
showing depth to bedrock is that typical of most areas,
but in many places soft, weathered rock extends to a
greater depth than that given.
Also given in table 5 is the estimated classification of
the soils according to the AASHO and the Unified sys-
tems. The estimated percentages of material passing
through sieves of various sizes are given in table 5.
The permeability was estimated for the subsoil in place.
That is, an estimate was made of the probable rate of water
percolation through material that was not compacted.

33
IREDELL COUNTY, NORTH CAROLINA
The estimates were based on observed characteristics and
were compared with permeability tests made on undis-
turbed cores of similar material.
The column that shows the available water capacity
gives the approximate amount of water held in a soil when
the soil is wet to field -capacity. The estimates given are
fof average conditions of texture and structure for each
layer of soil.
The shrink -swell potential is the volume change that
occurs in soil material when its content of moisture
changes. In general, soils classed as CH and A-1 have
"High" shrink -swell potential, although in some soils,
su�h as Iredell, the subsoil may be rated "Very high."
Clean sands and gravels (single -grain structure), and
those having small amounts of nonplastic to slightly
plastic clays have "Low" shrink -swell potential.
Engineering interpretations
In table 6 the most suitable locations for the highway
gradeline are given for the soils of the county. Also given
are ratings for the suitability of the soils as a source of
topsoil, borrow material for homogeneous earth dams and
shells, and of material for cores of earth dams. In addi-
tion, the suitability of the soils for farm ponds and terraces,
an1d as fields for septic tanks is shown, and the. need of the
soils for agricultural drainage is indicated. The ratings
are based on estimated data in table 5, on actual test data,
a Id on observations made in the field.
In many soils of the county, the highway gradeline can
b e I I located in any position on or in the soil. In some soils,
however, a high water table, bedrock; or very plastic clay
must be considered before the best position of the grade -
line is determined.
Cuts made in constructing highways need protection
from erosion in most soils of the county. Establishing a
cover of vegetation on slopes of all cuts and fills of new
roads will help provide protection, although the amount
o , cover needed varies from place to place.
The suitability of the soils for homogeneous dams and
for shells of dams, where the soil material is the same
throughout the dam, is rated according to the shear
strength, cohesion, settling potential, workability, resist
ante to erosion, and imperviousness of the material when
placed and compacted by normal construction equipment.
For soils that contain thin layers of material that differs.
greatly in texture, it is assumed that the soil material in
the layers will be mixed during normal construction opera-
tions. It is assumed that the unsuitable material in soils
that contain small amounts of rock, organic matter, and
other nonsoil material is not used in the dam.
For an earth dam, the material used as a core is rated
for suitability according to the imperviousness of the soil'
when it is properly placed and compacted.
Generally, large amounts of soil material are moved in
the construction of farm ponds, terraces, and other struc-
tures used to conserve soil and water. The soils of Iredell
County are suited to the use of normal construction prac-
tices, but in most of the soils there are obstacles that affect
the choice of site, the design, and the installing of struc-
tures to conserve soil and water.
In table 6 the suitability of the soils for farm pond
reservoirs is rated according to the natural ability of the
soil to store water without excessive seepage.. It is as-
sumed that the water is impounded by a dam that has an
adequate cutoff core.
The suitability of a soil as a foundation for a dam is
rated according to the ability of the soil, in the natural
state, to support the dam without excessive consolidation
of the foundation material. It is also rated according
to the difficulty in preventing excessive seepage through
the foundation material. It is assumed that, in normal
construction operations, all organic material and other
undesirable material are stripped from the surface layer
of the foundation and that a nominal keyway is provided.
Soils are rated as suitable for terraces if farm equip-
ment or light construction equipment can be used on them
to construct the terraces. They are rated unsuitable if,
the soil is too shallow, rocky, or plastic for normal con-
struction methods to be used. Terraces are not needed
on soils that are nearly level.
Also in table 6 the need for agricultural drainage is
indicated as related to the soil in its natural state and
to the use that is to be made of the soil. The response
to agricultural drainage is related to the ease with which
adequate drainage can be accomplished.
The suitability of a soil as a field for septic tanks is
rated according to the depth and natural drainage of the
soil and the permeability of the soil material. The rating
is useful for those who are selecting a homesite or who
are. investigating the suitability of an area for develop-
ment of real estate.
Also important in highway engineering is information.
about the need of reinforcing the subgrade if a flexible
pavement is to be laid. In Iredell County a porous sub-
base is used for all rigid pavements. For flexible pave-
ment, some soils, principally the Buncombe, Cecil, and
Lloyd soils, Moderately gullied land, and Severely gullied
land, need a reinforced subbase.
A subbase is needed as a foundation course for flexible
pavements constructed on most of the soils in the county.
A porous base course is also needed for all rigid
pavements.
There are no large commercial sources of sand and
gravel in the county. Gravel can be obtained in .the
form of crushed stone from various quarries. Sand is
available from several places along the Catawba River.

.34
SOIL SURVEY SERIES 1960, NO. 14
TABLE 5. Brief description of the soils of Iredell
Depth
Map
to sea -
sonally
high
Depth
to
Permea-
bility of
Reaction
Brief description of site and soil
symbol
Soil
water
bedrock
subsoil
table
Af6
Feet
Altavista fine sandy loam, 2 to 6 per- 3-8
Feet
8-30
Moderate __
pH
5. 1-5. 5
Moderately
of 6 stream
h y�consist ained soils
te ra es; well
8
cent slopes.
inches of fine sandy loam over 20 to
AfB2
Altavista fine sandy loam, 2 to 6 per-
50 inches of clay; underlain by 8 to
cent slopes eroded.
30 feet of unconsolidated, stratified
alluvium.
AmC3
Appling sandy clay loam, 6 to 10 per- 10 I
5-15
Moderate __
5. 1-5. 5
s and es
n helned soilon up ands; theydconsist ofl3 to
cent slopes severely eroded.
12 inches of sandy loam or sandy clay
AmD3
Appling sandy clay loam, 10 to 15 per-
loam over 24 to 48 inches of clay;
cent slopes, severely eroded.
underlain by 5 to 15 feet of weathered
AsB
Appling sandy loam, 2 to 6 percent
granite or granite gneiss.
AsB2
slopes.
Appling sandy loam, 2 to 6 percent
AsC
slopes, eroded.
Appling sandy loam, 6 to 10 percent
AsC2
slopes.
Appling sandy loam, 6 to 10 percent
AsD
slopes, eroded
Appling sandy loam, 10 to 15 percent
AsD2
slopes.
Appling sandy loam, 10 to 15 percent
AsE
slopes, eroded.
Appling sandy loam, 15 to 25 percent
AsE2
slopes.
Appling sandy loam, 15 to 25 percent
slopes, eroded.
Bn
Buncombe loamy sand. 6-10
6-20
Rapid ------
5. 6-6. 0
Excessively drained soil on flood plains
of streams; it consists of 36 to 60
inches of loamy sand over stratified
alluvium; subject to occasional over-
CcB3
Cecil clay loam, 2 to 6 percent slopes, 10+
6-15
Moderate___
5. 1-5. 5
flow. ,
On
in be uplands; they dconsat of slopes
severely eroded.
15 inches of sandy loam, fine sandy
CcC3
Cecil clay loam, 6 to 10 percenC slopes,
loam* or clay loam over 18 to 60
severely eroded.
inches of clay; underlain by weath-
CcD3
Cecil clay loam, 10 to 15 percent slopes,
Bred granite, gneiss, or schist.
severely eroded:
.CcE3
Cecil clay loam, 15 to 25 percent slopes,,
severely eroded.
CfB
Cecil fine sandy loam, 2 to 6 percent
CfB2
slopes.
Cecil fine sandy loam, 2 to 6 percent
CfC
slopes, eroded.
Cecil fine sandy loam, 6 to 10 percent
CfC2
slopes.
Cecil fine sandy loam, 6 to 10 percent
slopes, eroded.
CfD
Cecil fine sandy loam, 10 to 15 percent
CfD2
slopes.
Cecil fine sandy loam, 10 to 15 percent
slopes, eroded.
CmB
Cecil sandy loam, 2 to 6 percent slopes.
CmB2
Cecil sandy loam, 2 to 6 percent slopes,
CmC
eroded.
Cecil sandy loam, 6 to 10 percent slopes.
CmC2 ._
Cecil sandy loam, 6 to 10.percent slopes,
CmD
eroded.
Cecil sandy loam, 10 to 15 percent
CmD2
slopes.
Cecil sandy loam, 10 to 15 percent
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