NC0048712_Regional Office Historical File Pre 2018 (2)

A
-M411.,ftree&
Moeh4eW1 ley, Governor
William 1J Seaetary
North Carolina Department or Environmeni and Natural Resources
Alan W Klirnek P, F. Director
vi,ion. ot Water Quality
Coleen fl, Sallow,. Deputy Director
Water Qualoy
March 23, 2004
Mr. Joseph E. Mon aio' e
Alcoa Extrusions, Inc.
P. 0. BOX 100
CATAWBA, NC 28609
scutOE
AND NATURAL
MOORESW
Subject: Rescission of NPDES Permit
Permit Number NC0048712
Alcoa Extrusions — Catawba Operation
Catawba County
Dear Mr, Montaigne:
MAR 3 0 2004
Reference is made to your request for rescission of .the subject NPDES permit. Staff of the
looresville Regional Office have confirmed that this permit is no longer required. Therefore,
in accordance with your request. NPDES permit NC0048712 is rescinded, effective
immediately,
If in the future you wish to discharge 'wastewater to the Slate's surface waters, you must first
apply for and receive a new NPDES permit. Operating a facility without a valid NPDES permit
will subject the responsible party to a civil penalty of up to $25,000 per day.
If you have questions about this matter, please contact Bob Sledge at [phone]. extension
547 or the Water Quahty staff in our Mooresville Regional Office at (704) 663-169.9.
Sincerely,
Alan 'W. Klimek, P.E.
cc: Mooresville Regional Office w/attachments
NPDES Unit
Point Source Compliance — Bob Sledge - w/attachments
Central Files - w/attachments
Fran McPherson, DWQ Budget. Office
N, C, Division of Water Quality 1617 Mail Service Center
Raleigh, North Carolina 27699-1617 [phone]
Ettifk
Customer Service
1-S77-623-6741

David
NCD' Unit
1 17 Service Center
North` a27699-1617
Re qRequest to Rescind Pe 8 71
Alcoa E sioa -IncCatawba Operation
6555 CommScope Road, Catawba, NC 28609
" odrioh
During July 2002, AlcoaExtrusions, Inc, Alco a inst cd an inion- xchange system that has
allowedthe Catawba Operation to operate without discharging w ewater. The co 'cm to
the discharge point has been retrieved d preventive ce procedures have been
developed to prevent the accidental re l of r SS vv t w to to stortn sewers,.
t this tirrie, Alcoa requests that the DEls1R fo fly rescind the referenced e t
If you have any questions or co erns regarding this letter, please ` lfree to can meat 570-
385-8801 or email me at cla ,lon 1co .co rn,
Joseph E. Montaigne
a «g M ger
Alcoa xtrusions, Inc, Catawba ration
cc, Rex.n Etter ty Su « " sor
NCDE' - ooresville Regional Office
919 No
oores . c, NC 28115

Michael F. Easley
Governor
William G. Ross, Jr. Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, Director
Division of Water Quality
DIVISION OF WATER QUALITY
January 8, 2003
Mr. George Chapman, General Manager
ALCOA Extrusions, Inc.
P.O. Box 100
Catawba, North Carolina 28609
Subject: NPDES Permit No. NC00487 12
Alcoa Extrusions, Inc. WWTP
Catawba County, NC
Dear Mr. Chapman:
Our records indicate that NPDES Permit No. NC0048712 was issued on December 18, 2002
for the discharge of wastewater to the surface waters of the State from your facility. The purpose
of this letter is to advise you of the importance of the Permit and the liabilities in the event of failure
to comply with the terms and conditions of the Permit. If you have not already done so, it is
suggested that you thoroughly read the Permit. Of particular importance is Page 4
Page 4 sets forth the effluent limitations and monitoring requirements for your discharge.
Your discharge must not exceed any of the limitations set forth. The section headed "Monitoring
Requirements" describes the measurement frequencies, sample types and sampling locations. Upon
commencement of your discharge (or operation), you must initiate the required monitoring. The
monitoring results must be entered on reporting forms furnished or approved by this Agency. If you
have not received these forms, they should be arriving shortly. If you fail to receive the forms, please
contact this Office as quickly as possible. I have enclosed a sample of the "Effluent" reporting form
(DWQ Form MR-1), plus instructions for completing the form. It is imperative that a applicable
parts be completed, and the original and one copy be submitted as required.
Please be advised that an annual administering and compliance monitoring fee may be required
for your facility. You will soon be receiving a statement from our Raleigh Office. It is imperative
that the fee be paid in a timely manner so as to prevent enforcement action or possible revocation of
your permit.
The remaining parts of the Permit set forth definitions, general conditions and special
INDENE
Customer Service
aao 623-7748
Mooresville Regional C.7.tffice, 919 North Main Street, Mooresville, NC 28115 PHONE [phone]
FAX [phone]

Mr. George Chapman, General Manager
January 8, 2003
Page No. 2
conditions applicable to the operation of wastewater treatment facilities and/or discharge(s). The
conditions include special reporting requirements in the event of noncompliance, bypasses, treatment
unit/process failures, etc. Also addressed are requirements for a certified wastewater treatment plant
operator if you are operating wastewater treatment ficilities. Any changes in operation of wastewater
treatment facilities, quantity and type of wastewater being treated or dischargedexpansions and/or
upgrading of wastewater treatment facilities must be permitted or approved by trus Agency.
Failure to comply with the terms and conditions of an NPDES Permit subjects the Permittee
to enforcement action pursuant to Section 143-215.6 of the North Carolina General Statutes. A civil
penalty of up to $25,000 per violation (and/or criminal penalties) may be assessed for such violations,
If you find at any time that you are unable to comply with the terms and conditions of the Permit, you
should contact this Office immediately. A Special Order by Consent (SOC) may be necessary while
pursuing action to obtain compliance.
As a final note, an NPDES Permit is normally issued for a five-year period, Permits are DOT
automatically renewed. Renewal requests must be submitted to this Agency no later than 180 days
prior to expiration. Please make note of the expiration date ofyour Permit. This date is set forth on
Page 1 of the Permit. Also note that NPDES Permits are not automatically transferable. If you, as
the Permittee, cease to need this Permit, then you should request that the Division of Water Quality
rescind the Permit or request that DWQ reissue the Permit to another party, if necessary.
As mentioned previously, the purpose of this letter is to advise you of the importance ofyour
NPDES Permit. Please read the Permit and contact this Office at 704/663-1699 in Mooresville if you
have any questions or need clarification. We look forward to providing any assistance.
Sincerely,
D, Rex Gleason, P.E.
Water Quality Regional Supervisor
Enclosure
DRG: dee

•
State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, PE, Director
December 18, 2002
r. George Chapman, General Manager
Alcoa Extrusions, Inc.
P.O. Box 100
Catawba, North Carolina 28609
Dear Mr. Chapman:
NCX11404 CAROLINA DEPART4eNT OF
ENODORMNT AND NATURAL RE,V)URCES
F
DEC 3 1
Subject: Issuanc 'DES Permit
NC00487 12
Alcoa Extrusions, Inc. WWTP
Catawba County
Division personnel have reviewed and approved your application for renewal of the
subject permit. Accordingly, we are forwarding the attached NPDES discharge 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 U.S. Environmental
Protection Agency dated May 9, 1994 (or as subsequently amended).
The following changes have been made to your draft permit:
• The daily maximum limit for barium, based on federal water quality criteria has
been added to your permit. This limit is 1000 )2g/L.
• The pH limit has been corrected to read, "The pH shall be no less than 7.0
standard units nor greater than 9.0 standard units," as per your previous permit.
▪ A beryllium limit of 0.9 pig/L has been added to your permit with a compliance
schedule of 18 months. As discussed with Clay Long of Alcoa during the comment
period, the priority pollutant analysis submitted with your application indicated
the reasonable potential to exceed water quality criteria for beryllium. You may
submit 10-12 data points and apply for a modification to your permit to eliminate
both the monitoring requirement and limit at any time.
In addition, please note that as per your agreement with the Aquatic Toxicology. Unit,
no copper limits are being implemented in your permit at this time. it is anticipated that
your Catawba facility is converting to 100% reuse such that there will be no discharge from
permitted outfall 001.
If any parts, measurement frequencies or sampling requirements contained in this
permit are unacceptable to you, you have the right to an adjudicatory hearing upon written
request within thirty (30) days following receipt of this letter. This request must be in the
form of a written petition, conforming to Chapter 150B of the North Carolina General
Statutes, and riled with the Office of Administrative Hearings (6714 Mail Service Center.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer VISIT uS ON THE INTERNET http://h2o enr state,nc usINPDES

ei . , No Carol n 99 671 ). 'Unless such de nd is ad . this decision shall be
and binding.
Please note that this pet lit is not transferable except after notice to the Iiiior
The Division ion may require modification or revocation and reissuance of the permit. This
permit does not affect the legal requirements to obtain other permits hich may'be required
by the Division of Water Quality or permits required by the Division. of Land Resources, the
Coastal Area Management Act or any other Federal or Local governmental permit that may
be required,
If you have any questions once. in... this per
telephone number 1 ) 733-5083, extension 551.
NPD Ur
EPA Recap
Technical Assistance & ° llcation T. n it
Aquatic Toxicology Unit
please contact Natahe Terra at
Sincerely,;
Alan W. Klimek, PE

Permit NC00487 12
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATIONSYSTEM
In compliance with the -provision of North, Carolina General Statute 1.43-215.1.. other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Man agement Commission, and the Federal Water 'Pollution Control Act, as amended,
Alcoa Extrusions, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Alcoa Extrusions, Inc. WWTP
NCSR 1848 southwest of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to the Terrapin Creek arm
of Lake Norman in the Catawba River Basin in accordance with effluent limitations,
monitoring requirements, and other conditions set forth in Parts I, II, III and IV
hereof.
This permit, shall become effective February 1, 2003.
This permit and authorization to discharge shall expire at midnight on April 30, 2005.
Signed this clay December 18, 2002.
Original Signed By
David k Goodrich
Alan \V. Klimek, RE_ Director
Division of Water Quality
By .Authorit,y, of the Environmental Manai,,
(.11:1C
COninliSSi On

Permit NC0048712
SUPPLEMENT TO PER IT COVER SHEET
Alcoa Extrusions, Inc. is hereby authorized to:
1. Continue to discharge filter backwash (from an aluminum extrusion cooling
water filtration system) and cooling tower blowdown from facilities located at
Alcoa Extrusions, Inc.; NCSR 1848, southeast of Catawba in Catawba County
2. Discharge from said treatment works at thc location specified on the attached
map into an unnamed tributary to the Terrapin Creek arm of Lake Norman,
classified WS-IV waters in the Catawba River Basin.

IBC
Latitude
L©ngitUde
Ouad rx:
".ass
Receiving Stream:
Permitted Flow:
47
2 -- Alcoa Extrusions, Inc.
35°38'55" Sub -Basins 03-08-32
a 'or55"
El4NEECatawba, NC
W5-1V
unnamed tributary to Lake Norman
not limited
North
ALo Ertuusivns„
NCIQ487I
.... rn mi ter t ar tcatr

Permit NC0048712
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of this permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 001 filter backwash from aluminum extrusion cooling water and cooling
tower blowdown. Such discharges shall be limited and monitored by the Pennittee as specified below:
EFFLUENT
CHARACTERISTICS
Flow
Total Aluminum
Total Zinc
ChromurT
To
LIMITS
MONITORING REQUIREMENTS
Cyanide
Oil and Grease
Total Barium
Total Beryllium2
Chloride
Total Residual Chlorine (TRC)1
pH3
Temperature'
Acute Toxicit 5
Monthly Daily Weekly Daily Measurement Sample Type Sample
Average Maximum Average Maximum Frequency Location
(pounds/day) (pounds/day)
0,54
01
0.02
1 08
0.25
0.07
0,05
12,70
26,04
5 .a.11..
0941
Weekly Instantaneous
2/Month Composite
2/Month Composite
Monthi Composite
2/Month
2/Month
2/Month
Monthly
1000 fig/
Grab
Grab
Composite
Composite
Composite
Composite
Composite
Composite
Composite
Grab
Grab
Grab
Com e osite
Effluent
Effluent
Effluent
Effluent
Effluent
=ME
Effluent
Effluent
Notes:
.1, :Monitoring requirements only apply if chlorine is added to the cooling water.
2. This limit will become effective July 1„ 2004. The Permittee may, after submitting 10-12 samples,
petition the Division of Water Quality to have this monitoring requirement to the permit removed,
3. The ptil shall be no less than '7,0 standard units nor greater than 9.0 standard units.
4_ The temperature of the effluent shall be such as not to cause an increase in the temperature of
the receiving stream of more than 2,8°C and in no case cause the ambient water temperature to
exceed 32QC.
. Whole effluent toxicity shall be measure by acute toxicity (fathead minnow) 24-hour P/F at 90%.
Toxicity shall be monitored in March, June, September and December (see A. (3.) for details).
There shall be no discharge of floating solids or visible foam in other than trace amounts.
A. (2.) BIOCIDE CONDITION
There shall be no chromium, zinc or copper added to the treatment system except as
pre -approved additives to biocidal compounds.
The permittee shall obtain approval from the Division's Aquatic 'Toxicology Unit prior to the use of
any biocide (not previously approved by the Division) in the effluent discharged under this permit.
Approval for use of any biocide not previously approved should be requested at least 90 days in
advance of any planned usage.
C:olitaet the Aquatic Toxicology thin for detailed instructions on requesting approval of biocides:
NC DENR DWCJ / Aquatic Toxicoloq. llnit
162 I Mail Service Center
Raleigh, North Carolina 27699-162 1

Permit` 0 712
A. (3.) ACUTE TOXICITY PASS/FAIL PERMIT LIMIT
'Me Permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the
North Carolina Procedure Document entitled -Pass/Fail Methodology For Determining Acute. Toxicity
In A Single Effluent. Concentration" (Revised -July, 1992 or subsequent versions). The tnonitorin.g
shall be performed as a Fathead Minnow (Pinlepha(es promelas) 24-hour static test. Theeffluent
concentration at which there may he at no time significant acute mortality is 90% (defined as
treatment two in the procedure document). Effluent. sa„mples for self -monitoring purposes must be
obtained during representative effluent discharge below all waste treatment. The tests will be
performed during the months of March, June, September and December.
Alt toxicity testing results required as part of this permit condition will be entered on the Effluent
.Discharge Monitoring Form (MR-1) for the month in which it was performed, using the parameter
code TGE6C. Additionally, DWQ Form AT-2 (original.) is to be sent to the following address:
Attention: North Carolina Division of Water Quality
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no,
later than 30 days after the end of the reporting period for which the report is made.
'rest data shall be complete and accurate and include all supporting chemical/physical
mea.surements performed in association with the toxicity tests, as well as all dose/response data,
Total residual chlorine of the effluent toxicity sample must, be measured and reported if chlorine is
employed for disinfection of the waste stream.
Should there he no discharge of flow from the facility during a -month in which toxicity monitoring is
required, the Perrnittee will complete the information located at the top of the aquatic toxicity (AT)
test form indicating the facility name, .permit number, pipe number, county, and the month/year of
the report with the notation of "No Flow- in the continentarea of the .form. The report shall be
submitted to the Environmental Sciences Branch at the address cited above.
Should any single quarterly monitoring indicate a failure to meet specified limits, then month11,,,
monitoring will begin immediately until such (line that a single test is passed. Upon passing, this
monthly test requirement will revert to quarterly in the mouths specified above.
Should the Permitter fail to monitor during a month in which toxicity monitoring is required, then
monthly monitoring va1l begin immediately until such tittle that a single test is passed. Upon passing,
this monthlytest requirement will revert to quarterly in the months specified above.
Should any test data from either these monitoring requirements or tests performed by the North
Carolina Division of Water Quality indicate potential impacts to the receiving stream, this permit may
be re -opened and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival a.nd appropriate environmental controls, shall constitute an invalid test.
and will require immediate follow-up testing to be completed no later than the last , Gay of the month
following the month of the initial .rnonitoritig.

Sectiot
e of Compliance
Clue pen tree shall comply with fain
following schedule:
Permttee shall comply
unless specified below.
Penae shalt
facilities at opturn
es pro
efficiea e -.
No 14 calendar
permittee shall submit eitl
identified dates,
include the cause c
schedule requirements.
tten nottc
oncorpl
Final
PART I
(catuc
fluent tions s
cdf t
uett i nations by the e
the operation and tat:
ante
fa.allaac itg a date identifet in rhr
report of progress or, e case
of compliance or noncompliant
anee, an m retnedtal acetons taken, at
c
ecessar t
accordance is
date of the permit
aperare the eistit
above schedule cif ct-cm.pliance:, the
specific actions being required by,
Zn the latter case, the notice shall
the probability of meeting the next

PART H
STANDARD CONDITIONS FOR 'N 3DES 'PERMITS
SECTION A. DEFINITIONS
Permit "Issuing ,AuthoritY: Director of the .Division of Water it lity.
DEM of "the Division' Means the Division of Water Quality, Department of Environment and Natural
Resources.
EM C Used herein tneans the North Carolina. Environmental Management Commission,
4. Act or "the Act" The Federal Water Pollution Cm- I Act,. also known as the Clean Water Act, a.s amended
3 US(...: 12.51, et. seq.
5. Mass/Day 'Measurements
a. The "monthly average discharge" is defined as the total mass of all daily discharges sampled and/or
measured during a calendar month on which daily discharges are sampled and measured, divided by the
number of dai1 discharges sampled and/or measured during such month. It is therefore, an arithmetic
mean found bv adding the 'weights of the pollutant found each day of the month and then dividing this sum
by the number of days the tests were reported. The imitation is identified as "Monthly Average" in Part I of
the permit,
b. The "weekly average discharge" is defined as the total mass of all daily discharges sampled and/or measured
during the calendar week (Sunday - Saturday) on which daily discharges are sampled and measured, divided
by the number of daily discharges sampled and 'or measured during such week. It is, therefore, an
arithmetic mean found by adding the weights of pollutants found each day of the week and then dividing
this sum by the number of days the tests were reported This limitation is identified as "Weekly ,Average" in
Part I of the permit,
c. The "maximum daily discharge" is the total mass (weight) of a pollutant discharged during a calendar day. If
only one sample is taken during any calendar day the weight of pollutant calculated from it is the "maximuin
daily discharge." This limitation. is identified as "Daily Maximum," in Part .I of the permit,
d. 'Me "average annual discharge" is defined as the total mass of all daily discharges sampled and or measured
during the calendar rear on Which daily discharges are sampled and measured, divided by the number of
daily discharges sampled and, or measured during such Year. It is, therefore, an aridunetic mean found by
adding the weights of pollutants found each day of the year and then dividing this sum by the number of
days the tests were reported. This liiHnitation is defined as "Annual Average" in Part I of the permit.
6, Concentration .7\ leasurement
a. The "average monthly concentration," other than for fecal coliform bacteria, is the sum of the concentrations
of all daily discharges sampled and/or measured during a calendar month on which daily discharges are
sampled and measured, divided by the number of daily discharges sampled and/or measured during such
month (aaithinetic mean of the daily concentration values), The daily concentration value is equal to the
concentration of a composite sample or in the case of grab samples is the arithmetic mean (weighted by flow
value) of all the samples collected during that calendar day. The average monthly count for fecal coliform
bacteria is the geometric mean of the counts for samples collected during a calendar month, This limitation
is identified as "'Monthly „Average" under "Other Limits" in Part 1 of the permit.

Part II
,. of 11
6.. b. The. "average weekly concentration," other than for fecal conform. bacteria, is the stun of the concentrations
of all daily discharges sampled and/or measured during a calendar week (Sunday/Saturday) on which daily
discharges are sampled and measured divided by the number of daily discharges sampled and/or measured
during such week (arithmetic .mean of the daily concentration values). The daily concentration value is equal
to the concentration of a composite sample or in the case of grab samples is the arithmetic mean (weighted
by flow value) of all the samples collected during that calendar day. The average weekly count for fecal
conform bacteria is the geometric mean of the counts for samples collected during a calendar week. This
limitation is identified as "Weekly Average" under "( )ther Limits" in Part I of the perrnit.
c. The "maximum daily concentration" is the concentration of a pollutant discharge during a calendar day. If
only one sample is taken during any calendar day the concentration of pollutant calculated from it is the
"Maximum Daily Concentration". It is identified as "Daily Maximum" under "Other Limit' in Part I of the
permit.
d. The "average annual concentration," other than for fecal conform bacteria, is the sum of the concentrations
of all daily. discharges sampled and/or measured during a calendar year on which daily discharges are
sampled and measured divided by the number of daily discharges sampled and/or measured during such
year (arithmetic mean of the daily concentration values). lite daily concentration. value is equal to the
concentration of a composite sample or in the case of grab sample's is the arithmetic mean (weighted by flow
value) of all the samples collected during that calendar day. The average yearly count for fecal conform
bacteei-i is the geometric mean of the counts for samples collected during a calendar year. This :Limitation is
identified as t'..1.tinual Average" under "OtheriLimits" in Part I of the permit.
e. 'The "daily average concentration" (for dissolved oxygen) is the minimum .allowable a/110'nm of dissolved
oxygen required to be available in the effluent prior to discharge averaged over a calendar day. If only one
dissolved oxygen sample is taken over a calendar day, the sample is considered to be the "daily average
concentration" for he discharge. It is identified as "daih average" in the text of Part I.
g.
The "quarterly average concentration" is the average of all samples taken over a calendar quarter. it is,
identified as "Quarterly Average Limitation" in the text of Part I of the permit.
A calendar quarter is defined as one of the following distinct periods: ' a ary through March, ,,April through
June, July through September, and October through December.
Other Measurements
a. Flow, (MGD): The flow lirnit expressed in this permit is the 24 hours average flow, averaged monthly. It is
determined as the arithmetic mean of the total daily flows recorded during the calendar month.
b. An "instantaneous flow measurement" is a measure of flow taken at the dine of sampling, when both the
sample and flow will be representative of the total disch.arge.
c. A "continuous flow measurement" is a measure of discharge flow from the facility, which occiu-s continually
without interruption throughout the operating hours of the facility Flow shall. be monitored continually
except for the infrequent 'times when there may be no flow or for infrequent maintenance activities on the
flow device.
8. Types of Samples
a. Composite Sample: A composite sample shall consist of
(1) a series of grab samples collected at equal time intervals over a 24 hour period of discharge and
combined proportional to the rate of flow measured at the time of individual sample collection, or

Part II
Page 3 of 11
8. a. 1' a series of grab samples of equal volume collected over a 24-hour period with the time intervals between
samples determined by a preset number of gallons passing the sampling point. How measurement
between s'ample intervals shall be determined by use of a flow recorder and totalizer, and the present
gallon interval between sample collection fixed at no greater thanl /24 of the expected total daily flow at
the treatment system, or
(3) a single, continuous sample collected over a 24-hour period proportional to the rate of flow,
In accordance with (1) above, the time interval between influent grab samples shall be no greater than
once per hour, and the rime interval between effluent grab samples shall be no greater than once per hour
except at wastewater treatment systems having a detention time of greater than 24 hours. In such cases,
effluent grab samples may he collected at tune intervals evenly spaced over the 24-hour period which are
equal in number of hours to the detention time of the si-,stem in number of days. However, in no case
mar the time interval between effluent grab samples be greater than six (6) hours nor the number of
samples less than four (4) during a 24-hour sampling period.
b. Grab Sample: Grab samples are individual samples collected over a period of time not exceeding 15
minutes; the grab sample can be taken manually. Grab samples must be representative of the discharge or
the receiving waters.
Calculation of Me, as
a Arithmetic l\,lean: The arithmetic mean of any set of values is the summation of the individual values divided
by the number of individual values.
b. Geometric Mean: The geometric mean of any set of values is the Nth root of the product of the individual
values where N is equal to the number of individual values. The geometric mean is equivalent to the antilog
of the arithmetic mean of the logarithms of the individual values. For ptuposes of calculating the geometric
mean, values of zero (0) shall be considered to be one (1).
c. Weighted by Flow Value: Weighted by flow value .means the summation of each concentration times its
respective flow divided by the summation of the respective flows.
10.. Calendar Day: _A calendar day is defined as the period from midnight of one dav until midnight of the next
day. However, for purposes of this permit, any consecutive 24-hour period that reasonably represents the
calendar day may be used for sampling.
1 . Haza dous Substance: A hazardous substance means any substance designated under 40 CFR Pan 116
pursuant to Section 311 of the Clean Water Act.
12. Toxic Pollutant: A toxic pollutant is any pollutant listed as toxic under Sectionn 307(a)(1) of the Clean Water
Act.
SECTION B. GENEJALoNDITIoNs
1. Duty to .Comply
The permittee must comply with all conditions of this. permit. ..Any permit noncompliance. constitutes. a violation
of the Clean Water Act and .is grounds for enforcement action; for pen -rut termination, revocation and reissuance,
or modification; or denial of a permit renewal application.
a. The permittee shall comply with effluent standards or prohibitions established under section 307(a) of the
Clean Water .Act for toxic pollutants and with standards for sewage sludge useor disposal established under
section 405(d) of the Clean Water Act within the nine provided in the regulations that establish these
standards or prohibitions or standards for sewage sludge use or disposal, even if the permit has not yet been
modified to incorporate the requirement.

Part II
e 4 uf 11
1, b. The Clean Water
not to exceed $25
provides that a
et day ft r e
bject to criminal penalties o
or both, Any person Who knovvirrglr# xicalates permit conditions is subject to criminal penalties of
o $50,000 per dare of violation, or irnprisoninenr for not more than 3 years, or both. Also, any,
person who violates a permit condition may he assessed an administrative penalty not to exceed $10,000 per
violation with the maximum amount not to exceed $125,000, lRef. Section 309 of the federal .act 33 U.S.C..
1319 and 40 CFR 122.41 (a)l
Under state
against any person
permit. [Ref; North C
it penalty of no
hates or fail
enera
person who violates a permit condition is subject to a civil penalty
ioLation. An person who negligently violates am permit condition
a a25,000 per clay of violation, of imprisonment for not torte than
ore tlhatr ten thousand dollars (1(➢C&001 per violation rnav be assessed
dance with the terms, conditions, or .requirements of a
14 3-215.6A]
d. ;1n3- person rnav be assessed an adnhirustrative penalty by the i\,dnauristratcar fear violating section 301, 302,
306, 307, 308, 318, or 405 of the _ Act, or any permit condition or limitation implementing any of such
sections in a permit issued under section 402 of the ,Act. Administrative penalties for Class I violations are
not to exceed $10,000 per violation, with the rnaxinaum amount of any Class I penalty assessed not to
exceed $25,000. Penalties for Class II violations are not to exceed $10,000 per day for each da', during
which the violation continues, 'with the maximum amount of any Class II penalty not to exceed $1.25,000.
Duty to Mitigate
The pertnittee shall take all reasonable s7
violation of this permits which has a
environment.
Civil And Crux
Except as pre
nothing in this pen
is bill
ps to tnuurnize or prevent any -
reasonable likelihood of adversely' of
use or disposal ur
n health or the
C-4) and "Power Failures" Parr I1
responsibilities, liabilities, or pet
for noncompliance pursuant to NCGS 143-215.3, 143-215.6 or Section 3➢➢ of the Federal lct, 33 U'C
Furthermore, the perrnittee is responsible for consequential damages, such as fish kills, even though the
responsibility for effective compliance may be temporarily suspended.
rrrut conditions on "Bypa
be construed to relieve the petmittee
.El 4. )i1 and Hazardous Substance liability
Nothing in this permit shall be construed to preclude the utstint
front any responsibilities, liabilities, or penalties to wluch the perrnittee is
215.75 et seer. or Section 311 of the Federal _Act, 33 USG 1321. Further
consequential clarnages, such as fish kills, even though the responsi
temporarily suspended.
6.
1 action or relieve the perrruttee
be subject to under NCGS 143-
he pernuttec is responsible for
effective compliance may be
Property Rights
The issuance of this permit does not convey anv properry rights in either real or personal property'',or anv
exclusive privileges, nor does it authorize any injury to private property or anv invasion of personal rights, nor any
infringement of Federal, State or local laws or regulations.
Pe
or Offshore Constnicti
nit does not authorize or approve the construction of any onshore or offshore physical structures or
ar° the undertaking of any work in any navigable waters.
Trability
provisions of this pe•
provhs
circumstances, i
cable, and if any provision of this permit, or the application of any
circumstances, is held invalid, the application of such provision to other
yid the remainder of this permit, shall not be affected thereby.

Part 11
Page 5 of 11
8,. Duty to Provide 1 nforina tion
The pernuttce shall furnish to the Permit Issuing Authority, within a reasonable time, any information which the
Permit Issuing Authorih, may request to determine whether cause exists for modifiing, revoking and reissuing, or
terminating this permit or to determine compliance with this permit. The pemiittee shall also furnish. to the
Permit Issuing Authority upon request, copies of records required to be kept bv this permit,
9.. Duty to Reapply
If the perinittee wishes to continue an activity regulated by this permit after the expirationexpiranon dote of this permit, the
perinittee must apply for and obtain a new permit,
1.0. Expiration of 'Permit
The permittee is not authorized to discharge after the expiration date, In order to receive automatic authorization
to discharge beyond the expiration date, the permittee shall submit such information, forms, and fees as are
required by the agency authorized to issue permits no later than 180 days prior to the expiration date. .Any
permittee that has not requested renewal at least 180 days prior to expiration, or any permittee that does not have
a permit after the expiration and has not requested renewal at least 180 days prior to expiration, will subject the
permittee to enforcement procedures as provided in NCG 143-215.6 and 33 USC 1251 et. seq,
11, Signatory Requiremenu
applications„ reports, or information submitted to the Permit Issuing. Authorim shall be :signed and certified,
a. All permit applications shall be signed as follows:
(I) For a corporation: by a responsible corporate officer. For the purpose of this Section, a responsible
corporate officer means: (a) a president, secretary, treasurer or vice president of the corporation in
charge of a principal business function, or a.ny other person who performs similar policy or decision
making functions for the corporation, or (b) the manager of one or more manufacturing production or
operating facilities employing more than 25,0 persons or having gross annual .sales or expendirures
exceeding 25 rnillion (in second quarter 1980 dollars)., if authority to sign documents has been assigned or
delegated. to the manager in accordance with corporate procedures..
(2) For a partnership or sole proprietohip; by a general partner or the proprietor, respectively or
(3) For a municipality, State., Federal, or other public agency: by either a principal executive officer or ranking
elected official.
reports required by the permit and other information requested by the Permit- Issuing Authority shall be
signed by a person described above or by a duly authorized representative of that person. A person is a duly
authorized representative only if:
(1) .1 person describedabove makes the authorization in writing;
(2) The authorization specified either an individual or a position having responsibility for the overall operation
of the regulated .facility or activity, such as the position of plant manager, operator of a well or well field,
superimendent, a position of equivalent responsibility, or an individual or position having overall
responsibility for environmental matters for the company, (A duly authorized representative may thus be
either a named individual or .any individual occupying a named position); and
(3) The written authorization is submitted to the Permit Issuing Authorim
c. Certification, Any person signing a document under paragraphs a. or b. of this section shall make the
following certification:
"I certify, under penalty of law, that this document and all attachments were prepared under my direction or
supervision in accordance with a system designed to assure that qualified. personnel properly gather and
evaluate the information submitted. Based on tnv inquiry of the person or persons who manage the system,
or those persons 'directly responsible for gathering the inforniation, the information submitted is, to the best
of my knowledge and belief, true, accurate, and complete. I am awarethat there are significant 'penalties for
submitting false information, including the possibility of fines and imprisonment for knowing violations,"

Part II
Page 6 of 11
12. Pen -nit Actions
This permit may be modified, revoked and reissued, or terminated for cause. The filing of a request by. the
permittee for a permit modification, revocation and reissuance, or termination, or a notification of planned
changes or anticipated noncompliance does not stay any permit condition
13. Permit INIodification., Revocation and Reissuance, or Termination
1'he issuance of this permit does not prohibit the permit issuing authoriw from reopening and modifying the
permit, revoking and reissuing the permit, or terminating the permit as allowed by the laws, mles, and regulations
contained in Title 40, Code of Federal Regulations, Parts 122 and 123; 'fide I5A of the North Carolina
Administrative Code, Subchapter 21-1 .0100; and North Carolina General Statute 143-215.1 et. al.
1.4, Previous Permits
All previous National Pollutant Discharge Elimination System Permits issued to this .faciliw, whether for
operation or discharge, are hereby revoked by issuance of this permit. [Mc exclusive authority to operate this
facility arises under this permit. 'The authority to operate the facility under previously issued permits bearing this
number is no longer effective. The conditions, requirements, terms, and provisions of this permit authorizing
discharge under the National Pollutant Discharge Elimination Systemgovern discharges from, this facility.
SECTION C. OPERATION AND MAINTENANCE OF POLLUTION CONTROLS
1. Certified Operator
-Pursuant to Chapter 90A-44 of North Carolina. General Statutes, and upon classification of the facility by the
Certification Commission, the permittee shall employ a certified wastewater treatment plant operator in
responsible charge (ORC) of the wastewater treatment facilities. Such operator must hold a certificationof the
grade equivalent to or greater than the classification assigned to the wastewater treatment facilities by the
Certification Commission. The pernuttee must also employ a certified back-up operator of the .appropriate type
and any grade to comply with the conditions of Title 15A NCAC Chapter 8G.0202. The ORC of the facility
must visit each Class I facility at least .weekly and each Class II, III,. and IV facility at least daily,. excluding
weekends and holidays, and must properly manage and document daily operation and .maintenance of the facility
and must comply with all other conditions of Title 15.3. NCAC Chapter 8G.0202. Once the facility is classified,
the petraittee shall submit a letter to the Certification Commission, which designates the operator in responsible
chargewithin than- days after the wastewater treatment facilities are 500/0 complete.
Proper Operation and Maintenance
The permittee shall at all times properly operate and maintain all facilities and systems of treatment and control
(and related appurtenances) which are installed or used by the perrnittee to achieve compliance with the
conditions of this pennit. Proper operation and maintenance also includes adequate laboratory controls and
appropriate quality assurance procedures. This provision requires the operation of back-up or auxiliary facilities
or similar systenis installed by a perrnittee only when the operation is :necessary to achieve compliance with the
conditions of the permit
3. Need to Halt or Reduce not a De Tense
It shall not be a defense for a perrnittee in an enforcement action that it would have been necessary to halt or
reduce the permitted activity in order to maintain compliance with .the condition of this pen -nit
4. Bypassing of Treatment Facilities
a. 'Definitions
(1)
(2)
"Bypass" means the known diversion of waste streams from any portion of a treatment facility including
the collection system, which is not a designed or established or operating mode for the facility.
"Severe property damage" means substantial physical damage to property, damage to the treatment
facilities. which causes them to become inoperable, or substantial and permanent loss of nantral resources
which can reasonably be expected to occur in the absence of a bypass. Severe property damage does
not mean economic loss caused by delays in production.

Part 11
Page 7 of :II
4. b. Btpass not: exceeding limitations.
the Permittee mar allow any bypass to Occur which does not cause effluent lianitations to be exceeded, but
only if it also is for essential maintenance to assure efficient operation. 'These 'bypasses are not subject to the
provisions of Paragraphs c,„ and d. of this section.
c. Notice
(1) Anticipate rpass.. If the permittee knows in advance of the need for a bypass, it shall submit prior
notice, if possible at least ten days before the date of the bipass; including an evaluation of the
anticipated quality and affect of the bypass.
(2) Unanticipated bipass, 'The permittee shall submit notice of an unanticipated bypass as required in Part II,
E. 6. of this permit. (24-hour notice
d. Prohibition of Bypass
(1) Bypass is prohibited and the Permit Issuing ,.kuthority may take enforcement action against a permittee
for bypass, unless:
(r.c) Bypass was unavoidable to prevent loss of life, personal injury or severe property damage;
(B) 'There were no feasible alternatives to the bypass, such as the use of auxiliary .treatment facilities,
retention of untreated wastes or maintenance during normal. periods of equipment downtime. This
condition is not satisfied if adequate backup elLitdpment should have been installed in the exercise of
reasonable engineering judgment to prevent a bypass which occurred during normal periods of
equipment downtime or preventive tiiitinteriance: and
(C) The permittee submitted notices as required under Paragraph c. of this section.
(2) Bypass from the collection system is prohibited. Ile Permit Issuing „Authority may take enforcement
action against a Permittee for a bypass as provided in any current or future system -wide collection
system permit associated with the treatment facility.
(3). 'The Permit Issuing Authority mar approve an anticipated bypass, after considering its adverse affects, if
the Permit Issuing Authority determines that it i11 meet the three conditions listed above in Paragraph d.
(I) of this section.
5, Upsets
a. Definition: "Upset" means an exceptional incident in which there is unintentional and temporary
noncompliance with technology based permit effluent limitations because of factors beyond the reasonable
control of the permitter. An upset does not include noncompliance to the extent caused by operational
error, improperly designed treatment facilities, inadequate treatment facilities, lack of preventive maintenance,
or careless or improper operation,
b, :Effect of an upset: An .upset constitutes an affirmative defense to an action brought for noncompliance
with such technolo7 based permit effluent limitations if the requirements of paragraph c. of this condition
are met. .No determination made during administrative review of claims that noncompliance was caused by
upset, and before an action for noncompliance, is final administrative action subject to judicial review,
c. Conditions necessary for a demonstration of upset: A permittee who wishes to establish the
affirmative defense of upset shall demonstrate, through properly signed, contemporaneous operating logs, or
other relevant evidence that:
(1) ,An upset occurred and that .the .pennitter can identify the cause(s) of the upset;
(2) The permittee facilin- was at the time being properly operated; and
(3) The permittee :submitted nonce of the upset as required in Part 11, E. 6. (b) (2) of this pen -nit.
(4) The pennittee complied with any remedial measures required under Part II, :B. 2. of this permit.
d. Burden of proof: In any enforcement proceeding the permittee seeking to establish the occurrence of an
upset has the burden of proof.

Part II
Page 8 of 11
6, Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or control of :wastewaters
shall be utilized/disposed of in accordance with INCGS 143-215.1 and in a manner such as to prevent any pollutant
from such materials from entering waters of the State or navigable waters: of the United States, The permittee
shall comply: with all existing federal regulations governing the disposal of sewage sludge. Upon promulgation of
40 CFR. Part. 503., any permit issued bv the Permit Issuing Authority for the utilization/disposal of sludge may be
reopened and modified, or revoked and reissued, to incorporate applicable requirements at 40 CFR Part 503.
The permittee shall comply with applicable 40 CFR Part 503 Standards for the Use and Disposal of Sewage
Sludge (when promulgated) within the :time provided in the regulation, even if the permit is not modified to
incorporate the requirement. The perminee shall notify the Permit Issuing :Authority of an significant change in
its sludge use or disposal practices.
7. Power Failures
The permittee is responsible .for maintaining adequate safeguards as required by DEM Regulation, Title 15.
North Carolina Administrative Code, Subchapter 2II, 1)124 Reliability, to prevent the discharge: of untreated or
inade:quately treated wastes during electrical power failures either by means of alternate power sources, standby
generators or retention of inadequately treated effluent,
SE TION D. MONITORING AND RECORDS
1. Rept sentative Sampling
Samples collected and measurements taken, as required herein, shall be characteristic of the volume and nature of
the permitted discharge. Samples collected at a frequency less than daily shall be taken on a day and one that is
characteristic of the discharge over the entire period which the sample reprcsents All samples shall be taken at
the monitoring points specified in this permit and, unless otherwise specified, before the effluent joins or is
diluted by any other 'wastestream, body of :water, or substance. Monhtoring points shall not he changed without
notification to and the approval of the Perrnit Issuing _Authority.
Reporting
Monitoring results obtained during the previous month(s) shall be sunintirized for each month and reported on
a monthly Discharge Monitoring Report (DMR) Form (DEM No. MR 1, LI,2, 3) or alternative forms approved
by the Director, DEM, postmarked no later than the 30th day following the completed reporting period.
The first DMR is due on the last day of the month following the issuance of the permit or :in the case of a new
facilim on the last dav of the month following the conunencement of discharge. Duplicate signed copies of
these, and all other reports required herein, shall be submitted to the following address:
NC DENR / Division of Water Quality / Water Quality Section
ATTENTION: Central Files
1617 Mail Service Center
Raleigh, North Carolina 27699-'1617
3. :low Measurements
Appropriate flow measurement devices and methods consistent with accepted scientific practices shall be selected
and used to ensure the accuracy and reliability of measurements of the volume of monitored &charges. The
devices shall be installed, calibrated and maintained to ensure that the accuracy of the measurements are consistent
with the accepted capability of that type of device. Devices selected shall be capable of measuring flows :with a
maximum deviation of less than 10° o from the true .discharge rates throughout the range of expected discharge
volumes. Once -through condenser cooling water flow which is monitored by pump logs, or pump hour meters
as specified in Part I of this permit and based on the :manufacturer's pump curves shall not be subject to this
requirement.

Pan Il
of 11
4. Test Procedures
Test procedures for the analysis of pollutains shall conform to the EMC regulations pubbshed pursuant to
INCGS 143-215.63 et. seq., the Water and Air Quality Reporting Acts, and to regulations published pursuant to
Section 304(g), 33 ESC 1.314, of the Federal Water Pollution Control Act, as Amended, and Regulation 40 CFR
136, or in the case of sludge use or disposal, approved under 40 CFR 136, unless otherwise specified in 40 CFR
503, .unless other test procedures have been specified 'inthis permit.
To meet the intent of the monitoring required by this permit, all test procedures must paiduce minimum
detection and reporting levels that are below the permit discharge reqttirements and all data generated must be
reported down to the minimum detection or lower reporting level of the procedure. If no appro-ved methods
are determined capable of achieving minimum detection and reporting levels below permit discharge
requirements, then the most sensitive (method with the lowest possible detection and reporting level) approved
method must be used,
5. Penal 'es for Tainperiug
The Clean Water Act provides that any person who falsifies„ tampers with, or knowingly renders inac,curatc, any
monitoring device or method required to be maintained under this permit shall, upon conviction, be punished by
a fine of not more than $10,000 per violation, or by imprisonment for not more than two years per violation, or
by both. If a conviction of a person is for a violation committed after a first conviction of such person under
this paragraph, punishment is a fine of not more than $20,000 per day of violation, or bY imprisonment of not
more than 4 years, or both,
6. Records Retention
Except for records of monitoring information required by this permit related to the permittee's sewage sludge
use and disposal activities, which shall be retained for a period of at least five cars (or longer as required by 40
CFR 503), the permince shall retain records of all monitoring information, including all calibration and
maintenance records and all original strip chart recordings for continuous monitoring instrumentation, copies of
aU reports required by this permit, for a period of at least 3 years .from the date of the sample, measurement,
report or application 'This period may be extended by request of the Director at any time.
RecQrcljpg Results
For each measurement or sample taken pursuant to the requirements of this 'permit, the pennittec shall record the
following information:
a. The date, exact place, and time of sampling or measurements;
b. The individual(s) who performed the sampling or measurements;
c. The date(s) :analyses were performed;
d. The individual(s) who performed the analyses;
e. The analytical techniques or methods used; and
f„ 'The results of such analyses.
8. Inspection and Entry
The permittee shall allow the Director, or an authored representative ag an authorized contractor acting
as a representative of the Director), upon the presentation of credentials and other documents as may be required.
by law, to;
a, Enter upon the permittee's premises where a regulated facility or activity is located or conducted, or where
records must be kept under the conditions of this permit;
b. Have access to and copy, at reasonable times, any records that must be kept under the conditions of this
permit;
c, Inspect at reasonable times any facilities, equipment (including monitoring and control equipment), practices,
or operations regulated or required under this permit; and
d. Sample or monitor at reasonable times, for the purposes of assuring permit compliance or as otherwise
authorized by the Clean Water Act, any substances or parameters at anv location.

Part 11
Page 10 of 11
SECTION E REPORTING REQUIREMENTS
1. Change in Discharge
U1 discharges authorized herein shall be consistent with the terns and conditions of this permit. The discharge of
any pollutant identified in this pennit more frequently than or at a level in excess of that authorized shall constitute
a violation of the permit.
2, PlannedChans
The periaittee shall give notice to the Director as soon as possible of any planned physical alterations oi additions
to the permitted facility. Notice is required only when:
a. The alteration or addition to a permitted facility may meet one of the criteria for determining whether a
facility is a new source in 40 CFR Part .122.29 (b); or
b. The alteration or addition could significantly change the nature or increase the quantity of pollutants
discharged. This notification applies to pollutants which are subject neither to effluent limitations in the
permit, nor to notification requirements under 40 CFR Part 122.42 (a) (I).
c. The alteration or addition results in a significant change in the permittee's sludge use or disposal practices, and
such alteration, addition or change. may justify .the application of permit conditions that are different from or
absent in the existing permit, including notification of additional .use or disposal sites not reported during the
permit application process or not reported pursuant to an approved land application plan,
3. .Noncompliance
The permittee shall give advance notice to the Director of .any planned changes in the permitted facility or activity
which may result in noncompliance with permit requirements.
4, Transfers
This permit is not transferable to any person except after notice to the Director. The Director may require
modification or revocation and reissuance of the perrnittee and incorporate such other requirements as may he
necessary under the Clean Water Act.
5. Monitoring Reports
.Monitoring results shall be reported at the intervals specified. elsewhere in this pennit.
a. Monitoring results must be reported on a Discharge Monitoring Report (DMR) (See Part 11. D. 2 of this
permit) or forms, provided by the Director for reporting results of monitoring of sludge use or disposal
Practices.
b. If the pennittee monitors any pollutant more frequently than required by the permit, using test procedures
specified in Part II, D. 4. of this permit or in the case of sludge use or disposal, approved under 40 CFR
503, or as specified in this permit, the results of this monitoring shall be included in the calculation and
reporting of the data submitted in the DMR.
c. Calculations for all limitations which require averaging of measurements shall utilize an arithmetic mean unless
otherwise specified by the Director in the permit.
6. Twenty-four Hour Reporting
a. The permittee shall report to the central office or the appropriate regional office any noncompliance which
may endanger health or the environment. Any information shallbe provided orally within 24 hours from the
time the permittee became aware of the circumstances. A written submission shall also be provided within 5
days of the time the permittee becomes aware of the circumstances. The written submission shall contain a
description of the noncompliance, and its cause; the period of noncompliance, including exact dates and
times, and if the noncompliance has not been corrected, the anticipated time it is expected to continue: and
steps taken or planned to reduce, eliminate, and prevent reoccurrence of the noncompliance.

Part 11
Page 11 o.f 11
6., b. The following shall he included. as information wluch niut he reported wi1un 24 hours under this
paragraph:
(1.) „Any tit -anticipated bypass which exceeds anyeftiuen llnMtauorithe permit.
(2) „7'iny upset which exceeds any effluent limitation in the permit.
(3) Violation of a .maximum daily discha.rge limitation for any of the pollutants listed b rhe Director in the
permit to be reported within 24 hours,
c. The Director may waive the written. report on a case-bv-case basis for reports under paragraph h. above of
this condition if the oral report has been received .within 24 hours,
(„)thet ..Noncompliance
permittee shall report all instances of noncompliance not reported under Part II, E. 5 and 6, of this permit at
the time monitoring reports are submitted, Thc reports shall contain the infbmiation listed in Part 111, E, 6. of this
permit.
8. Other Information
Where the perm:ince becomes aware that it tailed to submit any relevant facts in a permit applicatio.n, or
submitted incorrect information in a permit application or in any report to the Director, it shall promptly submit
such facts or information.
9. .NoncomplianceNotifica lion
The pennince shall report by telephoneto either the central office or the appropriate regional office of the
Division as soon as possible, but i.n no case more than 24 hours or on, the next working day following the
occurrence or first knowledge of the occurrence of any of the following:
a.„Any occurrence at the water pollution control facility which results. in the discharge of significant amounts of
wastes which arc abnormal in quantity or characteristic, such as the dumping of the contents of a sludge
digester; the known passage of a slug of hazardous substance through the facility; or any other unusual
circumstances,
b. ,Any process unit failure, due to .known or unknown reasons, that render the facility incapable of adequate
wastewater treatment such as mechanical or electrical failures of pumps, aerators, compressors, etc.
c, Any failure of a pumping station, sewer line, or treatment faci10 resulting in a by-pass directly to receiving
waters without treatment of all or any- portion of the influent to such station or facility.
-Persons reporting such occurrences by telephone shall also file a written report in letter form within 5 days
following first knowledge of the occurrence,
10, .Availability of Reports
Except for data determined to be confidential under NCGS 143-215.3 (a)(2) or Section 308 of the Federal Act, 33
DSC 1318, all reports prepared in accordance with the terms shall be available for public inspection at the offices
of the Division of Water Quality, As required by the Act, effluent data shall not be considered confidential.
Knowingly making any false statement on any such report may result in the imposition of criminal penalties as
provided for in NCGS 143-215,1 (b)(2) or in Section 309 of the Federal .Act.
11, Penalties for Falsification of Reports
The Clean Water Act provides that any person who knowingly makes any false statement, representation, or
certification in any record or other document submitted or required to be maintained under this permit, including
monitoring reports or reports of compliance or noncompliance shall, upon conviction, be punished by a fine of
not more than $10,000 per violation, or by imprisonment for not more than two ears per violation, or by both.

PART III
OTHER ENTS
A. Construction
No construction of wastewater treatment facilities or additions to add to the plant"s treatment caf
change the type of process utilized at the treatment plant shall be begun until Final Plans and Specific
been submitted to the Division of Water Quality and written approval and Authoriz.ation to Constru
issued
city or to
Lions have
t has been
13. Gronndwater .Montto ng
The pertnittee shall, upon written notice from the Director of the Division of ter t uali.ty; conduct
groundwater monitoring as tray be required to determine the compliance of this NPDI, permitted facility with
the current groundwater standards.
C. Changes in Discharges of Toxic Subs,
The perrnittee shall notify the Permit
uing Authority as son as it knows or
That any activity has occurred or will occur which wou
basis, of any toxic pollutant which isnot limited in the permit; if
following "notification levels";
(1) One hundred micrograms per liter (100 µg/L);
(2) Two hundred micrograms per liter (200 µg/L) for aerolein and ac
per liter (500 µg/L) for 2.4--dinitrophenol and for et11)1-4fi-di
liter (1 mg/L) for antiinonv;
(3) Five (5) times the maximum concentration. value reported for that pc
as reason to believe,
thschart
charge vv
u
b. That any activity has occurred or will occur which would result in atiy
infrequent basis, of a toxic pollutant which is not limited in the permit,
highest of the following "notification levels";
(1) Five hundred micrograms per liter (500 Erg//L);
(2) One ntilliigram per liter (1 mg/L) for antimony;
(3) Ten (10) tomes the inaatittauin concentration value report
D. Requiren qit to Continually ) volt ate 'ticeritatives to Was
The perrnittee shall cont nually evaluate all wastewater disspo al alter atives and pursue the
sound alternative of the reasonably cost effective altertiatives if tlae facility is in substantial
the terms and conditions of the NPDES pernut or governing rules, tions or haws,
submit a report in such form and detail as required by the Division evaluating these alternati'
action within Stitt}, (60) days of notification by the Division.
n a routine tar frequent
Kceed the holiest of the
nitrite; five hundred micrograms
.,ophenol; and one milligram per
h.
a
the permit application.
ge, on a dean -routine or
discharge will exceed the
Ilutant in the permit application.
vironmentatty
mpliance with.
permittee shall
and a plan of
PART IV
ANNUAL ADMINISTERING AND COMPLLANCE MONITORING FEE
REQUIREMENTS
A. The perrnittee trust pay the annual administering and compliance monitoring fee within30 (thirty)
days after being billed by the Division. Failure to pay thefee in a timely manner in accordance with
151\ NCAC 2H ,0105(b)(4) may cause this Division to initiate action to revoke the permit..

DENRIDW Q
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No, NC0048712
Fa
Appiicant/Facihty Name::
ut
Applicant Address:
Facility Address:
Permitted Flow
S.R. 1848; I.O. Box 100: Catawba, North Caro.
NCSR 1848 southwest of Catawba, Cat,wba. County, NC
Not lirr►ited
Type of Waste: industrial 000%) fr
system and cooling tower blowdown
aluminum extrusio
Facility/Permit Status: Clans I /Active; Renewal
Catawba County
County:
M►scelianeous
Rec'iving Strea
earn Classifica
(d) List:ed?
Subbasin:
UT to Lake
Norman
Regional Office:
Drainage Area (mi
Summer 7Q10 (cl
Winter 7Q 10 (c
30Q2 (cis)
Average Flow (cfs):
TWC (%):.
n
S-I
0
0.26
Table I. Summanrormor NCOft487I2
Date:
id / USGS Quad:
ville (MRO)
E 14NE/Catawba, NC
Natalie V. Sierra
27Aueust 2002
BACKGROUND
Alcoa Extrusions, Inc. (formerly Alumax. Extrusions, Inc.) discharges filter backwash from an
alum inum extrusion cooling water filtration system and cooling tower blowdown to an unnamed
tributary to Lake Norman in the Catawba River Basin. This facility uses aluminum billets and through
the process of extrusion, manufactures aluminum extruded tube.
This facility practices a large amount of internal recycle and has an extremely small effluent flow as a
result. Due to a number of recent toxicity problems, it may be advantageous for the facility to go to a
full recycle system.
Instream Monitoring, Verification of Existing Conditions, DMR Data Review
Alcoa Extrusions, Inc,. discharges to an unnamed tributary to Lake Norman, whieh is a classified
W S-IV water in sub -basin 03-08-32 in the Catawba River Basin, This tributary is not impaired (303(d)
listed) as of the 2002 draft 303(d) list, The facility is not required to perform any instrearn monitoring,
inspection reports by the Mooresville Regional Office indicate that the stream at the outfall is clear.
Discharge Monitoring Reports (DMRs) were reviewed from 'January 1999-June 2002. The table
below summarizes the data review for conventional parameters (as well as oil and grease and total
residual chlorine).
Average
Maximum
Minimum
.0
0.0031
.0001
Temperature Total Suspended
(deg,, C) Solids (lbs./day)
Table 2. Summary D�4t1 information i"o ti .i10-487t2.
21.7
27.4
16,4
Temperatures appear to be seasonal
0.02
0.0687
0.0005
Total Residual
Chlorine (uglL)
0.09
0,24
a
appropriate. The flow is extremely to
Oil and Grease
(Ibs./day)
0.058
0.257
0M06
due to the high
amount of recycling that Alcoa performs within the plant.

Toxicants monitored include chlorides, aluminum, barium, cyanide, chromium, copper, nickel,.
lead and zinc. A reasonable potential analysis was performed on the data for these parameters and is
discussed below.
Reasonable Potential Analysis (RPA) and Priority Pollutant Analysis (PPA)
Data from January 1999-June 2002 were reviewed for a reasonable potential analysis. A number
of the results were expressed in pounds per day. These data were converted to mg/L or p.olL using the
daily flow data and the following equation:
lhs./ day
mg I L
flow(MGD)x8.34((lb.1 MG)I(mg I L))
Values expressed as '< x lbsIday' were converted using this same formula, but retaining the "<." sign.
Such values were therefore entered in as half of the converted "x" value resulting from the equation
above,
Aluminum, barium, chloride, chromium, cyanide, copper, lead, zinc and nickel were all analyzed
for reasonable potential. The analysis indicated that reasonable potential exists for aluminum, barium,.
cyanide, copper, zinc and nickel. No reasonable potential exists for chromium, chloride, and lead (all
values were "<" for lead). Aluminum, copper and zinc are all action level parameters. Unless their
presence is linked to effluent toxicity, no water quality limit is given for these parameters. Thus, water
quality limits will only be given for barium, cyanide and nickel. Twice monthly monitoring will be
given for all parameters showing reasonable potential.
The priority pollutant analysis indicated the presence of one parameter not currently monitored
through the NPDES permit — beryllium. Since this is considered a pollutant of concern, a monitoring
condition will be placed in the new NPDES permit.
Additional limits for chromiurn, cyanide, zinc and aluminum will also be included according to
the federal effluent guidelines for this industry.
Federal Effluent Guidelines
Alcoa Extrusions, Inc. is a categorical industry, regulated by 40 CFR 467 — Aluminum Forming
Point. Source Category. The applicable subpart is Subpart C — Extrusion Subcategory, Press Heat
Treatment Contact Cooling Water. Best Available Technology (BAT) criteria were employed in
determining limits for chromium, cyanide, zinc, and aluminum. Best Practicable Technology (BPT)
guidelines were used to determine limits for oil and grease, total suspended solids (TSS) and pH.
Daily maximum production provided by the facility was used in determination of the daily
maximum limits. The maximum. monthly production was used in the calculation of the monthly average
lirnits. These calculations result in production based limits as fellows:
Effluent Characteristics
Chromium
Cyanide
Zinc
Aiuminum
Oil and Grease
Total Suspended Solids (TSS)
pH
ximum Li lb
0.07
0.05
0.25
1.08
12.70
26 04
Between TO and 1
Monthly Avera e Limit bs.
0.03
0.02
0.10
0.54
7.71
12.52
0,0 standard units
Table 3 Effluent limits resulting from application of the federal effluent guidelines (40 CFR 467.32 and 467.33)
The limits for cyanide will appear on the perrnit in addition to the water quality based limits described
above.
Correspondence
The Mooresville, Regional Office (MRO) prepared a Staff Reports related to this permit renewal
( 0/31/00) This report confirms that the discharge still consists of cooling tower blowdown and filter
backwash and that biocides are added to the cooling towers.
In addition to providing a Staff Report, MR() has performed four Compliance Evaluation Inspections and
two Compliance Biomonitoring Inspections. While Alcoa passed both Biomonitoring Inspections, it

received a Notice of Violation (NOV) for three out of four of the Compliance Evaluation inspections,
Most of the non-compliance issues related to laboratory procedures (calibration, lab procedures) and
poor records keeping (not reporting parameters, not filling out DMRs correctly, not recording
calibrations). The facility has also received ten NOVs for toxicity failures in the past two years. Under
the new compliance policy, civil penalties were assessed for nearly all of those failures in 2002. The
failures have also triggered the new Action Level Policy, which requires the Peri iittee to perform a
Toxicity Identification Evaluation or other method indicating the cause of toxicity. This report is due to
be submitted — October of 2002, and this permit will not be finalized until such time as the report is
submitted. Such a submittal will help elucidate whether or not copper and zinc Limits are needed. As of
now, the facility is complying with the action level policy agreement between North Carolina and EPA
Region IV.
PERMFITING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA in 1995. The previous and current effluent limits were
based on guidelines and water quality standards. The Division has judged previous parameters and limits
to he appropriate for renewal with some exceptions (see Reasonable Potential Analysis and Federal.
Effluent Guidelines).
Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential for
toxicants to be discharged by this facility, based on three and a half years of DMR data (January 1999
through June 2002). Results suggest no reasonable potential for the facility to discharge chloride, lead
and chromium. The following parameters show reasonable potential: aluminum, barium, cyanide,
copper, zinc and nickel. Water quality limits and monitoring for these parameters are listed
below:
Effluent
Characteristic
Aluminum
Barium
Chloride
Chromium
Cyanide
Copper
Lead
Nickel
Zinc
Beryllium
Table 4.
Weekly Average Daily Mohr
Limit Limit
No limit action level parameter
1.0 jig/ 11000 µg/L
No limit - no reasonable potential
No limit - no reasonable potential
5 µg/L 22 µgiL
No limit - action level parameter
No limit - all values reported less than
25.0 µglL 1261 µg/L
No limit - action level parameter
No limit - detected in ppa
Monitoring
Frequency
2/Month
2/Month
Quarterly
Monthly
2/Month
2/Month
Quarterly
2/Month
2/Month
Monthly
Sammary of water quality based limits and monitoring resulting from reasonable potential analysis
Federal Effluent Guidelines
Updated production values have caused
guidelines: aluminum, chromium, cyanide, zinc
3, above, and are somewhat lower than those in
a change in the limits based on federal effluent
, TSS and oil and grease. These limits are listed in Table
the current permit_
SUMMARY OF PROPOSED CHANGES
In keeping with Division policies, the following will be incor
•
•
•
•
•
Updated water quality based limit for cyanide
Water quality based limits for barium and nickel
Monitoring for beryllium
Increased monitoring for copper (2/Month)
Updated technology based limits for aluminum,
grease, and TSS,
orated into t
perms
zinc, chromium, cyanide, oil and

New Weekly Average and Daily i t
Vs and aalloMPlle coarceartraations based on
are derived frorra the latest NC/EPA policiespohcies con id rirr r
ale potential.
PROPOSED SCHEDULE FOR PE ISSUANCE
Draft Permit to Public Notice
Permit Scheduled toIssue:
.nelomsrares.Reasonable patented l eataalsis,f,en dine
Full DAM data suraaaaxaaary aandppaa available upon request
IVDES DIVISION
If you have questions regarding any of the above
Natalie Sierra at (1 733-5083 exE55
NAME:
RFGIONA1 OFFICE COM Er
RV'Sa
nt
September 18, ?ll ?2
November 8, 2002
alcul dons, and toxicity summary,
ry#.
r on the attached permit Please contact

Qw (M(JD)
W'°T"P Clussitictttion
NPDES #
Receiving Stream.
fwC (%)•
easonable Potenti:!1 Summary
EimaLg :tRr?rs.:
Reasonable Putentlfh1
NC
e N*r
Stream Class
7Q1us (ef )=
30Q2 lcfs)
Qavg lets,)
0.28
urutnum
Max. Pred Cw
Allowable Cw
Imltlerrtenlation
11.97.0 pg/t IAre all reported values Iess than? No Limit? Nt (A..I1Monitoring
Nttl a POC ur/l lTs the detectitn lttttit acceptable? Yes onitor? Yes j Frequency 2
onth
Bar iu
Max. Pred Cw
Allowable Cw
Implementation
108121.4 µgfl IA all reported values less than?
1,0 µgll Is the detection limit acceptable;
No Limit? Yes 'Monitoring
Yes Monitor Yex Frequency 2(Month
oride
Cbromiur
Mla . Pred Cw
Allowable Cw
Max. Pred Cw
Allowable. Cw
Ilmplementation
61,7 mg/L. 'Are all reported values less than?
250.0 mglL ;Is the detection limit acceptable?
45.5 mg/L Are all reported values less than?
50.0 mg/l. is the detection limit acceptable"?
tide
tipper
AV)
Max. Pre(i i'w
�llow.sble Cw
112 AVI.
Max. Pred Cw
Allowable Cw
102.2 µg/I
5.0 µg/l
2
plernentat
e all reported values less than°?
Is the d.ctection limit acceptable?
Limit?
No V Monitoring
Yes ; Frequency luorlerly
No Limit? No Monitoring
Yes Monitor? Yes Frequency Monthly
No Limit? Yes
onitoring
Y'es Monitor'? Yes Frequency 2/Month
Implementation
2024,19 µg/1 Are all reported values less than"?
7;1 i lag'/1 Is the detection limit acceptable?
FAV
7
No Limit? No (A.L,.) Monitoring
Yea Monitor? Yes
Frequency 2/Month
ad
Max, Pred Cw
Allowable Cw
2 FAV
llmplementatlon
3975.7 pgli Are all reported values less than? Yes Lsmit7 No Monitoring
25.0 µg/1 Ss the detectioeptable? Y`e Monitor? Yes 'Frequency Monthly
n
Max, Pred (:w
Allowable C w
Implement.
2163.7 µg/1 'Are all reported values less than? No Limit? No (A.L.)!Monitoring
0 µg/l is the detection limit acceptable? Yes Monitor'? Yes 1Frequency 2/Month
FAV
7;0
Y
Max. Pred Cw
Allowable Cw
plementation
54.2 lujJl ; Are all reported values less than? No Limit? No 'Monitoring
6.$ 1tg11 Is die detection limit acceptable? Ye Monitor? Yes !Frequency Monthly
NTckel
Max, Pred Cw
Allowable Cw
IImplementation
1551.3 µgll jAreallreported values less than'? No Limit'? Yes jMonitorng
25.0 µgll ; Is the detection limit acceptable? Yes Monitor. Yes Frequency 2/Month

ALCOA Extrusions, Mc.
NC0048712
Determination of effluent guidelines limitations
by: Natalie Sierra, NPDES Unit
8/23/02
Guidelines 40CFR 467.32 (for TSS and Oil and Grease) and 467.33 (a other par.)
(Subpart Cr Press Heat Treatment Contact Cooling Water)
Daily maximum production
Monthly
Guidelines
Effluent r'
Characteristics
Chromium
Cyanide
Zinc
Aturninurn
Olt and Grease
Suspended olds
pH
82418 lbs.
83333 lbs,
Daily Max Monthly, 'Daily Monthly
(lbs./rfullion Average Maxirritirri Average
off-lbs.) (lbs./million Limit (lbs) limit (lbs)
off-lbs.)
0,9 0.37 0.074 0.031
0.59 0.25 0.049 0.021,
2.98 1.25 0.246 0.10.4
13.1 6.52 1.080 0.543
154.1 92.46 12.701 7,705
315.91 150.25 26,037 12.521
.7.0-10.0 standard units

Whole Effluent Toxicity Testing Self -Monitoring Summary
FACILITY REQUIRINIENT
AugUSI 76, 2(
YEAR J0N FEB MAR APR MAY 11.1N 11,11„ AUO OH' OCT NOV DEC
AA83181cQ20y, Por,i, thr lam 9031.• (Grab) 1998 -- Pass
NCOO9:465151001 Begire 115151996 Frequency, Q P401 5. Feb May Aim Noy NonComm Single 1999 Pass Pass
Comm: New Silsover Iteg.kor WIRO Subbas. CPF1.7 2000 -- Lore
Pr: 0.29$ Spada 2001 p.,, Pass
7Q10: 0.0 1WC(%),:400 2002 — H
Pass
J.-
Pass FAA
Pass Paws
Pass LAW
Pa. Pass
14
Pass
rare
Pass
Pass
Fait
AAF7McQu00, Iner002 Perm chr Ism: 90% (Grab)
NC11085658/00.2 Begin:115/5199h Fmk/matey: Q P525 Fob May Aug Nnv
Casual-, New Hanover Picea. WIRO S.ubbissac CPF17
Pr': 0,36 Ssesial
I7Q114 1),11 II0/CO510:1011 iThha,
Nn.nCarno: Single
1998
1999
2000
2001
2002
Aberdeen Pesticide Dumps Sae Perm chr lim: 2.5% 093
NC50086.398.5001 Begin:11152000 Frequency Q Feb May Aug Nov 4 NonComp:Single .109.9 --
Coanty Moore Region: FRO Subbasia: LUM50 2000 —
PE. 0.072 Sp.,' ,2001
7Q10! 4.3 I WC.lf%):2-.3 Or&r. 2002 --
4-1
41
41
11
41
AllIco„ Inc, Penn chr lim: 063%
000:0052665001 Begio.:Y121999 Pasyucncy: Q F Jan Apr Jul Oct NonCamp: Sines
County: Wilkes Region: WS.R0 Subbssin: YAM!
PI' 1.0 Spcsial
7Q10 228,0 I990(%),13675 tailer
1998 >100
1999 >100
2000 Pass
2001 p.ga
2002 Palls
Pass
39.4>100
>100
Pass
Pass
Pasasiu)
.100
Pa55
Pass
Pass
>100
Pass
Pass
Pass
>109
AGRA Co rpuratiun Perm ch,r Jiro: 174t6
NC00003375001 1300i0s 1211151996 Frequency: Q17/F 5- Jan AK Jul Oct
Cosmiy: Transylssinis, Region- ARO Suhhasin: FRB° 1
PP: 3.0 Sive.
7Q10: 14.4 P000(%):2.4 Ordsr:
NonCorrip Single
1998 Fad PASS Pass Pass
1999 Pass Pass Pass
2000 Fait >48 .48 Pass Pass
2001 pa,3 Pass Pass
2002 Pass — Farl A48 >4A
Pass
Pass
Pass
Pass
Alamac Acquisition, LLC Pam Oho Lino 3.20/ 1998 — Pass — — Pass Pass Pass
N000046 I WOO 1 Fletran711/201/1 Frequency; Q Mar Jun Sep Dec a NonComp:SINGLE 1999 — Pass 74 Pass Pass
County: Robeson Region: FRO Subbasin, LUM51 2000 — Psss Pass Pass Pass
PP 2 5 Special 2000 POSS _ Pass Pass Pass
?Oil): 120 1W0.5%33 2 ileitis, 2002 — Pass Pass
Alacissc Knit Palarics-E1timin Plant Perm 24119 ac mon 99'551, 00,0
14000035221001 Begin 65152002 Frequency: A
Caunty Bistlen Region: PRO Sulabosav CPE16
PP 2.5 Spnrsl
7Q117; 914.0 IWC43,1051,47 (inlet
NonComp; Singlr
199A — 16.1 111 4 A2.2 WA
81 '79 4 87 87
2000 -- 86.8 78,7 88.8 KR
2001 _ 87,3 >100 .100 .100
2002 -- >100 ,,_
Albemarle V579411119 Perth chr lint 90%
NCO0242445001 .Beg0n115152000 Frcqusisty Q Mar Jun Sep Dec
Counry: Sranly Region: MR0 Subbasin: YAD I 3
PR 16.0 Sprsrs1
71)19. 1.60 135507,494 (MM.
NonComp: Single
1998 --
1999.>90
2000 —
2001 —
2002 --
Pass
>90
Pass
Pass
Pass
Faii
Pass
Pass
SaSS
Pass
015,Lale >90,.90 .90 la
Pass Pass
Late Pass Pass
Late Pass Pass
Alcatel Network System.$ Inc. Pena .chr 6:15,52
'SC00861265001 Begin:11151998 FregLisiCr Q PIF Ian Apr Jul Oct
County: Wake Region: RI3.0 Subbasin: NE002
PF. 0,08 Specie
7Q10: 1.9 1300346.1 Orme.
A:LCOA. E.strasiou.$ Perm 2440 ac pi:TIM: 9U%
N(70048712501 Begin:81151995 Freq.00ricy: Q plr Mar Jun Sep
County: Catawba 11ags00: MRO Subbssin: CTB,1.2
PR: .0..0007 Spesial
71)40 0 INVC(1/41 Order'
Fre 1946.Dim Available
, NonComp:00191c
1998 —
1999 Pan
2000 Pass
2001 Pas,
2002 PasS
Pass
Pass Pass PaSS
Poss. Pass Pass
Sus PasS Pass
PS s1.00 42.4siss siPliPase PaSs
Sass
NonCornmSingle
1998 -- Pass Pass
1999 — Pass — Pa.
2000 Fail Fad Pass Pass PasS Fall
Pass Pass
2802 Pass Fail Foil Fail Pall Fail
PaSS,Pass Pass
Pass .Pass
Pass 01,81
Pass SasS
Pass Faid,Fail
LEGEND,
PERM= Permit Krosuiremem LET is Adrninistraiive Lasts - 'Tames Frequency 5, Mondon.ng frequency: Q- Quarterly:M. Monthly; BM- Bimonthly: SA- Sesoammrally, A- Annually; (3130... Only sell.) di -ssisarpinp: D- Discanrinsed nsonstrinng requirement
Eispin.,, Fust Plumb required 7Q 10 = Rocriving stream low Pow crittnan st`s..l ••• > quarterly awe:daring increases to monthly spun failure or NR Months. thin seating must occur - en. Jan, Apr, 111.1, Oss Noneorrio .55 Current Consonance R.paremen,
PF = Permitted flow 464,GD1 13155C5,2= Inane:am waSte COnCensration PIP = SusiFaS Id? AC - Acute CHR - Chronic
Data Notation: f - Fathead. Mionevy '' - Ceriuslaphnia sp,., my - Mysid shiinm, ChV - Chronic setae P - Al.ortslity of stated percentage at highest concenmation; at - Performed. by IDWQ Aquatic. Tess lind„ hi - Bad 1,*1
Rcporii.,,,g:N.taumr. -- - Data nor required; NE. , Not rspurled Pas:Pets, Act -wily Slaws: I - lnactive, N - Newly Issual(fu construct); JI. ' Active but nal discharging., t-Misc data available fur month la yiASStion., • s °RC signature rmedest
1

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
Mr. George Chapman, General Manager
Alcoa Extrusions, Inc.
P.O. Box 100
Catawba, North Carolina 28609
September 18, 2002
CDENR
NORTH CAROL -NA DEPARTMENT OF
ENVURONMENT AND NATURAL RESOURCES
17 4 2002
Subject: Draft NPDES Permit
Permit NC004871.2
Alcoa Extrusions, Inc. WWTP
Catawba County.
Dear Mr. Chapman:
Enclosed with this. letter is a copy of the draft NPDES permit for your facility. I encourage
you to review the draft carefully 'to ensure thorough understanding of the, 'information, conditions,
and requirements it contains.
The following changes have been made to your new permit:
A weekly average barium limit of 1 pig, has been placed in your permit. This
limit, with corresponding twice monthly tnonitoring, is the result of a 'reasonable
potential analysis that was .performed using your facility's effluent data. This
analysis indicates that levels of barium in your effluent have the potential to
violate North Carolina's barium criterionfor water supply waters• ,
The water quality (concentration based) chromium limit has been removed
from the permit. In addition, monitoring has been reduced to a monthly
frequency. The reasonable potential analysis for chromium indicates that the
effluent from your facility does not have the potential to exceed North Carolina and
Federal criteria for chromium_ You must still comply with the chromium limit
stipulated by the federal effluent guidelines (see below).
• The daily maximum limit for cyanide has been changed to 22 lig/L. This is
due to an updated recalculation of the federal criteria,. The previously permitted
daily maximum limit for cyanide was incorrect_ In addition, please note that the
cyanide limits that are stipulated by the federal effluent guidelines have been
included in this permit.
• Copper monitoring has been increased to twice monthly. The reasonable
potential analysis for copper indicates that your facility has the potential to exceed
North Carolina's action level criteria. for copper. Although no limit for copper is
being implemented, at this time, the effluent levels of copper at your facility are
sufficiently high as to warrant increased monitoring• _
Lead monitoring has been decreased to quarterly. The reasonable potential
analysis for lead indicates no potential to exceed North Carolina's water quality
criteria for lead. Please be sure, however, to report lead in, µ.g/L on your facility's
DMRs.
• A nickel limit has been included in the permit with twice monthly
monitoring. 'Mc reasonable potential analysis for nickel indicates that your
facility has the potential to exceed North Carolina and federal criteria for nickel. A

weekly average limit of 25pg/L and a daily maxirnum limit of 261 µ,g/L have been
added to your permit.
Monthly beryllium monitoring has been included in your permit. Your priority
pollutant analysis (PPA) indicates the presence of beryllium in your effluent, which
requires this parameter to be monitored through the NPDES permit. If you wish,
you may submit 10-12 effluent beryllium samples during the comment period, and
the need for monitoring will be reconsidered.
Limits for aluminum, zinc, chromium, cyanide, oil and grease and total
suspended solids, based on the federal effluent guidelines for aluminum
forming (40 CFR 467.22 and 467.23) have been updated to reflect current
production values.
In addition, please note that than noting a zero value on your facility's Discharge Monitoring,
Reports (DMRs), you are required to indicate the detection levels (i.e. '<10"). Please also note that,
this permit will not be finalized until you have submitted your Toxicity Identification Evaluation (TIE)
or equivalent report to the Aquatic Toxicology Unit. The results of that report may necessitate,
implementation of water quality (concentration based) limits for copper and/or zinc that have not
been included in the draft.
Submit any comments or questions concerning this draft permit no, later than thirty (30) days,
following receipt of this draft. Comments should be sent to:
Ms. Natalie Sierra
NCDENR DWQ -NPDES Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
If you have any questions or comments concerning this draft permit, please contact me via telephone'
at [phone] extension 551 or e-mail at: Natalie.Sierragnemail.net.
Sincerely,
N talie V. Sierra
NPDES Unit.
cc: Mooresville Regional Office/Water Quality Section
NPDES Unit
Mr. Roosevelt Childress, EPA Region 4
Aquatic Toxicology Unit
1617 Mail Service Center, Raleigh, North Carolina 27699-161'7 919 733-5083, extension 551 (ax) 919 733-0719
VISIT OS ON THE INTERNET @ http://h2o.enr.state.nc.us/NPDES
Natake,[e-mail]

Pernut NC0048712
STATE OF NORTH CAROLINA
DEP. TMEI T OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMPI'
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTE.
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,
Alcoa Extrusions, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Alcoa Extrusions, Inc. VVWTP
NCSR. 1848
Southwest of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to Lake Norman in the
Catawba River Basin
in accordance with effluent .1_in itations, monitoring requirement s, and other
conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective
This permit and authorization to discharge sha11 expire at midnight on April o,. 2005.
Signed this day
Alan W, Klimek, P. F.. Director
Division of Water Quality
By Authority of the. Fnvironnrental i" far agemer° t C rnrrais ion

Permtt NC0048712
SUPPLE
Alcoa Ext
E TO PE T C
ions, Inc. i; hereby` autl onzed to:
ontinue to discharge filter backwash U a1. a lion cooling
water filtration system) and cooling tower blowdown rom acilittes located d at
Alcoa Extrusions, Inc.; NCSR 1848, southeast f Cat . ba in Catawba County
2, Discharge f m said treatment
a.p into unnamed trib t.
r s at th+ lacati n specined on the attached
to Lake Norman, which is classifiedWS-117
at waters in the Catawba ° r Bast

Permit NC0048712
A. (1.) EFFLUENT LIMITATIONS AND MONITORING E UIREMENTS — DRAFT
During the period beginning on the effective date of this permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 001 - filter backwash from aluminum extrusion cooling water and cooling
tower blowdown. Such discharges shall be limited and monitored by the Petinittee as specified below:
ONITO
Rgt
Flow
Total Aluminu
0
I Zinc
Total Chr0miu
4.64
IU
tla
eelcl° Instantaneous E luen
08
0.25
h Corn rsite E'Itluen
onth
Composite
Eftluen
onthly Composite Efiluen
Cyanide tl.02 tl,ti 5lu iL 22onth Grab Etilu
Oil and Greas
Total Suspended Solids (TSS
To Copper
Total Lead
Total Nye
Total 6ariu
Total Be' Ilia
Chloride
7.7
52
Total Residual Chtvrtne (TRC)1
PH3
Temperature4
Acute T
26.04
26
n
on
Crab Effluen
ornrrosrte Etfltien
on Compraslte Effluent
onthly Composite Etfluen
ortttt Composite Ettluent
onComposite Efftuen
nihl Com«osite Etttuent
uarterly Composite Effluent
Grab Effluent
21'onth Grab Effluent
2/Month Grab Ettluent
uarterly Composite Effluen
Notes,
1. Monitoringrequirements only apply if chlorine is added to the cooling water.
2. The Permittee rnay, after submitting 10-12 samples, petition the Division of Water Quality to have
this monitoring requirement. to the permit removed..
3. The pi-i shall be no less than 7.0 standard units nor greater than 10.0 standard units.
4. The temperature of the effluent shall be such as not to cause an increase in the temperature of
the receiving stream of more than 2.80C and in no case cause the ambient water temperature to
exceed 32'C.
5. Whole effluent toxicity shall be measure by acute toxicity (fathead minnow) 24 hr PJF at 90%.
Toxicity shall be monitored in March, June, September and December. See Part A. (2.) for details.
THERE SHALL BE NO CHROMIUM, ZINC OR COPPER ADDED TO THE COOLING WATER
EXCEPT AS PRE -APPROVED ADDITIVES TO BIOCIDAL COMPOUNDS. The Permittee shall obtain
authorization from the Division of Water Quality prior to utilizing any biocide in the cooling water
(see Part A.(3.)).
There shall be no discharge of floating solids or visible foam in other than trace
amounts.

Permit NC0048712
A. (2. ACUTE TOXICITY PASS/FAIL PERMIT LIMIT
The Permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the
North. Carolina Procedure Document entitled "Pass/Fail Methodology For Deteriiuning Acute Toxicity
In A Single Effluent Concentration' (Revised -July. 1992.or subsequent versions). The monitoring
shall be performed as a Fathead Minnow (Pirnephales proinetas) 24 hour static test. The effluent
concentration at which there may be at no time significant acute mortality is 900/0 (defined as
treatment two in the procedure document). Effluent samples for self -monitoring purposes must be
obtained during representative effluent discharge below all waste treatment. The tests will be
performed during the months of March, June, September and December.
All toxicity testing results required as part of this permit condition will be entered on 'the Effluent
Discharge Monitoring. Form (MR-1) for the month in which it was performed, using the parameter
code TGE6C. Additionally, DWQ Form AT-2 (original) is to be sent to the following address:.
Attention: North Carolina Division of Water guality
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Science, Branch no
later than 30 days after the end of the reporting period forwhich the report is made.
Test data shall be complete and accurate and include all supporting chemical/physical
measurements performed in association with the toxicity tests, as well as all dose/response data,
Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is
employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the Permittee will complete the information located at the top of the aquatic toxicity (All
test form indicating the facility name, permitnumber, pipe .number, county, and the month/year of
the report with the notation of "No Flow" in the comment area of the form. The report shall be
submitted to the Environmental Sciences Branch at the address cited above.
Should any single quarterly monitoring, indicate a failure to meet specified limits, then monthly
monitoring will begin immediately until such time that a single test is passed. Upon passing, this
monthly test requirement will revert to quarterly in the months specified above.
Should the Permit.tee fail to monitor during a month in which toxicity monitoring is required, then
monthly monitoring will begin immediately until such time that a single test is passed. Upon passing,
this monthly test requirement will revert to quarterly in the months specified above.
Should any test data from either these monitoring requirements or tests performed by the North
Carolina Division of Water Quality indicate potential impacts. to the receiving stream, this permit rnay
be re -opened and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival and appropriate environmental controls, shall constitute an invalid test
and will require immediate follow-up testing to be completed no later than the last day of the month
following tl'ie month of the initial monitoring.

Permit NC0048712
A. (3.) BIOCIDE CONDITION
The Perrnittee shall obtain authortzation from the Division of Water Quality prior to
utilizing any biocide in the cooling water. The Permittee shall notify the Director in writing
not later than ninety (90) days prior to instituting use of any additional biocide used in the
treatment system which may be toxic to aquatic life other than those previously reported to
the Division of Water Quality. Such notification shall include completion of Biocide
Worksheet Form 101 and a map locating the discharge point and receiving stream.
Concentrations of chromium, copper or zinc added to biocides shall not exceed applicable
water quality standards or action levels in the receiving stream, as determined by
calculations from the Biocide Worksheet Form 101 with Supplemental Metals Analysis
Worksheet.

DENRJDWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0048712
Applicant Facilit N
A. licant Address:
Facility Address:
Permitted Flow
Type of Waste;
Fac.ili' Perrnit Stattu.
Coun
Receiving Strea
Stream Classification:
Alcoa. Extrusions. Inc.
S.R. 1848; P.Q. Box 100; Catawba., North Carolina 28609
NCSR I1348 southwest of Catawba, Catawba Count , NC
industrial (100%) from aluminum extrusion cooling water filtration
system and cooling tower blowdown
Class 1 /Active; Renewal
Catawba County
UT to Lake
Norman
Subbasin: 03-0
Drainage Area (txti). 0.26
Su mer NI 0 (cfs 0
Winter 7Q10 {ifs): 0.07
30Q2 (cfs 0.10
Average Flow
rWC (°r'al:
0.28
100% (90 A for
tv purposes)
s
Regional Ofl
State Grid ! USGS Qu
Date:
ooresville tMRO
EI4NE/Catawba. NC
Natalie V. Sierra.
27August 2002
Lat, 35' 38' 55' N Long. 81" 01' 55" W
Table 1, Summary Information for NC110414712
BACKGROUND
Alcoa Extrusions, Inc. (formerly Alumax. Extrusions, Inc.) discharges filter backwash from an
aluminum extrusion cooling water filtration system and cooling tower blowdown to an unnamed tributary
to Lake Norman in the Catawba River Basin, This facility uses aluminum billets and through the process
of extrusion, manufactures aluminum extruded tube.
This facility practices a large amount of internal recycle and has an extremely small effluent flow as a
result. Due to a number of recent toxicity problems, it may beadvantageous for the facility to go to a full
recycle system.
Instream Monitoring, Verification of Existing Conditions, DMR Data Review
Alcoa Extrusions, Inc. discharges to an unnamed tributary to Lake Norman, which is a classified.
WS-IV water in sub -basin 03-08-32 in the Catawba River Basin. This tributary is not impaired (303(d)
listed) as of the 2002 draft 303(d) list. The facility is not required to perform any instream monitoring.
Inspection reports by the Mooresville Regional Office indicate that the stream at the outfall is clear,
Discharge Monitoring Reports (DMRs) were reviewed from January 1999-June 2002. The table
below summarizes the data review for conventional parameters (as well as oil and grease and total
residual chlorine).
Flow (MGD)
Average 0.00136
Maximum 0.0031
Minimum 0.0001
Temperature
(deg. C)
21.7
27.4
16.4
Total Suspended
Solids (1bs.Iday)
0.02
0.0687
0.0005
Total Residual
Chlorine (41L)
0.09
0.24
0
Table 2. Summon° I)MR information for NC0048712
Temperatures appear to be seasonally appropriate. The flow is extreme
amount of recycling that Alcoa performs within the plant.
ly
Oil and Grease -
(Ibsfday)
0.058
0.257
0.006
ow` due to the high
�NrOo,,t1'

Toxicants monitored include chlorides, aluminum, barium, cyanide, chromium, copper, nickel,
lead and zinc. A reasonable potential analysis was performed on the data for these parameters and is
discussed below.
Reasonable Potential Analysis (RPA) and Priority Pollutant Analysis (PPA)
Data from January 1999-June 2002 were reviewed for a reasonable potential analysis. A number
of the results were expressed in pounds per day. These data were converted to mg/L or p.g/L using the
daily flow data and the following equation:
lhs. / day
rng I L=
flow(MGD)x 8.344/b./MG I( mg L))
Values expressed as ‘< x Ibsiday' were converted using this same formula, but retaining the "<" sign.
Such values were therefore entered in as half of the converted "x" value resulting from the equation
above.
Aluminum, barium, chloride, chromium, cyanide. copper, lead, zinc and nickel were all analyzed
for reasonable potential. The analysis indicated that reasonable potential exists for aluminum, barium,
cyanide, copper, zinc and nickel, No reasonable potential exists for chromium, chloride, and lead (all
values were "<" for lead), Aluminum, copper and zinc are all action level parameters. Unless their
presence is linked to effluent toxicity, no water quality limit is given for these parameters. Thus, water
quality limits will only be given for barium, cyanide and nickel. Twice monthly monitoring will be given
for all parameters showing reasonable potential,
The priority pollutant analysis indicated the presence of one parameter not currently monitored
through the NPDES permit — beryllium. Since this is considered a pollutant of concern, a monitoring
condition will be placed in the new NPDES permit.
Additional limits for chromium, cyanide. zinc and aluminum will also be included according to
the federal effluent guidelines for this industry.
Federal Effluent Guidelines
Alcoa Extrusions, Inc. is a categorical industry, regulated by 40 CFR 467— Aluminum Forming
Point Source Category. The applicable subpart is Subpart. C — Extrusion Subcategory, Press Heat
Treatment Contact Cooling Water. Best Available Technology (BAT) criteria were employed in
determining limits for chromium, cyanide, zinc, and aluminum. Best Practicable Technology (BPT)
guidelines were used to determine limits for oil and grease, total suspended solids (TSS) and pH.
Daily maximum production provided by the facility was used in determination of the daily
maximum limits. The maximum monthly production was used in the calculation of the monthly average
limits. These calculations result in nroduction based limits as follows:
Effluent Characteristics
Chromium
Cyanide
Zinc
Aluminum
Oil and Grease
Total Suspended Solids (TSS)
pH
bs.
0.07
0.05
0.25
1.08
12.70
26.04
Between 7.0 and 1
Monthy Average
0,03
0.02
0 10
0.54
7.71
12.52
0.0 standard units
Lim' I
Table 3. 1.:Auent limits resulting from application of the federal effluent guidelines (40 CFR 46732 and 46733)
The limits for cyanide will appear on the permit in addition to the water quality based limits described
above,.
Correspondence
The Mooresville Regional Office (MRO) prepared a Staff Reports related to this permit renewal
(10/31/00). This report confirms that the discharge still consists of cooling tower blowdown and filter
backwash and that biocides are added to the cooling towers..
In addition to providing a Staff Report, MRO has performed four Compliance Evaluation Inspections and
two Compliance Biomonitoring inspections. While Alcoa passed both Biornonitoring Inspections, it
Lacz Shol
NI,01 m '004N-712 Rc.nc\A.C. ,,,er:,;On: 8 2.7 02
2

received a Notice of Violation (NOV) for three out of four of the Compliance Evaluation Inspections:
Most of the non-compliance issues related to laboratory procedures (calibration, lab procedures) and poor
records keeping (not reporting parameters, not filling out DMRs correctly, not recording calibrations).
The facility has also received ten NOVs for toxicity failures in the past two years. Under the new
compliance policy, civil penalties were assessed for nearly all of those failures in 2002. The failures
have also triggered the new Action Level Policy, which requires the Permittee to perform a Toxicity
1dentification Evaluation or other method indicating the cause of toxicity, This report is due to be
submitted — October of 2002, and this permit will not be finalized until such time as the report is
submitted, Such a submittal will help elucidate whether or not copper and zinc limits are needed.
PERMITTING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA in 1995. The previous and current effluent limits were
based on guidelines and water quality standards. The Division has judged previous parameters and limits
to be appropriate for renewal with some exceptions (see Reasonable Potential Analysis and Federal
Effluent Guidelines).
Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential for
toxicants to be discharged by this facility, based on three and a half years of DMR data (January 1999
through June 2002). Results suggest no reasonable potential for the facility to discharge chloride, lead
and chromium. The following parameters show reasonable potential: aluminum, barium, cyanide,
copper, zinc and nickel. Water quality limits and monitoring for these parameters are Listed
below:
Effluent
Characteristic
Weekly Average
Limit
Daily Maximum Monitoring
Limit Frequency
Aluminum
Barium
Chloride
Chromium
Cyanide
Copper
Lead
Nickel
Zinc
Beryllium
No limit — action level parameter 2/Month
1.0 µg/l.. I 1000 µg/L 2/Month
No limit — no reasonable potential Quarterly
No limit — no reasonable potential Monthly
5 µg/L 22 µg/L 2/Month
No limit — action level parameter 2/Month
No limit — all values reported less than Quarterly
25.0 µg/L I 261 µg/L 2/Month
No limit — action level parameter 2/Month
No limit — detected in ppa t Monthly
Table .1. Summary of water quality based limits and monitoring resulting from reasonable potential analysis
Federal Effluent Guidelines
Updated production values have caused a change in the limits based on federal effluent
guidelines: aluminum, chromium, cyanide, zinc, TSS and oil and grease. These limits are listed in Table
3, above.
SUMMARYOF PROPOSED CHANGES
In keeping with Division policies, the following will be incorporated into the permit:
• Updated water quality based limit for cyanide
• Water quality based limits for barium and nickel
• Monitoring for beryllium
• Increased monitoring for copper (2/Month)
• Updated technology based limits for aluminum, zinc, chromium, cyanide, oil and
grease, and TSS.
racl
N 11 )1 Ni 004 I 1;;:ricy, di;

ict ed F E
y Average and Daily Maximum lamits are derived from the latest NC/EPA policiesMcoans]
Towable concentrations based on reasonable potential. William G. Ross, Jr.,Secretary
North Carolina department of Environment and Natural Resources
D SCHEDULE FOR PERMIT ISSUANCE AianW. Klimek, Director
Permit Scheduled to Issue:
Division of Water Quality
z)eptemf,� iti, u0 _ . _—
November 8a 2002
Enclosures: Reasonable potential ana sis, effluent guideline calculations, and toxicity summary.
Full DMR data summary and ppa available upon request.
NPDES DIVISION CONTACT
If you have questions regarding any of the above info
Natalie Sierra at [phone] ext., 551.
NAME:
REGIONAL OFFICE COMMENTS
NAME:
DATE:
a
n the attached permit, please contact
DATE:
SUPERVISOR: DATE:
Mooresville Regional ice, 919 North Main Str
©C} 6 r`'i4
ville, NC 28115 PHONE [phone]
FAX [phone]

Permit NC1004nargsm;Yr
William G. Ross, Jr.,Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, Director
STATE OF NORTH CAROLINA Division of Water Duality
AM'FMIilNT OF ENV1KUN ML1V1 AIND NA URAL NOUN(LS
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
Alcoa Extrusions, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Alcoa Extrusions, Inc. WWTP
NCSR 1848
Southwest of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to Lake Norman in the
Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective
This permit and authorization to discharge shall expire at midnight on April 30, 2005.
Signed this day
lik ,
- 2r3-S7e7N4l8ce
Alan W. Klimek, P.E., Director
Division of Water 9ua1ity _
By Authority of the Environmental Management Commission
Mooresville Regional Office, 919 North Main Street, Mooresville, NC 28115 PHONE [phone]
FAX [phone]

SUPPLEMENT TO PERMIT COVER -SHEET
Alcoa Extrusions, Inc. is hereby authorized to:
Permit NUU14t ktrni:Isejr
William G. Ross, Jr.,Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, Director
Division of Water Quality
Continue to discharge filter backwash (from an aluminum extrusion cooling
water filtration system) and cooling tower blowdown from facilities located at
Alcoa Extrusions, Inc.; NCSR 1848, southeast of Catawba in Catawba County
2. Discharge from said treatment works at the location specified on the attached
map into an unnamed tributary to Lake Norman, which is classified WS-IV
waters in the Catawba River Basin.
Customer Service
1 800 623-7748
Mooresville Regional Office, 919 North Main Street, Mooresville, NC 28115
PHONE [phone]
FAX [phone]

A
PerrrttNG% i°r
rnor
William G. Ross, Jr„Secretary
North Carolina Department of Environment and Natural Resources
LUENT LIMITATIONS AND MONITORING REQUIREMENTS
avt`"airector
Division of Water Quality
he period beginning on the effective date of thicpry ;t and L��r" g ,sytir1n, flag 1?er • ttive
authorized to discharge from outfall 001 — filter backwash from aluminum extrusion cooling water and cooling
tower blowdown. Such discharges shall be limited and .monitored by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
Flow
Total Aluminum
Total Zinc
Total Chromium
Cyanide
Clil and Grease
Total Suspended Solids (TSS)
Total Copper
Total Lead
Total Nickel
Total Barium
Total Beryllium
Chloride
Total Residual Chlorine
Temperature3
Acute Toxicity4
,TRC)t
Monthly
Average
(Ibsldayj
0.54
0.10
0.03
0.02
7.71
12,52
ll[T
Daily
Maximum
lips/clay)_
1.08
0,25
0.07
0.05
12,70
26,04
511 22 lack/
MONITORING REQUIREMENTS.
Frequency
Weekly
Month
2ltonth
Monthly
2/Month
2/Month
2/Month
2/Month
Monthly
onth
iionth
nthly
lrterly
ionth
ilonth
Aonth
arterly
Instantaneous
Effluent
Composite Effluent
Composite_ Effluent
Composite Effluent
Grab Effluent.
Grab
Effluent
Composite Effluent
Compo
Effluent
Composite Effluent
Composite Effluent
posite
Effluent
Composite Effluent
Composite Effluent
Grab Effluent
Grab Effluent
Grab Effluent
Composite Effluent
Notes:
1. Monitoring requirements only apply if chlorine is added to the cooling water.
2. The pH shall be no less than 7,0 standard units nor greater than 10.0 standard units.
3. The temperature of the effluent shall be such as not to cause an increase in the temperature of
the receiving stream of more than 2.80C and in no case cause the ambient water temperature to
exceed 32°C.
4, Whole effluent toxicity shall be measure by acute toxicity (fathead minnow) 24 hr P/F at 90%.
Toxicity shall be monitored in March, June, September and December. See Part A.(2.) for details.
THERE SHALL BE NO CHROMIUM, ZINC OR COPPER ADDED TO THE COOLING WATER
EXCEPT AS PRE -APPROVED ADDITIVES TO BIOCIDAL COMPOUNDS. The Permittee shall obtain
authorization from the Division of Water Quality prior to utilizing any biocide in the cooling water
(see Part A.(3.)),
There shall be no discharge of floating solids or visible foam in other than trace
amounts.
Customer Sery
1 800 623-774
Mooresville Regional Office, 919 North Main Street, Mooresville, NC 28115 PHONE "04} 663-1699
FAX t7o4't 663-6040

To:
Permits and Engineering Unit
Water Quality Section
Attention: Charles Weaver
SOC PRIORITY PROJECT: NO
Date: October 31.2000
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Catawba
NPDES Permit No.: NC0048712
MRO No.: 00-15
PART I - GENERAL INFORMATION
Facility and address: Alcoa Extrusions, Inc.
Post Office Box 100
Catawba, N.C. 28609
2. Date of investigation: October 24, 2000
3. Report prepared by: Michael L. Parker, Environ. Engr. II
4. Person contacted and telephone number: George Chapman, [phone].
Directions to site: From the jct. of SR 1833 (Long Island Road) and SR 1931
(CornmScope Road), travel southeast on SR. 1931 to the guard house. The Alcoa
Extrusions plant is located on the right side of the road, 0.8 mile past the guard house.
6. Discharge point(s), List for all discharge points: -
Latitude: 35° 38' 55"
Longitude: 81 ° 01' 55"
Attach a USGS Map Extract and indicate eatrnent plant site and discharge point on map.
USGS Quad No.: E 14 NE
7. Site size and expansion area consistent with application: Yes. Sufficient area exists for
the construction of WWT facilities, if necessary.
Topography (relationship to flood plain included): The site is well removed from any
flood plain.
9. Location of nearest dwelling: Approx. 600 feet from the point of discharge..

Page Two
10. Receiving stream or affected surface waters: Unnamed Tributary to Terrapin Creek*
* change from previously listed receiving waters
a. Classification: WS-IV
b. River Basin and Subbasin No.: Catawba 030832
c. Describe receiving stream features and pertinent downstream uses: Wastewater is
discharged into a storm draM leading to a conveyance ditch that discharges into a
small lake located on the property. The overflow from the lake empties into the
headwaters of a UT where it mixes with effluent from outfall 001 from
CommScope, Inc. (NC0034754).
PART I DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
a. Volume of wastewater: Flow averages 1,910 gpd", with a maximum of 4032
gpd' C based on past 12 months operating data)
b. What is the current permitted capacity: N/A
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: The existing
WWT facilities consist of a storage tank where sufficient detention time is
provided to allow for the biocides to decompose into non -toxic components prior
to discharge. There are also two (2) in -line, turbine flow meters with totalizers.
Description of proposed WWT facilities: There are no proposed WWT facilities at
this time.
g.
Possible toxic impacts to surface waters: Biocides are added to the cooling water.
h. Pretreatment Program (POTWs only): Not Needed.
Residual handling and utilization/disposal scheme: There are no residuals generated as a
result of the aluminum extrusion process.
Treatment piant classification: N/A
4. SIC Code(s): 3354
Wastewater Code(s): 15, 14 MTU Code(s): N/A
PART III - OTHER PERTINENT INFORMATION
Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? No

•
Page Three
Special monitoring or limitations (including toxicity) requests: None at this time.
Important SOC/iOC or Compliance Schedule dates: N/A
4. Alternative analysis evaluation
a. Spray Irrigation: Insufficient area, surrounding soils impacted by grading.
b. Connect to regional sewer system: None presently available to serve the site.
c. Subsurface: Insufficient area, surrounding soils impacted by grading.
d. Other disposal options: None that we are aware.
PART IV - EVALUATION AND RECOMMENDATIONS
The permittee, Alcoa Extrusions, Inc., has requested renewal of the subject permit. It
should be noted that the current Permit lists the permittee as Alumax Extrusions, whereas, the
renewal application lists the name of the company as Alcoa Extrusions. In a letter dated May 6,
1999, a company official notified the Division of the name change. The renewed permit should
reflect the appropriate company name, which is Alcoa Extrusions, Inc.
The discharge from this facility consists of filter backwash from an aluminum extrusion
cooling water filtration system and cooling water blow down. Biocides are added to the cooling
towers.
There have been no changes to the permit and/or the nature of the discharge since the
permit was last renewed. Pending a review by the NPDES Unit, it is recommended that the
permit be renewed as requested.
Signature of Report Preparer
Water Quality Regional Supe
hAdsr\cisAgoicoaextdst
Date

�48712
Subject: permit renewal - NC0048712
Date: Thu, 13 Jan 2000 07:06:19 -0500
From: Charles Weaver <charles.weaver@ncmail,net>
To: clay.long©alcoacom
Mr, Long, the Division of Water Quality received the permit renewal
application (and supporting documentation) for the Alcoa Extrusions -
Catawba Operation plant on January 4, 2000, Thanks for submitting this
package in a timely fashion.
I'm sorry to inform you that the NPDES Unit currently has several vacant
positions, and has not been fully staffed for over a year. This staff
shortage is delaying all of our permit renewals. Our remaining staff
are currently reviewing Authorizations to Construct, speculative limit
requests, major permit modifications and 201 plans ahead of permit
renewals. This is necessary due to a variety of factors, including
mandatory deadlines in the statutes which govern our program.
If this staff shortage delays reissuance of NC0048712, the existing
requirements in that permit will remain in effect until the permit is
renewed (or other action is taken by the Division). We appreciate your
patience and understanding as we operate with a depleted staff.
If you have any questions about your permit (or the permit renewal
process in general), simply reply to this e-mail..
Sincerely,
Charles H. Weaver, Jr.
NPDES Unit
9 2000
1 of 1

ALCOA
„ - „
not
December 27, 1999
Mr, Charles H. Weaver, Jr.
NC DENR / Water Quality / NPDES Unit
1617 Mail Service Center
Raleigh, NC 27633-1617
Alcoa Engineered
Products
Alcoa Extrusions, Inc.
Route 1 State Road 1848
PO Box 100
Catawba, NC 28609 USA
Tel: [phone]
Fax: [phone]
Subject: Renewal NPDES Permit NC0048712
Alcoa Extrusions, Inc. — Catawba Operation
Dear Mr, Weaver:
Please find enclosed the following items relative to the above referenced permit
renewal:
• Two (2) copies of this cover letter
• One (1) original and two (2) copies of the renewal application (Short Form C)
A flow diagram is included with the application.
Solids are not generated in our wastewater process, therefore the facility is not required
to prepare a sludge management plan.
The necessary samples for a Priority Pollutant Analysis have been collected, however
we do not expect results before the January 2, 2000 renewal deadline. The results will
be forwarded to your office as soon as they become available.
If you have any question regarding this renewal, please contact Clay Long,
Environmental Services Manager for Alcoa Engineered Products, at 570-385-8801.
George Chapman
General Manager
Enc.
CC: Clay Long, Cressona

NPDES PERMIT APPLICATION - SHORT FORM C
For rnaufacturing or commercial facilities with a discharge <1 MGD (or WTPs)
N. C. Department of Environment and Natural Resources
Division of Water Quality! NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
North Carolina NPDES Permit Number
Please print or type
1. Applicant and facility producing discharge
A. Name Alcoa Extrusions, Inc,
B. Mailing address of applicant
1. Street address P.O. Box 100
2. City Catawba
4. State NC
C. Location of facility:
1. Street Rt. #1 e Road
2. City Catawba
4. State NC
NCOO 487 2
3. County Catawba
5. Zip Code 28009
3. County Catawba
5. Zip Code 28609
D. Telephone Number ( 704 ) 241-3301
E. Fax Number ( 704 ) 241-4944
F. e-mail address
aNt • • PalC0a,CQM
2, Standard Industrial Classification (SIC) code(s): 3354
3. Number of employees: 36
4. Principal product(s) produced: aluminum extruded tube
Principal raw material(s) consumed: inu bi
5. Principal process(es): aluminum extrusion
6. Amount of principal product produced or raw material consumed
List specific amounts consumed and/or units of production
per Month
per Year
Product Produced or Raw Material Consumed
(AVERAGE)*
80,495 lbs.
2,2442
29,300,000 lbs.
Produced or Raw Material Consuned
TEAK)
82,418 lbs.
2,
30,000,
bs.
7. (a) Check here if discharge occurs all year X, or
(b) Circle the month(s) in which discharge occurs: January February March April
May June July August September October November December
Days per week discharge occurs: 7
(c)
2
version —6-99

For un rco
NOTE: if the facility has separate discha
diagramat
der
(Each
2 of

ry
NPDES PERMIT
For maufacturing or commercial
8. Types of wastewater discharged to surface waters only (check as applicable).
CATION - SHORT FORM C
ties with a discharge <1 MGD (or WTPs)
Discharge per operating day
Sanitary - daily average
Cooling
Maximum per of
total discharge all ty
daily average
9. If any of the
other than surface
10.
11.
12.
(GA
Flow Volume treated before discharging
ONS PER OPERATING DAY) (PERCENT)
0
1910,2 *
0
40;32 `
ed in item 8 (either treated or u
s) discharged below
A. Municipal sewer system
B. Underground well
C. Septic tank
D. Evaporation lagoon or
E. Other, specify
0 gPd
0 gpd
500 gpd
0 gpd
18 gpd
NA
100
NA
100
are dischaurged to places
(Above Ground Storage Tank for
Spent NaOH - Material is sent off
ci4© rnr root ion
Number of separate discharge points.
Name of receiving stream(s): unnamed tributary to Lake Norman in the Catawba River Basin
Does your discharge contain or is it possible for your discharge to contain one or more of the following
as a result of your operations, activities, or processes? Circle
copper
phenols
cadmium
mercury
chromium
nickel
None of the above
I certify that I am familiar with the information contained in the application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
George R. Chapman
General Statute 1
record, repot, plan,
alagement Commission implementing
method required to be operated or mardaned under
shall be guilty of a misdemeanor punishable by a fine
Page3of2
omen' representation„ or in
of the Envircnmerdal
recording or monitoring device or
ission implementing that Article,
to exceed six months, or by both,
Version -6-99

For
. . Scion 1001
actunng
punishment by ap
ei_ f cilitle .. discharge <1 GD(jai ..Ps
of not mom ttaan$t0 5 years, or lot, fo
tar
Page 4af
6 99

Gallon
Underground
Storage Tank
Alcoa Engineered Products - Catawba Operation: Flow Diagram
CeoII
Towerir3
Tower
Used Des
from
Presses
Aluminum
Billet
Alu rnirxmt
Billet
Billet
Heater
Billet
Heater
NCCW
Cleaned
Dies
Spent NaOH
Extrusion Line ONO
Extrusion Press - Heat
Exchangers
(NCCW)
Wastewater
Sanitary
Wastes Omstte Septic Tank
Shipped off
site for reuse
A tPatl441
Press Heat
Treatment
(CCWY
Press Heat
Treatment
(CCW1
Aluminum
Extruded Tube
flow meter
Rfa ._..___r OutfaU 001
AJun nurn
Extruded Tube
Process Flow
Process Water
Waste Water
Sampknp Pent
CA_Flow Diagram
20-Dec-fit

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Bill Holman, Secretary
Kerr T. Stevens, Director
TIMOTI•IY KINSLEY
ALCOA EXTRUSIONS, INC,
I.O. BOX 100
CATAWBA, NC
Dear Permlttee:
28609
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Navernber 4, 1999
Subject: Renewal of NPDES Permit NC0048712
ALCOA EXTRUSIONS, INC.
CATAWBA County
The subject permit expires on June 30, 2000. North Carolina Admirhstrative Code 15A NCAC 2110105(e)
requires that an application for permit renewal be filed at least 180 days prior to expiration of the current permit.
To satisfy this requirement, your renewal package must be sent to the Division postmarked no later than
January 2, 2000. Failure to request renewal of the permit by this date will result in a civil assessment of at least
$250.00. Larger penalties may be assessed depending upon the delinquency of the request.
If r ny wastewater discharge w.11 occur after June 30, 2000 (or if continuation of the per is desired)„ the
current permit must be renewed. Operation of wastewater treatment works or continuation of discharge after
June 30, 2000 would violate North Carolina General Statute 143-215.1 and could result in assessment of civil
penalties of up to $25,000 per day,
If all wastewater discharge has ceased at your facility and you wish to rescind 'this pert €t, contact Robert
Farmer of the Division's Compliance Enforcement. Unit at [phone], extension 531. You may also contact
th.e Mooresville Regional Office at [phone] to begin the rescission process.
Use the enclosed checklist to complete your renewal package. The checklist identifies the items you must
submit with the permit renewal application. If you have any questions, please contact me. Mir telephone
number, fax number and e-mail address are listed at the bottom of this page.
Sincerely,
Charles H. Weaver, Jr.
NPDES Unit
cc: Central Files
NPDES File
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 919 733-5083, extension 511 (tax) 919 733-0719
VISIT US ON THE INTERNET @ http:flh2©.enrstate.nc us/NPDES Chartes.Weaver1ncmail.net

NPDES Permit NC0048712
ALUMAX EXTRUSIONS, INC.
CATAWBA County
The following items are REQUIRED for all renewal packages:
A cover letter requesting renewal of the permit and documenting any changes at the
facility since issuance of the last permit. Submit one signed original and two copies.
'J'J The completed application form (copy attached),, signed by the permittee or an Authorized
Representative. Submit one, signed original and two copies.
If an Authorized Representative (see Part I1.13.1Lb of the existing NPDES perry t) prepares
the renewal package, written documentation must be provided showing the authority
delegated to the Authorized Representative.
C! A narrative description of the sludge management plan for the facility. Describe how
sludge (or other solids) generated during wastewater treatment are handled and
disposed. If your facility has no such plan (or the permitted facility does not generate
any solids), explain this in writing. Submit. one signed original and two copies.
J
The following items roust be submitted ONLY by Industrial facilities
discharging process wastewater:
Industrial facilities classified as Primary Industries (see Appendix A to Title 40 of the
Code of Federal Regulations, Part 122) must submit a Priority Pollutant Analysis (PPA) in
accordance with 40 CFR Part 122.21. If the PPA is not completed within one week of
January 2, 2000, submit the application package without the PPA. Submit the PPA as
soon as possible after January 2, 2000..
The above requirement does NOT apply to municipal or non -industrial
facilities.
PLEASE NOTE:
Due to a change in fees effective January 1, 1999, there is no renewal fee
required with your application package.
Send the completed renewal package to:
Mr. Charles H. Weaver, Jr.
NC DENR / Water Quality / NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
June 26. 19
Mr, Tinnotl y Insley
Alumax Extrusions, Inc.
P.O. Box 10(
Catawba; NC
> aw1RON MENa
et NATURAL RESOt,:'
JUN 20 ti95
Subject: Permit Issuance
NPDES Permit NC"()t' 487
Alumax Extrusions, Inc.
Catawba County
Dear Mr. y:
In accordance with your application fear discharge perrn.it received on January 2, 1995, we are
forwarding herewith the subject State - NPDES permit. This permit is issued pursuant to the
reciuire.ments of North Carolina General Statute 143-215.1_ and the Memorandum. of Agreement
between North Carolina and the US Environmental Protection Agency dated December 6, 1983.
Based on comments received during public notice period from .Alumax, the plant location has been
changed to NCSR 1848 on the permit cover page. Also, the parameters on the effluent sheet that
had the monthly averages and daily maximum limits reversed have been corrected. The whole
effluent toxicity test contained in the draft permit was not the appropriate type for this discharge.
An acute 24 hr passlfail test using fathead minnows is now specified on the effluent sheet.
If any parts, measurement frequencies or sampling requirements contained in this per tare
unacceptable to you, you have the right to an adjudicative hearing upon written request within thirty
(30) days following receipt of this letter. This request must bbe in the form of a written petition,
conforming to Chapter 150B of the North Carolina General Statutes, and tiled with the Office of
Administrative Hearings, Post Office. Drawer 27447, Raleigh, North. Carolina 27611-7447., Unless
such demand is made, this decision shall be final and binding.
Please take notice this permit is not transferable. Part Il, E.4. addresses the. requiirerne°nts ttr be
followed in case of change in ownership or control of this discharge.
This permit does not affect the legal requirements to obtain other permits which may be required by
the Division of Environmental Management or permits required by the Division of La Resources,
Coastal Area Management Act or any other ;Federal or Local governmental. permit that riay be
requi red.
P.©. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An 'Equal Opportunity Affirmative Action Employer 50% recycled/ '10% post -consumer paper

you have any questions concerning this permit, please contact Mr Greg Nizich at telephone
number 1f7-5O, ext. 51.
cc: Central Files
wills Regional
Mr. Roosevelt Childress, EPA
Facilities Assessment Unit
Operator Training rtification Unit
Permits and Engineering Unit
Sincerely,
A. Preston How r.„
Section

Permit No. NC0048712
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCIJARGE 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,
Alumax Extrusions, Incorporated
is hereby authorized to discharge wastewater from a facility located at
Alumax Extrusions, Incorporated
NCSR 1848
southwest of Catawba
CatawbaCounty
to receiving waters designated as the an unnamed tributary to Lake Norman in the Catawba River
Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, and III hereof.
This permit shall become effective August 1, 1995
This permit and authorization to discharge shall expire at midnight on June 30, 2000
Signed this day June 26, 1995
Gi:14111
1,:jav1(1.!'.„
A. Preston Howard, Jr., Director
Division of Environmental Management:
By Authority of the Environmental Management Commission

is hereby authorized to:
Permit No. NC0048712
SUPPLEMENT TO PERMIT COVER SEIEET
Alurnax Extrusions, hicorporated
1. Continue to discharge filter backwash from an aluminum extrusion cooling water filtration system
and cooling tower blowdown from facilities located at Alumax Extrusions, Incorporated, NCSR,
1848 southeast of Catawba, Catawba County (See Part III of this Permit) and
2 After receiving an Authorization to Construct horn the Division of Environmental Management,
make modifications as necessary to meet permit limits, and
3 Discharge from said treatment works at the locanon specified on the attached map into an unnamed
tributary to Lake Norman which is classified Class WS-IV waters in the Catawba River Basin

A. ( ), EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL Permit No. NC004871,2
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 001 - Filter Backwash from aluminum extrusion cooling water and Cooling Tower Blowdown. Such discharges shall.
be limited and monitored by the permittee as specified below:
ffluent_ Characteristic q Pischr.J.imitations Monitoring , Requirements
.Us/day V_IiiIPOcit . ) Measurtagnt_ ,SAniple *jnpJ
nAvg_. Atto_ri—.. Avg, gilly„___Ni ax‘ ELPARLOSS
Flow Weekly Instantaneous E
Aluminum 2,2 4.41 .2/Month Composite E
Zinc 0,42 1.00 2/Month Composite E
Chromium 50 1.gill+ 200 tg,11 2/Month Composite E
Cyanide. 5 tgli+ 20 itgll 2/Month Grab E
Oil: and Grease 8.23 13:7 2/Month Grab E
ISS 13.4 28.1 2/Month Composite E
Copper Monthly. Composite E
Lead Monthly Composite E
Nickel Quarterly Composite E
Barium Quarterly Composite E
* Sample Locations: E - Effluent.
+ Weekly average Emit.
** The temperature of the effluent shall be such as not to cause an increase, in the temperature of the receiving stream of more than 2.8°C and in
no case cause the ambient water temperature, to exceed 32°C.
*** Monitoring requirements only apply if chlorine is added to the cooling wawr„
**** Acute 'foxicity (Fathead Minnow) 24hr P/F @ 90%; March, June, September and December: See Part UL condition E.
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE COOLING WATER EXCEPT AS PRE -APPROVED
ADDruvEs TO BIOCID.AL COMPOUNDS, The permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water (See Part III of this Permit).
The p11 shall not be less than 7.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month at the effluent by grab
sample.
There shall be no discharge of floating soJids or visiblefoam in other than trace amou

A.
l T LIMITATIONS AND I T I QU NTS FINAL
During the period in on the effective date of the permit and lasting until expiration, the Pet inittee is authorized to is h from
outfall(s) serial number 001 - Filter Backwash from aluminum extrusion cooling water and Cooling Tower Blowdown. (Continued)
n . hratria
Chiond
Temperature
Total Residual Chlorine**
Acute Taxiulty**`
Lblday
Mon. Av
Disc
ru
ts
Permit No. NC00487
1fiequirent
urn Basra
Fro u n
Quarterly
2/Month
2/Month'
quarterly;
Tyre
Combos
Lutirt
E
Grab
Grab
to

PART 1
Section B. Schedule of Compliance
1. The permittee shall comply with Final Effluent Limitations specified for discharges in
accordance with the following schedule:
Permittee shall comply with Final Effluent Limitations by the effective date of the permit unless
specified below.
2. Permittee shall at all times provide the operation and maintenance necessary to operate the
existing facilities at optimum efficiency.
3. No later than 14 calendar days following a date identified in the above schedule of compliance,
the permittee shall submit either a report of progress or, in the case of specific actions being
required by identified dates, a written notice of compliance or noncompliance. In the latter
case, the notice shall include the cause of noncompliance, any remedial actions taken, and the
probability of meeting the next schedule requirements.

Part II
Page l of 14
PART II
STANDARD CONDITIONS FOR NPDES PERMITS
SECTION A, DEFINITIONS
1. Permit Issuing Authgrity
The Director of the Division of Environmental Management.
2. DEM or Division
Means the Division of Environmental Management, Department of Environment, Health and
Natural Resources.
3. Ees.
Used herein means the North Carolina Environmental Management Commission.
4, Act or "the Act"
The Federal Water Pollution Control Act, also known as the Clean Water Act, as amended, 3
USC 1251, et. seq.
5. Mass/Dkv Measurements
a. The "monthly average discharge" is defined as the total mass of all daily discharges
sampled and/or measured during a calendar month on which daily discharges are sampled
and measured, divided by the number of daily discharges sampled and/or measured during
such month. It is therefore, an arithmetic mean found by adding the weights of the
pollutant found each day of the month and then dividing this sum by the number of days
the tests were reported. The limitation is identified as "Monthly Average" in Part I of the
permit.
b. The "weekly average discharge" is defined as the total mass of all daily discharges sampled
and/or measured during the calendar week (Sunday - Saturday) on which daily discharges
are sampled and measured, divided by the number of daily discharges sampled and/or
measured during such week. It is, therefore, an arithmetic mean found by adding the
weights of pollutants found each day of the week and then dividing this sum by the
number of days the tests were reported. This limitation is identified as "Weekly Average"
in Part I of the permit.
c. The "maximum daily discharge" is the total mass (weight) of a pollutant discharged during
a calendar day. If only one sample is taken during any calendar day the weight of pollutant
calculated from it is the "maximum daily discharge." This limitation is identified as "Daily
Maximum," in Part I of the permit.
d. The "average annual discharge" is defined as the total mass of all daily discharges sampled
and/or measured during the calendar year on which daily discharges are sampled and
measured, divided by the number of daily discharges sampled and/or measured during such
year. It is, therefore, an arithmetic mean found by adding the weights of pollutants found
each day of the year and then dividing this sum by the number of days the tests were
reported. This limitation is defined as "Annual. Average" in Part I of the permit,

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

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

Part II
Page 4 of 14
c. Weighted by Flow Value: Weighted by flow value means the summation of each
concentration times its respective flow divided by the summation of the respective flows.
10. Calendar Dyv
A calendar day is defined as the period fr+orn midnight of one day until midnight of the next
day. However, for purposes of this permit, any consecutive 24-hour period that reasonably
represents the calendar day may be used for sampling.
l 1. J-iazafdous Substance
A hazardous substance means any substance designated under 4f1 (FR Part 116 pursuant to
Section 311 of the Clean Water Act
12. Toxic Pollutant
A toxic pollutant is any pollutant listed as toxic under Section 307(a)(1) of the Clean Water Act.
S CT1ON 1, GENERAL CQNIDMONS
1. Duty to Comply
The permittee must comply with all conditions of this permit. Any permit noncompliance
constitutes a violation of the Clean Water Act and is grounds for enforcement action; for permit
termination, revocation and reissuance, or modification; or denial of a permit renewal
application.
a. The permittee shall comply with effluent standards or prohibitions established under
section 307(a) of the Clean Water Act for toxic pollutants and with standards for sewage
sludge use or disposal established under section 405(d) of the Clean. Water Act within the
time provided in the regulations that establish these standards or prohibitions or standards
for sewage sludge use or disposal, even if the permit has not yet been modified to
incorporate the requirement.
b. The Clean Water Act provides that any person who violates a permit condition is subject to
a civil penalty not to exceed $25,000 per day for each violation. Any person who
negligently violates any permit condition is subject to criminal penalties of $2,500 to
$25,000 per day of violation, or imprisonment for not more than 1 year, or both. Any
person who knowingly violates permit conditions is subject to criminal penalties of $5,000
to $50,000 per day of violation, or imprisonment for not more than 3 years, or both. Also,
any person who violates a permit condition may be assessed an administrative penalty not
to exceed $10,000 per violation with the maximum amount not to exceed $125,000. [Ref:
Section 309 of the Federal Act 33 U.S.C. 1319 and 40 CFR 122.41 (a)]
c. Under state law, a civil penalty of not more than ten thousand dollars ($10,000) per
violation may be assessed against any person who violates or fails to act in accordance with
the terms, conditions, or requirements of a permit. [Ref: North Carolina General Statutes
§ 143-215.6A]
d. Any person may be assessed an administrative penalty by the Administrator for violating
section 301, 302, 306, 307, 308, 318, or 405 of the Act, or any permit condition or
limitation implementing any of such sections in a permit issued under section 402 of the
Act. Administrative penalties for Class I violations are not to exceed $10,000 per violation,
with the maximum amount of any Class 1 penalty assessed not to exceed $25,000.

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

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

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

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

Part 11
Page 9 of 14
periods of equipment downtime. This condition is not satisfied if adequate backup
equipment should have been installed in the exercise of reasonable engineering
judgment to prevent a bypass which occurred during normal periods of equipment
downtime or preventive maintenance; and
(C) The permittee submitted notices as required under Paragraph c. of this section.
(2) The Permit Issuing Authority may approve an anticipated bypass, after considering its
adverse affects, if the Permit Issuing Authority determines that it will meet the three
conditions listed above in Paragraph d. (1) of this section.
Lauda
a. Definition.
"Upset " means an exceptional incident in which there is unintentional and temporary
noncompliance with technology based permit effluent limitations because of factors
beyond the reasonable control of the permittee. An upset does not include noncompliance
to the extent caused by operational error, improperly designed treatment facilities,
inadequate treatment facilities, lack of preventive maintenance, or careless or improper
operation.
b. Effect of an upset.
An upset constitutes an affirmative defense to an action brought for noncompliance with
such technology based permit effluent limitations if the requirements of paragraph c. of this
condition are met. No determination made during administrative review of claims that
noncompliance was caused by upset, and before an action for noncompliance, is final
administrative action subject to judicial review.
c. Conditions necessary for a demonstration of upset.
A permittee who wishes to establish the affirmative defense of upset shall demonstrate,
through properly signed, contemporaneous operating logs, or other relevant evidence that:
(1) An upset occurred and that the permittee can identify the cause(s) of the upset;
(2) The permittee facility was at the time being properly operated; and
(3) The permittee submitted notice of the upset as required in Part II, E. 6, (b) (B) of this
permit.
(4) The permittee complied with any remedial measures required under Part II, B. 2. of this
permit.
d. Burden of proof.
In any enforcement proceeding the permittee seeking to establish the occurrence of an upset
has the burden of proof,
6. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or
control of wastewaters shall be utilized/disposed of in accordance with NCGS 143-215.1 and in
a manner such as to prevent any pollutant from such materials from entering waters of the State
or navigable waters of the United States. The permittee shall comply with all existing federal

Part II
Page l0 of 14
regulations governing the disposal of sewage sludge. Upon promulgation of 40 CFR Part 513,
any permit issued by the Permit Issuing Authority for the utilization/disposal of sludge may be
reopened and modified, or revoked and reissued, to incorporate applicable requirements at 40
CFR Part 503. The permittee shall comply with applicable 40 CFR Part 503 Standards for the
Use and Disposal of Sewage Sludge (when promulgated) within the time provided in the
regulation, even if the permit is not modified to incorporate the requirement. The permittee
shall notify the Permit Issuing Authority of any significant change in its sludge use or disposal
practices.
7. Power Failures
The permittee is responsible for maintaining adequate safeguards as required by DEM
Regulation, Title L5A, North Carolina Administrative Code, Subchapter 2H, .0124 Reliability,
to prevent the discharge of untreated or inadequately treated wastes during electrical power
failures either by means of alternate power sources, standby generators or retention of
inadequately treated effluent.
SECTION D. MONITORING AND RECORDS
1. Representative Sampling
Samples collected and measurements taken, as required herein, shall be characteristic of the
volume and nature of the permitted discharge. Samples collected at a frequency less than daily
shall be taken on a day and time that is characteristic of the discharge over the entire period
which the sample represents. All samples shall be taken at the monitoring points specified in
this permit and, unless otherwise specified, before the effluent joins or is diluted by any other
wastestream, body of water, or substance. Monitoring points shall not be changed without
notification to and the approval of the Permit Issuing Authority.
2. Reporting
Monitoring results obtained during the previous month(s) shall be summarized for each month
and reported on a monthly Discharge Monitoring Report (DMR) Form (DEM No. MR 1,1.1, 2,
3) or alternative forms approved by the Director, DEM, postmarked no later than the 30th day
following the completed reporting period.
The first DMR is due on the last day of the month following the issuance of the permit or in the
case of a new facility, on the last day of the month following the commencement of discharge.
Duplicate signed copies of these, and all other reports required herein, shall be submitted to the
following address:
Division of Environmental Management
Water Quality Section
ATTENTION: Central Files
Post Office Box 29535
Raleigh, North Carolina 27626-0535
3. Flow Measurrmenu
Appropriate flow measurement devices and methods consistent with accepted scientific
practices shall be selected and used to ensure the accuracy and reliability of measurements of
the volume of monitored discharges. The devices shall be installed, calibrated and maintained
to ensure that the accuracy of the measurements are consistent with the accepted capability of
that type of device. Devices selected shall be capable of measuring flows with a maximum
deviation of less than + 10% from the true discharge rates throughout the range of expected

Part II
Page 11of14
discharge volumes. Once -through condenser cooling water flow which is monitored by pump
logs, or pump hour meters as specified in Part I of this permit and based on the manufacturer's
pump curves shall not be subject to this requirement.
4. Test Procedures
Test procedures for the analysis of pollutants shall conform to the EMC regulations published
pursuant to NCGS 143-215.63 et. seq, the Water and Air Quality Reporting Acts, and to
regulations published pursuant to Section 304(g), 33 USC 1314, of the Federal Water
Pollution Control Act, as Amended, and Regulation 40 CFR 136; or in the case of sludge use or
disposal, approved under 40 CFR 136, unless otherwise specified in 40 CFR 503, unless
other test procedures have been specified in this permit.
To meet the intent of the monitoring required by this permit, all test procedures must produce
minimum detection and reporting levels that are below the permit discharge requirements and
all data generated must be reported down to the minimum detection or lower reporting level of
the procedure. If no approved methods are determined capable of achieving minimum
detection and reporting levels below permit discharge requirements, then the most sensitive
(method with the lowest possible detection and reporting level) approved method must be used.
5. Penalties for Tampering
The Clean Water Act provides that any person who falsifies, tampers with, or knowingly
renders inaccurate, any monitoring device or method required to be maintained under this
permit shall, upon conviction, be punished by a fine of not more than $10,000 per violation, or
by imprisonment for not more than two years per violation, or by both. If a conviction of a
person is for a violation committed after a first conviction of such person under this paragraph,
punishment is a fine of not more than $20,000 per day of violation, or by imprisonment of not
more than 4 years, or both.
6. Records Retention
Except for records of monitoring information required by this permit related to the perrnittee's
sewage sludge use and disposal activities, which shall be retained for a period of at least five
years (or longer as required by 40 CFR 503), the permittee shall retain records of ail
monitoring information, including all calibration and maintenance records and all original strip
chart recordings for continuous monitoring instrumentation, copies of all reports required by
this permit, for a period of at least 3 years from the date of the sample, measurement, report
or application. This period may be extended by request of the Director at any time,
7. Recording Results
For each measurement or sample taken pursuant to the requirements of this permit, the
permittee shall record the following information:
a. The date, exact place, and time of sampling or measurements;
b. The individual(s) who performed the sampling or measurements;
c. The date(s) analyses were performed;
d. The individuals) who performed the analyses;
e. The analytical techniques or methods used; and
f. The results of such analyses.

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

Part II
Page 13 of 14
4. Transfera
This permit is not transferable to any person except after notice to the Director. The Director
may require modification or revocation and reissuance of the permittee and incorporate such
other requirements as may be necessary under the Clean Water Act.
5. Monitoring Reports
Monitoring results shall be re
a
the intervals specified elsewhere in this pet
a. Monitoring results must be reported on a Discharge Monitoring Report (DMR) (See Part II.
D. 2 of this permit) or forms provided by the Director for reporting results of monitoring of
sludge use or disposal practices.
b. If the permittee monitors any pollutant more frequently than required by the permit, using
test procedures specified in Part II, D. 4. of this permit or in the case of sludge use or
disposal, approved under 40 CFR 503, or as specified in this permit, the results of this
monitoring shall be included in the calculation and reporting of the data submitted in the
DMR.
c. Calculations for all limitations which require averaging of measurements shall utilize an
arithmetic mean unless otherwise specified by the Director in the permit.
6. Twenty-four Hour Repotting
a. The permittee shall report to the central office or the appropriate regional office any
noncompliance which may endanger health or the environment. Any information shall be
provided orally within 24 hours from the time the permittee became aware of the
circumstances. A written submission shall also be provided within 5 days of the time the
permittee becomes aware of the circumstances. The written submission shall contain a
description of the noncompliance, and its cause; the period of noncompliance, including
exact dates and times, and if the noncompliance has not been corrected, the anticipated time
it is expected to continue; and steps taken or planned to reduce, eliminate, and prevent
reoccurrence of the noncompliance.
b. The following shall be included as information which must be reported within 24 hours
under this paragraph:
(1) Any unanticipated bypass which exceeds any effluent limitation in the permit
(2) Any upset which exceeds any effluent limitation in the permit
(3) Violation of a maximum daily discharge limitation for any of the pollutants listed by the
Director in the permit to be reported within 24 hours.
c. The Director may waive the written report on a case -by -case basis for reports under
paragraph b. above of this condition if the oral report has been received within 24 hours.
7. Other Noncompliance
The permittee shall report all instances of noncompliance not reported under Part fi. E. 5 and 6.
of this permit at the time monitoring reports are submitted. The reports shall contain the
information listed in. Part II. E. 6. of this permit.

Part II
Page 14 of 14
8 . Other In form ation,
Where the permittee becomes aware that it failed to submit any relevant facts in a permit
application, or submitted incorrect information in a permit application or in any report to the
Director, it shall promptly submit such facts or information.
9. Noncomplia,nce Notification
The permittee shall report by telephone to either the central office or the appropriate regional
office of the Division as soon as possible, but in no case more than 24 hours or on the next
working day following the occurrence or first knowledge of the occurrence of any of the
following:
a. Any occurrence at the water pollution control facility which results in the discharge of
significant amounts of wastes which are abnormal in quantity or characteristic, such as the
dumping of the contents of a sludge digester-, the known passage of a slug of hazardous
substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures of
pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass
directly to receiving waters without treatment of all or any portion of the influent to such
station or facility.
Persons reporting such occurrences by telephone shall also file a written report in letter forrn
within 5 days following first knowledge of the occurrence.
10.
Except for data determined to be confidential under NCGS 143-215.3(0(2) or Section 308 of
the Federal Act, 33 USC 1318, all reports prepared in accordance with the terms shall be
available for public inspection at the offices of the Division of Environmental Management. As
required by the Act, effluent data shall not be considered confidential. Knowingly making any
false statement on any such report may result in the imposition of criminal penalties as provided
for in NCGS 143-215.1(b)(2) or in Section 309 of the Federal Act.
11. Penalties for Falsification of Reports
The Clean Water Act provides that any person who knowingly makes any false statement,
representation, or certification in any record or other document submitted or required to be
maintained under this permit, including monitoring reports or reports of compliance or
noncompliance shall, upon conviction, be punished by a fine of not more than $10,000 per
violation, or by imprisonment for not more than two years per violation, or by both.

PART III
OTHER REQUIRE l TENTS
A. Construction
No construction of wastewater treatment facilities or additions to add to the plant's treatment
capacity or to change the type of process utilized at the treatment plant shall be begun until
Final Plans and. Specifications have been submitted to the Division of Environmental
Management and written approval and. Authorization to Construct has been issued.
B. Groundwater Monitoring
The permittee shall, upon written notice from the Director of the Division of Environmental
Management, conduct groundwater monitoring as may be required to determine the
compliance of this NPDES permitted facility with the current groundwater standards.
C. Changes in Discharges of Toxic Substances
The permittee shall notify the Permit Issuing Authority as s
believe:
n
or has reason to
a.That any activity has occurred or will occur which would result in the discharge, on a
routine or frequent basis, of any toxic pollutant which is not limited in the permit, if that
discharge will exceed the highest of the following "notification levels";
(1) One hundred micrograms per liter (100 ug/1);
(2)Two hundred micrograms per liter (200 ug/l) for acrolein and acrylonitrile; five
hundred micrograms per liter (500 ug/1) for 2.4-dinitrophenol and for 2-methyl-4.6-
dinitrophenol; and one milligram per liter (1 mg/1) for antimony;
(3) Five (5) times the maximum concentration value reported for that pollutant in the
permit application.
b. That any activity has occurred or will occur which would result in any discharge, on a
non -routine or infrequent basis, of a toxic pollutant which is not limited in the permit, if
that discharge will exceed the highest of the following "notification levels";
(1) Five hundred micrograms per liter (500 ug/1);
(2) One milligram per liter (1 mg/1) for antimony;
(3) Ten (10) times the maximum concentration value reported for that pollutant in the
permit application.
D. Requirement to Continually Ey4luate Alternative�.to Wastewater Discharges
The permittee shall continually evaluate all wastewater disposal alternatives and pursue the
most environmentally sound alternative of the reasonably cost effective alternatives. If the
facility is in substantial non-compliance with the terms and conditions of the NPDES permit
or governing rules, regulations or laws, the permittee shall submit a report in such form and
detail as required by the Division evaluating these alternatives and a plan of action within
sixty (60) days of notification by the Division.

Part. III
Permit N NC(:11148712
E. ACUTE, TO, ICITY. PASS/FAIL PERMIT L1.MIT (QRTRLY)
The perrnittee shall conduct acute toxicity tests on a quarterly basis thing protocols defined in the
North Carolina Procedure Document entitled'Pass/Fail Methodology For Determining Acute
Toxicity In ASingle Effluent Concentration." The monitoring shall he performed as a Fathead
Minnow (Pimep.hales promelas) 24 hour static test, using effluent collected as a 24 hour
composite. The effluent concentration at which there may be at no time significant acute mortality
is 90% (defined as treatment two in the North Carolina procedure document). Effluent samples for
self -monitoring purposes must be obtained during representative effluent discharge below all waste
treatment. The first test will be performed after thirty days from the effective date of this permit
during the months of March, June, September and. December.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the month in which it was performed, using the parameter
code TGE6C. Additionally, DEM Forrn AT-2 (original) is to be sent to the following address:
Attention:
Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemica1Jphysical measurements
performed in association with the toxicity tests, as well as all dose/response data, 'J'otal residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream,.
Should any single quarterly monitoring indicate a failure to meet specified then monthly
monitoring wbegin immediately' until such time that a single test is passed. Upon passing, this
monthly test requ ir: ement will revert to quarterly in the months specified above..
Should any test data from either these monitoring requirements sts performed by the North
Carolina Division of Environmental Management indicate potential impacts to the receiving stream,
this permit may be re -opened and modified to include alternate monitoring requirements or limits.
NOTE Failure to achieve test conditions as specified in the cited document, sueh as minimum
control organism survival and appropriate environmental controls, shall constitute an invalid test
and will require immediate retesting(within 30 days of initial monitoring event)„ Failure to submit
suitable test results will constitute noncompliance with monitoring requirements.
F. Biocide Condition
The permittee shall obtain authorization from the Division of Environmental Management prior to
utilizing any biocide in the cooling water. The Permittee shall notify° the Director in writing not
later than ninety (90) days prior to instituting use of any additional biocide used in treatment system,
which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map locating the discharge point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream, as determined by calculations from the Biocide Worksheet
Forrn 101 with. Supplemental Metals Analysis worksheet.

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,c1.0 of No'r, Cc >tlno
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P,E., Directo
September 2S, 1996
Mr, Larry Teague
Alumax Extrusions, Inc.
P.O, Box 100
Catawba, North Carolina 286I19
Subject: Return of Biocide Usage Request
Permit .Modification
Permit No, NC0048712
Alumax Extrusions, Inc.
Catawba County
Dear Mr. Teague:
This letter is to confirm your telephone conversation with Charles Weaver of my staff on September 19,
1996, After a review of your request for biocide usage, it was determined that an error was made in Part III,
Section F. of your permit. The requirement to notify the Division prior to the use of any biocides is obviated by
the Acute Toxicity testing requirements in Part 111, Sectionof your permit.
Therefore,, the Division is returning the attached Biocide 101 'Form and supporting data received on
August 30, 1996. Biocide usage at your facility may proceed.
Please find enclosed an amended page for Part 1II, which should be inserted into your permit_ The old
page should be discarded. All other terms and conditions contained in the original permit remain unchanged
and in full effect. This permit modification is issued pursuant to the requirements of North Carolina General
Statutes 143-215,1 and the Memorandum of Agreement between North Carolina and the U. S, Environmental
Protection Agencv.
If anti parts, measurement frequencies or sampling requirements contained in this permit modification
are unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30)
days, following receipt of this letter. This request must be in the form of a written petition, conforming to
Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings,
Post Office Drawer 27447, Raleigh, North. Carolina 27611,-7447, Unless such demand is made, this decision
shall be final and binding.
u have any questions, please call Charles Weaver at [phone], extension 51,1.
Sincerely,
cc: Central Files
Mooresville Regional Office
NPDES File
Aquatic Surve ' & To gy Unit
P 0. Box 29535,Raleigh. North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled / 10% post -consumer paper

Alumax Extrusions, Inc.
Part ill Permit No, NC0048712
E. ACUTE T.OXIC1TY PASS/FAIL. PER, =1IT LIMIT (Quarterly)
The permittee shall conduct acute totests on a quarterly basis using protocols defined in the
North. Carolina Procedure Document entitled `Pass/Fail Methodology For Determining Acute Toxicity
in A Single Effluent Concentration'' The monitoring shall be performed as a Fathead Minnow
(Pimephales promelas) 24-hour static test, using effluent collected as a 24-hour composite. The
effluent concentration at which there may be at no time significant acute mortality is 90% (defined as
treatment two in the North Carolina procedure document). Effluent sampling for self -monitoring
purposes shall be performed during representative effluent discharge below all waste treatment, The.
first test will be performed after thirty days from the effective date of this permit during the months of
March, June, September and. December.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form. (MR-1) for the month in which it was performed, using the parameter code
TG'E6C. Additionally, DEM Form AT-2 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of Water Quality
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity.• tests, as well as all dose/response data, Total residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the ti •aste stream,
Should any single quarterly monitoring indicate a failure to meet specified limits, thenmonthly
monitoring will begin immediately until. such time that a single test is passed. Upon passing, this
monthly test requirement will revert to quarterly in the months specified above.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re-
opened and .modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival and appropriate environmental controls, shall. constitute an invalid test and will
require immediate retesting (within 30 days of the initial monitoring event). Failure to submit suitable
test results will constitute noncompliance with monitoring requirements.

State of North Carolina
Department of Environment,
Healt-1 and Natural Resources
Mooresville Regional Office
James B, Hunt£ Jr., Governor
Jonathan B. Howes, Secretary
Linda Diane Long, Regional Manager
DIVISION OF ENVIRONMENTi
July 13, 1995
Mr. Timothy Kinsley
Alumax Extrusions, Inc.
Post Office Box 100
Catawba, North. Carolina 28609
AG ENT
Subject: NPDES Permit No. NC0048712
Alumax Extrusions, Inc.
Catawba County, NC
Dear Kinsley:
Our records indicate that NPDES Permit No. NC0048712 was
issued on June 26, 1995 for the discharge of wastewater to the
surface waters of the State from your facility. The purpose of
this letter is to advise you of the importance of the Permit and
the liabilities in the event of failure to comply with the terms
and conditions of the Permit. If you have not already done so, it
is suggested that you thoroughly read the Permit. Of particular
importance are Pages 4-5.
Pages 4-5 set forth the effluent limitations and monitoring
requirements for your discharge(s). Your discharge(s) must not
exceed any of the limitations set forth. The section headed
"Monitoring Requirements" describes the measurement frequencies,
sample types and sampling locations. Upon commencement of your
discharge (or operation), you must initiate the required
monitoring. The monitoring results must be entered on the
reporting forms furnished to you by this Agency. If you have not
received these forms, they should be arriving shortly. If you fail
to receive the forms, please contact this Office as quickly as
possible. I have enclosed a sample of the "'Effluent" reporting
form (DEM Form MR-1), plus instructions for completing the form.
It is imperative that all applicable parts be completed, and the
original and one copy be submitted as required.
The remaining Parts of the Permit set forth definitions,
general conditions and special conditions applicable to the
operation of wastewater treatment facilities and/or discharge(s).
The conditions include special reporting requirements in the event
of noncompliance, bypasses, treatment unit/process failures, etc.
Also addressed are requirements for a certified wastewater
treatment plant operator if you are operating wastewater treatment
919 North Main Street, Mooresville,, North Carolina 281 15 Telephone [phone]'699 FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycieda' 1O% post -consumer papev

Mr. Timothy Kinsley
July 13, 1995
Page Two
facilities. Any changes in operation of wastewater treatment
facilities, quantity and type of wastewater being treated or
discharged, expansions and/or upgrading of wastewater treatment
facilities must be permitted or approved by this Agency.
Failure to comply with the terms and conditions of an NPDES
Permit subjects the Permittee to enforcement action pursuant to
Section 143-215.6 of the North Carolina General Statutes. A civil
penalty of up to $10,000 per violation (and/or criminal penalties)
may be assessed for such violations. If you find at any time that
you .are unable to comply with the terms and conditions of the
Permit, you should contact this Office immediately. A Consent
Order may be necessary while pursuing action to obtain compliance.
As a final note, an NPDES Permit is normally issued for a
five-year period. Permits are not automatically renewed. Renewal
requests must be submitted to this Agency no later than 180 days
prior to expiration. Please make note of the expiration date of
your Permit. This date is set forth on Page 1 of the Permit. Also
note that NPDES Permits are not transferable. If you, as the
Permittee, cease to need this Permit, then you should request that.
the Permit be rescinded.
As mentioned previously, the purpose of this letter is to
advise you of the importance of your NPDES Permit. Please read the
Permit and contact this Office at 704/663-1699 in Mooresville if
you have any questions or need clarification. We look forward to
providing any assistance.
Sincerely,
D. Rex Gleason, P. E.
Water Quality Regional Supervisor
Enclosure
DRG.si

State of North Carolina
Department of Environment,
Health and Natural Resources
Mooresville Regional Office
James B. Hunt, Jr., Governor
Jonathan B, Howes, Secretary
Linda Diane Long, Regional Manager
DIVISION OF ENV"IRO
Mr. Timothy Kinsley
Alumax Extrusions, Inc.
Post Office Box 100
Catawba, North Carolina 28609
July 11, 1995
iTAI, �AGEMENT
Subject: NPDES Permit No. NC0048712
Alumax Extrusions
Catawba County, NC
Dear Mr. Kineley:
Our records indicate that NPDES Permit No. NC0048712 was .issued on ne 26,
1995 for the discharge of wastewater to the surface waters of the State from your
facility. The purpose of this letter is to advise you of the importance of the
Permit and the liabilities in the event of failure to comply with the terms and
conditions of the Permit. If you have not already done so, it is suggested that
you thoroughly read the Permit. Of particular importance are Pages 4-5.
Pages 4-5 set forth the effluent limitations and monitoring requirements
for your discharge(s). Your discharge(s) must not exceed any of the limitations
set forth. The section headed "Monitoring Requirements" describes the
measurement frequencies, sample types and sampling locations. Upon commencement
of your discharge (or operation), you must initiate the required monitoring. The
monitoring results must be entered on the reporting forms furnished to you by
this Agency. If you have not received these forme, they should be arriving
shortly. If you fail to receive the forms, please contact this Office as quickly
as possible. I have enclosed a sample of the "Effluent" reporting form (DEM Form
MR-1), plus instructions for completing the form. It is imperative that all
applicable parts be completed, and the original and one copy be submitted as
required.
The remaining Parts of the Permit set forth definitions, general conditions
and special conditions applicable to the operation of wastewater treatment.
facilitie= and/or diecharge(s). The conditions include special reporting
requirements in the event of noncompliance, bypasses, treatment unit/process
failures, etc. Also addressed are requirements for a certified wastewater
treatment plant operator if you are operating wastewater treatment facilities.
Any changes in operation of wastewater treatment facilities, quantity and type
of wastewater being treated or discharged, expansions and/or upgrading of
wastewater treatment facilities must be permitted or approved by this Agency.
Failure to comply with the terms and conditions of an NPDES Permit subjects
the Permittee to enforcement action pursuant to Section 143-215.6 of the North
Carolina General Statutes. A civil penalty of up to $10,000 per violation
(and/or criminal penalties) may be assessed for such violations. If you find at
any time that you are unable to comply with the terms and conditions of the
Permit, you should contact this Office immediately. A Consent order may be
necessary while pursuing action to obtain compliance.
As a final note, an NPDES Permit is normally issued for a five-year period.
Permits are not automatically renewed. Renewal requests must be submitted to
this Agency no later than 180 days prior to expiration. Please make note of the
expiration date of your Permit. This date is set forth on Page 1 of the Permit.
919 North Main Street, Mooresville, North Carolina 28115 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

Mr. Timothy KibalaY
July 11, 1995
Page Tw'o
Also note that NPDES Permits are not transferable. If you, as the Permittee,
cease to n this Permit, then you should est that the Permit be rescinded.
As mentioned previously, the pu se of this letter is to advise you of the
...rtanice of your NPDES Permit. Please read the Permit and contact this office
at 704/663-1699 in Mooresville if you have any questions or need clarification.
We look forward to providing any assistance.
Enclosure
DRG:sl
incerely,
D. Rex Gleason, P. E.
Water Quality Regional Supervisor

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
September 9, 1994
Mr, Timothy Kinsley
Alumax Extrusions, Inc.
P. 0, Box 100
Catawba, NC 28609
flF
R
SEP 13 VAI
F UtitiRaMUITAL OANAGEMENT
tJUR[W ONE
Subject: NPDES No. NC0048712
Alumax Extrusions, Inc,
Permit correction
Catawba County
Dear Mr, Kinsley:
The Division has reviewed the subject permit and has discovered an error on the cover
page. The signed date on the permit should be for 1994, not 1995. Enclosed please find the
corrected permit cover page. This page should be inserted into your permit and the old one
discarded. 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 U. S.
Environmental Protection Agency dated December 6, 1983.
If any parts, measurement frequencies or sampling requirements contained in this
permit modification are unacceptable to you, you have the right to an adjudicatory hearing upon
written request within thirty (30) days following receipt of this letter, This request must be
in the form of a written petition, conforming to Chapter 150B of the North Carolina General
Statutes, and filed with the Office of Administrative Hearings, Post Office Drawer 27447,
Raleigh, North Carolina 27611-7447, Unless such demand is made, this decision shall be final
and binding.
Please take notice that this permit is not transferable. Part II, E.4, addresses the
requirements to be followed in case of change in ownership or control of this discharge. This
permit does not affect the legal requirement to obtain other permits which may be required by
the Division of Environmental Management or permits required by the Division of Land
Resources, Coastal Area Management Act or any other Federal or Local governmental permit that
may be required. If you have any questions concerning this permit, please contact Susan Robson
at telephone number 919/733-5083,
cc: Mr. Jim Patrick, EPA
Mooresville Regional Office
Compliance -Jeanne Phillips, ISB
Central Files
Kim Brantley
Aquatic Toxicology Unit
ncerely,
A. Preston Howard, Jr., P,E.
P.O. Box 29535, Raleigh, North Carolina 27626-0535
An Equal Opportunity Affirmative Action Employer
Telephone [phone] FAX 919-7'33-9919
50% recycled/ 10% post-0011SUrher paper

permit No, NC0048712
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT MC. DEPT. OF
ENVIRONMENT, HEALTH,
& NATURAL RESOURCES
PERMIT
TO DISCHARGE WASTEWATER UNDER THE SEP 13 1994
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
tam ttf EXVlRONMENTAL a aattAGEMcatt
MOORESVILLE RECIOKAt OFFICE
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,
Alutnax Extrusions, Incorporated.
is her eby authorized to discharge wastewater from a facility located at
Alumax Extrusions, Incorporated
NCSR 1931.
southeast of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to L.al e Norman in the Catawba River Basin
in accordance with effluent
Parts I, II„ and III hereof,
nitoring requirements, and other conditions set forth in
This permit shrill become effective September 9,,, 1994
This permit and the authorization to discharge shall. expire at midnight on June 30, 1.995
Signed this day September 9, 1994
A. Preston. Howard, Jr.,, P,E., Director
Division of Environrnental. Management
By Authority of the Environmental. Management. Commission

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environment& Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Timothy Kinsley
Alumax Extrusions, Inc.
P. O. Box 100
Catawba, NC 28609
Dear Mr. Kinsley:
On September 30, 1993, the Division of Environmental Management (DEM) issued Certificate of
Coverage (COC) NCG500209 NPDES for General Permit NCG500000 to Alumax Extrusions, Inc. as a
replacement for Permit No, NC0048712, It has been determined that the characteristics of the wastewater
discharged from the subject facility do not meet the guidelines for coverage under the General Permit cited,
Therefore DEM is reinstating the individual permit for your facility and rescinding the previously issued
COC. Replace the COC and General Permit with the enclosed individual permit. The reinstated NPDES
permit becomes effective immediately.
This permit is reinstated pursuant to the requirements of North Carolina General Statute 143-215.1 and the
Memorandum of Agreement between North Carolina and the U.S. Environmental Protection Agency dated
December 6, 1983.
1.-1NJ Fl
N.C. DF,PT. 0
ENViRON.NITNT, HFALTTI,
May 11, 1994 & NATURAL NESOUCES
MAY 20 ip(lik
WAV.TIBT
.140@kt"SU'LL.,WiAl,,, CFO'
Subject: Reinstatement'ot NPDES Permit
NPDES Permit #NC0048712
Alumax Extrusions, Inc.
Catawba County
If you have any questions concerning this permit, please contact Mr. Greg Nizich at telephone
number 9191733-5083.
enclosure
cc:
entral Files
Permit File
Sincerely,
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E.
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

Permit No. NCI4g7i2
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT pISCHARGE ELIMINATION SY
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 Env
Management Commission, and the Federal Water Pollution Control Act, as amended,
Alumax Extrusions, Incorporated
is hereby authorized to discharge wastewater from a facility located at
Alumax Extrusions, Incorporated
NCSR 1931
southeast of Catawba
Catawba County
nmental
to receiving waters designated as an unnamed tributary to Lie Norman in the Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, and III hereof.
This permit shall become effective May 10, 1994
This permit and the authorization to discharge shall expire at midnight on June 30, 1995.
Signed this day May 10, 1995
Original Signed By
David A. Goodrich
A. Preston Howard, Jr., P.E., Director
Division of Environmental Management
By Authority of the Environmental Management Commission

is hereby authorized to:
Permit No, NC0048712
E ENT TO PE COVER SHEET
Extrusions, lr corpur t d
1. Continue to `sharge non-contactand con cooling water Crum facilities located atAdo/rim
io s, eorp rated, N . 1 1, south t f Cat e ba, t wb ounty (See Part III
o e it, d
2. Discharge from said tr at nt
unned tributary to Lake No
Catawba River Basin,
at the 1
filch is e
on s i ed on tl
1� ifed Class -:
ehed map into
d B waters in the

A. O. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS FINAL
Permit No. NC()(W8712
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) sepal number 001 - Filter Backwash and Cooling Tower Blowdown. Such discharges shall be limited and monitored by the permittee
as specified below:
t,bs/day
Mon. Avg, Daily
Flow
Temperature
Total Residual Chlorine***
TSS
Settleable Solids
Discharge Limitations
Units (specify)
Monitoring
Measurement
Mon, Avg. Daily Max. Frequenca[
Weekly
* * 2/Month
2/Month
30.0 mg/I 45.0 mg/I 2/Month
0.1 m I/I 0.2 min/ I 2/Month
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO TIIE TREATMENT SYS
ADDITIVES TO BIOCIDAL COMPOUNDS.
* Sample Locations: E - Effluent
** The temperature of the effluent shall be such as not to cause an increase in the temperature of the rea
no case cause the ambient water temperature to exceed 32°C.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior to utili
Part III, Condition E of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
g
Requirements
Sample
Tyne
Instantaneous
Grab
Grab
Grab
Grab
*Sampler
Location
E
E
E
E
E
EXPECT AS PRE -APPROVED
ng stream of more than 2.8°C and in
anny biocide in the cooling water (See
2/month at the effluent by grab

PART I
n B chedule, of Cornl
The permute shall compl!° with Final
accordance rith the following schedule:
one specified for discharges in
Pe tree shall comply with Final Effluent L t.tidn.s by the effective date of the t unless
specified below.
Perrantee shall at all tunes provide the op ration and maintenance necessar) to operate the
existing facilities at; opt imum efficiency,
No later than l4 calehdar class folio ;Jug a date identified in the a o e schedule of compliane ,
the perrnotte shall submit either a report of progress or, in the case of specific actions being
required by identified dates. a wititten notice of compliance or noncompliance. In the latter
case, the notice shall include the cause of nonconipliance, any remedial actions taken, and the
probability of meeting the next schedule requirements,

Part II
Page of 14
PART .II
STANDARD COND1TI©NS FOR NPDES PERMIITS
SECTION A, DEFINITIONS.
1. Permit ..Issuing Authority
The Director of the Division of EnEnvironmental l °ianagement,
DE I or Division
Means the Division of Environmental. Management, Department of Environment, Health and
Natural Resources.
3. SIC
Used herein means the North Carolina Environmental Management Commission,
4. Act or 'the Act
The Federal \Vtiter Pollution Control Act, also known as the Clean Water Act, as amended. 33
USC 1251, et, seq.
5 Mass/Day 11easurements
a, The "monthly° average discharge" is defined as the total mass of all daily discharges
sampled and/or measured during a calendar month on which daily discharges are sampled
and measured, divided by the number of daily discharges sampled and/or measured during
such month. It is therefore, an arithmetic mean found by adding the weights of the
pollutant found each day of the month and then dividing this sum by the number of days
the tests were reported. The limitation is identified as "Monthly Average" in Part I of the
permit.
b. The ""weekly average discharge" is defined as the total mass of all daily discharges sampled
and/or measured during the calendar week (Sunday - Saturday) on which daily discharges
are sampled and measured, divided by the number of daily discharges sampled. a.ndior
measured during such week. It is, therefore, an arithmetic mean found by adding the
weights of pollutants found each day of the week and then dividing this sum by the
number of days the tests were reported. This limitation is identified as "Weekly Average"
in Part I of the permit.
c. The "Maximum daily discharge" is the total mass (weight) of a pollutant discharged during
a calendar day. If only one sample is taken during any calendar day the weight of pollutant
calculated from it is the ".maximum daily discharge." This limitation is identified as "Daily
Maximum," in Part I of the permit.
d. The "'average annual discharge" is defined as the total mass of all daily discharges sampled
and/or measured during the calendar year on which daily discharges are sampled and
measured, divided by the number of daily discharges sampled and/or measured during such
v'ear. It is, therefore, an arithmetic mean found by adding the weights of pollutants found
each day of the year and then dividing this sum by the number of days the tests were
reported. This limitation is defined as "Annual Average" in Part I of the permit.

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

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

Part II
Page 4of 14
c, Weighted by Flo ,° `Value, Weighted by flow value means the summation of each
concentration tunes its respective flow divided by the summation of the respective flows,
10. Calendar Dav
A calendar day is defined as the period from midnight of one day until midnight of the next
day. However, for purposes of this permit, any consecutive 24-hour period that reasonably
represents the calendar day may be used for sampling.
Hazardous Substance
A hazardous substance means any substance designated under 40 CFR Part 116 pursuant to
Section 311 of the Clean Water Act.
12, Toxic Pollutant
A toxic pollutant is any° po]lutrtt Jilted as toxic under Section 37(a)(l) ofthe Clean Water Act.
SECT]QN B. GE. `« R. 1 CQNDITIQ" S
Duty to Comply
The perrnittee must comply with all conditions of this permit. Any permit noncompliance
constitutes a violation of the Clean Water Act and is grounds for enforcement action; for permit
termination, revocation and reissuance, or modification; or denial of a permit renewal
application.
a. The perrnittee shall comply with effluent standards or prohibitions established under
section 3C ?ia) of the Clean Water Act for toxic pollutants and with standards for sewage
sludge use or disposal established under section 405(d) of the Clean Water Act within the
e provided in the regulations that establish these standards or prohibitions or standards
for sewage sludge use or disposal, even if the permit has not yet been modified to
incorporate the requirement.
b. The Clean Water Act, provides that any person who violates a permit condition is subject to
a civil penalty not to exceed S25,000 per day for each violation. Any person who
negligently violates any permit condition is subject to criminal penalties of S2,500 to
525,000 per day of violation, or imprisonment for not more than 1. year, or both. Any
person who knowingly violates permit conditions is subject to criminal penalties of S5,000
to S50,000 per day of violation, or imprisonment for not more than 3 years, or both. Also,
any person who violates a permit condition may be assessed an administrative penalty not
to exceed S10,000 per violation with the maximum amount not to exceed S125,000. [Ref:
Section 309 of the Federal Act 33 U.S.C. 1319 and 40 CFR 122.41 (a)]
c.. Under state law, a civil penalty of not more than ten thousand dollars (510,000) per
violation may be assessed against any person who violates or fails to act in accordance with
the terms, conditions, or requirements of a permit. [Ref: North Carolina General Statutes
§ 143-215.6A]
d. Any person may be assessed an administrative penalty by the Administrator for violating
section 301, 302, 306, 307, 308, 318, or 405 of the Act, or any permit condition or
limitation implementing any of such sections in a permit issued under section 402 of the
Act. Administrative penalties for Class I violations are not to exceed S10 000 per violation,
with the maximurri 'mount of any Class I penalty assessed not to exceed S25,000.

Part II
Page 5 of 14
Penalties for Class II violations are not to exceed S10 000 per day for each day during
which the violation continues, with the maxis rum amount of any Class II penalty not to
exceed S 125.000.
Dune to 'Mitigate
The permirtee shall take all reasonable steps to minimize or prevent any discharge or sludge use
or disposal in violation of this permit which has a reasonable likelihood of adversely affecting
human health or the environment.
Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part II, C-4) and "Power Failures
(Part II, C-7), nothing in this permit shall be construed to relieve the permittee from any
responsibilities, liabilities, or penalties for noncompliance pursuant to NCGS 143-215.3, 143-
215.6 or Section 309 of the Federal Act, 33 USC 1319. Furthermore, the permittee is
responsible for consequential damages, such as fish kills, even though the responsibility for
effective compliance may be temporarily suspended.
4. Oil and Hazardops5ubstancellability
Nothing in this permit shall be construed to preclude the institution of any legal action or relieve
the permittee from any responsibilities, liabilities.. or penalties to which the perrn,ittee is or may
be subject to under NCGS 143-215,75 et seq. or Section 311 of the Federal Act, 33 USG 1321.
Furthermore, the permittee is responsible for consequential damages, such as fish kills. even
though the responsibility for effective compliance may be temporarily suspended,
Property Rights
The issuance of this permit does not convey any property rights in either real or personal
property. or any exclusive privileges,. nor does it authorize any injure to private property or any
invasion of personal rights, nor anv infringement of Federal, State or local laws or regulations.
Onshore or Offshore Construction
This permit does not authorize or approve the construction of any onshore or offshore physical.
structures or facilities or the undertaking of any work in any navigable waters.
7. Seyerahility
The provisions of this permit are severable, and if any provision of this permit, or the
application of any provision of this permit to any circumstances, is held invalid, the application
of such provision to other circumstances, and the remainder of this permit, shall not be affected
thereby.
S . _Duty to Provide Information
The permittee shall furnish to the Permit Issuing Authority, within a reasonable time, any
information which the Permit issuing Authority may request to determine whether cause exists
for modifying. revoking and reissuing, or terminating this permit or to determine compliance
with this permit. The permittee shall also furnish to the Permit Issuing Authority upon
request. copies of records required to be kept �+y this permit,

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

Part II
Page 7 of 14
c. Certification. Any person signing a document under paragraphs a. or b. of this section
shall make the following certification:
"I certify, under penalty of law, that this document and all attachments were prepared under
my direction or supervision in accordance with a system designed to assure that qualified
personnel properly gather and evaluate the information submitted. Based on my inquiry of
the person or persons who manage the system, or those persons directly responsible for
gathering the information, the information submitted is, to the best of my knowledge and
belief, true, accurate, and complete. I am aware that there are significant penalties for
submitting false information, including the possibility of fines and imprisonment for
knowing violations,"
permit. Actions
This permit may be modified, revoked and reissued, or terminated for cause. The filing of a
request by the permittee for a permit modification, revocation and reissuance, or termination,
or a notification of planned changes or anticipated noncompliance does not stay any permit
condition.
13. Permit Nlodification, Revocation and Reissuance, or Termination
The issuance of this permit does not prohibit the permit issuing authority from reopening and
modifying the permit, revoking and reissuing the permit, or terminating the permit as allowed
by the laws, rules, and regulations contained in Title 40, Code of Federal Regulations, Parts
122 and 123; Title 15A of the North Carolina Administrative Code, Subchapter 2H .0100; and
North Carolina General Statute 14.3-215.1 et. al„
14. Previous Permits
All previous National Pollutant Discharge Elimination System Permits issued to this facility,.
whether for operation or discharge, are hereby revoked by issuance of this permit. [The
exclusive authority to operate this facility arises under this permit. The authority to operate the
facility under previously issued permits bearing this number is no longer effective. ] The
conditions, requirements, terms, and provisions of this permit authorizing discharge under the
National Pollutant Discharge Elimination System govern discharges from this facility.
SE TION C OPERATION AND NIAINTEN.ANCE OF POLLUTION CONTROLS
1. Certified Operator
Pursuant to Chapter 90A-44 of North Carolina General Statutes, and upon classification of the
facility by the Certification Commission, the permittee shall employ a certified wastewater
treatment plant operator in responsible charge (ORC) of the wastewater treatment facilities.
Such operator must hold a certification of the grade equivalent to or greater than the
classification assigned to the wastewater treatment facilities by the Certification Commission.
The perrnittee must also employ a certified back-up operator of the appropriate type and any
grade to comply with the conditions of Title 15A, Chapter 8A .0202. The ORC of the facility
must visit each Class I facility at least weekly and each Class II, III, and IV facility at least
daily, excluding weekends and holidays, and must properly manage and document daily
operation and maintenance of the facility and must comply with all other conditions of Title
15A, Chapter 8A .0202. Once the facility is classified, the permittee shall submit a letter to the
Certification Commission which designates the operator in responsible charge within thirty
days after the wastewater treatment facilities are 50% complete.

Pan ll
Page 8 of 14
2. Proper ©,peratio t_aradMaintenance
The permittee shall at all times properly operate and maintain all facilities and systems of
treatment and control (and related appurtenances) which are installed or used by the permittee to
achieve compliance with the conditions of this permit. Proper operation and maintenance also
includes adequate laboratory controls and appropriate quality assurance procedures. This
provision requires the operation of back-up or auxiliary facilities or similar systems which are
installed by a permittee only when the operation is necessary to achieve compliance with the
conditions of the permit.
Need to Halt or Reduce r}1 Defense
It shall not be a defense for a permittee in an enforcement action that it would have been
necessary to halt or reduce the permitted activity in order to maintain compliance with the
condition of this permit.
B
past
pf Treatment Faci1ities
a. Definitions
(1 ) "Bypass"' means the known diversion of waste streams from any potion of a treatment
facility including the collection system, which is not a designed or established or
operating mode for the facility.
( ) "Severe property damage means substantial physical damage to property. damage to
the treatment facilities which causes them to become inoperable, or substantial and
permanent loss of natural resources which can reasonably be expected to occur in the
absence of a 'bypass. Severe property damage does not mean economic loss caused by
delays in production.
b. Bypass not exceeding limmitations,
The permittee may allow any bypass to occur which does not cause effluent limitations to
be exceeded, but only if it also is for essential maintenance to assure efficient operation.
These bypasses are not subject to the provisions of Paragraphs c, and d. of this section..
Notice
(1) Anticipated bypass. If the permittee knows in advance of the need for a bypass, it
shall submit prior notice, if possible at least ten days before the date of the bypass;
including an evaluation of the anticipated quality and affect of the bypass.
(7) Unanticipated bypass. The permittee shall submit notice of an unanticipated bypass as
required in Part II, E. 6. of this permit. (24 hour notice).
d. Prohibition of Bypass
(1) Bypass is prohibited and the Permit issuing Authority may take enforcement action
against a permittee for bypass, unless:
(A) Bypass was unavoidable to prevent loss of life, personal injury or severe property
damage;
(B) There were no feasible alternatives to the bypass, such as the use of auxiliary
treatment ntion of untreated wastes or maintenance during normal

Part II
Page 9 of 14
periods of equipment downtime. This condition is not satisfied if adequate backup
equipment should have been installed in the exercise of reasonable engineering
judgment to prevent a bypass which occurred during normal periods of equipment
downtime or preventive maintenance; and
(C) The permittee submitted notices as required under Paragraph c, of this section.
The Permit Issuing Authority may approve an anticipated bypass, after considering its
adverse affects, if the Permit Issuing Authority determines that it will meet the three
conditions listed above in Paragraph d. (1) of this section.
Up s et s
a. Definition.
"Upset " means an exceptional incident in which there is unintentional and temporary
noncompliance with technology based permit effluent limitations because of factors
beyond the reasonable control of the permittee. An upset does not include noncompliance
to the extent caused by operational error, improperly designed treatment facilities,
inadequate treatment facilities, lack of preventive maintenance, or careless or improper
operation.
b. Effect of an upset.
An upset constitutes an affirmative defense to an action brought for noncompliance with
such technology based permit effluent limitations if the requirements of paragraph c; of this
condition are met.. No determination made during administrative review of claims that
noncompliance was caused by upset; and before an action for noncompliance, is final
administrative action subject to judicial review,
c. Conditions necessary for a demonstration of upset..
A permittee who wishes to establish the affirmative defense of upset shall demonstrate,
through properly signed, contemporaneous operating logs, or other relevant evidence that:
( I .An upset occurred and that the permittee can identify the cause(s) of the upset;
(2) The permittee facility was at the time being properly operated; and
(3) The permittee submitted notice of the upset as required in Part II, E. 6. (b) (B) of this
permit.
(4) The perrnittee complied with any remedial measures required under 'Part II, B. 2.. of this
permit.
d. Burden of proof.
In any enforcement proceeding the permittee seeking to establish the occurrence of an upset
has the burden of proof;
6. Removed Substances
Solids. sludges, filter backwash, or other pollutants removed in the course of treatment or
control of wastewaters shall be utilized/disposed of in accordance with NCGS 143-21.5.1. and in
a manner such as to prevent any pollutant from such .materials from entering waters of the Stan,,,
or navigable waters of the United States. The permittee shall comply with all existing federal

Part II
Page 10 of 14
regulations governing the disposal of sewage sludge. Upon promulgation of 40 CFR Part 503,
any permit issued by the Permit Issuing Authority for the utilization/disposal of sludge may be
reopened and modified, or revoked and reissued, to incorporate applicable requirements at 40
CFR Part 503. The perrnittee shall comply with applicable 40 CFR Part 503 Standards for the
Use and Disposal of Sewage Sludge (when promulgated) within the time provided in the
regulation, even if the permit is not modified to incorporate the requirement. The perrnittee.
shall notify the Permit Issuing Authority of any significant change in its sludge use or disposal
practices.
7. Power Failures,
The permittee is responsible for maintaining adequate safeguards as required by DEM
Regulation, Title 15A, North Carolina Administrative Code, Subchapter 2H, .0124 Reliability',
to prevent the discharge of untreated or inadequately treated wastes during electrical power
failures either by means of alternate power sources, standby generators or retention of
inadequately treated effluent,
SECTION D. MONITORING ►ND RECORDS
1, Representative Sarnpling
Sarnples collected and measurements taken, as required herein, shall be characteristic of the
volume and nature of the permitted discharge. Samples collected at a frequency less than daily
shall be taken on a day and time that is characteristic of the discharge over the entire period
hich the sample represents: All samples shall be taken at the monitoring points specified in
this perrnit and, unless otherwise specified, before the effluent joins or is diluted by any other
w astestream,, body of water, or substance. Monitoring points shall not be changed without
notification to and the approval of the Permit Issuing Authority.
Reporting.
Monitoring results obtained during the previous month(s) shall be summarized for each month
and reported on a monthly Discharge Monitoring Report (DMR) Form (DEM No. MR 1, 1.1, 2,
) or alternative forms approved by the Director, DEM, postmarked no later than the 30th day
following the completed reporting period.
The first DMR is due on the last day of the month following the issuance of the permit or in the
case of a new facility, on the last day of the month following the commencement of discharge.
Duplicate signed copies of these, and all other reports required herein, shall be submitted to the
following address:
Division of Environmental Management
Water Quality Section
ATTENTION:: Central Files
Post Office Box 29535
Raleigh, North Carolina 27626-0535
deasurements
Appropriate flow measurement devices and methods consistent with accepted scientific
practices shall be selected and used to ensure the accuracy and reliability of measurements of
the volume of monitored discharges. The devices shall be installed, calibrated and maintained
to ensure that the accuracy of the measurements are consistent with the accepted capability of
that type of device. Devices selected shall be capable of measuring flows with a maximum
deviation of less than + 10% from the true discif^:xge rates throughout the range of expected

Part 11
Page 11 of 14
discharge volumes. Once -through condenser cooling water flow° which is monitored by pump
logs, or pump hour meters as specified in Part I of this permit and based on the manufacturer's
pump curves shall not be subject to this requirement.
4, Test Procedures
Test procedures for the analysis of pollutants shall conform to the EMC regulations published
pursuant to NCGS 143-215,63 et. seq, the Water and Air Quality Reporting Acts, and to
regulations published pursuant to Section 304(g), 33 USC 1314, of the Federal. Water
Pollution Control Act, as Amended, and Regulation 40 CFR 136; or in the case of sludge use or
disposal, approved under 40 CFR 136, unless otherwise specified in 40 CFR 503, unless
other test procedures have been specified in this permit.
To meet the intent of the monitoring required by this permit, all test procedures must produce
minimum detection and reporting levels that are below the perrnit discharge requirements and
all data generated must be reported down to the minimum detection or lower reporting level of
the procedure. If no approved methods are determined capable of achieving minimum
detection and reporting levels below permit discharge requirements, then the most sensitive
(method with the lowest possible detection and reporting level) approved method must be used.
Pe a]ties for Tampering
The Clean Water Act provides that any person who falsifies, tampers with, or knowingly
renders inaccurate, any monitoring device or method required to be maintained under this
permit shall, upon conviction, be punished by a fine of not more than 510,000 per violation, or
by imprisonment for not more than two years per violation, or by both, If a conviction of a
person is for a violation committed after a first conviction of such person under this paragraph,
punishment is a fine of not more than 520,000 per day of violation, or by imprisonment of not
more than 4 years, or both.
6. Records Retention
Except for records of monitoring information required by this permit related to the perrnittee's
sewage sludge use and disposal activities, which shall be retained for a period of at least five
years (or longer as required by 40 CFR 503), the permittee shall retain records of all
monitoring information, including all calibration and maintenance records and all original strip
chart recordings for continuous monitoring instrumentation, copies of all reports required by
this permit, for a period of at least 3 years from the date of the sample, measurement,. report
or application. This period may be extended by request of the Director at any time.
7. Recording Results
For each measurement or sample taken pursuant to the requirements of this permit, the
perrnittee shall record the following information:
a. The date, exact place, and time of sampling or measurements;
b. The individuals) who performed the sampling or measurements;
c. The date(s) analyses were performed;
d . The indiyidual(s) who performed the analyses;
e. The analytical techniques or methods used; and
f. The results of such analyses.

Part II
Page 12 of 14
8. Inspection and Entry
The perrnittee shall allow the Director, or an authorized representative (including an authorized
contractor acting as a representative of the Director), upon the presentation of credentials and
other documents as may be required by law, to;
a. Enter upon the permittee's premises where a regulated facility or activity is located or
conducted, or where records must be kept under the conditions of this permit;
b. Have access to and copy, at reasonable times, any records that must be kept under the
conditions of this permit;
c. inspect at reasonable times any facilities, equipment (including monitoring and control
equipment), practices, or operations regulated or required under this permit; and
d. Sample or monitor at reasonable times, for the purposes of assuring permit compliance or
as otherwise authorized by the Clean Water Act, any substances or parameters at any
location,
SECTION E. REPORTING REQUIREMENTS
1.. Chance in Discharge
All discharges authorized herein shall be consistent with the terms and conditions of this
permit, The discharge of any pollutant identified in this permit more frequently than or at a
level in excess of that authorized shall constitute a violation of the permit,
Planned Changes
The perrnittee shall give notice to the Director as soon as possible of any planned physical
alterations or additions to the permitted facili Notice is required only when:
a. The alteration or addition to a permitted facility may meet one of the criteria for determining
tivhether a facility is a new source in 40 CFR Pan 122,29 (b); or
b, The alteration or addition could significantly change the nature or increase the quantity of
pollutants discharged. This notification applies to pollutants which are subject neither to
effluent limitations in the permit, nor to notification requirements under 40 CFR Part 122.42
(a) (1).
The alteration or addition results in a significant change in the perrnittee's sludge use or
disposal practices, and such alternation, addition or change may justify the application of
permit conditions that are different from or absent in the existing permit, including
notification of additional use or disposal sites not reported during the permit application
process or not reported pursuant to an approved land application plan.
Anticipated Noncompliance
The permittee shall give advance notice to the Director of any planned changes in the permitted
facility or activity which may result in noncompliance with permit requirements.

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

Part II
Paae 14 of 14
her Information
Where the perrnittee becomes aware that it failed to submit any relevant facts in a permit
application, or submitted incorrect information in a permit application or in any report to the
Director, it shall promptly submit such facts or information.
9. Noncompliance Notification
The perrnittee shall report by telephone to either the central office or the appropriate regional
office of the Division as soon as possible, but in no case more than 24 hours or on the next
working day following theoccurrence or first knowledge of the occurrence of any of the
following:
a Any occurrence at the water pollution control facility which results in the discharge of
significant amounts of wastes which are abnormal in quantity or characteristic, such as the
dumping of the contents of a sludge digester; the known passage of a slug of hazardous
substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures of
pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass
directly_ to receiving waters without treatment of all or any portion of the influent to such
station or facility,
Persons reporting such occurrences by telephone shall also file a written report in letter form
within 5 days following first knowlethie of the occurrence,
wl .hility of Reports
Except for data determined to be confidential under NCGS 143-215.3(a)(2) or Section 308 of
the Federal Act, 33 USC 1318, all reports prepared in accordance with the terms shall be
available for public inspection at the offices of the Division of Environmental Management. As
required by the Act, effluent data shall not be considered confidential. Knowingly making any
false statement on any such report may result in the imposition of criminal penalties as provided
for in NCGS 143-21.5.1(b)(2) or in Section 309. of the Federal Act.
Penalties for Falsification of Reports
The Clean Water Act provides that any person who knowingly makes any false statement,
representation, or certification in any record or other document submitted or required to be
maintained under this permit, including monitoring reports or reports of compliance or
noncompliance shall, upon conviction, be punished by a fine of not more than S10,000 per
violation, or by imprisonment for not more than two years per violation, or by both.

PART III
OTHER REQUIREMENTS
A. Construction
No construction of wastewater treatment facilities or additions to add to the plant treatment
capacity or to change the type of process utilized at the treatment plant shall be begun until
Final Plans and. Specifications have been submitted to the Division of Environmental
Management and written approval and Authorization to Construct has been issued.
The permittee shall, upon written notice from the Director of the Division of Environmental
Management, conduct groundwater monitoring as may be required to determine the
compliance of this NPDES permitted facility with the current groundwater standards.
C. Changes in Discharges of Toxic Substances
The permittee shall notify the Permit Issuing Authority as soon as it knows or has reason to
believe:
a.That any activity has occurred or will occur which would result in the discharge, on a
routine or frequent basis, of any toxic pollutant which is not limited in the permit, if that
discharge will exceed the highest of the following "notification levels";
(1) One hundred rrmicrograms per liter (100 ug/1);
(2)Two hundred micrograms per liter (200 ug/1) for acrolein and acrylonitrile; five
hundred micrograms per liter (500 ug/1) for 2.4-dinitrophenol and for 2-methy1-4.6-
dinitrophenol; and one milligram per liter (1 mg/1) for antimony;
(3) Five (5) times the maximum concentration value reported for that pollutant in the
permit application.
b. That any activity has occurred or will occur which would result in any discharge, on a
non -routine or infrequent basis, of a toxic pollutant which is not limited in the permit, if
that discharge will exceed the highest of the following "notification levels";
(1) Five hundred micrograrns per liter (500 ug/1);
(2) One milligram per liter (1 mg/1) for antimony;
(3) Ten (10) times the maximum concentration value reported for that pollutant in the
permit application.
D. Requirement to C9rltin4ljy Evaluate Alternatives tq Wastewater. Discharges
The permittee shall continually evaluate all wastewater disposal alternatives and pursue the
most environmentally sound alternative of the reasonably cost effective alternatives. If the
facility is in substantial non-compliance with the terms and conditions of the NPDES permit
or governing rules, regulations or laws, the permittee shall submit a report in such form and
detail as required by the Division evaluating these alternatives and a plan of action within
sixty (60) days of notification by the Division.

Part III Permit No. NC0048712
E. The Permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water. The Permittee shall notify the Director in writing not
later than ninety (90) days prior to instituting use of any additional biocide used in the treatment
system which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map indicating the discharge point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream, as determined by calculations from the Biocide Worksheet
Form 101 with Supplemental Metals Analysis Worksheet.

Of NATur
COMMUNO
State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Manage
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
TIMOTHY KINSLEY
ALUMAX EXTRUSIONS, INC
ROUTE 1, P. O. BOX 100
CATAWBA NC 28609
Dear Permittee:
SEP 5 0 1993
e
September 30, 1993
RIGIONAL
Subject: ALUMAX EXTRUSIONS, INC
Certificate of Coverage NCG500209
General Permit NCG500000
Formerly NPDES Permit NC0048712
Catawba County
The Division of Environmental Management has recently evaluated all existing individual permits for potential
coverage under general permits currently issued by the Division. 15A N.C.A.C. 2H .0127 allows the Division to
evaluate groups of permits having similar discharge activities for coverage under general permits and issue
coverage where the Division finds control of the discharges more appropriate in this manner. The Division has
determined that the subject discharge qualifies for such coverage. Therefore, the Division is hereby issuing the
subject Certificate of Coverage under the state-NPDES general permit no. NCG500000 which shall void NPDES
Permit NC0048712. This Certificate of Coverage is issued pursuant to the requirements of North Carolina and the
US Environmental Protection Agency Memorandum of Agreement dated December 6, 1983 and as subsequently
amended.
If any parts, measurement frequencies or sampling requirements contained in this general permit are unacceptable to
you, you have the right to submit an individual permit application, associated processing fee and letter requesting
coverage under an individual permit. Unless such demand is made, this decision shall be final and binding. Please
take notice this Certificate of Coverage is not transferable. Part II, E.4. addresses the requirements to be followed
in case of change of ownership or control of this discharge.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those as may be required by this Division, such as the
construction of additional or replacement wastewater treatment or disposal facilities. Construction of any
wastewater treatment facilities will require issuance of an Authorization to Construct from this Division.
Failure to abide by the requirements contained in this Certificate of Coverage and respective general permit may
subject the Permittee to an enforcement action by the Division of Environmental Management in accordance with
North Carolina General Statute 143-215.6A to I43-215.6C. Please note that the general permit does require
monitoring in accordance with federal law. The monitoring data is not required to be submitted to the Division
unless specifically requested, however, the permittee is required to maintain all records for a period of at least
three (3) years,
Post Office Box 29535, Raleigh, North Caro na 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled - 10% post-consurner paper

Page 2
TIMOTHY KINSLEY
ALUMAX EXTRUSIONS, INC.
Certificate of Coverage No. NCG500209
The issuance of this Certificate of Coverage is an administrative actin n initiated by the Division of
Environmental Management and therefore, no fees are due at this time. In accordance with current rules, there
are no annual administrative and compliance monitoring fees for coverage under general permits. The only fee
you will be responsible for is a renewal fee at the time of renewal. The current permit expires July 31, 1997.
This coverage will remain valid through the duration of the attached general permit. The Division will be
responsible for the reissuance of the general permit and at such time, you will be notifiedof the procedures to
follow to continue coverage under the reissued permit. Unless you fail to follow the procedures for continued
coverage, you will continue to be permitted to discharge in accordance with the attached general permit.
The issuance of this Certificate of Coverage does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances which may be required by the Division of Environmental Management
or permits required by the Division of Land Resources, the Coastal Area Management Act or any Federal or
Local other governmental permit that may be required.
If you have any questions or need additional information regarding this matter, please contact either the
Mooresville Regional Office, Water Quality Section at telephone number [phone], or a review engineer in
the NPDES Group in the Central Office at telephone number 919/733-5083.
cc: Mooresville Regional Offic
Central Files
e ly,
d__
A. Preston Howar w 'r„ RE,

STATE OF NORTH CAR©LINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
GENERAL PERMIT NO. NCG500000
CERTIFICATE OF COVERAGE No. NCG500209
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER BLOWDOWN,
CONDENSATE AND SIMILIAR WASTEWATERS UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-21.5.1, other lawful standards and regulation
promulgated and adopted by the North. Carolina Environmental Management Commission, and the Federal Water
Pollution Control Act, as amended,
ALUMAX EXTRUSIONS, INC
is hereby authorized to discharge non -contact cooling water, cooling tower and boiler blowdown wastewater from a
facility located at
ALUMAX EXTRUSIONS, INC
Catawba. County
to receiving waters designated as the UT LAKE NORMAN/CATAWBA RIVER BASIN
ccordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III ar
IV of General Permit No. NCG500000 as attached.
This certificate of coverage shall become effective November 1, 1993.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day, September 30, 1993.
A. Preston Howar�r., P.E.,Director
Division of Environmental Management
By Authority of the Environmental Management Co ion

Permit No. NC004871.2
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DSCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1,
other lawful standards and regulations promulgated and adopted by the North Carolina
Environmental Management Commission, and the Federal Water Pollution Control Act, as
amended,
Alumax Extrusions, Incorporated
is hereby authorized to discharge wastewater from a facility located at
Alumax Extrusions, Incorporated
NCSR 1931
southwest of Catawba
CatawbaCounty
to receiving waters designated as the an unnamed tributary to Lake Norman in the Catawba River
Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, and III hereof.
This permit shall become effective
This permit and authorization to discharge shall expire at midnight on June 30, 2000
Signed this day
A, Preston or
Division of E ntal. Management
By Authority of e Environmental Management Commission.

Perm t No, t 71.
SUPPLEMENT TO PE ® COVER SHEET
Adurnax Extrusions,Incorporated
Continue to discharge filter backwash from
and cooling tower blowdown from facilities located at
1931, southeast f Catawba, Catawba County (See
extrus cooling water filtration system
Extrusions, Incorporated, N
of this Permit), and
2. After receiving an Authorization to Construct from the Division o En. "Yrr
.sake modi. i ations as necessary t rrteet permit limits, and
3 Discharge
tributary t
�ntal
agement,
said eatmenttreatment coe location specified on the attached map into an umlauted
e Nonnanwhich is classified Class -IV caters in the Catawba River Basin,

A. ( ). EFFLUENT LIMITATIONS .AND MONITORING REQUIREMENTS FINAL Permit No. NC0048712
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to .discharge from
outfall(s) serial number 001 - Filter Backwash from aluminum extrusion cooling water and Cooling Tower Blowdown. Such discharges shall
belimited and monitored by the permittee as specified below:
Efftuept
Characteristic
Flow
Alum 1 num
Zinc
Chromium
Cyanide
Oil and Grease
TSS
Copper
Lead
Nickel
Barium
Lbs/day Viliia_A P_P_P cilv Waskt_LPIllent _ Sample *Sample
A . Daily Max Mon. Avq. Da I y Max . ELP.SLILeJLPY LY_Le Location
Weekly Instantaneous E
4.41 2.2 2/Month Composite E
1.00 0.42 2/Month Composite E
50 pg/I+ 200 pg/I 2/Month Composite E
5 lig/I+ 20 jigfl 2/Month Grab E
13.7 8.23 2/Month Grab E
28.1 13.4 2/Month Composite E
Dipchti.rge Limit a flow Miiojl2iilig FlegArrements
* Sample Locations: E - Effluent.
+ Weeklyaverage limit.
** The, temperature of the effluent shall be such as not to cause an increase in the temperature
no case cause, the ambient water temperature to exceed 32°C.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
**** Acute Toxicity (Daphnia pulex) PIP @ 90%; March, June, September and December; See Part III, condition E.
Monthly Composite E
Monthly Composite E
Quarterly Composite E
Quarterly Composite E
eceiving Stream of more than 2.8°C and in
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE COOLING WAFER EXCEPT AS PRE -APPROVED
ADDITIVES TO BIOCIDAL COMPOUNDS. The permittee shall obtai.n authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water (See Part III of this Permit).
The, pH shall not be less than 7.0 standard units nor greater than 90 standard units and shall be mot
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
2.1month at the, effluent by grab

A. `. EFICUENT LIMITATIONS N MONITORING R QU1REMENTSFINAL Pen
Dining the period beginningbegnming on the effective dawof the it Ind lasting until expir
outfall(s) serial number 1 1 - Filter Backwash from aluminum extrusion cooling water a
Chloride
Temperature
Total ResidualChlorine***
Acute Toxicity****
Di harge irrr itat'oa
Vojta 4
kVA. Daily a ' on Ava,lv
No iC IQ X71
in, the Perintriees rtitlarrrid to discharge1rrrr
Cooling ow .r° 1 lra rdo n. (Confirm cl
Mon
,F r qr n
Quarterly
2/Month
2/MiDrith
Quarterly
gstsual
aen
pie
,t on
Combo lte
Grab E
Grab
Composite

Part III Permit No. NC0048712
E. ACUTE TOXICITY PASS/FAIL PERMIT LIMI'1 (QRTRLY)
The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the
North Carolina Procedure Document entitled "Pass/Fail Methodology For Determining Acute
Toxicity In A Single Effluent Concentration." The monitoring shall be performed as a Daphnia
pulex or Ceriodaphnia 48 hour static test, using effluent collected as a 24 hour composite. The
effluent concentration at which there may be at no time significant acute mortality in any toxicity
test is 90% (defined as treatment two in the North Carolina procedure document). Effluent
samples for self -monitoring purposes must be obtained during representative effluent discharge
below all waste treatment. The first test will be performed after thirty days from the effective date
of this permit during the months of March, June, September and December,
The parameter code for this test if using Daphnia pulex is TGA3D. The parameter code for this test
if using Ceriodaphnia is TGA3B. All toxicity testing results required as part of this permit
condition will be entered on the Effluent Discharge Form (MR-1) for the month in which it was
performed, using the appropriate parameter code. Additionally, DEM Form AT-2 (original) is to
be sent to the following address:
Attention:
Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements
performed in association with the toxicity tests, as well as all dose/response data, Total residual
chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream.
Should any single quarterly monitoring indicate a failure to meet specified limits, then monthly
monitoring will begin immediately until such time that a single test is passed. Upon passing, this
monthly test requirement will revert to quarterly in the months specified above.
Should any test data from either these monitoring requirements or tests perforned by the North
Carolina Division of Environmental Management indicate potential impacts to the receiving stream,
this permit may be re -opened and modified to include alternate monitoring requirements or limits..
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival and appropriate environmental controls, shall constitute an invalid test
and will require immediate retesting(within 30 days of initial monitoring event). Failure to submit
suitable test results will constitute noncompliance with monitoring requirements.
F. Biocide Condition
The permittee shall obtain authorization from the Division of Environmental Management prior to
utilizing any biocide in the cooling water. The Permittee shall notify the Director in writing not.
later than ninety (90) days prior to instituting use of any additional biocide used in treatmentsystem
which may be toxic to aquatic life other than those previously reported to the Division of
Environmental Management. Such notification shall include completion of Biocide Worksheet
Form 101 and a map locating the discharge point and receiving stream. Concentrations of
chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream, as determined by calculations from the Biocide Worksheet
Form 101 with Supplemental Metals Analysis worksheet.

DIVISION OF ENVIRONMENTAL MANAGEMENT
April 26, 1995 - -
MEMORANDUM
To: Rex Gleason, Water Quality Supervisor
Mooresville Regional Office
From: Greg Nizich
NPDES Permits Unit
Subject: Permit Application Info
NPDES Permit NC0048712
Alumax Extrusions, Inc.
Catawba County
APR .26
DivIsut Liia2ValAt tISMiEtatil
Ufhi';L
I am resending the permit application for this facility. Kim and I discussed the revised
limits for this facility several times (since we determined that they should be covered by
EPA guidelines for aluminum extrusion) and I am certain he received the application
back in February. I will be sending the draft permit out to notice on May 10, so please let
me know if you have any comments on the permit other than what were made on the
WLA fact sheet when it was reviewed. Thanks.
Enclosures
cc: Permit file

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
January 24, 1995
Mr. Timothy Kinsley
Alumax Extrusions, Inc.
P.O. Box 100
Catawba, NC 28609
Subject: Permit Renewal
NPDES Permit NC0048712
Alumax Extrusions, Inc.
Catawba County
Dear Mr. Kinsley:
This is to acknowledge receipt of the following documents on 1 /2/95:
• NPDES Permit Application
• Application Processing Fee of 5200.00
The following items are needed before review can be completed:
• Completion of Standard Form C (enclosed)
• Production information -The average daily off -pounds of extruded aluminum for a representative
maximum production month must be provided.
• A priority pollutant analysis as required by 15 NCAC 2H .0105(j) for primary industries listed in 40
CFR 122.21 Appendix D. An Annual Pollutant Analysis Monitoring forth is enclosed.
If the requested information is not provided by February 24, 1995, it will be returned to you and may be
resubmitted when complete.
I am, by copy of this letter, requesting that our Regional Office Supervisor prepare a staff report and
recommendations regarding this discharge. If you have any questions regarding this application, please
contact Mr. Greg Nizich at 919-733-5083, ext. 541.
enclosures
cc: Mooresville Regional Office
Permit File
Sincerely,
/1/
David A. Goodrich, Supervisor
NPDES Permits Group
Pollution Prevention Pays
P.Q. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

])avid Citiodrich
TqPDES Pernuts Group
Division ofEn ° ental':
North Carolina Ef
512 N. Salisbury
Raleigh,2'7603
Mr, Goodrich;
Please find the following attached'
DES Pe NC0048712 Renewal application
1/24/95 Information bequest
s as per you instructions;
completed Standard Form C application
The average daily off -pounds of extmded alunim rn for representattvena i to
production ction month is q, i pounds per day,
Analytic resets for the priority pollutants as required by 15 NCAC 2H,010501
f you have any questions, or require additional info anon please contact trio at the
number listed above.
Sincerely,
,tarn Extrusions fn:
Christopher Rowland
Environmental Special
Enc,
co La
Teague wf Eno.)

DIVISION I "'IR N MEN 1". MANAGEMENT
EM RANDI
February 27, 1995
Rex Gleason, Water Quality Supervisor.
Mooresville Regional Office
Greg Nizic
NPDES R its" °nit
Renewal Add Info
NPDES Permit NC0048712
Alumax Extrusions, Inc.
Catawba County
Application Form C has been received from the subject facility s r nested in my letter
of January , 1995. Based on the information received - SIC classificationand
production information - 1 have recommended that federal guideline limits be
implemented for this facility. Since this facility has not been evaluated on this basis in
the past, I would like the Region"s input on the relevance of applying these limits and the
facilities ability to meet them. Let me know if you need any addtional information.
Enclosur
cc: Perm

N . C DEFT. OF NATURAL RESOURCES AND COMMUNITY DEV.
ErVIRONMENTAL MANAGEMENT COMMISSION
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
APPLICATION FOR PERMIT TO DISCHARGE WASTEWATER
STANDARD FORM C — MANUFACTURING AND COMMERE I.,
SECTION 1., APPLICANT AND FACILITY DESCRIPTION
Utiles& otneerwW specified on fhls form aft Komi an 10 be eornpaated. If elk ittfn k ssot aMfttc Is inalialte WA,'
ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION •00%LET AS INr'CMPBO.
BOOKLET BEFORE FILLING OUT THESE ITEMS.
A.
e of Applicant
ctIons)
Aell ese of Apptleant
ructions',
bey ter S Street
City
Stu.
ZIi Code
Applicant's Authorised Agent
(see Instructions)
Name and •flu.
Number 1. Street Adams
cIt y
State
Zip Cade
Telephone
Previous Apsiiaeatl#n
if a previous Epp' iCattt>n 1or a
National or Federal tetsoharge Per-
mit feat been made, give the date
of appltcetion. Use numeric
designation 1dr date,
Pilaf Prim or Type
ALUMAX EXTRUSIONS INC.
II MIA TO
2700 INTERNATIONAL DR. SUITE 200
WEST CHICAGO
L
60185
TIMOTHY KINSLEY
MANAGER OF ENVIRONMENTAL SERVICES
2700 INTERNATIONAL DR., SUIJE 200
WEST CHICAGO
L
60185
(708)
Area
Coale
584-10'O0
Number
94 12 29
YR MO DAY
certify that 1 am familiar with the Information contained In this application and that 10 the best of my knowledge ante belief such IMorrnatlon
Is true, complete, and accurate,
LARRY TEAGUE
Printed Name of person Signing
f ADD:ant or Autlp{tspled Agent
Carolina Geuferal Statute 143-215.6(b)
Ise statement xeprerentetioD, or cert:
or other document files or required to be ma
Env-iron:m nta' Mrtiegement Commission implemp!nting
or kno ly renders inaccurate any recording or mo
cr crated cr maintained under Article 21 or regulations of the Environmental Merril gettent Commissio
imalerertitg that Article, shell be guilty of a 'misdemeanor ' unisrable by a fine not to exceed,
$10,001, or by imprisonment not to exceed six months, or by both. (15 t7,S.C, Section 1001 provi1
a punishment by a fine of rot more than $10,000 or imprisonment not more than 5 yearc, br both,
for a similar offense.)
PLANT MANAGER
Title
that: A:ay person who knrar. infily makes
on in any appli.ca.tion, record, report, plan,
ed under Article 21 or regulations of the
hat. Article, or who falsifies, tamers vitb,
toriag device or method required to be

Moro
Ownership (Public, Priests or
Both Public and Priests)
Chock shock If Federal Facility
and Mee GSA inventory Control
Number
trocatlon
C4ty
County
State
tauten of Business Stabs Ina
nature of the bu100ne14 conductao
at the Plant or op.rating faculty.
Facility Intake Seater (see tnetruc-
Cons) Indicate water Intake volume
Per day by sources. Estimate
average volume Per day in thousand
gailoro Per day.
Municipal or priw►te water system
5urtau water
Groundwater
Other
Total Item 7
sit there Is Inteste water from
'otnsr,' tlpeclty the sours..
Facility wept the E*Ornate
average eoturrne pat day in thousand
gallons pair day for the following
tYPst of water usage at the facility.
(sae Instructions)
hfoncontect cooling water
dotter teed water
Protsu water (18C1001r* contact
cooling water)
Sanitary water
getter'
Total Item •
•)f there gra discharges to
•other,' specify.
If there fa 'Sanitary' wetsr use, give
the number of people served.
ALUMAX EXTRUSIONS, IN
pPrty cDOPP
NCSR 1848
CATAWBA
ATAWBA
PRODUCTION Of EXTRUDE
cY u5
1 • 4 .... thousand gallons der day
lobs per day
13.4
1 thouand gallons per 48Y
;Kirland geitons per day
6.8
thousand gallons Per day
1. 5 �a►sendMllon% Par day
thousand gallon$ Par dr/
3 .4 thousand gallon$ per day
people $i
I-2

USE
Db. antes aM ettrer
bar anO CiatcI i 4 lase
vonoms Speclry the
arise points and the
isChar9e0 or
according to
Est.imata
In ttesesand
r day.
Surlace Water'
Sanitary wastewater transport
aystern
S torm water transport system
Combined sanitary and storm
water transport system
Syriac* Impoundment with no
' Meant
Undar9round percolation
Wolf injection
Waste acceptance tlrm
Eroaporal ion
ConsurnOti on
Other.
FeClIlty dlscharyes and volume
Total item 9.
•If there are eittharpet to other,'
specify.
* 10. Permits, Licenaat and Applications
List all existing, banding or denied
I I. &taps and Drawings
Attach all required maps and drawings to lha back of thh appliCation.lase instruCtlona(I
12. Additional information
111
a
SCHEMATIC OF WATER FLOW
lIb LOCATION MAP

STANDARD FORM C -- MANUFACTURING AND COMMERCIAL
SECTION II. BASIC DISCHARGE DESCRIPTION
Complete this section for each dIKharee in Rc4tad rn Se+Ctidn f, Item 1, that is to surface wailers, This incIu isi alienation ID rn%nrclpal is rsril�r a$Ie
!y'ttaml to which the wastfwlter Oats not works PUCK IQ POMO diSCharsieC to surface waters. DiKtWrees t1,4 walls ntus4
be dfscrrbect where there are also discharges iD lurfilCe welers from (his faCitity, SEPARATE DESCRIPTIONS OF EACH DISCHARGE ARE
REQUIRED EVEN IF SEVERAL DISCHARGES ORIGIMATE iN THE SAME FACILITY. An values IO en eillt►np Orsctterge ►houl0 tit reyre
ientatrre or Ine twelve previous months of Operation„ If this is a prOPOPPd Mich/roe, values ►nouSe reflect Omit ring(neerine eeltmates,
ADDIT I1)NAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLET AS INDICATED, REFER
TO BOOKLET BEFORE FIl LING OUT THESE ITEMS.
Dlteharle Serial Pio. and Odense
Discharge f+lrlal No.
(see trim ructionII
C. Dnttlaree Nuns
Garr name or discharge, it any.
(sH instructions)
c. Preeiout, Dtichiree Ser;it No.
It previous permit appliCition
was made for this discharge (see
Item 4, Section 1), provide previ,
ous discharge eerie; number,
Drteharee Operating Dates
a. Discharge elan Date It the
discharge described below
operation., give the date Iwitnln
best estimate) the discharge
begin.
b.. Dneharte ID Sevin Date 11 the
Discharge has never Occurred bu1.
is ptanneo for some tulure dale.
Qive lrieDare Iwrthrn best esti.
mate) the eitcnatee will begin.
Efigineering Repert Avattable
Crec I. it an enerneerrng report is
aveoa Ole to rev.ewtrsg agency %non
request. (see rnstr%cti0nst
s. Discharge LOC/lion Mama lire
P0IilrCal bqundartes within which
the Do flt tit ttiK haroe is lDCal*O.
State
County
(it applicable) City or town
Discharge Point Description
Ditchetge n 1,nt0 (Check one);
(lea instructions)
Stream (includes Miens, arroyos,
end Other in1ermrtient wale/courlei)
001
NPDESUUTFALL
©0 1
8
V R MO
Lake OLKE
Ocean O V CE
OMT5
Municipal Sanitary wastewitei
Transport System
Muncrpa1 Comboned Sanitary inc
51orm Transport System ©MCS
NC
CATAWBA
CATAWBA
AganCy Use
This( e
9 pages..

DISCHARGE $EsiiAL NUM$ER
0 AG NC'Y" USE
ateuniCIpal Morin Water Transport
SOUPY,
Well (MOMC i)
Other
etc Give
the preChe location oft
Pt discharge to tM nearest second.
Latitude
L0Mrtwee
rge Itepfv'iee Vaster Nefe
the waterway it Ma point.
hsrga,lssa instructions)
ti Ina 0i$chargs Is througr an out -
tall that extend* DeYOnd the shore-
i1M Or i$ tallow the mean low
water IiM. Complete item 8.
Of 'share Des Charge
t. Discharge Distinct) 'from Shore
D. DlssMrQ' Depth Aglow l+Yater
Surtsca
Discharge Type and OcCurllnce
a. Type of Discharge Check
whither the discharge 1.1 Cone
tihuOUs Or intermitlint,
ttdd in$truttlOnsl
D. Discharge Octurrente DaYt per
'Attu Enter snit average rum
Der of days per week (OWing
periods of disCharQet trill, 0+5.
Charge Occur$.
Discharge Occurrence —Months
If trig discharge normally
Operate$ tettntr inlermitten1IK
or Continuous+Yi On Tess inert
a year•areund DA$rs tartcludrng
shutdowns for routine mainte-
nance). Check Inc mOntnt dur-
ing the year wren the diK harge
is operating, (tee instructions)
;omplafe Items 10 via 11 If "inset.
tlttent" Is Checked in item 9.e.
)tnsrwlM, proceed to Item 12.
0. Intermittent DI$chargs Quantity
State Iha average voiumu per dis-
Charge OCCurrente rn tnOutand1 Or
gallont-
11. Intermittent Discharge Duration
anti FreciuentY
1. Intermittent Dlschatgt Duration
ter Day Slats snit arara0e
number di hours per day lnt
discharge It operating.
Ditehargs NA discharge ISccurreress per day
State the average gf1S
rrt OCCUr-
ey during days
DEG
DEG
3SttuN _L').SEC
_MIN SEC
UNNAMED TRURIITARY T
N/A _feet
N/A
C
delft, per week
AN fE8 OMAR ©APR
A� JUN °JUL QAUG
e OCT ©Nov ODEC
NA thousand gallons per dtttharge OCCurrenCe,
12. Maatrnum Flow Period Girl the
time period In which the maximum
ftow of this discharge OCCurL
NA ,p
month mrrnth
i1.7

DISCMARGE 1E01IAL NUMf1ER
001
t3 Aetfrfty D*scription Glye a
naN/lnr* dllskrlptlon of aclI ty
Productns tnls dtscnartr*•(tos
Inslructeort l
t4. Actirily Causing Olsehama for
*.Cn SIC Coo* wUKh °ascribes
the aCtlroly C*using this G+Kl4ryI,
aup ,$y the tyre* and maairnurn
*mount or either Ina raw maternal
Consum*d ('item 1.4a) or the proCuct
produclld (Item 14b) In the unit"
s'resctfild to Tablet of 1'he Ihstruc•
Ion 5ooiset . for SIC Cobol, not
Iteled in lab(' 1, use raw material
or prottut loon units normally uasd
for measuring produClton.tsM
snstrutlioni)
SIC Code
Name
CONTACT COOLING OE EXTRUDED ALUMINUM TUB INGAND
NON -CONTACT EQUIPMENT COOLING H2O. BOTH SYSTEMS
UTILIZE A RECIRCULATING COOLING LOOP AND TOWER _
SYSTEM.
....110111.1111.111614
Mallmum Untl Shared DISCherees
Arnount/Ctay (3ree TatSle I) (Serial Number)
354
© ALUMINL
2,400
X-
b. Products NA
SIC Cats
1)
Malllmum
Amount/0*y (
Unit
II-3

25
00
11-4

DISCHARGE SERI:AL NU ISER
001
II. W.ata.sslet cwarr.lRbt*c SEE ATTACHED SAMIPL NG RESULTS
Check MS boor anon* o•cn carotitu•MM Inner k broom M the ortlusint ldssusan no water). Talk Ootorn Inatl•n b to Iw brood on actual •nalyfis
or b•a1 o.tlrn tcloos Instructineisl
ratimeter
416
Cltosphorus
00665
S uUa ie
00945
Sulfode
©0745
Sulfite
00740
Chloride
00440
Cyanide
00720
Fluoride
009S1
Alumint
01I05
Antlmot
01047
Arsenic
01002
$etyliiu
010122
0i022
Cadmium
01027
Calcium
00916
Cobalt
01037
Chromium
01034
Fee 1 ctiliiia�
74055
7
•specify substances, compounds and,+or alarnatYtt ha item 26.
Pesticides (insecticides, funggicides, and rodentici rnlisl be reported in terms of the acceptable common
names specified in 4cceCommon Names and C7icrilkat Names for the Ingredient Statement on
Pesticide Labels 2nd Ed6tion, Environmenul Protection Agency, Washington, D.C. 202.50, June 1972, as
required by Subsection 16i2.7(b) of the Regulations for the Enforcement of the Federal insecticide,
Fungicide, and Rodenticide Act,
11-5

001
17. orM• pben of lrtaea awl Dram+ I
Pot arch of 174 psrs+r+adin nstad billow, ♦ntw in tM aprobriata boa tt►s value do dodo Nttw WNW caned 1a.r.tara Instructions)
ors Own wort
r addition. •nlw tna pararrrrna+ norm end inum CInl n,'cahrromium. top9at. n velum for any of 1bo 1 4ry.Mck0,�a+un�M+ n� PM`na+$. cII Ann ;mast.
ammonia, cysnkls, snuaninu� ars.nic, ba►y
and enlerino trasndosil•
Taennperature Comma)
XYX©C
74025
*Other du+char=n touring intake flow (serial numbers}.(we instructions)

17.
�Cwwt'a.)
(1)
SEE ATTACHED NA
ANALYTICAL DATA NA
NA
IL tltant Controls Check If the tt-
towing plant controls are available
for tnis dlicharge.
Alternate power source toe major
pump,ng faculty.
Alarm or emergency procedure for
power or equipment failure
Comptite item 19 if Macneill" Is
frorn cooling and/or steam water
generation find water treatment
additives are used.
a Name of Materiaits)
a Name and address ct rrtil Md.
facturir
C Quantity (pounds added par
million gallons of water treated).
Influent
A
ALM
(2)
NA
NA
NA
CTW -806- RUST INHIBITOR
uent
(S)
2. CAI(-501- 'jtac106
ELEMENTS ILLUSTRATED INC.
2714 FIRST AVE. NW
HICKORY, NC 28601
83.5 #s per million gallons water treated (10 ppm)
100.1 #s per million gallons water treated (12 ppm)
1 1-7

piCHARGE SERIAL NUNM$ .M
Q
d. Chemical composition of these
edditlYes tees Instructions).
Corn/Pets Items G 23 if there N a thermal discharge n
(co., its©ciatIG with a steam anG/trr powerge
glint, steel mill, pett mourn refinery,or any Mbar
is
u
facturing pr0tsi and the tnotal Media4rye flow
10 ?Millen gsiiorti per dry or
tiociel
2111. Thermal ©N1iUrge Smarm Check
the appropriate Rams) indiuting
the source of the discharge, leare
Maul ru ct l ohs)
seller lildwdown
11041M Chemical Cteaning
Ash Font Overflow
*oiler Water Treatment — Evaporo
for slowdown
Oil or Coal Fired Plants — Effluent
from Air Pollution Control Devices
Condense Cooling Water
Cooling Tower slowdown
Manufacturing piroc+els
Other
21. Discharge i'Reeetwine Wilier Temper.
More Differs nor
Give the maximum temperature
difference between the discharge
end receiving witerl /Or summer
end winter operatnttconditions.
Summer
Winter
__. plscharge Tsmperiture. Rate of
Change Per Hour
Give the meximurrl p br.l of of
temperature change p+hour
discheros un4er operating con.
Onions- (Iwo lnstructtonll
13. Water Temperature. Percentile
Ra90ri (Fr*CuenCY of Occurs Mel
In the table Dillow, enter the
temperature which is exceeded 10%
of the year. 5% of the year, 1% of
the year end not at ell (maximum
yearly temperature). ewe instructions}
Frequency Of occurrence
a intake Water Temperature
(,Subject t0 natural changes)
O. pllcherge Water Temperature
24. Water Intake Veieetty
(lee Inittuctl0ni)
21. Retention Time Give the length of
time, In minutes, tract', start of
water temperature rise to discharge
of cooling water.. (see InatruCtldrll)
SEE ATTA _yams
NA
SO
CL
QCFP
CONO
MID
D
diFPR
OTHR.
_*F./flour
minutes
OF
Ma Kl mum
OF

DISCHARGE SERIAL NUMBER
001
POR AGENCY USE
2i. AENININaI Intor oGoo
17(1) WATER SOURCE - PRIVATE WELL
1.6 I7 ATTACHED ANALYTICAL
19 (D) 1. MANUFACTURERS Jsas . ATTALHEn
MANUFACTURERS MSDS. ATTACHED
1.1•9

N. C. DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DES" LOP
ENVIRONMENTAL MANAGEMENT CO*!ISSION
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
APPLICATION FOR PERMIT TO DISCHARGE
ADDITIONAL REOUIRED INFORMATION
AF !CATION NUMBER
DISCHARGE SERIAL NUMBER
REFER TO DIRECTIONS ON REVERSE SIDE BEFORE ATTEMPTING TO COMPLETE THIS FORM
Parameter
(Code)
..301)
SEE ATTACHED ANALYTIC
NA
[t}
•
901
z<
REMARKS:
my knowIWge an© Dell«f wen In
11,
ontaln.p In thls report and that to U s
Is true, tompleta antl aeturata>

Directrarrs,—For each parameter listed, complete the
Information requested in each column in the uniu specified
according to the instructions given below.
Column 1,—Enter the daily average value of the inuke
water at the point it enters the facility, If intake water is
from more than one source, and enters the facility at
separate entry points, the value given in column 1 should be
weighted proportional to the quantity of flow contributed
from each source. If water is treated before use, completion
of this column is not required (see instructions for column
2). Values of intake art not required for mining activities.
Cohwnn 2.—lf all or part of intake water is treated before
use, provide values for total inuke here instead of in
Column I. Also describe briefly in item 26 "additional
information," the type of treatment performed on intake
water (e.g., rapid sand filtration, coagulation, flocculation,
ion exchange, etc.) and the percent of intake water
contributing to this discharge that has been treated.
C©hrmn 3.—Supply daily average value for the days when
discharge is actually operating or is expected to be operat•
ing (a new discharge). Daily average values are to be com-
puted by weighting the daily value in proportion to the daily
Cow. If a discharge occurs irregularly, the value supplied
in the column marked "Daily Average" should represent
an average for the average for the days the discharge actually
occurs. Average values are not to be supplied for pH,
specific conductance, and bacteriological parameters (e.g.,
coliforrn bacteria).
Columns 4 and S.—Supply minimum and maximum value
observed (or expected for new discharge) over any one day
when the discharge is operating.
Column 6.—Specify the average frequency of analysis fur
each parameter as number analyses per number of days (e.g.,
"3/7" is equivalent to three analyses performed every 7
days). If continuous, enter "CONT." When analyses are
conducted on more than one individual grab sample col
lected during the same day, the analysis frequency should
reflect one analysis whose value is the average of the
individual grab sample measurements. Average frequency
should be based on an operating month.
Column 7.—Specify the number of analyses performed at
the average frequency specified in column 6, up to 365.
Column 8.—Specify sample type as follows:
G For grab sample (individual sample collected in less
than lS minutes).
SIC For composite temple "#" is to be replace
average number of hours over which the com.ii
sample was collected, Composite sample: rr;
binations of individual samples obtained at h i
veer a time period. Either the volume of cart rr'
dividual sample is directly proportional to disct,.,ve
flow rates or the sampling interval (for consia+,r
volume samples) is inversely proportional 1,. ie
flow rates over the time period used to produe.'
composite.
NA If "CoNT' was entered in column 6.
Analytical method's. —Appendix A contains all pa, ,
with their reporting levels, test descriptions, and referent.
The parameter values can be determined either by use 4%1
of the standard analytical methods as described in table A ,,
by methods previously approved by the EPA Itcw-ilai
Administrator or Director of s federally aprv,,c;7 .I
program (or their authorized representative wtir
jurisdiction over the State in which the discitarpe
the test used is not one shown in table A. the lest
should be referenced in "Remarks" or on a sepaIetr •I', ,
values are determined to be less than the detect awe ikwi'
determined by referenced standard analytical
and/or irtstrument manufacturer's literature). spew) t_ 1
(value of detectable limit)" in the appropriate %pace.
example, if the detectable limit is .005 mg/I and qu.rartttE,
of less than this are determined, specify "LT ,005," DO tu'
enter descriptors such as "NIL," "TRACE." "NE(;," etc..
for this purpose. If it is your reasoned judgement that one
more of the required parameterf is not present in the initial
untreated or treated process water and/or the disctiar,,,.
enter an "A" (meaning "absent") in the appropriate space.
In order for values reported to be representative, it is
recommended that they be based on from at least five i'
seven analyses of composite samples (if applicable). Each of
the composite samples should be obtained by compusiting
frequent samples in proportion to flow over an 'operating.
day, Samples should be taken during period of maximum
production, if possible. If samples are taken at periods of
Tess than maximum production, state in "Remarks" the
percent of maximum production that was obtained during
the sampling period.
GP cI IA1410

SECTION
STANDARD FORM C MANUFACTURING AND COMMERCIAL
AEIATEMENT REQUIREMENTS & IMPLEMENTATION CSTRUCTION) $ICHEDULE
TN! viatt*On requlnet Information On any unc ImplernentatIon ICheduhs which may haw been Imposed for construction of waste abate
meat facilities. Such reguirementi and Implementation ticfiedules may have Men eltabdiahad by local, State, Or Federal egantlfa or by court
action. In atldliton to completing the following Items, a copy of an refitted Immeros++tation atheaute should be attached 10 this eppllCatlOn,
IF YOU ARE sUeJECT TO SEVERAL DIFFERENT IMPLEMENTATION SCHEDULES. EITHER SECAUSE of DIFFERENT LEVELS or
AUTHORITY IMPOSING DIFFERENT SCHEDULES flrim la.) ANOJOR STAGED CONSTRUCTION OF SEPARATE OPERATION UNITS
(item 1c), SUBMIT A SEPARATE SECTION III FOR EACH ONE.
1. f apreeewtelets
a Desefurgs Serial NueaM'
ArfeetN List the discharge
aerial numbers, assigned In
Section II, that ars cowered by
this implementation Ichreduie.
b. Autherlty Im'aWwg Relulre.
meets Check the appropriate
item indicating the authority for
implementation schedule. If
the Identical implementation
afhadule has been ordered by
more than one authority. Check
the appropriate items. (tee
lnstrutttons)
Locally developed plan
Armories Plan
tlaalc Pun
State aoproved Implement*.
thin schedule
Federal approved water
quality standards impiemsntb
Novi plan.
Federal enforcement procel'd.
ure Or action
State Court circler
Federal court Order
c. Factllty Rfqulrement., Specify
IM S-character coos Of those
listed below that best describes
in general terms tree rectulrt
resent of tna Implementation
Schedule and the applicable Oa -
character abatement code(si
from Table. II of tna instruction
booklet. If more than one
schedule applies to ina laclllty
becauae of a staged COn1trUctlOn
schsclule, state the 1111e of COM
stru'CIIOn being described here
with the aPPIOPfiatl general
action code. Submit a separate
Section 111 for each stage of
•
Construction Planned.
QLOC
DARE
©SAS
©SOS
©w©s
I„.) E N F
OCRT
O FED
NOT APP .IAE
New Facility NEW
Modification (no increase In capacity or treatment) MOD
Increase In Capaclly INC
Increase in Treatment Level INT
both Increase in Treatment Level and Capacity IC'T
Profess Chan)e
PRO
Eilmination of Discharge ELI

r, 9.

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr, Timothy Kinsley
Alumax Extrusions, Inc.
P. O. Box 100
Catawba, NC 28609
Dear Mr, Kinsley:
ED NII
September 9, 1994
N.C. DEPT. OF
ENVI1RONMENT, HEALTH.
& NATURAL RESOURCES
sEp 13 199A,
Subject: NPDEV110114401 Mitlf0ANAGEMENT
Alumax h4!•SIM/6.11frICE
Perrnit correction
Catawba County
The Division has reviewed the subject permit and has discovered an error on the cover
page. The signed date on the permit should be for 1994, not 1995. Enclosed please find the
corrected permit cover page. This page should be inserted into your permit and the old one
discarded. 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 U. S.
Environmental Protection Agency dated December 6, 1983.
If any parts, measurement frequencies or sampling requirements contained in this
permit modification are unacceptable to you, you have the right to an adjudicatory hearing upon
written request within thirty (30) days following receipt of this letter, This request must be
in the form of a written petition, conforming to Chapter 150B of the North Carolina General
Statutes, and filed with the Office of Administrative Hearings, Post Office Drawer 27447,
Raleigh, North Carolina 27611-7447. Unless such demand is made, this decision shall be final
and binding.
Please take notice that this permit is not transferable. Part II, E.4. addresses the
requirements to be followed in case of change in ownership or control of this discharge, This
permit does not affect the legal requirement to obtain other permits which may be required by
the Division of Environmental Management or permits required by the Division of Land
Resources, Coastal Area Management Act or any other Federal or Local governmental permit that
may be required. If you have any questions concerning this permit, please contact Susan Robson
at telephone number 919/733-5083.
ncerely,
741 A, Preston Howard, ;r.141-1(-Elf---
cc: Mr. Jim Patrick, EPA
Mooresville Regional Office
Compliance -Jeanne Phillips, ISB
Central Files
Kim Brantley
Aquatic Toxicology Unit
P.O. Box 29535, Raleigh, North Carona 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative. Action Employer 50% recycle / 10% post -consumer paper

Permit No, N'004471
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
N.C, DEPT. OF
DIVISION OF ENVIRONMENTAL MANAGEMENT ENVIRONMENT, HEALTH,
Co NATURAL RE9OURCY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
SEP 13 199A,
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTMIN OF mIRONMENTAL MANAi
MOORESNItII REGIONAL OFFJC
In compliance with the provision of North CarolinaGeneral Statute 143-215.1,
other ].awful standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
'eby autho
Alumax Extrusions, Incorporated
ed to discharge wastewater fromaJacility located at
Alumax Extrusions, incorporated
NCSR 1931
southeast of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to Lake Norman in the Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions se t forth in
Parts 1, II, and III hereof.
This permit shall become effective, September 9, 1994
This perrrnt and the authorization to discharge shall expire at ,midnight on June 30, 1995
Signed this day September 9, 1994
A. Preston IIcrward, Ir., P.F., Director
Divisic rr of E ivircrnmental Management
By Authority of t:he Environmental i!.1anagernent Commission

C„ 111717'.. OF NAM -Ur
ft" AND
'?.P;MEISIT;
State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management:
512 North Salisbury Street • Raleigh, North Carolina '27611
James G. Martin, Governor
William W. Cobey, Jr., Secre
Timothy Kinsley
Route 1, P. O. Box 1. 0
Catawba, NC 28609
George T. 'Everett, Ph„D
Director
July 25, 1991
Subject: Permit No. NaX)48712
Alumax Extrusions, Incorporated
Catawba County
NT
Dear NIL Kinsley:
In accordance with your application for discharge permit received on February ,4_1991„ we
are forwarding herewith the subject state - NPDES permit. This permit is issued pursuant to the
requirements of North Carolina General Statute 143-215 .1 and the Memorandum of Agreement
between North Carolina and the US Environmental Protection agency dated December 6, 1983
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within
thirty (30) days following receipt of this letter. This request must be in the form of a written
petition, conforming to Chapter 150B of the North Carolina General Statutes, and filed with the
Office of Administrative Hearings, Post Office Drawer 27447, Raleigh, North Carolina 27611
-7447. Unless such demand is made, this decision shall be final and binding.
Please take notice this permit is not transferable. Part II„ E.4. addresses the requirements to
be followed in case of change in ownership or control of this discharge.
This permit does not affect the legal requirements to obtain other permits which may be
required by the Division of Environmental Management or permits required by the Division of
Land Resources, Coastal Area Management Act or any other Federal or Local governmental permit
that may be required.
If you have any questions concerning this permit, please contact Mr, Jule Shanklin at
telephone number 91.9/733-5083.
Sincerely,
Original signed by
Dale Overcash for
George T. Everett
cc: Mr. Jim Patrick, EPA,
ML!WPisRe-
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-05.35 Telephipm 919-733-7015
An E,qual. Opportunity .Affirmative Action Employe,

Permit No. NC004871.2
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF ENVIRONMENTAL MANAGEMENT N
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
Via.....
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,
Alumax Extrusions, Incorporated
y authorized to discharge wastewater from a facility located at
Alumax Extrusions, Incorporated
NCSR 1931
southeast of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to Lake Norman in theCatawba River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, and III hereof,
This permit shall become effective September 1, 1991
This permit and the authorization to discharge shall expire at midnight on June 30, 1995
Signed this day July 25, 1991
Original sued by
Dale Qvercash for
George T. Everett, Director
Division of Environmental Management
By Authority of the Environmental Management Cornmi sign
:NT

is hereby authoried to;
Permit No, NC 48712
SUPPLEMENT TO PERMIT COVER S ET
Alumax Extrusions, Incorporated
1. Continue to discharge non -contact and contact cooling water fromfacilities located at Aluinax
Extrusions, Incorporated, NCSR 1931, southeast of Catawba, Catawba County (See Part III
of this Permit), and
. Discharge from said treatment works at the iocation specif d on e atta hed map into an
unnamed tributary to Lake Norman which is classified Class W =IIId B waters in the
Catawba River Basin,

A. ). EFFLIJENT LIMITATIONS .AND MONITORING REQUIREMENTS FINAL, Permit No. NC0048712
During the period beginning on the effective date of the penult and lasting until expiration, the Permittee is .,Iiiithorized to discharge from
outfall(s) serial number OW - Filter Backwash and Cooling Tower Blowdown, Such discharges shall be limited and monitored by the -permittee
as specified below:
Etfluent Ch
Flow
Temperature
Total Residual Chlorine"
TSS
Settleable Solids
Ls/day Units (specifyMeasurement
Mom Ayg, Pplly Max Mon, Avq. Daily M x. Frequency
Weekly
30.0 mg/I
0.1 ml/l
* 2/Month
2/Month
45.0 mg/I 2/Month
0.2 m1/I 2/Month
—13P(WirPRIPtits,
Sample *Sample
Type Location
Instantaneous E
Grab
Grab
Grab
Grab
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE COOLING WATER,
* Sample Locations: E - Effluent
** The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in
no case cause the ambient water temperature to exceed 32°C.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See
Part III, Condition D of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month at the effluent by grab
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Section IT Schedule,
rasp
nc
PART
1. the pernaittee shall comply v =iti Fine
accordance °it} the following schedule.
Pernuttee shall comply with Final Ef
permit unless specified below,
., Pennittee shall at all tunes provide the operation and maintenance ne
existing facilities at opfioptimum efficiency.
calendar da s follow
cor aplite e, the perm sites shall s
ons being requiredity identified date
the latter case, the notice shall include
n, and the probability of meeting the tie
bons specifies for° di.
ins by he el'fec,
es
ha
e date
s
es ii
the
to operate the
ed in the above schedule;
f progress or, in the c.°
iotice of corsrpliance or
compliance, tt
it anent
se ofspc
Mnc°ctrsplia
tech l trcti

Pan
Page
PART 1I
STANDARD CONDITIONS F(R NPDES PERMJTS
SECTION A. , ICI FINITIONS
I. Permit Issuing Authority
The Director of the Division of Environmental Management.
DEM or Division.
of 14
Means the Division of Environmental Mann ement, Department of E-nviromnent, Health
and Natural Resources.
EMC
Used herein means the North Carolina En €iroanaaental Management Commis,
4, Act or "theAct°'
The Federal Water Pollution Control Act, alsaa ktao as Gas the lean a'xtt r Ae:
33 USC 1251, et. seq.
1\°lass/Day, Measurements
ta. The ortthhv average discharf:
sampled and/or measured dui ita to calcnelar month on svhic.
sampled and measured, divided by tlae ntatarber of daily dischargais
measured during such month. It is therefore, an arithmetic mean found.
weights of the pollutant found each day of the month and then dividing thi
number of days the tests were reported. The limitation is idemified as
Average'" in Part I of the permit.
b. The ''weekly average discharge"" is elefined tas the total mass of all daily dischai�. es
sampled and/or measured during the calendar week (Sunday - Saturday) on which daily
discharges are sampled and measured, divided by the number of daily discharges
sampled and/or measured during such week. It is, therefore, an arithmetic paean found
by adding the weights of pollutants found each day of the week and then dividing this
sum by the number of days the tests were reported. This limitation is identified as
" \\ eekly Average" in Part 1 of the permit.
The imum daily disc
during a calendar day. If or
of pollutant calculated from
identified as "Daily Maximum,
mass (v'
taken dur
n daily
e permit.
al mass
-.)(allutant
dar day
This limitation id

Part II
Page 2 of 14
d. The "average annual discharge" is defined as the total mass of all daily discharges
sampled and/or measured during the calendar year on which daily discharges are
sampled and measured, divided by the number of daily discharges sampled and/or
measured during such year. It is, therefore, an arithmetic mean found by adding the
weights of pollutants found each day of the year and then dividing this sum by the
number of days the tests were reported. This limitation is defined as "Annual Average"
in Part I of the permit,
6. Concentration Measur mein
a. The "'average monthly concentration,'" other than for fecal conform bacteria, is the sum
of the concentrations of all daily discharges sampled and/or measured during a calendar
month on which daily discharges are sampledand measured, divided by the number of
daily discharges sampled and/or measured during such month (arithmetic mean of the.
daily concentration values), The daily concentration value is equal to the concentration
of a composite sample or in the case of grab samples is the arithmetic mean (weighted
by flow value) of all the samples collected during that calendar day, The average
monthly count for fecal conform bacteria is the geometric mean of the counts for
samples collected during a calendar month. This limitation is 'identified as "Monthly
Average' under "Other Units" in Part I of the permit.
b. The "average, weekly concentration," other than for fecal conform bacteria, is the SUM
of the concentrations of all daily discharges sampled and/or measured during a calendar
week (Sunday/Saturday) on which daily discharges are sampled and measured divided
by the number of daily discharges sampled and/or measured during such week
(arithmetic mean of the daily concentration values). The daily concentration value is
equal to the concentration of a composite sample or in the case of grab samples is the
arithmetic mean (weighted by flow value) of all the samples ,collected during that
calendar day. The average weekly count for fecal conform bacteria is the geometric
mean of the counts for samples collected during a calendar week, This limitation is
identified as "Weekly Average" under "Other Units" in Part I of the permit.
c. The "maximum daily concentration" is the concentration of a pollutant discharge during
a calendar day. If only one sample is taken during any calendar day the concentration
of pollutant calculated from it is the "Maximum Daily. Concentration", It is identified
as "Daily Maximum" under "Other Units" in Part I of the permit.
d. The "average annual concentration," other than for fecal conform 'bacteria, is the sum of
the concentrations of all daily discharges sampled and/or measured during a calendar
year on which daily discharges are sampled and measured divided by the number of
daily discharges sampled and/or measured during such year (arithmetic mean of the
daily concentration values), The daily concentration value is equal to the concentration
of a composite sample or in the case of grab samples is the arithmetic mean (weighted
by flow value) of all the samples collected during that calendar day . The average
yearly count for fecal conform bacteria is the geometric mean of the counts for samples
collected during a calendar year.
e. The "daily average concentration" (for dissolved oxygen) is the MillMRIM allowable
amount of dissolved oxygen required to be available in the effluent prior to discharge
averaged over a calendar day. If only one dissolved oxygen sample is taken over a
calendar day, the sample is considered to be the "daily average concentration" for the
discharge. It is identified as "daily average" in the text of Part I.

Part 11
Page 3 of 14
The "quarterly average concentration" is the average of all samples taken over a
calendar quarter. It is identified as "Quarterly Average Limitation"' in the text of Part 1
of the permit.
g. A calendar quarter is defined as one of the following distinct periods: January through
March, April through June, July through September, and October through December.
7. Other Measurements
a. Flow, (MGD): The flow limit expressed in this permit is the 24 hours average flow,
averaged monthly. It is determined as the arithmetic mean of the total daily flows
recorded during the calendar month.
b. An "instantaneous flow measurement" is a measure of flow taken at the time of
sampling, when both the sample and flow will be representative of .the total discharge.
c. „A "continuous flow measurement" is a measure of discharge flow from the facility
which occurs continually without interruption throughout the operating hours of the
facility. Flow shall be monitored continually except for the infrequent times when
there may be no flow or for infrequent maintenance activities on the flow device.
Types of Samples
a. Composite Sample: A composite sample shall consist of:
(i) a series of grab samples collected at equal time intervals over a 24 hour period of
discharge and combined proportional to the rate of flow measured at the time of
individual sample collection, or
(2) a series of grab samples of equal volume collected over a 24 hour period with the
time intervals between samples determined by a preset number of gallons passing
the sampling point. Flow measurement between sample intervals shall be
determined by use of a flow recorder and totalizer, and the present gallon interval.
between sample collection fixed at no greater than 1/24 of the expected total dailv
flow at the treatment system, or
(3) a single, continuous sample collected over a 24 hour period proportional
to the rate of flow,
In accordance with (1) above, the time interval between influent grab samples shall be
no greater than once per hour, and the time interval between effluent grab samples shall
be no greater than once per hour except at wastewater treatment systems having a.
detention time of greater than 24 hours. hi such cases, effluent grab samples may be
collected at time intervals evenly spaced over the 24 hour period which are equal in
number of hours to the detention time of the system in number of days. However, in
no case may the time interval between effluent grab samples be greater than six (6)
hours nor the number of samples less than four (4) during a 24 hour sampling period.
b. Grab Sample: Grab samples are individual samples collected over a period of time not
exceeding 15 minutes; the grab sample can be taken manually.
9. Calculation of Means
a
Arithrnetic Mean: The arithmetic mean of any set of values is the summation of the
individual values divided by the number of individual values,

Part 11
Page 4 of 14
b. Geometric Mean: The geometric ntettn of arty set of values is the Nth root of the
product of the individual values hereto the number of individual values.
The geometric mean is equivalent to the antilog of the arithmetic mean of the logarithms
of the individual values. For purposes of calculating the geometric mean, values of
zero (0) shall be considered to be one (1),
c. Weighted by Flow Value: Weighted by flow value toeans the summation of each
concentration times its respective flow divided by the summation of the respective
flows.
0. Calendar Day
A calendar day is defined as the period from midnight of one day until midnight of the next
day. However, for purposes of this permit, any consecutive 24-hour period that
reasonably represents the calendar day may be used for sampling.
Hazardous Substance
A hazardous substance means any substance designated under 40 CFR Part 1.16 pursuant
to Section 311 of the Clean Water Act.
12. Toxic Pollutant
A toxic pollutant is any pollutant listed as toxic under Section 307(a
Act.
SECTION B_,.__(3FJ RAL CON T I FIQNS
Duty to Comply
The perrnittee must comply with a]1 conditions of this permit. Any persttit taratc:ontpliance
constitutes a violation of the Clean Water Act and is grounds for enforcement action; for
permit termination, revocation and reissuance, or modification; or denial of a permit
renewal application.
a. The permittee shall comply with
section 307(a) of the Clean Wat
sewage sludge use or disposal esta
within the time provided i
prohibitions, even if the permit has r
requirement.
ndards or prohibitions cstablishcd under
xic pollutants and with standards for
ider section 405(d) of the Clean Water Act
that establish these standards or
been modified to incorporate the
b. The Clean Water Act provides that any person who violates a permit condition is
subject to a civil penalty not to exceed S2 5,00() per day for each violation.
Any person who negligently violates any permit condition. is subject to criminal
penalties of $2,500 to S25,000 per day of violation, or imprisonment for not grace than
1. year, or both. Any person who knowingly violates permit conditions is subject to
critttittal penalties of S5,000 to $50,000 per day of violation, or imprisonment for not
more than 3 years, or both. Also, any person who violates a permit condition may be
assessed an administrative penalty not to exceed $10,000 per violation with the
maximum amount not to exceed $125,(1(}0, Ref: Section 309 of thederal Act 33
H.S.C. 1319 and 40 CFR 122.41 (a)1

Part II
Page 5 of 14
Under state law, a daily civil penalty of not more than ten thousand do
per violation may be assessed against any person who violates or
accordance with the terms, conditions, or requirements of a permit. [Ref:
Carolina General Statutes § 143-215.6 (a)I
Duty tit�igate
10,000)
7t in
The permittee shall take all reasonable steps to mini ize or prevent any discharge in
violation of this permit which has a reasonable likelihood of adversely affecting human
health or the environment.
3. Civil and Criminal Liability
Except as provided in permit conditions on "Bypass ing"° (Part Il, C.4.) and "Power
Failures" (Part II, C.7.), nothing in this permit shall be construed to relieve the permittee
from any responsibilities, liabilities,. or penalties for noncompliance pursuant to NCGS
143-215.3, 143-215.6 or Section 309 of the Federal Act, 33 USC 1319. Furthermore, the
permittee is responsible for consequential damages, such as fish kills, even though the
responsibility- for effective compliance may be temporarily suspended..
4. Oil and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the institution of an
relieve the pennittee from any responsibilities, liabilities, or penaities to which
is or may be subject to under NCGS 143-21.5,75 et seq.. or Section 311 of the
33 USG 1321. Furthermore, the perrnittee is responsible for consequential damages, such
as fish kills, even though the responsibility for effective compliance may be temporarily
suspended:
Property Rights
The issuance of this perrnit does not convey any parolrerty rights in ei
property, or any exclusive privileges, nor does it authorize and° injury to private pro
any invasion of personal rights, nor any infringement of Federal, State or local
regulations.
6. Onshore or Offshore. Construction
This permit does not authorize or approve the construction of any
physical structures or facilities or the undertaking of any work in any Ili
7. Severability
The provisions of this perrnit are severable, and if any provision
application of any provision of this permit to any circumstance
application of such provision to ether circumstances, and the remain
not be affected thereby.
son
ore or offshore
ie waters.
pert
Id in
or the
d, the

Duty to Provide Information
Pan II
Page 6 of 14
The pemtittee shall furnish to thePemnit Issuing Authority, within a reasonable time, any
infomration which the Permit Issuing Authority may request to determine whether cause
exists for modifying, revoking and reissuing, or terminating this permit. or to determine
compliance with this permit. The permittee shall also furnish to the Permit Issuing
Authority upon request, copies of records required to be kept by this permit.
9. Duty to Reapply
If the 'pernnittee wishes to continue an activity regulated by this permit after the expiration
date of this permit, the permittee must apply for and obtain a new permit.
10. Expiration t f Permit
The permittee is not authorized to discharge after the expiration date. In order to receive
automatic authorization to discharge beyond the expiration date, the permittee shall submit
such information, forms, and fees as are required by the agency authorized to issue permits
no later than 180 clays prior to the expiration date. Any discharge that has not requested
renewal at least 180 days prior to expiration, or any discharge that does not have a permit
after the expiration and has not requested renewal at least 180 days prior to expiration, will.
subject the permittee to enforcement procedures as provided in NCGS 143-215.6 and 33
USC 1251 et. seq.
11. Signatory Requirements
All applications, reports, or information submitted to the Permit Issuing Authorit snrll be
signed and certified.
All perrmit applications shall he signed as follows:
(1)
For a corporation: by a responsible corporate officer. For the purpose of this
Section, a responsible corporate officer means: (a) a president, secretary,°, treasurer
or vice president of the corporation in charge of a principal business function, or
any other person who performs similar policy or decision making functions for the
corporation, or (b) the manager of one or more manufacturing production or
operating facilities employing more than 250 persons or having gross annual sales
or expenditures exceeding 25 million (in second quarter 198(1 dollars), if authority to.
sign documents has been assigned or delegated to the manager in accordance with
corporate procedures.
) For a partnership or sole proprietorship: by a general partner or the proprietor,
respectively; or
(3) For a municipality, State, Federal, or other public agency: by either a principal
executive officer or ranking elected official.
b. All reports required by the permit and other information requested by the Pennnit Issuing
Authority shall be signed by a person described above or by a duly authorized
representative of that person. A person is a duly authorized representative only if
(1) The authorization is made in writing by a person described above:
(2) The authorization specified either an individual or a position ha
for the overall operation of the regulated facility or activity, suci
plant manager, operator of a well or well field, superintendent, a
ibilit)`
ion of

Part 1I
Page 7 of I -1
equivalent responsibility, or an individual or position having overall responsibility
for environmental matters for the company. (A duly authorized representative n ay
thus be either a named individual or any individual occupying a named position.);
and
(3) The written authorization is uhmitted to the Permit Issuing Authority.
Certification. Any person signing a document under paragraphs a. or b. of this section
shall make the following certification:
"I certify, under penalty of law, that this document and all attachments were prepared.
under my direction or supervision in accordance with a system designed to assure that
qualified personnel properly gather and evaluate the information submitted. Based on
my inquiry of the person or persons who manage the system, or thosepersons directly
responsible for gathering the information, the information submitted is, to the best of
my knowledge and believe, true, accurate, and complete. I am aware that there are
significant penalties for submitting false information, including the possibility of fines
and imprisonment for knowing w�io1aations_""
Permit Actions
This permit may be modified, revoked and
request by the perrnittee for a permit
termination, or a notification of planned c
stay any permit condition.
13. Permit Modification, Revocation and Reissuance. or Termination
The issuance of this permit does not prohibit the permit issuing authorit f from reopening
and modifying the peranit, revoking and reissuing the permit, or terminating the faerra it as
allowed by the laws, rules, and regulations contained in Title 40, 'ode of Federal
Regulations, Parts 122 and 123; Title 15A of the North. Carolina Adnairaistratiw°e Code,
Subchapter 2H .0100, and North Carolina General Statute 143-215.1 et. al.
14. Previous .Permits
All previous National Pollutant Discharge Elimination. System 1 ermits is ued to this
facility, whether for operation or discharge, are hereby revoked by issuance of this permit.
The conditions, requirements, terms, and provisions of this permit authorizing discharge
under the National Pollutant Discharge Elimination System govern discharges from this
facility.
SECTION C. OPERATION AND MAINTENANCE OF POLLUTION CONTROLS
1. Certified Operator
Pursuant to Chapter 90A-44 of North Carolina General Statutes, the Fmern rttee shall
employ a certified wastewater treatment plant operator in responsible charge (ORC) of the
wastewater treatment facilities. Such operator must hold a certification of the grad
equivalent to or greater than the classification assigned to the wastewater treatment
facilities. The pernait.tee shall notify the Division's Operator Training and Certification Unit
within thirty days of any change in the ORC status.

Part II
Page 8 of 14
Proper Operation and Maintenance
The permittee shall at all times properly operate and maintain all facilities and systems of
treatment and control (and related appurtenances) which are installed or used by the
pennittee to achieve compliance with the conditions of this permit. Proper operation and
maintenance also includes adequate laboratory controls and appropriate quality assurance
procedures. This provision requires the operation of back-up or auxiliary facilities or
similar systems which are installed by a permittee only when the operation is necessary to
achieve compliance with the conditions of the permit.
3. Need to Halt or Reduce not a Defense
It shall not be a defense for a permittee in an enforcement action that it would have been
necessary to halt or reduce the permitted activity in order to maintain compliance with the
condition of this permit.
4. Bypassing of Treatment .Facilities
a. Definitions
(I) "Bypass" means the known diversion of waste streams from any portion of a
treatment facility including the collection system. .which is not a designed or
established or operating mode for the facility.
(2) "Severe property damage" means substantial physical damage to property, damage
to the treatment facilities which causes them to hecome inoperable, or substantial
and permanent loss of natural resources which can reasonably be expected to occur
in the absence of a bypass. Severe property damage does not mean economic loss
caused by delays in production.
b. Bypass not exceeding limitations.
The permittee may allow any bypass to occur which does not cause effluent limitations
to be exceeded, but only if it also is for essential maintenance to assure efficient
operation. These bypasses are not subject to the provisions of Paragraphs c. and d. of
this section.
c, Notice
(I) Anticipated bypass. If the permittee knows in advance of the need for a bypass, it
shall submit prior notice, if possible at least ten days before the date of the bypass;
including an evaluation of the anticipated quality and affect of the bypass.
(2) Unanticipated bypass. The permittee shall submit notice of an unanticipated bypass
as required in Part II, E. 6. of this permit. (24-hour notice).
d. Prohibition of Bypass
(I) Bypass, is .prohibited and the Permit Issuing .Authority may ttitke enforcement acti011
against a permittee for bypass, unless:
(a) Bypass was unavoidable to prevent loss of life, personal injury or severe
property damage;

Part II
Page 9. of 14
(b) There were no feasible alternatives to the bypass, such as the use of auxiliary
treatment facilities, retention of untreated wastes or maintenance during normal
periods of equipment downtime. This condition is not satisfied if adequate
backup equipment should have been installed in the exercise of reasonable
engineering judgment to prevent a bypass which occurred during normal
periods of equipment downtime or 'preventive, maintenance; and
(c) The pennittee submitted notices as required under Paragraph c. of this section.
The .Permit Issuing Authority may approve an anticipated bypass, after considering
its adverse affects, if the Permit Issuing Authority determines that it will meet the
three conditions listed above in Paragraph d. (1) of this section,
5.. Upsets
a.. Definition.
"Upset " means an exceptional incident in which there is unintentional and
temporary noncompliance with technology based permit effluent limitations because of
factors beyond the reasonable control of the permittee. An upset does not include
noncompliance to the extent caused by operational error, improperly designed treatment
facilities, inadequate treatment facilities, lack of preventive maintenance, or careless or
'improper operation.
b„ Effect of an upset.
An upset constitutes an affirmative defense to an action brought for
noncompliance with such technology based permit effluent limitations if the
requirements of paragraph c. of this condition are met. No determination made during
administrative review of claims that noncompliance was caused by upset, and before. an
action for noncompliance, is final administrative action subject to judicial review.
c. Conditions necessary for a demonstration of upset.
A permittee who wishes to establish the affirmative defense of upset shall demonstrate,
through properly signed, contemporaneous operating logs, or other relevant evidence
that:
(a) An upset occurred and that the permiuee can identify the cause(s) ol the upset;
(b) The permittee facility was at the time being properly operated; and
(c) The permittee submitted .notice of the upset as required in Part 11, E. 6. (b) (B) of
this permit.
(d) The permittee complied with any remediai measures required under Part 11, B. 2, of
this permit.
d. Burden of proof.
In any enforcement proceeding the permittee seeking to establish the occurrence of an
upset has the burden of proof.

Part 1.I
Pate 10 of l 4
6. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of tredttrraent or
control of wastewaters shall be disposed of in accordance with NCGS 143-215.1 and in a.
manner such as to prevent any pollutant from such materials from entering waters of the
State or navigable waters of the United States. The permittee shall comply, with all existing
federal regulations governing the disposal of sewage sludge. Upon promulgation of 40
CFR Part 503, any permit issued by the Permit Issuing Authority for the disposal of sludge
may be reopened and modified, or revoked and reissued, to incorporate applicable
requirements at 40 CFR Part 503. The permittee shall comply with applicable 40 CFR Part
503 Standards for the Use and Disposal of Sewage Sludge (when promulgated) within the
time provided in the regulation, even if the permit is not modified to incorporate the
requirement. The permittee shall notify the Permit Issuing Authority of any significant
change in its sludge use or disposal practices,
7. Power Failures
The permittee is responsible for naainta.ining adequate safeguards as required. by DEM
Regulation, Title ISA, North. Carolina Administrative Code, Subchapter .0124
Reliability, to prevent the discharge of untreated or inadequatelytreated wastes during
electrical power failures either by means of alternate power sources, stand generators or
retention of inadequately treated effluent.
SECTION D. MONITORING AND RECORDS
1. Representative Sampling
Samples collected and measurements taken, as required herein, shall be characteristic of the
volume and nature of the permitted discharge. Samples collected at a frequency less than
daily shall be taken on a day and time that is characteristic of the discharge over the entire
period which the sample represents. All samples shall be taken at the monitoring points
specified in this permit and, unless otherwise specified, before the effluent joins or is
diluted by any other wastestreana, body of water, or substance. Monitoring points shall
not be changed without notification to and the approval of the Perriit Issuing Authority,
Reportin7
Monitoring results obtained during the previous month(s) shall be sunanaarized for each
month and reported on a monthly Discharge Monitoring Report (DMR) Form (DEM No.
MR I, 1.1, 2, 3) or alternative forms approved by the Director, DEM, postmarked no later
than the 30th day following the completed reporting period.
The first DMR is due on the last day of the month following the issuance of rite peat tt or in
the case of a new facility, on the last day of the month following the commencement of
discharge. Duplicate signed copies of these, and all other reports required herein, shall be
submitted to the following address:
Division of Fnvirorimental Management
Water uality Section.
ATTENTION: Central Files
Post Office Box 27687
Raleigh, North Carolina 27611

Part 11
Page 11 of 14
Flow Measurements
Appropriate flow measurement devices and methods consistent with accepted scientific
practices shall be selected and used to ensure the accuracy and reliability of measurements
of the volume of monitored discharges. The devices shall be installed, calibrated and
maintained to ensure that the accuracy of the measurements are consistent with the accepted
capability of that type of device. Devices selected shall be capable of measuring Flows with
a maximum deviation of less than 1.0% from the true discharge rates throughout the range
of expected discharge volumes. Once -through condenser cooling water flow which is
monitored by pump logs, or pump hour meters as specified in Part. I of this permit and
based on the manufacturer's pump curves shall not be subject to this requirement.
4. Test Procedures
Test procedures for the analysis of pollutants shall conform to the EMC regulations
published pursuant to NCGS 143 15.63 et, seq, the Water and Air Quality Reporting Acts,
and to regulations published pursuant to Section 304(g), 33 USC 1314, of the- Federal
Water Pollution Control Act, as Amended, and Regulation 40 CFR 136.
To meet the intent of the monitoring required by this permit, aI] test procedures must
produce minimum detection and reporting levels that are below the permit discharge
requirements and all data generated must be reported down to the minimum detection or
lower reporting level of the procedure. If no approved methods are determined capable of
achieving minimum detection and reporting levels below permit discharge req
then the most sensitive (method with the lowest possible detection and
approved method must be used.
Penalties for Tampering
The Clean Water Act provides that any person who fa
renders inaccurate, any monitor' ng device or method requi
permit shall, upon conviction, be punished by a fine of not more than
violation, or by imprisonment for not more than two years per violation, or by
b. Records Retention
ing
per
The perrnittee shall retain records of all monitoring information, including all c::alibration
and maintenance records and all original strip chart recordings for continuous monitoring
instrumentation, copies of all reports required by this permit, for a period of at least 3
years from the date of the sample, measurement, report or application, This period may be
extended by request of the Director at any time,
7, Recordin.g Results
For each measurement or sample taken pursuant to the requirements of this
pernainee shall record the following information:
a. The date, exact place, and time t f saamp]ng or measurements;
b. The individual(s) who performed the sampling or measurements;
c. The date(s) analyses were performed;
d. The individual(s) who performed the analyses;
e. The analytical techniques or methods used; and
f. The results of such analyses.

Part II
Page 12 of 14
8. Inspection and Entry
The permittee shall allow the Director, or an, authorized representative, upon the
'presentation of credentials and other documents as may be required by law, to;
a. Enter upon the permittee's premises where a regulated facility or activity is located or
conducted, or where records must be kept under the conditions of this permit;
b. Have access to and copy, at reasonable times, any records that must be kept under the
conditions of this permit;
c. Inspect at reasonable times any facilities, equipment (including. monitoring and control
equipment), practices, or operations regulated or required under this permit; and
d. Sample or monitor at reasonable times, for the purposes of assuring permit compliance
or as otherwise authorized by the Clean Water Act, any substances or parameters at any
location.
SECTION E. REPORTING REQUIREMENTS
1. flange in Discharge
All discharges authorized herein shall be consistent with the terms and conditions of this
permit. The discharge of any pollutant identified in this permit more frequently than or at a
level in excess of that authorized shall constitute a violation of the pemni,
Planned Changes
The perrnittee shall give notice to the Director as soon as possible of any planned physical
alterations or additions to the permitted facility. Notice is required only when:
a. The alteration or addition to a permitted facility may meet one of the criteria for
determining whether a facility is a new source in 40 CFR Part 122,29 (11); or
b. The alteration or addition could significantly change the nature or increase the quantity
of pollutants discharged. This notification applies to pollutants which are subject
neither to effluent limitations in the permit, nor to notification requirements under 40
CFR Part 122,42 (a) (1).
Anticipated Noncompliance
The pemiittee shall give advance notice to the Director of any planned. changes in the
pm -titled facility or activity which may result in noncompliance with permit requirements,
4. Transfers
This permit is not transferable to any person except after notice to the Director. The
Director may require modification or revocation and reissuance of the permittee and
incorporate such other requirements as may be necessary under the Clean Water Act

Part II
Page 13 of 14
Monitoring R .ports
Monitoring results shall be reported at the intervals specified elsewhere in this permit.
a. Monitoring results must be reported on a Discharge Monitoring Report (DMR) (See
Part II. D. 2. of this permit).
b. If the permittee monitors any pollutant more frequently than required by the permit,
using test procedures specified in Part 11, D. 4. of this permit, the results of this
monitoring shall be included in the calculation and reporting of the data submitted in the
DMR.
c. Calculations for all limitations which require averaging of measurements shall utilize an
arithmetic mean unless otherwise specified by the Director in the permit.
6. Twent-fourFlotrr Reporting
a. The perrnittee shall report to the central office or the appropriate regiona
noncompliance which may endanger health or the environment. Any i nfon
be provided orally within 24 hours from the time the perrnittee became aware of the
circumstances. A written submission shall also be provided within 5 days of the tint e
the perrnittee becomes aware of the circumstances. The written submission shall
contain a description of the noncompliance, and its cause; the period of noncompliance,
including exact dates and times, and if the noncompliance has not been corrected, the
anticipated time it is expected to continue; and steps taken or planned to reduce,
eliminate, and prevent reoccurrence of the noncompliance.
b, The following shall be included as information which must be reported within 24 hours
under this paragraph.
(A) Any unanticipated bypass w
y effluent lilt atatron in the permit;
(B) Any upset which exceeds any effluent limitation in the per tit.
(C) Violation of a maximum daily discharge limitation for any of the pt:alltttatnts listed by
the Director in the permit to be reported within 24 hours.
c. The Director may waive the written report on a case -by -case basis fear re ports under
paragraph b. above of this condition if the oral report has been receive w °ithin 24
hours,
7, Other Noncompliance
The perrnittee shall report all instances of .noncompliance not reported under Dart I1. E. 5
and 6, of this permit at the time monitoring reports are submitted. The reports shall contain
the information listed in Part 11. E. 6. of this permit.
Other information
Where the perm ittee becomes aware that it failed to subn
application, or submitted incorrect information in a permit applteat
Director, it shall promptly submit such facts or information.
or in a.
permit
report to the

Part Il
Page 14 of 1.4
9. Noncompliance Notification.
The permitter°- shall report by telephone to either the central office or the appropriate regional
office of the Division as soon as possible, but in no case more than 24 hours or on the next
working day following the occurrence or first knowledge of the occurrence of any of the
following:
a. Any occurrence at the water pollution control facility which results in the discharge of
significant amounts of wastes which are abnormal in quantity or characteristic, such as
the dumping of the contents of a sludge digester; the known passage of a slug of
hazardous substance through the facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate wastewater treatment such as mechanical or electrical failures of
pumps, aerators, compressors, etc.
Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass
directly to receiving waters without treatment of all or any portion of the influent to
such station or facility.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 5 days following first knowledge of the: occurrence.
10. Availability of Reports
Except for data determined to be confidential under NCGS 14:-215.3(a)(2) or Section 308
of the Federal Act, 33 USC 1318, all reports prepared in accordance with the terms shall be
available for public inspection at the offices of the Division of Environmental Management.
As required by the Act, effluent data shall not be considered confidential. Knowingly
making any false statement on any such report may result in the imposition of criminal
penalties as provided for in NCGS 143-215.1(b)(2) or in Section 309 of the Federal Act.
1, Penalties for Falsification of Reports
The Clean Water Act provides that any person who knowingly makes any false statement,
representation, or certification in any record or other document submitted or required to be
maintained under this permit, including monitoring reports or reports of compliance or
noncompliance shall, upon conviction, be punished by a fine of not more than $10,000 per
violation, or by imprisonment ftrr not more than two years per violation, or by both.

PART IIl
OTHER REQUIRE ENTS
A, Construction
No construction of wastewater treatment facilities or additions to add to the plant's treatment.
capacity or to change the type of process utilized at the treatment plant shall be begun until Final
Plans and Specifications have been submitted to the Division of Environmental Management
.and written approval and Authorization to Construct has been issued,
B.. Groundwater Monitoring
The permittee shall, upon written notice from the Director of the Division of Environmental
Management, conduct groundwater monitoring as may be required to detenT ine the compliance
of this NPDES permitted facility with the current groundwater standards,
C. Charge ire Discharges of Toxic Substances
The 'perntittee shall notify the Fern) t Issuing Authority as soon as it knows or has reason to
believe:
That any activity has occurred or will occur which would result in the discharge, on a
routine or frequent basis, of any toxic pollutant which is not limited in the permit, if that.
discharge will exceed the highest of the following "'notification levels'
(1) One hundred micrograms per liter (100 ug/1),
(2) Two hundreograms per liter (200 ug!.) for acrolein and acrylonitrile; five hundred
micrograms per liter (50(:) ug/1) for 2,4-dinitrophetlot and for
2-methy1-4.6-dinitrophenol; and one triilligrann per liter (1 mg/1) for antimony;
(3) Five (5) tia
applacaatao1
the maximum concentration value reported for that pollutant in the permit
b. That any activity has occurred or will occur which would result in any discharge, on a
non -routine or infrequent basis, of a toxic pollutant which is not limited in the permit, if
that discharge will exceed the highest of the following "notification levels'
(1) Five hundred micrograms per liter (500 ugl1)
(2
One milligram per liter (1 mg/1) for antimony;
(3) Ten (1.()) times the maximum concentration value reported for that pollutant in the permit
application.

Part III
Permit No, NC0048712
D. The permittee shall not use any biocides except those approved in conjunction with the permit
application. The permittee shall notify the Director in writing not later than ninety (90) days prior
to instituting use of any additional biocide used in cooling systems which may be toxic to aquatic
life other than those previously reported to the Division of Environmental Management. Such
notification shall include completion of Biocide Worksheet Form 101 and a map locating the
discharge point and receiving stream.

PART 1'
ANNUAI AD .Nf!'f: RTNG AN[) COMP1 f ANCEF f?T UTEIT:II}^;N'
as ;T adnfiniste
n,g Ta T 1 ed by t,h f Ir i s f
rage it: 15 I'( AC 2H .0105(b) K � ay cause this r ;r
ca ica t evoke the efa:ga.tr..

PERMIT NO.: N
70048712
PERMITTEE NAME:
FACILITY NAME
NPDES WASTE LOAD AL
Alumax fixtiusions, lncotporatcd
Alumax kxtrusions,
ated
Facility Status: Existing,
Permit Status: Renewal
Major Minor
Pipe No.: 001
Design Capacity: 7 D
Domestic (% of Flow):
Industrial (% of Flow):
Comments:
* Filter backwash from CONTACT cooling of aluminum extrusion
process (includes 300 gpdcooling tower blow& wn with 'approved
biocide), See effluent guidelines itLchet,
,STREAMlNDEX: 11- 8141); Terrapin Cr.Arm of L Norman
RECEIVING STREAM: an unnamed tributary i 1 ake Norman
Class: WS-IV
Sub -Basin: 03-08-32
Reference USGS Quad: El4Nli, Catawba
County: Catawba
Regional Office: Mooresville Reliional Office
Previous Exp. Date: 6/30/95 Treatment Plant Class:
Classification changes within three miles:
n/a
Requested by:
Prepared by
Reviewed by:
/JO
Date:
(please attach)
2/23/95
Dale: 47V 7
7ATION
Modeler
Drainage Area
7QI0 (cis) o
Da
Rec..
) o,
„
ENVIRO,Nr]!4ENT, I EA
& NATIJRAL
APR 27 1995
OF
alaSMIE
Avg., Streamflow
Winter 7Q10 (cis)
Toxicity Limits: IWC 90 %
stream .Monitoring:
Parameters
Upstream
Downstream
(31 , 0 7
30Q 2 (c fs ) ©. / 0
Location
Location
pecnrouv-i1iet1)
Aluminum (1baiday):
Zinc (Ibsiday):
Chnosnium WA):
Cyanide (JJ&l):
Oil & Grease (lbsiday):
Suspended Solids (lbs./day):
pH (SU):
C01:90/ (13/40):
Lead (WO:
Nickcl (.4/11):
Barium (rugil):
Chloride (rug/1):
Comments:.
Monthly Average
4.41
1.00
50 (Weekly Avg)
5 (Woskly Avg)
13.7
28.1
7-10
Monthly merman
Monthly monitor
Qru-ly monitor
cirtrty MOCLIWr
Qui-1y monitor
Daily Max.
2.2
0.42
200
20
8.23
13.4
7-10
WQ cr EL
El.
EL
WQ
WQ
EL
EL
EL

Chronniun
Cyanide
Zinc
Alurnit um
Oil and Grease
Suspcndcd Solids
Alulmax Extrusions , N C0025 5
Effluent Guideline Limitations
Av
Mont
0.2
.0()
4.41
3.7
28.1
7 to 10
y Daily
dav) lt�iu.innurn {lh
0.12
0.08
0.42
2,2
8.23
3,4
February 2=1, I)C5
at Treatnnent Contact. C >c Zing Water
id
it
br
tt
n tt
cun:el
Type of Product Produced
Extnided Aluminum
Highest mot
y aver
Lbs/T7►uv Produced
89,000
156,000 gpd during the last years.
uent Guideline Reference
40 CFR 467.32 (Sol. Fleat Treatment CCW)

Facility Name:
NPDES No,:
Type of Waste:
Facility Status:
Permit Status:
Receiving Stream:
Stream Classification:
Subbasin:
County:
Regional Office:
Requestor:
Date of Request:
Topo Quad:
FAC:1SHEET FOR WAS
Alumax Extrusions
NC0048712
Industrial - 100%
Existing
Renewal
UT Lake Norman
WS-IV
030832
Catawba
MRO c:
Nizich
Za7,95
E14NE
ALLOCATION
Request # 8262
5tearli Char�cteristi
USGS #
Date:
Drainage Area (mi2): 0.26
Summer 7Q10 (cfs): 0
Winter 7Q10 (cfs): 0.07
Average Flow (cfs):. 0.28
30Q2 (cfs): 0.10
IWC (%): 100
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
Facility requesting renewal of existing NPDES permit. The plant will now receive effluent
guidelines for a solution heat treatment contact cooling water. New limits will be applied for Cr,
Cn, Zn, Al, O&G, Suspended Solids, pH and other constituents detected in the effluent sample.
Aquatic Tox also recommends the inclusion of an acute P/F @ 90%
Special Schedule Requirements and additional comments from Reviewers:.
Recommended by:
Reviewed by
Instrearn Assessment:
Regional Supervisor:
Permits & Engineering:
Date: 3/2O/95
RETURN TO TECHNICAL SERVICES BY:

Type of Toxicty Test:
Existing Limit:
Mot
bleal'
TSS
pH (SU)
T
AltunMum Ohs/day):
Zinc (Ibs7day)
Chromium
Cy
Oil & G{1
n alid
p (1,
Copper )_
Nickel
Bairiurn(ink
Chloride (m )
lei
Change in 7Q10
Change in s
Rekration
Change in wasteflo
New pre * ent !Hirst
Other (onsite toxicity study,
P
receiving w
dischargers wit
No
y
Ibsli
y
Due Tel
S
Acute
NA
cation
te
T l.......
ailQrtrly
DEC
Mo, Avg.
E1
30
a
not to e 32C
Daily
0.2
45
Monthly Average Daily Max.
4AI 2..2
t142
rly Avg) 200
y Avg) 20
13.E 8.23
28.1 13.4
7-10-10
Monthly monitor
►nthly monitor
y monitor
Qruly monitor
ly monitor
ion, etc.)
r water quality limited. p'c
tl is may
on of
Cr, en
e r eters, the awe
ate:quality b
OR
but disc ge y
VirQ
WQ
El'.
WQ or EL
ad acity of coeds
efllu t lanai ions for arid. do ° 1
u
nse

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

Facility Name ALIJMAX EXTRUSIONS, INC. Permit # NC0048712
ACUTE TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the North Carolina
Procedure Document entitled "Pass/Fail Methodology For Determining Acute Toxicity In A Single Effluent
Concentration." The monitoring shall be performed as a Daphnia pulex or Ceiiodaphnia 48 hour static test, using
effluent collected as a 24 hour composite. The effluent concentration at which there may be at no time significant
acute mortality in any toxicity test is 90% (defmed as treatment two in the North Carolina procedure document).
Effluent samples for self -monitoring purposes must be obtained during representative effluent discharge below all
waste treatment. The first test will be performed after thirty days from the effective date of this permit during the
months of _MAR JUN SEP DEC
The parameter code for this test if using Daphnia pulex is TGA3D. The parameter code for this test if using
Ceriodaphnia is TGA3B. All toxicity testing results required as part of this permit condition will be entered on
the Effluent Discharge Form (MR-1) for the month in which it was performed, using the appropriate parameter
code. Additionally, DEM Form AT-2 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical measurements performed in
association with the toxicity tests, as well as all dose/response data. Total residual chlorine of the effluent toxicity
sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
Should any single quarterly monitoring indicate a failure to meet specified limits, then monthly monitoring will
begin immediately until such time that a single test is passed. Upon passing, this monthly test requirement will
revert to quarterly in the months specified above.
Should any test data from either these monitoring requirements or tests performed by the North Carolina Division
of Environmental Management indicate potential impacts to the receiving stream, this permit may be re -opened and
modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism
survival and appropriate environmental controls, shall constitute an invalid test and will require immediate
retesting(within 30 days of initial monitoring event). Failure to submit suitable test results will constitute
noncompliance with monitoring requirements.
7Q10 0 cfs
Permitted Flow _No limit MGD
IWC 100
Basin & Sub -basin CTB32 ---- c-.1
Receiving Stream UT LAKE NORMAN
County CATAWBA
ReCommended by:
Date 3/20/95
P aphnid 48 Version 10191

Permit No. NC004871
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESO
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
C DEM or NATURAL
RESOYRCE3 AN t.)
tvmrs Y VEVEYOPMIAT
lggo
01VISIVI YPVIEMENT
MOORE ,;EidiNAL OFFICE
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,
Alumax Extrusions, Incorporated
is hereby authorized to discharge wastewater from a facility located at
Alurnax Extrusions, Incorporated
on NCSR 1931
southeast of Catawba
Catawba County
to receiving waters designated as an unnamed tributary to Terrapin Creek in the Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set forth in
Parts I, II, and III hereof.
This permit shall become effective
This permit and the authorization to discharge shall expire at midnight on September 30, 1991
Signed this day
George T. Everett,Director
DiVitii011. of Environmental Management
By Authority of the Environmental. Management Commission

Perm No. NC0002
SUPPLEMENT TO PERMIT COVER SHEET
Alumax Extrusions, Incorporated
is hereby authorized to:
I. Continue to discharge non ant t and contact c ling water, and commence to discharge an
additional 1 i'gallons/day of non-contaaµtand contact cooling water located at .fit u
Extrusions, Incorporated, on NCSR 1931 southeast of Catawba, Catawba County (See Part
III of this Permit), and
2s Discharge frtrn said treatment NVors at the location specified on the attached map into an
unnamedtributary to Terrapin Creek which is classified Class WS III and B waters in the
Catawba River Basin,

E
CA &J Pk ovR•
\•-\
wuwaexve
P rnary a
had wm«
wQ«Zk@
QG«Qe
ROAD CLASSI FICA2?u
GyQ«Zroad, hard «
unproved surface .
Route
4p
46
am

A, EFFIXENT .1.,IMITA'11oNs AND MONITORING REQUIREMENTS FINAL Permit No, NC0048712
'During the perkx1 beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from
outfall(s) serial number 00 l Suc'h discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics D.Ischarge Limitation* Monitoring Requitomnta
Units (specify} Meaevrernept pample "Sample
Mon. Avg, Pally Max. Frequency 1112/ Location
now Monthly Instantaneous E
Temperan i „ ,k
Monthly Grab E, U, D
. .
'Total Residual Chlorine— Monthly Grab E
blign_Aya. Daily Max
MERE SHALL BE„NO CHROMIUM,. ZINC, OR COPPER ADDED TO THE COOLING WATER.
*Sample Locations: E - Effluent, U - Upstream,. D - Downstream
**The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of more than 2.8°C and in
no case cause the ambient water temperature to exceed 32°C.
***Monitoring requirements only apply if chlorine is added to the cooling water.
"The permittee shall obtain authorization from the Division of Environmental Management prior to utilizing any biocide in the cooling water (See
Part III of this Pemit).
The p11 shall not be less than 6.0 standard units nor greater than 9,0 standard units and shall be monitored monthly at the effluent by grab
sample.
There shall be no disclarg.e of floating solids or visible foam in other than trace amounts.

Permit No, NC0048712
D, The peintittee shall not use any biocides except those approved in conjunction with the permit
application. The pennittee shall notify the Director in writing not later than ninety (90) days prior
to instituting use of any additional biocide used in cooling systems which may be toxic to aquatic
life other than those previously reported to the Division of Environmental Management such
notification shall include completion of Biocide Worksheet Form 101 and a map locating the
discharge point and receiving stream.

Permit No, NC0048712
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESC3FICES
DIVISION OF ENVIRONMENTAL MANAGEMENT
RUN
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
1411.4#'
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,
Alumax Extrusions, Incorporated
is hereby authorized to discharge wastewater from a facility located at
Aluma.x Extrusions, Incorporated.
NCSR 1931
southeast of Catawba
Catawba. County
to receiving waters designated as an unnamed tributary to Lake Norman in the Catawba River Basin
in accordance with effluent lirnaions, monitoring requirements, and other conditions set forth in
Parts 1, 11, and 111 hereof,
This permit shall become effective
This permit and the authorization to discharge shall expire at midnight on June 30, 1995
Signed this day
George T. Everett, Director
Division of Environmental Management
By Authority of the Environmental Management Commission

s hereby authorized to:
Permit No, N 48712
SUPPLEMENT TO PERMIT COVER SF ET
Alum Extrusions, Incorporater
1. Continue to discharge non-contac and contact cooling water from facilities located at Alumax
Extrusions, Incorporated, NCR 1931, southeast of Catawba, Catawba County (See Part III
of this Permit), and
Discharge from said treatment works at the location specified on the attached map into an
unnamed tributary to Lake Norman which is classified Class W-III and B waters in the
Catawba River Basin,

1 11=1 TENT 1..,1Mrl". TIONS ANF MONI'F()R1NG Rl;QU1RFM[.N'l'S C`1N
During the period beginttirtg can the effective date of the permit and lasting trnti
outfall(s) serial number 001 - Filter Backwash and Cooling Tower Blowdown.
as specified below:
Etftuent Characteristics
lye
Mon. Avq,
Flow
Temperature
Total Residual Chlorine***
TSS
Settleable Solids
rt
Y.
:piration, the I'ermitt t is a
uch discharges shall be lire
Discharge Limitations
Units {specify),
Mon, Avg, Daily Max,
30.© mg/I
0.1 ml/I
45.0 mg/I
0.2 ml/I
Monitoring
Measurement,
Frequency
Weekly
2/Month
2/Month
2/Month
2/Month
crr rit No. NC0048712
zecl try discharge frorn
nd nit nitored by the .perm ee
Requirements
Sample
Type
Instantaneous
Grab
Grab
Grab
Grab
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE COOLING WATER.
* Sample Locations: E - Effluent
** The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving stream of -
no case cause the ambient water temperature to exceed 32°C.
*** Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environrnental Management prior to utilizing any biocide in the cooling water (See
Part III, Condition D of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored 2/month a
sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
E
E
E
E
E
p Le
ion
ore than 2.8°C and in
he effluent by grab

a ll Permit No. NC0048712
D. The permatee shall not use any biocides except those approved in conjunction with the permit
application. The pertnittee shall notify the Director ctor in writing not later than ninety days prior
to instituting use of any additional biocide used in cooling systems which may be toxic to aquatic
life other than those previously reported to theDivision of "Environmental Management, Such
notification shall include completion of Biocide Worksheet Form 101 and a map locating the
discharge point and receiving tr a ,

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0048712
PERMI lE'E NAME: Alumax Extrusions, IncorRorated
Facility Status: Existing
Permit Status: Renewal
Major Minor
Pipe No.: 001
Design Capacity: 0.0007* MGD
Domestic (% of Flow):
Industrial (% of Flow): 100 %
Ofle N A TURAL
)1,{ ES, AN D
CONIMUN ITIV DV V.I.„OP
4Pii 1 9 1991
Modeler
Date Rec,
2
Drainage Area (mi
(op 3ci
O. ZG
Avg. Streamflow (cfs): 0- l'st
7Q10 (cfs) c.ch, Winter 7Q10 (cfs) 0.1 30Q2 (cfs) 0.
LNr Toxicity Limits: IWC %
IPELLVINTAI MANA631011
MZOL.S111.11 REGIONAL
Comments:
* Filte .l)ackwa5h from contact cooling of aluminumextrus,'on process
(includes 300 gpd cooling tower. blowdown with approved biocide),
Suggest BPJ sim, to Wil? - S . rface Watet
STREAM MDEX; 11-81
//1441/4r.'
RECEIVING STREAM: an unnamed tributaryto Lake NornianL1t
Class: 'WS-III and B
Sub -Basin: 03-08-32
Reference USGS Quad: E14NE, Catawba
County: Catawba
Regional Office: Mooresville Regional Office
(please attach)
Previous Exp. Date: 9/30/91 Treatment Plant Class:
Classification changes within three miles:
rila
Requested by:
Prepared by:
Reviewed by:
tNri \
Jule Shank
Date: 2 6
Date:
Date:
Acute/Chronic
Instreatn Monitoring:
Parameters
Upstream Location
Downstream Location
Effluent
Characteristics
Summer
Winter
TSS (mg/1)
(11
pH (SU)
TuroPeorraLe
0 (0.
Nix
vwxli4A,RAO r cAusc 446
wertttils •ferriP6i2Arut.6 foExcKID z•S
AelpvE, 8oic4,4Roaup (11417. vs NO CA50 To
6XC,
WAT156---
Comments:
rf jLCzteseN
+II MC

Facility Name
NPDES No.
Type of Waste
Facility Status
Permit Status
Receiving Stream
FACT SHEET FOR WASTELOAD ALLOCATIONS
:Alumax Extrusions, Inc.
NC0048712
:100% industrial
:Existing
:Renewal
:UT Terrapin Creek (Lake
Stream Classification:WS-III,B
Subbasin
County
Regional. Office
Requestor
Date of Request
Topo Quad
030832
:Catawba
:MR0
:J. SAnkl
:2/6/91
:E14NE
Requestj
Norman)
Stream Characterist :
USGS # 0214253378 Date 90
in Drainage Area: 0.26
Summer 7Q10: 0.06
Winter 7Q10: 01
Average Flow: 0.29
30Q2: 0.12
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
The effluent from Alumax consists of non -contact cooling water
contact cooling water (that is recirculated through a filter system).
cooling tower water does contain approved biocides. 4
Technical Support recommends standard requirements for cioling wa
along with an additional solids limit due to WS waters.
The facility should resubmit a biocide worksheet if their biocide
concentration is expected to change.
sq.mi.
cfs
cfs
cfs
cfs
Special Scheduled Requirements and additional comments from Reviewers:
Recommended by:
Reviewed by
Instream Assessment:
Regional Supervisor:/
Permits & Engineering:
RETURN TO TECHNICAL SERVICES BY:
Date:
1-+L) 061991

Existina Limits
CONVENTIONAL PA ETERS
Monthly r Average
Summer/Winter
Da ly a um
asteflor (M
RODS (mg/1)
(g/1)
DO (mg/1)
TSS (mg/1)
eca Colif s (/1 ml) :
pH (E) -
Temperature (neat to cause rece? ring water temperature tc
exceed above e background)
)
Recommend
stetlo ( D) :
OD (mg/11
i (mg/1):
D (mg/1)
Temperature
10tal Iaa solved
(t
Mon hly average Daily aximum
Summer/Winter
0.0002
INSTREAM MONITORING RE UI ". ,-,EFTS
Upstream:- Location
I:cnstrea: Iocation..
Changes Due T
6-9
The discharge mall not cause the receiving
seater° s temperature to exceed 2.8 C above
background and in no case to emceed
Para seer (s) cte(
to facility info ation Solids
Solids Standard
(explanation of an modifications to past modeling analysis
incluc i ing new flossy rates, field data:, interacting discharges, etc.)

To: Permits and Engineering Unit,
Water Quality Sect
Date: ly 10,
NP ES STAFF REPORT AND RECOMMENDATION S
County: Catawba
NPDES Permit Teo.: NC 0048712
MRO No.: 90-115
PART I - GENERAL INFORMATION
1. Facility and Address: Alumax Extrusions, Inc..
Larry Teague, Plant Manager
Route 1, Post Office Box 100
Catawba, North Carolina 28609
Date of Investigation: July 6, 1990
Report Prepared By: Kim H. Coison, Environmental. Engineer
4 Person Contacted and Telephone Number: Larry Teague, Plant
Manager; [phone]
Directions to Site: From the intersection of S. R.3:3
(Long Island Road) and S. R. 1931 (Scope Road), proceed on
Scope Road to the guard house at the Comm/Scope facility.
Proceed approximately 0.9 mile to the end of the service
road.
Discharge Point(s), List for all discharge Points:
Latitude: 35° 38' 55"
Longitude: 81° 01.' 55"
Attach a USGS Map Extract and indicate treatment plant site
and discharge point on map.
USGS Quad No.: E 14 NE
Si- e (land available for expansion and upgrading): There is
adequate land available for expansion and upgrading.
Topography (relationship to flood plain included):.
Topography is flat to moderate slopes.
9 Location of Nearest Dwelling: The nearest dwelling is
located approximately 600 feet. west of the discharge point.
10. Receiving Stream or Affected Surface Waters: Unnamed
tributary to Lake Norman
a. Classif.icatiorl: WS-III & B
b River Basin and Subbasin No.: Catawba 03-08-32

Page Two
c. Describe. receiving stream features and pertinent
downstream uses: Wastewater is discharged via a earthen
channel to a lake located on the property. The small
lake is used for recreational. purposes. Unnamed
tributary flows to the flooded area of the Terrapin
Creek on Lake Norman.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
Type of Wastewater: 0% Domestic
100% Industrial
a. Volume of Wastewater: 1000 gals/day (Additional
Capacity)
b. Types and quantities of industrial wastewater:
Wastewater consists of contact and non -contact cooling
water. Contact cooling water quenches extruded
aluminum. Filter system removes dirt and debris in the
cooling water.
c. Prevalent toxic constituents in wastewater: Biocides
are used in the cooling water. The biocides used were
approved for use during the last permit renewal.
d. Pretreatment Program (POTWs only): N/A
2. Production Rates (industrial discharges only) in Pounds:
N/A
3. Description of Industrial Process (for industries only) and.
Applicable CFR Part and Subpart: N/A
4. Type of Treatment (specify whether proposed or existing):
No treatment exists or is. proposed.
J. Sludge Handling and Disposal. Scheme: N/A
6. Treatment Plant Classification: Less than 5 points; no
rating (include rating sheet). No rating
. SIC Code(s): 3354
Wastewater Code(s):
Primary: 15
Secondary: 14
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grants
Funds (municipals only)? N/A.
2. Special monitoring requests: N/A
3. Additional effluent limits requests: N/A
4. Other: N/A

Page Three
PART IV - EVALUATION AND RECOMMENDATIONS
The Permittee, Alumax Extrusions, Inc. (Alumax), has
requested a modification to their existing T F Permit. The
modification consists of the addition of non -contact and contact
cooling water.
The existing facility is leased from Comm/Scope. Comm/Scope
owns the surrounding ProPertY including the pond. Alumax serves
as a just -in -time manufacturing facility for Comm/Scope. The
wastewater is discharged to a storm drain that enters an earthen
ditch which flows to the pond. The stream that is impounded has
a 7Q10 flow of 0.0 cfs. The domestic waste for the Comm/Scope
facility is discharged immediately downstream from the dam (NPDES
No. NC 0034754).
This Office recommends the Permit be modified provided the
biocides used in conjunction with this discharge are acceptable.
.0/ a,/
Signature of Report Preparer Date
/
) / e
Watel QuallfY Regional Supervisor Date

ROAD . tSS(i
1 1p proves;,.to
. S Roue

State of North Carolina
Department of i`nvironrnent, Health, and Natural R ces
Division of Environmental Management e r a-
ft
512 North Salisbury Street • Raleigh, North Carolina 27611 �`LL
jarnes G. Martin, Governor
William W. Cobey, Ir•, Secretary
Mr. Timothy Kinsley
Alumax Extrusions, Incorporated
One Foxfield Square
St, Charles, I1 60174
Dear Mr. Kinsley :
This is to acknowledge rece
6/25/90
pt of the
George T. Everett, °r,D..
Director
Subject: NPDES Permit Application
NPDES Permit No.NC0048712
Alumax Extrusions, Incorporated
Catawba County
following documents on June 25, 1990:
Application Form
Engineering Proposal (for proposed control facilities),
Request for permit renewal,
Application Processing Fee of $100.00,
Other Modification.(Addition of non -contact cooling water & Filter backwash)
The items checked below are needed before review can begin:
Application Form
Engineering proposal (see attachment),
Application Processing Fee of $100.00
Delegation of Authority (see attached)
Biocide Sheet (see attached)
Other
If the application is not made complete within thirty (30) days, it will be
returned to you and may be resubmitted when complete.
This application has been assigned to Mack Wiggins
(919/733-5083) of our Permits Unit for review. You will be advised oaf any
comments recommendations, questions or other information necessary for the
review of the application.
I am, by copy of this letter, requesting that our Regional Office
Supervisor prepare a staff report and recommendations regarding this
discharge. If you have any questions regarding this applications,
please contact the review person listed above.
Sincerely,
CC:
Mooresviile Regional Office
1. Dale Ova'i-rCash, P.E.
Pollution Prevention Pays
P.O. Box Z7687, I Leigh, North Carolina Z7611-7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

PIVALUMAX
EXTRUSIONS INC
April 2, 1990
Dale Overcash Leader
NPDES Permits Group
State of North Carolina
Department. of Natural Resources
and Community Development
Division of Environmental Management
PO Fox 27687
Raleigh, North Carolina 27611-7687
Dear Mr. Overcash:
[hij ['Med Square
Si Charles, 60174
7081584,1(10(1
EAX 70877584, '243
RE: NPDES Permit # NC004871
The Alurrwx Extrusion- Inc., Catawba, North Carolina facility, is
expanding it's operating capacity. The facility expansion will include
installation of a new extrusion press line and other auxiliary sys-
tems. The new process i- scheduled to come on line June 1990.
Per a phone conversation between Larry Teague of Alumax and Mr. Mack
Wiggens, the following information is being provided. Also, enclosed
is a $100.00 check for the permit modification processing fees.
This new line requires the addition of two cooling towers. The 90 ton
Marley Aqua Tower will cool the hydraulic oil from the new extrusion
press line and the new air compressor. The waste water which will
result is non contact cooling water blow down. The second tower system
is a Baltimore Air Coil. This system. will circulate 600 gpm through a
filter and then. through an extrusion quench system. The waste water
discharge from this system will be the filter back wash. The enclosed.
process flow diagram specifies the expected. flow ra es from the oper-
ation of these new processes.

IlilyALUMAX
EXTRUSIONS INC
Page 2
April 2, 1990
One FE01-eld Square
Si, CliaOes, O. 601.74
108/584-1000
rAx 708/584-,1243
The new cooling tower systems will be controlled using the same, treat-
ment program and chemicals that are currently permitted. We therefore
expect the. chemical characteristics of these new discharges to meet
the existing NPDES parameters. We are requesting that the existing
NPDES permit he modified to accommodate these additional flows inour
process.
If we can be of any further assistance, please contact Larry Teague at
our Catawba facility at 704-241-3301 or Tim Kinsley at 708-584-1000.
Sincerely,
Timothy Kinsley
Manager, Environmental Services
cc: Larry Teague, Catawba, NC..
enc.

ALUMAX EXTRUSIONS, INC,
CATAWBA, NC,
PROCESS FLOW DIAGRAM
CONTACT COOLING SYSTEM
MARLEY
COOLING
TOWER
TOWER BLOW -DOWN
300 PD
FLOW METER
CONTACT COOLING SYSTEM
COOLING
WATER SUPPLY
PUMP @
600 GPM
FILTER, BACK
WASH 700 GPO
NPDES DISCHARGE
PERMIT # NC0048712
COOL NG
WATER
BALTIMORE
AIR COIL
COOLING
TOWER.
FILTER SYSTEM
BACK WASH
FLOW METER
AIR COMPRESSOR
SYSTEM
PRESS HYDRAULIC
OIL SYSTEM
EXTRUSION
QUENCH SYSTEM
COOLING WATER
RETURN PUMP
PRODUCT

EXTRUSIONS INCa
April 2,
Dale 0vercash, Leader
NPDES Permits Group
State of. North Carolina
Department of Natural Resources
and Community Development
Division of Environmental. Management
PC Box 27687
Raleigh, North Carolina 27611-7687
RE: NPDES Permit # NC0048712
Dear Mr. ©vercash.
The Alumax Extrusions, Inc., Catawba, North Carolina facility, is
expanding it's operating capacity. The facility expansion will include
installation of a new extrusion press line and other auxiliary sys-
tems. The new process is scheduled to come on line June 1990.
Per a phone conversation between Larry Teague of Alumax and Mr. Mack
Wiggens, the following information is being provided. Also, enclosed
is a $100.00 check for the permit modification processing fees.
This ne line requires the addition of two cooling towers. The 90 ton
Marley Aqua. Tower will cool the hydraulic oil from the new extrusion.
press line and the new air compressor. The waste water which will
result is non contact cooling water blow down. The second tower system
is a Baltimore Air Coil. This system will circulate 600 gpm through a
filter and then through an extrusion quench system. The waste water
discharge from this system will be the filter back wash. The enclosed
process flow diagram specifies the expected flow saes from the oper-
ation of these new processes.

II
Aiu Mx
EXTRUSIONS INC.
Page 2
April 2, 1990
One Fjx±sCIF1 'S' a;r,
5[y Cltarl?y.. IL y6.0'17 4
8.4
FAX
The new cooling tower systems will be controlled using the same treat-
ment program and chemicals that are currently permitted. We therefore
expect the chemical characteristics of these new discharges to meet.
the existing NPDES parameters. We are requesting that the existing
NPDES permit be modified to accommodate these additional flows in our
process.
If we can be of an, further assistance, please contact Larry Teague at
our Catawba facility at 704-241-3301 or Tim Kinsley at. 708-584-1000.
Sincerely,
Timothy Kinsley
Manager, Environmental Services
cc: Larry Teague, Catawba, vC.
enc.

ALUMAX EXTRUSIONS, INC.
CATAWBA, NC.
PROCESS FLOW DIAGRAM
NON -CONTACT COOLING SYSTEM
MARLEY
COOLING
TOWER
COOL, NG
TOWER BLOW -DOWN WATER
3OQ4PD LipLy PUMP
FLOW METER
CONTACT COOLING SYSTEM
COOLING
WATER SUPPLY
PUMP @
600 GPM
FILTER BACK
00 GPD
FLOW METER
NPDES DISCHARGE
PERMIT # NO0048712
BALTIMORE
AIR COIL
COOLING
TOWER
FILTER SYSTEM
AIR COMPRESSOR
SYSTEM
PRESS HYDRAULIC
OIL SYSTEM
EXTRUSION
QUENCH SYSTEM
OOLING WATER
SUMP TANK
COOLING WATER
RETURN PUMP
PRODUCT

''ALUMAX
EXTRUSIONS INC.
June 28
Mack Wiggins
State of .North Carolina
Department of Environment, Health and Natural. Resources
Division of Environmental. Management
512 North Salisbury Street
Raleigh, North Carolina 27611
Mr. Wiggins:
S. [lades, 11 t „'4
^"5 C4.10.0
FAX 708/5 ;4• `? 4
RE: NPDES Permit # NC0048712
Per your acknowledgment which was received on 6-28-90, we are provid-
ing the enclosed check for $100.00. We are sending this check and
cover letter by next day delivery and would appreciate a prompt
review. The original application was sent to this agency on April 2,
1990 and it seems to have taken an unusual amount of time to review.
If we can be of any further assistance, please contact Larry Teague
our Catawba facility at 704-241-3301 or Tim Kinsley at 708-584-1000.
Sincerely,
4 3
Timothy Kinsl,ey
Tanager, Env. i,ronmiental Services
cc: Larry Teague, Catawba, NC.
enc.
PERMITS ti �E

State of North Carolina
Department o Environment, Health, and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor
1�Ii'liam W Coney, jr., Secretary
6/25/90
Mr. Ti c thy Kinsiey
Alumax Ext,rusi :s, In
One Foxfield Square
St, Charles, I1 60174
Dear Mr.. Kinsley
This
orpurate
is to acknowledge receipt of the
Applicatn Form
George T. Everett, Ph.D.
Director
Subject: NPDES Permit Application
NPDES Permit No.NC0048712
Alumax Extrusions, Incorporated
Catawba County
lowing documents on June
Engineer' rg Proposal (for proposed control facilities),
Request for permit renewal,
Application Processing Fee of
Other ation. (Addition of non —
cooling water Falter backwash
The items checked below are needed before review can begin:
Application Form,
Engineering proposal (see attachment),
Application Processing 'ee of $100.001
Delegation of Auth©rity, (see attaced)
Biocide Sheet. (see attached)
Other
Tf the application i not made complete within thirty (30) days, It will be
returned to you and may .be resubmitted when complete.
This application has been assigned to Mack Wiggins
(919/733-5083) of our Permits Unit for review. You will be advised of any
comments recommendations, questions or other information necessary for the
review of the application.
I am, by copy of this letter, requesting that our Regional, Office
Supervisor prepare a staff report and recommendations regarding this
discharge. If you have any questions regarding this applications,
please contact the review person listed .above.
Sincerely,
CC:
Mooresville Re c iorial Off'
Dale OvH a;sh, P.E.
Pollution Prevention Pays
Box 176 7, Raleigh, North Carolina I7611-'7687 Telephone [phone]
An Equal opportunity Af5rmattve Action Employer

Jot
S. comas Rhodes, Secretary
State of North Carolina
Department of Natural Resources and Cornmu
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
August 3, 1987
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
in, Governor
Mr. Larry Teague
Alumax Extrusions
PC Box 100
Catawba, NC 28609
Dear Mr. Teague:
Subject: Permit No. NC0048712
Alumax Extrusions
Catawba County
R. Paul Wilms
Director
In accordance with your application for discharge permit received on
May 19, 1986, we are forwarding herewith the subject State - NPDES permit.
This permit is issued pursuant to the requirements of North Carolina General
Statute 143-215.1 and the Memorandum of Agreement between North Carolina and
the US Environmental Protection Agency dated December 6, 1983.
If any parts, measurement frequencies or sampling requirements
contained in this permit are unacceptable to you, you may request a waiver
or modification pursuant to Regulation 15 NCAC 2B .0508(b) by written
request to the Director identifying the specific issues to be contended.
Unless such request is made within 30 days following receipt of this permit,
this permit shall be final and binding. Should your request be denied, you
will have the right to request an adjudicatory hearing.
Please take notice that this permit is
addresses the requirements to be followed in case of change in ownership or
control of this discharge.
This permit does not affect the legal requirement to obtain other
permits which may be required by the Division of Environmental Management or
permits required by the Division of Land Resources, Coastal Area Management
Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning this -permit, please contact Mr.
Dale Overcash, at telephone number 919/733-5083.
t 5, ,ncerel
R. Paul Wilms
ansferable. Part II, B.2.
cc: Mr. Jim Patrick, EPA
Mooresville Regional Supervisor
Pollution Pre ttendon Pugs
PO Box 27687, Raleigh, North Carolina 27611-7687 Telephone [phone]
An Equal Opportunity Atfirmarive Action Employer

Permit No. NCO048712
STATE OF NORTH CAROLINA
DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
To Discharge Wastewater Under the NATIONAL
POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions 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,
ALUMAX EXTRUSIONS, INCORPORATED
is hereby authorized to discharge wastewater from a facility located
off of NCSR 1931
Catawba County
to receiving waters designated as an unnamed tributary to Terrapin Creek in the
Catawba. River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions
set forth in Part I, II, and III hereof.
This permit shall become effective August 3, 1987
This permit and the authorization to discharge shall expire at midnight on
September 30, 1991.
Signed this day of August 3, 1987
R. PAUL WILMS, DIRECTOR
DIVISION OF ENVIRONMENTAL MANAGEMENT
BY AUTHORITY OF THE ENVIRONMENTAL
MANAGEMENT COMMISSION
M1 & 11

is hereby autiarar*zed
.Corttinue to disci -tar e contact and non- ,Cntaer front a facility
located at Alum.tricn, 1rrcrrrted in Catawba County (see Part
111 f this Permit) into an unnamed tributary ry to 'Terrapin Creek vsl i 1
is classifi'ed Class l' li waters in the Catawiaa River Basin.
P rmiil No. 1
UPP1 ENT TO PERMIT COVER SHEET
Alu ax Es tru lcrn , 1n e r rar t d

A. EFFLUENT LIMITATION AN➢ MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration,
the permittee is authorized to discharge from outfall(s) serial number(s) 001.
Such discharges shall be limited and monitored by the permittee as specified below:
uent Characteristi
Flow
Temperature
Residual Chlorine
Discharge Limitation
Monitoring Requirements
Other Units (Specify) Measurement
Daily Avg. Daily Max. Daily Avg. Daily Max. Frequency
kg/day (lbs/day)
THERE SHALL BE NO C}TRCMIUM, ZINC, OR COPPER ADDED TO THE COOLING WATER
Sample locations:
ffluent
Sample
Type
*Sample
Location
Monthly Instantaneous E
Monthly Grab E
Monthly Grab E
**The temperature of the effluent shall be such as not to cause an increase in the temperature of the
receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed 32°C
***Monitoring requirements only apply If chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water (See part III of this Permit).
The pH shall not be less than 6.0 standard units r.or greater than 9.0 standard units and shall be
monitored monthly at the effluent by grab samples
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Per i tee shall so
t.tispfid
owingschedule
laterNo
the agog
either
being rocin
conSlinnce 0
shall elude.
No. NC
con') ancewith the effl
discharges in accordance
14 calendardays ol
d.s of compliance
of progress nr,
by identified dates,a
li.n,In the It
he cause of nonco pliance,
taker and the pzobability of meeting the
e,ir°eet
a date identified in
e shall submit
specific actions
notice of
case, the .otic
any remedial actions
next scheduled
14

C. MONITORING AND REPORTING
1. Representative Sampling
Samples collected and measurements taken as required herein
shall be characteristic of the volume and nature of the
permitted discharge. Samples collected at a frequency less
than daily shall be taken on a day and time that i.s
characteristic of the discharge over the entire period which
the sample represents.
2. Reporting
Monitoring results obtained during the previous month(s)
shall be summarized for each month and reported on a monthly
Discharge Monitoring Report (DMR) Form (DEM No. MR 1, 1.1,
2, 3,) or alternative forms approved by the Director, DEM,
postnmarked no later than the 30th day following the
completed, reporting period.
The first DMR is due on the last day of the month fo
the issuance of the permit or in the case of a new f_ac:
on. the last day of the month Billowing the commencement.
discharge. Duplicate signed copies of these, and all other
reports required, herein, shall be submitted to the following
address:
Division of Environmental Management
WaterQuality Section
ATTN: Central Files
Post Office Pox 27687
Raleigh, NC 27611
Definitions
a. Act or "the Act": The Federal Water Pollution Control
Act, also know as the Clean Water Act, as amended, 3 I.S.C.
1251, et. seq.
h. The "daily average" discharge means the total discharge
by weight during a calendar month divided by the number of
days in the month that the production or commercial faci_Li_ty
was operating. Where less than daily sampling is required b'
this permit, the daily average discharge shall be determined
by the summation of all the measured daily discharges by
weight divided by the number of days sampled during the
calendar month when the measurements were made.
c. The "daily maximum" discharge means the total dichara_c
kav weight during any calendar day.
I 5

d. DEM or Division:
Management, Department.
Development..
means the Division of Environmental
of Natural Resources and Community
e. EMC: used herein means the North Carolina Env:.ronm
Management Commission.
f. Flow, M3/day (MGD): The flow limit expressed in
permit is the 24 hour average flow, averaged monthly.
determined as the arithmetic mean of the total daily
recorded, during the calendar month;
g. Arithmetic Mean: The arithmetic mean of any set of
values is the summation. of the individual values divided by
the number of individual values.
ntal
this
t is
lows
h. Geometric Mean: The geometric mean of any set of values
is the Nth root of the product of the individual values
where N is equal to the number of individual values. The
geometric mean is equivalent to the antilog of the
arithmetic mean of the logarithms of the individual values.
For purposes of calculating the geometric mean, values of
zero (0) shall be considered to be one (1) .
i . Compo
collected
flow, a
flow, or
composite
ite Sample. These samples consist. of grab samples
at equal intervals and combined proportional to
sample continuouslycollected proportionally to
equal volumes taken at varying time intervals. If a
sample is obtained from grab samples, the
followi. g requirements apply. The intervals between influent
gran samples shall be no greater than hourly. Intervals
between effluent grab samples shall be no greater than
hourly. except where the detention. time of the wastewater in
the facility is greater than 24 hours, in which case, the
interval between grab samples shall be no greater in number
of hours than the detention time in number of days;
provided,, however, in no case may the time between effluent
grab samples be greater than six hours nor the number of
grab samples less than four during any discharge period of
24 hours or less.
j. Grab Sample: Grab samples are individual samples
collected over a period of time not exceeding 15 minutes;
the grab sample can be taken manually.
16

4. Test Procedures
Test procedures for the analysis of pollutants shall conform
to the EMC regulations published pursuant to N.C.G.S.
143-215.63 et seq, the Water and Air Quality Reporting Act,
and to regulations published pursuant to Section 304(g), 33
USC 1314, of the Federal Water Pollution Control Act, As
Amended, and Regulation 40 CFR 136.
. Recording Results
For each measurement or sample taken pursuant to the
requirements of this permit, the permittee shall record. the
following information:
a. The exact place, date, and time of sampling;
b. The dates the analyses were performed; and
c. The person(s) who performed the analyses.
6. Additional Monitoring by Permittee
If the permittee monitors any pollutant at the location(s)
designated hereinmore frequently thanrequired by this
permit, using approved analytical methods as specified
above, the results of such monitoring shall be included in
the calculation and reporting of the values is required in
the DMR. Such increased frequency shall also be indicated.
The DEM may require more frequent monitoring or the
monitoring of other pollutants not required in this permit
by written notification.
. Records Retention
All records and information resulting from the monitoring.
activities required by this Permit including all records of
analyses performed and calibration and maintenance of
instrumentation and recordings from continuous monitoring
instrumentation shall be retained for a minimum of three (3)
years. This period of retention shall be extended during the.
course of any unresolved litigation or if requested by the
Division of Environmental Management or the Regional
Administrator of the Environmental Protection Agency.
17

PART II GENERAL CONDITIONS
A. MANAGEMENT REQUIREMENTS
Change in Discharge
All discharges authorized. herein shall be consistent with
the terms and conditions of this permit. The discharge of
any pollutant identified in this permit more frequently than
or at a level in excess of that authorized shall constitute
a violation of the permit. Any anticipated facility
expansions, production increases, or process modifications
which will result in new, different, or increased discharges
of pollutants must be reported by submission of a new NPDES
application or, if such changes will not violate the
effluent limitations specified in this permit, by notice to
the DEM of such changes. Following such notice, the permit
may be modified to specify and limit any pollutants not
previously limited.
2. Noncompliance Notification
The permittee shall report by telephone to either the
central office or appropriate regional office of the
division as soon as possible but in no case more than 24
hours or on the next working day following the occurrence or
first knowledge of the occurrence of any of the following:
a. Any occurrence at the water pollution control
facility which results in the discharge of significant
amounts of wastes which are abnormal in quantity or
characteristic, such as the dumping r•f the contents of a
sludge digester, the known passage of a slug of
hazardous substance through the facility or any other
unusual circumstances.
b. Any process unit failure, due to known or unknown.
reasons, that render the facility incapable of adequate
wastewater treatment, such as mechanical or electrical
failures of pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or
treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion
of the influent to such station or facility.
d. Any time that self -monitoring information indicates
that the facility has gone out of compliance with its
NPDES permit limitations.
T 8

Persons reporting such occurrences by telephone shall also
file a written report in letter form within 15 days
following first knowledge of the occurrence.
. Facilities Operation
The permittee shall at all times maintainin good working
order and operate as efficiently as possible all treatment
or control facilities or systems installed or used by the
permittee to achieve compliance with the terms and
conditions of this permit.
4. Adverse Impact
The permittee shall take all reasonable steps to minimize
any adverse impact to navigable waters resulting from
noncompliance with. any effluent limitations specified in
this permit, including such accelerated or additional
monitoring as necessary to determine the nature and impact
of the noncomplying discharge.
5. Bypassing
Any diversion fromor bypass of facilities is prohibited,
except (i) where unavoidable to prevent loss of life or
severe property damage, or (ii) where excessive storm
drainage or runoff would damageany facilities necessary for
compliance with the effluent limitations and rohibitions of
this permit. All permittees who have such sewer bypasses or
overflows of this discharge shall submit, not. later than six
months from the date of issuance of this permit, detailed
data or engineering estimates which identify:
a. The location of each sewer system bypass or overflow;
b. The frequency, duration and quantity of flow from
each sewer system bypass or overflow.
The permittee shall report by telephone to either the
central office or appropriate regional office of the
division as soon as possible but in nocase more than, 24
hours or on the next working day following the occurrence or
first knowledge of the occurrence of any diversion from or
bypass of facilities.
19

6. Removed Substances
Solids, sludges, filter backwash, or other pollutants
removed in the course of treatment or control of wastewaters
shall be disposed of in. accordance with NCGS 143-215..1 and
in a manner such as to prevent any pollutant from such
materials from entering waters of the State or navigable
waters of the United States.
7. Power Failures
The permittee is responsible for maintaining adequate
safeguards to prevent the discharge of untreated or
inadequately treated wastes during electrical power failures
either by means of alternate power sources, standby
generators or retention of inadequately treated effluent.
Onshore or Offshore Construction
This permit does not authorize or approve the construction
of any onshore or offshore physical structures or facilities
or the undertaking of any work in any navigable waters.
RESPONSIBILITIES
1. Right of Entry
The permittee shall allow the Director of the Division of
Environmental Management, the Regional Administrator, and/or
their authorized representatives, upon the presentations of
credentials:
a. To enter upon the permittee's premises where an
effluent source islocated or in which any records are
required to be kept under the terms and conditions of
this permit; and
b. At reasonable times to have access to and copy any
records required to be kept under the terms and
conditions of this permit; to inspect any monitoring
equipment or monitoring method required in this permit;
and to sample any discharge of pollutants.
I 10

2. Transfer of Ownership or Control
This permit is not transferable. In the event of any
change in name, control or ownership of facilities from
which the authorized discharge emanates or is contemplated,
the permittee shall notify the prospective owner or
controller by letter of the existence of this permit and of
the need to obtain a permit in the name of the prospective
owner. A copy of the letter shall be forwarded to the
Division of Environmental Management.
Availability of Reports
Except for data determined to be confidential under NCGS
143-215.3(a) (2) or Section 308 of the Federal. Act, 33 USC
1313, all reports prepared in accordance with the terms
shall be available for public inspection at the offices of
the Division of Environmental Management. As required by
the Act, effluent. data shall not be considered
confidential. Knowingly making any false statement on any
such report may result. in the imposition of criminal
penalties as provided for in NCGS 143-215.1(b) (2) or in
Section 309 of the Federal Act.
4. Permit Modification
After notice and opportunity for a hearing pursuant to NCGS
143-215.1.(b) (2) and NCGS 143-215.1(e) respectively, this
permit may be modified, suspended, or revoked in whole or
in part during its term for cause nclu:di.ng, but not
limited to, the f llowing:
a. Violation of any terms or conditions of this perm
b. Obtaining this perm:: by
failure to disclose fully all. rel.
representation or
facts; or
c. A change in any condition that requires either a
temporary or permanent reduction or elimination of the
authorized discharge.
111

. Toxic Pollutants
Notwithstanding Part 11, B-4 above, if a toxic effluent
standard or prohibition (including any schedule of
compliance specified in such effluent standard or
prohibition) is established under Section 307(a) of the Act
for a toxic pollutant which is present in the discharge, if
such standard or prohibition is more stringent than any
limitation for such pollutant in this permit, this permit
shall be revised or modified in accordance with the toxic
effluent standard prohibition and the permittee so notified.
6. Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part
11, A-5) and "Power Failures" (Part II, A-7), nothing in.
this permit shall be construed to relieve the permittee from
any responsibilities, liabilities, or penalties for
noncompliance pursuant to NCGS 143-215.3, 143-215.6 or
Section 309 of the Federal Act, 33 USC 1319. Furthermore,
the permittee is responsiblefor consequential damages, such
as fish killS, even though the responsibility for effective
compliance may be temporarily suspended.
7. Oil and. Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the
institution of any legal action or relieve the permittee
from any responsibilities, liabilities, or penalties to
which the permittee is or may be subject to under NCGS
143-215.75 et seq. or Section 311 of the Federal Act, 33 USC
1321. Furthermore, the permittee is responsible for
consequential damages such as fish kills, even though the
responsibility for effective compliance may be temporarily
suspended.
. Property Rights
The issuance of this permit does not conveyany property
rights in either real or personal property, or any exclusive
privileges, nor does it authorize any injury to private
property or any invasioof personal rights, nor any
infringement of Federal, State or local laws or regulations.
I 12

9. Severability
The provisions of this permit are severable, and if any
provision of this permit to any circumstance is held
invalid, the application of such provision to other
circumstances, and the remainder of this permit shall not be
affected thereby.
10. Expiration of Permit
Permittee is not authorized to discharge after the
expiration date. In order to receive authorization to
discharge beyond the expiration date, the permittee shall
submit such information, forms, and fees as are required by
the agency authorized to issue permits no later than 180
days prior to the expiration date. Any discharge without a
permit after the expiration will subject the permittee to
enforcement procedures as provided in NCGS 143-215.6, and 33
USC 1251 et seq.
1 13

PART III OTHER REQUIREMENTS
A. Previous Permits
All previous State water quality permits issued to this
facility,. whetherfor construction or operation or discharge,
are hereby revoked by issuance of this permit. The, conditions,
requirements,. terms, and provisions of this permit authorizing
discharge under the National Pollutant Discharge Elimination.
System govern. discharges from this facility.
B. Construction
No construction of wastewater treatment facilities or additions
thereto shall be begun until Final Plans and Specifications have
been submitted to the Division of Environmental Management and
written approval and Authorization to Construct has been issued.
C. Certified Operator
Pursuant to Chapter 90A of North Carolina General Statutes, the
permittee shall employ a certified wastewater treatment plant
operator in responsible charge of the wastewater treatment
facilities. Such operator must hold a certification of the grade
equivalent to or greater than the classification assigned to the
wastewater treatment facilities.
D. Groundwater Monitoring
The permittee shall, upon written notice from the Director of
the Division of Environmental Management, conduct groundwater
monitoring as may be required to determine the compliance of
this NPDES permitted facility with the current groundwater
standards.
F. Limitations Reopener
This permit shall be modified or alternatively, revoked and
reissued, to comply with any applicable effluent guideline or
water quality standard issued or approved under Sections
302 (b) (2) (c) , and (d), 304(b)(2), and 307 (a) (2) of the Clean
Water Act, if the effluent guideline or water quality standard
so issued or approved:
1. contains different conditions or is otherwise more
stringent than any effluent limitation in the permit; or
2. controls any pollutant not limited in the permit.
1 14

Part i1I
Perm No. NC004d 12
Toxicity Reopener
This permit shall be modified, or revoked and reissued to
incorporate toxicity limitations and monitoring requirements in the
event toxic testing or other studies conducted on the effluent o
receiving stream indicate that detrimental effects may be expected
in the receiving a eam as a result of this discharge
-
The perm tee shall not use any biocides except these approved in
conjunction with the per it application. The p rmittee hat1
the Director in writing not later than ninet ) days prior to
n tuting use of any additional biocide used in cooling systems
which may be toxic to aquatic life other than those previously
reported to the Division of Environmental ManagemenManagement Such
notification shall include completion of Biocide Wotksheet Form 1
and a map locating the discharge point and receivingstream.

C. DEPT. OF NATURAL
R c DEP (.77.1. 4ND
COW' 9
7 1990
DIVI!`r r;"
State of North Carolina effiCE
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street . Raleigh, North Carolina 27611
James G. Martin, Governor George T. Everett, Ph.D.
William W. Cobey, Jr., Secretary Director
September 6, 1990
Mr. Larry Teague
Rt. 1, PO Box 100
Catawba, NC 28609
Subject: NPDES Permit No. NC0048712
Alumax Extrusions Inc.
Catawba County
Dear Mr. Teague:
It is our understanding that chemical additives will be included in the additional non -contact
cooling water and filter backwash. Please complete the attached Biocide/Chemical worksheet
concerning the additional discharge and return by October 5, 1990.
If you have any questions on this permit modification request, please advise.
Sincerely
IfIGL/6//- 1/4
Mack Wiggins
Environmental Technician
cc: Mooresville Regional Office
Permits and Engineering Unit
Central Files
Pollution Prevention Pays
PO, Box 27687, Raleigh, North Carolina 2761.1-.7687 Telephone. [phone]
An Equal Opportunity Affirmative Action Employer

July 1, 1986
NPDES STAFF REPORT AND RECOMMENDATIONS
Catawba County
NPDES Permit No, NC0048712
PART 1 - GENERAL INFORMATION
1. Facility and Address: Alumax Extrusions, Inc.
P. O. Box 100
Catawba, N. C. 28609
2. Date of Investigation: June 6, 1986
3. Report Prepared By: J. Thurman Horne, P. E.
4. Persons Contacted and Telephone Number: Mr. Larry Teague, Plant Manager
704/241-3301
5. Directions to Site: From the intersection of S.R. 1833 and S.R. 1931
(Comm Scope Dr.) travel east on S.R. 1931 approx. 0.3 mi., turn right
at the guard house for Comm -Scope, Inc. From the guard house travel
southeast on a paved service road thru the Comm -Scope industrial complex,
approx. 0.9 mi. Alumax is at the end of the service road.
6. Discharge Point - Latitude: 35° 38 55"
Longitude: 81° 0200"
Attach a USGS Map Extract and indicate treatment plant site and
discharge point on map.
USGS Quad No. El4NE
or USGS Quad Name - n/a
7. Size (land available for expansion and upgrading): The existing site
encompasses approx. 20 acres. There is adequate land available to
construct treatment facilities if necessary.
8. Topography (relationship to flood plain included): rolling terrain, slopes
are generally less than 10%. The existing plant appears to be well
removed from any potential flood plain.
9. Location of nearest dwelling: None within 500 feet.
10. Receiving stream or affected surface waters: an unnamed tributary to
Terrapin Creek.
a. Classification: C
b. River Basin and Subbasin No.: 03-08-32
c. Describe receiving stream features and pertinent downstream uses:
There are no known downstream users, other than for secondary
recreation and agriculture, prior to confluence with Lake Norman.
Lake Norman is Class WS-III & B waters and is used extensively for
primary and secondary recreation. The confluence with Lake Norman is
approx. 3 miles below the point of discharge.
Note: The actual point of discharge is into an impoundment of the
unnamed tributary to Terrapin Creek.

Page Two
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
Type of wastewater: 0% Domestic
I00% Industrial
a. Volume of Wastewater: less than .0001 MGD (based on conversation with Mr.
Larry Teague)
b. Types and quantities of industrial wastewater: The wastewater consists
entirely on non -contact cooling water.
c. Prevalent toxic constituents in wastewater: Note: Information on biocides
and additives has been submitted by Alumax to the Raleigh Central Office
for review.
d. Pretreatment Program (POTWs only) - n/a
in development - n/a approved - n/a
should be required - n/a not needed - n/a
2. Production rates (industrial discharges only) in pounds - n/a
a. highest month in the last 12 months - n/a
b. highest year in last 5 years - n/a
Description of industrial process (for industries only) and. applicable CFR
Part and Subpart: n/a
4. Type of treatment (specify whether proposed or existing): There are no
treatment facilities existing or proposed.
5. Sludge handling and disposal scheme: n/a
6. Treatment plant classification: n/a
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grants Funds
(municipals only)? n/a
2. Special monitoring requests: The existing permit was amended on January
4, 1985 to delete upstream and downstream monitoring. It is recommended
that there be no stream monitoring requirements in the reissued permit.
Additional effluent limits requests: n/a
4. Other: n/a

PART IV - EV EVALUATION
RECO1 NDATIONS
Page Three
A review of the past years zaanthl r self- onitoring data indicates
that the facilltY is in compliance with the limitations of the existing
permit.
reco ended that the permit be renewed.
TT :pb
Mual
y Regional Supervisor

a y46 • vE ErxrPRNnr+
Primary highway,
hard surface
E.
ROAD CLASSIFICAT}ON
Light -duty road, hard or
improved surface —_ _._
40'
4.
4
"44

Depa
State of North Carolina
Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor
S. Thomas Rhodes, Secretary
Dear
R. Paul Wilms
Director
Subject: NPDES Permit Application
NPDES Permit No. NCO() ,.
This is to acknowledge receipt of the following documents
Application Form,
Engineering Proposal (for proposed control facilities).
Request for permit renewai
Application Processing Fee of $
Other
The items checked below are needed before review can begin:
Application form (Copy enclosed),
Engineering Proposal. TSee Attachment),
Application Processing Fee of
Other pc
'Cola
If the application is not made compiete within thirty (3) days,
be returned to you and may be resubmitted when complete.
This application has been assigned to
(919/733-5083) of our Permits Unit for review. You will. be advised o
any comments recommendations, questions or other information necessary
for the review of the application.
I am, by copy of this letter, requesting that our Regional Office
Supervisor prepare a staff report and recommendations regarding this
discharge. If you have any questions regarding this application, please
contact the review person listed above.
cc:
hur Mouberry, P.E.
ervisor, Permits and Engineering
Pollution Prevention Pay
PO, Box 27687, Raleigh, North Carolina 27611-7687 Telephone 9t '733-70.15
An Equal Opportunity Affirmative Action Employer

EXTRUSIONS INC.
May 14, 1986
Permits and Engineering Unit
N.C. Division of Environmental Management
P.O.Box 27687
Raleigh, N.C. 27611-7687
Dear Sirs:
Please find enclosed, a check payable to N.C. Department of
Natural Resources and Community Development in the amount of
$25,00. This is a processing fee to cover renewal of our NPDES
Permit No. NC0048712.
We do request renewal of the above permit. There have been no
changes to our process or discharge levels per operating day and
none is being contemplated.
If there are any questions or need for more information, please
call me at [phone].
Sincerely,
arr Te
Plat(t Mg
encl.. 1
LT/db
ue
RT. #1'• P.O. BOX 100 • CATAWBA, NORTH CAROLINA 28609 • A SUBSIDIARY OF ALUMAX INC.

MEMORANDUM TO: Dave Adkins
FROM: D. Rex Gleason
PREPARED BY: Larry D. Coble -g7
SUBJECT:
DIVISION OF ENVIRONMENTAL MANAGEMENT
Permit Amendment
NPDES Permit No. NC 0048712
Alumax Extrusions, Inc.
Catawba County, North Carolina
October 17, 1983
Reference is made to the attached letter dated October 13, 1983, from
Mr. Larry Teague, Plant Manager with the subject Company. In essence this
letter requests the upstream and downstream self -monitoring be deleted from
the NPDES Permit.
Members of the staff of this Office have investigated the request. The
Company has a very small cooling water discharge which flows overland and
enters a rather large lake. Based on these findings, we have no objection
to the Permit being amended.
If you have any questions, please advise.
Attachment
LDC:se

EXTRUSIONS tNC
October 13, 1983
Mr. Larry D. Coble
North Carolina Dept. of Natural Resources
and Community Development
Division of Environmental Management
919 North Main Street
Mooresville, North Carolina 28115
Dear r. Coble;
Thank you for the copy of the Compliance Evaluation Analysis
conducted by yourself on October 11, 1983.
In response to the letter from Mr. Gleason dated October 11,1983
citing the non-compliance of Upstream and Downstream Self-rnonitari.ng,,
the following is submitted.
Non-compliance was due entirely to a misunderstanding internal to
our Company, and a lack of oversight of the monitoring program/personnel.
I feel that this situation no longer exists and do not expect any
further problems with proper monitoring and proper reporting.
Due to a re -configuration of the storm -drain system by our lessor,
our effluent is fed into a common drain system which goes under
our parking lot and then emerges to discharge across grade prior to
entering the lake. Based on this and on observation/recommendation
number two (2) of Mr. Gieasons letter dated May 20, 1983, we request
a reconsideration of the requirement to monitor the receiving s.
Please do not hesitate to contact me if there are any further
recommendations or requirements.
LT/db
Since fly,
arry / eagu
Plan Mana
47ATAWPA Nr1r 7i-I rAI7r11 INA 7RR(K9 • 6 CI IRCI#"IIACiV rip Al 1 IIKAA1( IW('

Pn rn r=M
hare: hr,:F_,?

Permit No. NC0048712
STATE OF NORTH CAROLINA
DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
To Discharge Wastewater Under the NATIONAL
POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions 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,
ALUMAX EXTRUSIONS, INCORPORATED
is hereby authorazetl to discharge wastewater from a facility located
off of NCSR 1931
Catawba County
to receiving waters designated as an unnamed tributary to Terrapin Creek in the
Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions
set forth in Part I, I I , and III hereof.
This permit shall become effective
This permit and the authorization to discharge shall expire at midnight on
September 30, 1991.
Signed this day of
D
R. PAUL WILMS, DIRECTOR
DIVISION OF ENVIRONMENTAL MANAGEMENT
BY AUTHORITY OF THE ENVIRONMENTAL
MANAGEMENT COMMISSION

Permit No. NC0048712
SUPPLEMENT TO PERMIT COVER SHEET
Alumax Extrusions, Incorporated
is hereby authorized to:
1. Continue to discharge contact and non --contact cooling water from a facility
located at Alumax Extrusions, Incorporated in Catawba County (see Part
III of this Permit), into an unnamed tributary to Terrapin Creek which
is classified Class C" waters in the Catawba River Basin.

***Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water (See Part III of this Permit).
The pH shall not be less th
monitored monthly at the of
6.0 standard uni
uent by grab camp
s nor greater than 9.0 standard units and shall be
es
There shall be no discharge of floating solids or visible foam in other than trace amounts.
EFFLUENT LIMITATION AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration
the permittee is authorized to discharge from outfall(s) serial number(a) 001.
Such discharges shall be limited and monitored by the permittee as specified below:
cent Characteristics Discharge Lind at
Flow
Temperature
Residual Chlorine
Monitoring Requirese
kg/day (lbs/day) Other Units (Specify) Measurement
Daily Avg. Daily Max. Daily Avg. Daily Max. Frequency
q y
**
* * *
Sample *Sample
Type Location
Monthly Ins tantane°ous
Monthly Grab
Monthly Grab
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE COOLING WATER
*Sample locations: E - Effluent
**The temperature of the effluent shall be such as not to cause an increase in the temperature of the
receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed32°C

Pert III
Permit No. NC0048712.
Toxicity Reopene
This permit shall be modified, or revoked and reissued to
incorporate toxicity limitations and monitoring requirements in the
event toxicity testing or other studies conducted on the effluent or
receiving stream indicate that detrimental effects may be expected
in the receiving stream as a result of this discharge.
G. The permittee shall not use any biocides except these approved in
conjunction with the permit application. The permittee shall notify
the Director in writing not later than ninety (90) days prior to
instituting use of any additional biocide used in cooling systems
which may be toxic to aquatic life other than those previously
reported to the Division of Environmental Management. Such
notification shall include completion of Biocide Worksheet Form 101
and a map locating the discharge point and receiving stream.

Larry Teague
alums rus on.s )6,111
V. o. a iE
as North Caroli
Teague*
accordance with you!
I are forwarding; her
sued pursuant to the re=
L43-2151 and the Memorand
Enviro b.nta1 Protection
tee
ele
any parts, requirei
abl to you you have
officer upon written d
of this Permit, identityi
such demand is de, this
* tak
the requi
this discharg
This Permit doet
y be required.
q anions noncet
e gi9)733-5181.
No. NC
Eatttusa
County
ion for
subject
of Nett h Caro.
ent betwe Noy,
dated October
.
limitations touts, ined in thie fermis
t to an adjudicatery ring before a.
to the Direct within 54 days following
e specific isauea to be contended.
rmit shall b fi and binding.
e we it is not tr:setable. Part i1 , R. 2.
11ed in case c i change in ownership or
feet the legal requ
Division of Environme
ing this Permit, plea** contact ° David
Sinner yalsa
Original
ROBERT F
Robert F. Nelms
Director
cct Mr. T. ehael Taimi, IPA
Mooresville Regional Office
Mooresville Regional Office Manager

Permit No NCO 0 4 871 2
STATE OF NORTH CAROLINA
DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
To Discharge Wastewater Under the NATIONAL
POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance, with the provisions 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,
Alumax Extrusions, Inc.
is hereby authorized to discharge wastewater from a facility located at
Catawba
Catawba County
to receiving waters
Unnamed Tributary to Terrapin Creek in the Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II and III. hereof.
This permit shall become effective OCT 30 9$1
This permit and the authorization to discharge shall expire at midnight
0 CT 3 0 1988
on
Signed this day of OCT 3 0 rIto
Orisiinei Signed By
ROBERT F. HELMS
Robert F. Helms, Director.
Division of Environmental Management
By Authority of the Environmental
Management Commission

SUPPLEMENT TO PEN IT COVER SHEET
Alumax Extrusions, Inc.
Page of
permit no- NC
is hereby authorized to:
*le Continue to discharge contact and non -contact cooling water from
hYdr°Pness extrusion Process located at Alumax Extrusions, inc. into
an unnamed tNibutarY t° TonneOin Creek which is classified Class
"C" waters (Note Part III of this Permit).

A. (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL
During the period beginning on the effective date and lasting until expiration,
permittee is authorized to discharge from outfall(s) serial number(s)D01.
Such discharges shall be limited and monitored by the permittee as specified below:
haracteai sti cs
Kg/day (lbs/day)
ly Avg. Daily Max.
Discharge Limitations Monitoring Requirements
emperature
Other Units (Specify) Measurement ** Sample * Sample
Daily Avg. Daily Max. Frequency type Location
* * *
here shall be no chromium, zinc or copper added to the cooling water.
Monthly Grab E, U, D
Sample Locations: I -Influent, E-Effluent, U-Upstream, D-Downstream **All stream samples shall be grab.
**The temperature shall be such as not to cause an increase in the stream water temperature of more than 5°F above ambient
tream water temperature and in no case cause the stream water temperature to exceed 90°F.
-v
p.
rt
1.44
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units
and shall be monitored at E, U, D by grab samples.
There shall be no di scharge,rof floating solids or visible foa# in mother f t han trace amounts .

Part l
Permit , NC
SCHEDULE OF COMPLIANCE
The permittee shall achieve compliance with the effluent limitations
specified for discharges in accordance with the following schedule:
No later than 14 calndar days following a date identified in the above
schedule of compliance, the pnrmtte shall submit either a report of
progress or, in the case of specific actions being required by identified
dates, a written notice ef compliance or noncompliance. In the latter
case, the notice shall include the cause of noncompliance, any remedial'
actions taken, and the probability of meeting the next scheduled requirement

PART
Permit No. NC
Act used herein means the Federal Water Pollution Control Act, As amended.
DEM used herein means the Division of Environmental Management of the
Department of Natural Resources and Community Development
"EMC" used herein means the North Carolina Environmental Management
Commission.
C. MONITORING AND REPORTING
1. Representative Sampling
Samples and measurements taken as required herein shall be representative
of the volume and nature of the monitored discharge.
2. Reporting
Monitoring results obtained during the previous month(s) shall be
summarized for each month and reported on a Monthly Monitoring Report
Form (DEM No. MR 1.0, 1.1, and 1.4) postmarked no later than the 45th
day following the completed reporting period. The first report is due on
JAN 1 4 1981 . The DEM may require reporting of additional monitoring
results by written notification. Signed copies of these, and all other
reports required herein, shall be submitted to the following address:
Division of Environmental Management
Water Quality Section
Post Office Box 27687
Raleigh, North Carolina 27611
. Definitions
a. The "daily average" discharge means the total discharge by weight
during a calendar month divided by the number of days in the month
that the production or commercial facility was operating. Where less
than daily sampling is required by this permit, the daily average
discharge shall be determined by the summation of all the measured
daily discharges by weight divided by the number of days sampled
during the calendar month when the measurements were made.
b. The "daily maximum" discharge means the total discharge by weight
during any calendar day.
4. Test Procedures
Test procedures for the analysis of pollutants shall conform to The EMC
regulations published pursuant to N. C. G. S. 143-215.63 et seq.. The
Water and Air Quality Reporting Act, Section 304(g), 13 USC 1314, of the
Federal Water Pollution Control Act, As Amended, and Regulation 40 CFR 136.
. Recording Results
For each measurement or sample taken pursuant to the requirements of
this permit, the permittee shall record the following information:

PART'
Permit Jo. iJC
a. The exact place, date, and time of sampling;
b. The dates the analyses were performed;
c. The person(s) who performed the analyses;
d. The analytical techniques or methods used; and
e. The results of all required analyses.
6. Additional Monitoring by Permittee
If the permittee monitors any pollutant at the locations) designated
herein more frequently than required by this permit, using approved
analytical methods as specified above, the results of such monitoring
shall be included in the calculation and reporting of the values required
in the Monthly Monitoring Report Form (DEM MR 1.0, 1.1, 1.4)
Such increased monitoring frequency shall also be indicated. The DEM
may require more frequent monitoring or the monitoring of other pollu-
tants not required in this permit by written notification.
7. Records Retention
All records and information resulting from the monit©ring activities
required by this permit including all records of analyses performed and
calibration and maintenance of instrumentation and recordings from
continuous monitoring instrumentation shall be retained by the permittee
for a minimum of three (3) years, or longer if requested by the State
Division of Environmental Management or the Regional Administrator of
the Environmental Protection Agency.
I6

PART IL
Permit No. NC
A. MANAGEMENT REQUIREMENTS
1. Change in Discharge
All discharges authorized herein shall be consistent with the terms and
conditions of this permit. The discharge of any pollutant identified
in this permit more frequently than or at a level in excess of that
authorized shall constitute a violation of the permit. Any anticipated
facility expansions, production increases, or process modifications which
will result in new, different, or increased discharges of pollutants must
be reported by submission of a new NPDES application or, if such changes
will not violate the effluent limitations specified in this permit, by
notice to the DEM of such changes. Following such notice, the permit
may be modified to specify and limit any pollutants not previously limited.
Non compliance Notification
If, for any reason, the permittee does not comply with or will be unable
to comply with any effluent limitation specified in this permit, the per-
mittee shall provide the Division of Environmental Management with the
following information, in writing, within five (5) days of becoming aware
of such condition:
a. A description of the discharge and cause of noncompliance; and
b. The period of noncompliance, including exact dates and times; or,
if not corrected; the anticipated time the noncompliance is expected
to continue, and steps being taken to reduce, eliminate and prevent
recurrence of the noncomplying discharge.
Facilities Operation
The permittee shall at all times maintain in good working order and
operate as efficiently as possible all treatment or control facilities
or systems installed or used by the permittee to achieve compliance with
the terms and conditions of this permit.
4. Adverse Impact
The permittee shall take all reasonable steps to minimize any adverse
impact to navigable waters resulting from noncompliance with any effluent
limitations specified in this permit, including such accelerated or
additional monitoring as necessary to determine the nature and impact of
the noncomplying discharge.
5. Bypassing
Any diversion from or bypass of facilities necessary to maintain compliance
with the terms and conditions of this permit is prohibited, except i} where
M8&I7

PART II
Permit No. NC
unavoidable to prevent loss of life or severe property damage, or
(i1) where excessive storm drainage or runoff would damage any
facilities necessary for compliance with the effluent limitations
and prohibitions of this permit. The permittee shall promptly
notify the Water Quality Section of DEM in writing of each such
diversion or bypass.
6. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the
course of treatment or control of wastewaters shall be disposed of in
a manner such as to prevent any pollutant from such materials from
entering waters of the State or navigable, waters of the United States.
7. Power Failures
In order to maintain compliance with the effluent limitations and
prohibitions of this permit, the permittee shall either:
a. In accordance with the Schedule of Compliance contained in Part I,
provide an alternative power source sufficient to operate the waste-
water control facilities;
or, if such alternative power source is not in existence, and no date for
its implementation appears in Part I,
b. Halt, reduce or otherwise control production and/or all discharges
from wastewater control facilities upon the reduction, loss, or
failure of the primary source of power to said wastewater control
facilities.
8. Onshore or Offshore Construction
This permit does not authorize or approve the construction of any onshore
or offshore physical structures or facilities or the undertaking of any
work in any navigable waters.
I8

PART II
Permit No. NC
R. RESPONSIBILITIES
1. Right of Entry
The permittee shall allow the Director of the Division of Environmental.
Management, the Regional Administrator, and/or their authorized represen-
tatives, upon the presentations of credentials:
a. The enter upon the permittee's premises where an effluent source is
located or in which any records are required to be kept under the
terms and conditions of this permit; and
b. At reasonable times to have access to and copy any records required
to be kept under the terns and conditions of this permit; to inspect
any monitoring equipment or monitoring method required in this permit;
and to sample any discharge of pollutants.
2. Transfer of Ownership or Control
This permit is not transferable. In the event of any change in control
or ownership of facilities from which the authorized discharge emanates
or is contempleted, the permittee shall notify the prospective owner or
controller by letter of the existence of this permit and of the need to
obtain a permit in the name of the prospective owner. A copy of the
letter shall be forwarded to the Division of Environmental Management.
3. Availability of Reports
Except for data determined to be confidential ur der N. C. G. S. 143-215.
3(a)(2) or Section 308 of the Federal Act, 33 USC 1318, all reports prepared
in accordance with the terms shall be available for public inspection at the
offices of the Division of Environmental Management. As required by the Act
effluent data shall not be considered confidential. Knowingly making any
false statement on any such report may result in the imposition of criminal
penalties as provided for in N. C. G. S. 143-215.6(b)(2) or in Section
309 of the Federal Act.
4. Permit Modification
After notice and opportunity for a hearing pursuant to N. C. G. S. 143-
215.1(b)(2) and G. S. 143-215.1(e) respectively, this permit may be
modified, suspended, or revoked in whole or in part during its term for
cause including, but not limited to, the following:
a. Violation of any terms or conditions of this permit;
b. Obtaining this permit by misrepresentation or failure to disclose
fully all relevant facts; or
c. A change in any condition that requires either a temporary or
permanent reduction or elimination of the authorized discharge.
M1O&I9

PART II
Permit No. NC
Toxic Pollutants
Notwithstanding Part II, B-4 above, if a toxic effluent standard or
prohibition (including any schedule of compliance specified in such
effluent standard or prohibition) is established under Section 307(a)
of the Act for a toxic pollutant which is present in the discharge and
such standard or prohibition is more stringent than any limitation for
such pollutant in this permit, this permit shall be revised or modified
in accordance with the toxic effluent standard or prohibition and the
permittee so notified.
6. Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing(Part II, A-5)
and "Power Failures" (Part II, A-7), nothing in this permit shall be
construed to relieve the permittee from civil or criminal penalties for
noncompliance pursuant to N. C. G. S. 143-215.6 or Section 309 of the
Federal Act, 33 USC 1319.
7. Oil and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the institution
of any legal action or relieve the permittee from any responsibilities,
liabilities, or penalties to which the permittee is or may be subject
under N. C. G. S. 143-215.75 et seq. or Section 311 of the Federal Act,
33 USC 1321.
8. Property Rights
The issuance of this permit does not convey any property rights in either
real or personal property, or any exclusive privileges, nor does it
authorize any injury to private property or any invasion of personal
rights, nor any infringement of Federal,State or local laws or regulations.
g. Severability
The provisions of this permit are severable, and if any provision of this
permit, or the application of any provision of this permit to any circum-
stance, is held invalid, the application of such provision to other cir-
cumstances, and the remAinder of this permit shall not be affected thereby.
M 11 &I1©

Expiration of pe,
Permittee is not authorizedi to discharge after the expiration date.
In order to receive authorization to discharge beyond the expiration
date, the pe mitt e shall submit such information, forms, and fees as
are required OY the agency authorized to issue Permits no later than 180
days prior to the expiration date Any discharge without a pe it after
the expiration will subject the pe.:ittee to enforceeoferce nt procedures
provided it N. C. s. 143-215.6 and gsc 1261 et see..
PART
PermitNo NC

PART
Permit No. NC
B. Previous Permits
All previous State water quality permits issued to this facility,
whether for construction or operation or discharge, are hereby revoked
by issuance of this permit. The conditions, requirements, terms, and
provisions of this permit authorizing discharge under the National
Pollutant Discharge Elimination System governs discharges from this
facility.
C. Construction
No construction of wastewater treatment facilities or additions thereto
shall be begun until Final. Plans and Specifications have been submitted
to the Division of Environmental Management and written approval and
Authorization to Construct has been issued. If no objections to Final
Plans and Specifications has been made by the DEM after 30 days following
receipt of the plans or issuance of this permit, whichever is latter, the
plans may be considered approved and construction authorized.
D. Certified Operator
Pursuant to Chapter 90A of North Carolina General Statutes, the permittee
shall employ a certified wastewater treatment plant operator in responsible
charge of the wastewater treatment facilities. Such operator must hold a
certification of the grade equivalent to the classification assigned to
the wastewater treatment facilities.
12

Part
STAFF EPORT AN'
IMS
Place v
!p
to
Date: July 29
3, By: David T. Adkins
4. 'parson contacted : Mr. Larry TeaE
TIMIS
WAS TER RT PEA SITE
x Extrusions, Tnc*
a 'County
5. Directions to site: The site is located on the north s
18483 in Cat ba County adjacent to Corm Scope, Inc.
The bearing and distance to the proposed point of effluent discharge
is: N/A. The co-ordinates of the discharge are: h 50 +45"
and W 81002105 ".
7. Size: There is adequate o
ea available.
b Topography: Graded level slog is less than 3%.
Location of nnarest dwelling: gone within 500 fit of the lac
0
S. R.
Receiving Streaa: Irrnamed tributary to Terrapin k.
(a) Classificaion: "C"
b Minimum 7-Day, 10-Year discharge at site: Big cfs (est
(c) Usage: Fishing, boating, wading and any other best usage except
for bathing or as a source of water supply for drinking, culinary
or fond --processing purges s.
Part 11 0ESCRIPTI3 i OF TREATMENT WORKS
onslsts of untreated contract a non-c
e hydropr€ess extrusion process.
11 I yA AT IU I AND RECOMMEN TI
The dlscha a consists of contact and no can ct ling water from the
hydropre:ss extrusion process. The only problemrill be heat as the contact
cooling water is to cool the extruded aluminum I
It is recommended an WOES Permitbe issued for this discharge.

ROD CLASSIFICATION
Primary highway,
hard surface improved sur'iacii
Secondary highu;ay,
hard surface -- Un nfrcM1eY rca
0 Interstate Route ,3 U. S. Route
Li
-duty road, i

De
a
James G. Martin, Governor
S. Thomas Rhodes, Secretary
Mr. Larry Teague
Alumax Extrusions
PO Box 1©0
Catawba, NC 28609
Dear Mr. Teague:
State of North Carolina
ent of Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
October 1, 1986
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Subject: Permit No. NC0048712
Alumax Extrusions
Catawba County
R. Paul Wilms
Director
In accordance with your application for discharge permit received on
May 19, 1986, we are forwarding herewith the subject State - NPDES permit.
This permit is issued pursuant to the requirements of North Carolina General
Statute 143-215.1 and the Memorandum of Agreement between North Carolina and
the US Environmental Protection Agency dated December 6, 1983.
If any parts, measurement frequencies or sampling requirements
contained in this permit are unacceptable to you, you may request a waiver
or modification pursuant to Regulation 15 NCAC .0508(b) by written request
to the Director identifying the specific issues to be contended. Unless
such request is made within 30 days following receipt of this permit, this
permit shall be final and binding. Should your request be denied, you will
have the right to request an adjudicatory hearing.
Please take notice that this permit is not transferable. Part II, 8.2.
addresses the requirements to be followed in case of change in ownership or
control of this discharge.
This permit does not affect the legal requirement to obtain other
permits which may be required by the Division of Environmental Management or
permits required by the Division of Land Resources, Coastal Area Management
Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Mr.
Dale Cvercash, at telephone number 919/733-5083.
Sincerely
OR1QtNi ,L SIGNED BY
A HI R PAaul EWilms
cc: Mr. Jim Patrick, EPA
Mooresville Regional Supervisor
Pollution Preventron Pays
P.O. Box 27687, Raleigh, North Carolina 27611 7687 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

Permit No. NC0048712
j
STATE OF NORTH CAROLINA
DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT
PERMIT
To Discharge Wastewater Under The
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions 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,
Alumax Extrusions, Inc.
is hereby authorized to discharge wastewater from a facility located
off of NCSR 1931
Catawba County
to receiving waters designated as an unnamed tributary to Terrapin.
Creek in the Catawba River Basin
in accordance with effluent limitations, monitoring requirements, and
other conditions set forth in Parts I, II, and III hereof.
This permit shall be effective October 1, 1986
This permit and the authorization to discharge shall expire at
midnight on September 30, 1991
Signed this day of October I, 1986
R. Pau Wl.im, Director
Division of Environmental Management
By Authority of the Environmental
Management Commission

Permit No. NC0048712
SUPPLEMENT TO PERMIT COVER SHEET
Alumax Extrusions, Inc.
is hereby authorized to:
1. Continue to discharge non -contact cooling water from a
facility located at Alumax Extrusions, Inc. in Catawba
County into an unnamed tributary to Terrapin Creek
which is classified Class "C" waters in the Catawba
River Basin (See Part III of this Permit).

A. EFFLUENT LIMITATION AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration,
the permittee is authorized to discharge from outfall(s) serial number(s) 001.
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristics
Flow
Temperature
Residual Chlorine
Discharge Limitations Monitoring Requirements
kg/day (lbs/day) Other Units (Specify)
Daily Avg. Daily Max. Daily Avg. Daily Max.
Measurement Sample *Sample
Frequency
Type Location
Monthly Instantaneous
** ** Monthly Crab
*** *** Monthly Grab
THERE SHALL BE NO CiIR01IUM ZINC, OR COPPER ADDED TO THE COOLING WATER
Sample locations: E - Effluent
**The temperature of the effluent shall be such as not to cause an increase in the temperature of th
receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed 2 C
***Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water (See Part III of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be ;
monitored monthly at the effluent by grab samples
There shall be no discharge of floating solids or visible foam in other than trace amounts.
co
rt
0
•

Part
FermitNo, NC
NDULF OF COMPLIANCE
The per ittee shall a hie e omp1ia ee with the efflneut
ationa specified for diacharges i accordance with the
oi.ilowing schedule
No cater than i4 calends days faii°i.. a' date identi
the above aeheduce of compliance, the permittee shal
either a
.report progress or, in the case of ape
being required hy ideuidentified dates, a written not
compliance normomP can e in the latter ease, the n
shall include the cause of noncompliance, any remedial act
taken, and the probability of aeeti.ng the neat scheduled
requirement.
14

C. MONITORING AND REPORTING
1. Representative Sampling
Samples collected and measurements taken as required herein
shall be characteristic of the volume and nature of the
permitted discharge. Samples collected at a frequency less
than daily shall be taken on a day and time that is
characteristic of the discharge over the entire period which
the sample represents.
2. Reporting
Monitoring results obtained during the previous month(s)
shall be summarized for each month and reported on a monthly
Discharge Monitoring Report (DMR) Form (DEM No. MR 1, 1.1,
2, 3,) or alternative forms approved by the Director, DEM,
postmarked no later than the 30th day following the
completed reporting period.
The first DMR is due on the last day of the month following
the issuance of the permit or in the case of a new facility,
on the last day of the month following the commencement of
discharge. Duplicate signed copies of these, and all other
reports required herein, shall be submitted to the following
address:
Division of Environmental Management
Water Quality Section
ATTN: Central Files
Post Office Box 27687
Raleigh, NC 27611
Definitions
a. Act or "the Act": The Federal Water Pollution Control
Act, also know as the Clean Water Act, as amended, 33 U.S.C.
1251, et. seq.
b. The "daily average" discharge means the total discharge
by weight during a calendar month divided by the number of
days in the month that the production or commercial facility
was operating. Where less than daily sampling is required by
this permit, the daily average discharge shall be determined
by the summation of all the measured daily discharges by
weight divided by the number of days sampled during the
calendar month when the measurements were made.
c. The "daily maximum" discharge means the total discharge
by weight during any calendar day.
15

d. DEM or Division: means the Division of Environmental
Management, Department of Natural Resources and Community
Development.
e. EMC: used herein means the North Carolina Environmental
Management Commission.
f. Flow, M3/day (MGD): The flow limit expressed in this
permit is the 24 hour average flow, averaged monthly. It is
determined as the arithmetic mean of the total daily flows
recorded during the calendar month.
g. Arithmetic Mean: The arithmetic mean of any set of
values is the summation of the individual values divided by
the number of individual values.
h. Geometric Mean: The geometric mean of any set of values
is the Nth root of the product of the individual values
where N is equal to the number of individual values. The
geometric mean is equivalent to the antilog of the
arithmetic mean of the logarithms of the individual values.
For purposes of calculating the geometric mean, values of
zero (0) shall be considered to be one (1).
i. Composite Sample: These samples consist of grab samples
collected at equal intervals and combined proportional to
flow, a sample continuously collected proportionally to
flow, or equal volumes taken at varying time intervals. If a
composite sample is obtained from grab samples, the
following requirements apply. The intervals between influent
grab samples shall be no greater than hourly. Intervals
between effluent grab samples shall be no greater than
hourly except where the detention time of the wastewater in
the facility is greater than 24 hours, in which case, the
interval between grab samples shall be no greater in number
of hours than the detention time in number of days;
provided, however, in no case may the time between effluent
grab samples be greater than six hours nor the number of
grab samples less than four during any discharge period of
24 hours or less.
j. Grab Sample: Grab samples are individual samples
collected over a period of time not exceeding 15 minutes;
the grab sample can be taken manually.
16

4. Test Procedures
Test procedures for the analysis of pollutants shall conform
to the EMC regulations published pursuant to N.C.G.S.
143-215.63 et seq, the Water and Air Quality Reporting Act
and to regulations published pursuant to Section 304(g), 33
t1SC 1314, of the Federal Water Pollution Control Act, As
Amended, and Regulation 40 CFR 136.
Recording Results
For each measurement or sample taken pursuant to the
requirements of this permit, the permittee shall record the
following information:
a. The exact place, date, and time of sampling;
b. The dates the analyses were performed; and
c. The person(s) who performed the analyses.
6. Additional Monitoring by Permittee
If the permittee monitors any pollutant at the location(s)
designated herein more frequently than required by this
permit, using approved analytical methods as specified
above, the results of such monitoring shall be included in
the calculation and reporting of the values is required in
the DMR. Such increased frequency shall also be indicated.
The DEM may require more frequent monitoring or the
monitoring of other pollutants not required in this permit
by written notification.
7. Records Retention
All records and information resulting from the monitoring
activities required by this Permit including all records of
analyses performed and calibration and maintenance of
instrumentation and recordings from continuous monitoring
instrumentation shall be retained for a minimum of three (3)
years. This period of retention shall be extended during the
course of any unresolved litigation or if requested by the
Division of Environmental Management or the Regional.
Administrator of the Environmental Protection Agency.
17

PART II GENERAL CONDITIONS
A. MANAGEMENT REQUIREMENTS
1. Change in Discharge
All discharges authorized herein shall be consistent with
the terms and conditions of this permit. The discharge of
any pollutant identified in this permit more frequently than
or at a level in excess of that authorized shall constitute
a violation of the permit. Any anticipated facility
expansions, production increases, or process modifications
which will result in new, different, or increased discharges
of pollutants must be reported by submission of a new NPDES
application or, if such changes will not violate the
effluent limitations specified in this permit, by notice to
the DEM of such changes. Following such notice, the permit
may be modified to specify and limit any pollutants not
previously limited.
2. Noncompliance Notification
The permittee shall report by telephone to either the
central office or appropriate regional office of the
division as soon as possible but in no case more than 24
hours or on the next working day following the occurrence or
first knowledge of the occurrence of any of the following:
a. Any occurrence at the water pollution control
facility which results in the discharge of significant
amounts of wastes which are abnormal in quantity or
characteristic, such as the dumping of the contents of a
sludge digester, the known passage of a slug of
hazardous substance through the facility or any other
unusual circumstances.
b. Any process unit failure, due to known or unknown
reasons, that render the facility incapable of adequate
wastewater treatment, such as mechanical or electrical
failures of pumps, aerators, compressors, etc.
c. Any failure of a pumping station, sewer line, or
treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion
of the influent to such station or facility.
d. Any time that self -monitoring information indicates
that the facility has gone out of compliance with its
NPDES permit limitations.
18

Persons reporting such occurrences by telephone shall also
file a written report in letter form within 15 days
following first knowledge of the occurrence.
• Facilities Operation
The permittee shall at all times maintain in good working
order and operate as efficiently as possible all treatment
or control facilities or systems installed or used by the
permittee to achieve compliance with the terms and
conditions of this permit.
4. Adverse Impact
The permittee shall take all reasonable steps to minimize
any adverse impact to navigable waters resulting from
noncompliance with any effluent limitations specified in
this permit, including such accelerated or additional
monitoring as necessary to determine the nature and impact
of the noncomplying discharge.
5. Bypassing
Any diversion from or bypass of facilities is prohibited,
except (i) where unavoidable to prevent loss of life or
severe property damage, or (ii) where excessive storm
drainage or runoff would damage any facilities necessary for
compliance with the effluent limitations and prohibitions of
this permit. All permittees who have such sewer bypasses or
overflows of this discharge shall submit, not later than six
months from the date of issuance of this permit, detailed
data or engineering estimates which identify;
a. The location of each sewer system bypass or overflow;
b. The frequency, duration and quantity of flow from
each sewer system bypass or overflow.
The permittee shall report by telephone to either the
central office or appropriate regional office of the
division as soon as possible but in no case more than 24
hours or on the next working day following the occurrence or
first knowledge of the occurrence of any diversion from or
bypass of facilities.
19

. Removed Substances
Solids, sludges, filter backwash, or other pollutants
removed in the course of treatment or control of wastewaters
shall be disposed of in accordance with NCGS 143-215.1 and
in a manner such as to prevent any pollutant from such
materials from entering waters of the State or navigable
waters of the United States.
7. Power Failures
The permittee is responsible for maintaining adequate
safeguards to prevent the discharge of untreated or
inadequately treated wastes during electrical power failures
either by means of alternate power sources, standby
generators or retention of inadequately treated effluent.
. Onshore or Offshore Construction
This permit does not authorize or approve the construction
of any onshore or offshore physical structures or facilities
or the undertaking of any work in any navigable waters.
B. RESPONSIBILITIES
1. Right of Entry
The permittee shall allow the Director of the Division of
Environmental Management, the Regional Administrator, and/or
their authorized representatives, upon the presentations of
credentials:
a. To enter upon the permittee's premises where an
effluent source is located or in which any records are
required to be kept under the terms and conditions of
this permit; and
b. At reasonable times to have access to and copy any
records required to be kept under the terms and
conditions of this permit; to inspect any monitoring
equipment or monitoring method required in this permit;
and to sample any discharge of pollutants.
1 10

2. Transfer of Ownership or Control
This permit is not transferable. In the event of any
change in control or ownership of facilities from which the
authorized discharge emanates or is contemplated, the
ermittee shall notify the prospective owner or controller
y letter of the existence of this permit and of the need to
obtain a permit in the name of the prospective owner. A copy
of the letter shall be forwarded to the Division of
Environmental Management.
. Availability of Reports
Except for data determined to be confidential under NCGS
143-215.3(a) (2) or Section 308 of the Federal Act, 33 USC
1318, all reports prepared in accordance with the terms
shall be available for public inspection at the offices of
the Division of Environmental Management. As required by the
Act, effluent data shall not be considered confidential.
Knowingly making any false statement on any such report may
result in the imposition of criminal penalties as provided
for in NCGS 143-215.1(b) (2) or in Section 309 of the
Federal Act.
4, Permit Modification
After notice and opportunity for a hearing pursuant to NCGS
143-215.1(b) (2) and NCGS 143-215.1(e) respectively, this
permit may be modified, suspended, or revoked in whole or in
part during its term for cause including, but not limited
to, the following;
a. Violation of any terms or conditions of this permit;
b. Obtaining this permit by misrepresentation or failure
to disclose fully all relevant facts; or
c. A change in any condition that requires either a
temporary or permanent reduction or elimination of the
authorized discharge.
I 11

5. Toxic Pollutants
Notwithstanding Part II, 3-4 above, if a toxic effluent
standard or prohibition (including any schedule of
compliance specified in such effluent standard or
rohibition) is established under Section 307(a) of the Act
for a toxic pollutant which is present in the discharge, if
such standard or prohibition is more stringent than any
limitation for such pollutant in this permit, this permit
shall be revised or modified in accordance with the toxic
effluent standard prohibition and the permittee so notified.
6. Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part
II, A-5) and "Power Failures" (Part 11, A-7), nothing in
this permit shall be construed to relieve the permittee from
any responsibilities, liabilities, or penalties for
noncompliance pursuant to NCGS 143-215.3, 143-215.6 or
Section 309 of the Federal Act, 33 USC 1319. Furthermore,
the permittee is responsible for consequential damages, such
as fish kiliS, even though the responsibility for effective
compliance may be temporarily suspended.
7. Oil and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the
institution of any legal action or relieve the permittee
from any responsibilities, liabilities, or penalties to
which the permittee is or may be subject to under NCGS
143-215.75 et seq. or Section 311 of the Federal Act, 33 USC
1321. Furthermore, the permittee is responsible for
consequential damages, such as fish kills, even though the
responsibility for effective compliance may be temporarily
suspended.
. Property Rights
The issuance of this permit does not convey any property
rights in either real or personal property, or any exclusive
privileges, nor does it authorize any injury to private
property or any invasion of personal rights, nor any
infringement of Federal, State or local laws or regulations.
1 12

9. Severability
The provisions of this permit
provision of this permit to
invalid, the application of
circumstances, and the remainder
affected thereby.
10. Expiration of Permi
are severable, and if any
any circumstance is held
such provision to other
of this permit shall not be
Permittee is not authorized to discharge after the
expiration date. In order to receive authorization to
discharge beyond the expiration date, the permittee shall
submit such information, forms, and fees as are required by
the agency authorized to issue permits no later than 180
days prior to the expiration date. Any discharge without a
permit after the expiration will subject the permittee to
enforcement procedures as provided in NCGS 143-215.6, and 33
USC 1251 et seq.
113

PART III OTHER REQUIREMENTS
A. Previous Permits
All previous State water quality permits issued to this
facility, whether for construction or operation or discharge,
are hereby revoked by issuance of this permit. The conditions,
requirements, terms, and provisions of this permit authorizing
discharge under the National Pollutant Discharge Elimination
System govern discharges from this facility.
B. Construction
No construction of wastewater treatment facilities or additions
thereto shall be begun until Final Plans and Specifications have
been submitted to the Division of Environmental Management and
written approval and Authorization to Construct has been issued.
C. Certified Operator
Pursuant to Chapter 90A of North Car mina General Statutes, the
permittee shall employ a certified wastewater treatment plant
operator in responsible charge of the wastewater treatment
facilities. Such operator must hold a certification of the grade
equivalent to or greater than the classification assigned to the
wastewater treatment facilities.
D. Groundwater Monitoring
The permittee shall, upon written notice from the Director of
the Division of Environmental Management, conduct groundwater
monitoring as may be required to determine the compliance of
this NPDES permitted facility with the current groundwater
standards.
E. Limitations Reopener
This permit shall be modified or alternatively, revoked and
reissued, to comply with any applicable effluent guideline or
water quality standard issued or approved under Sections
302 (b) (2) (c) ► and (d) , 304 (b) (2) , and 307 (a) (2) of the Clean
Water Act, if the effluent guideline or water quality standard
so issued or approved:
1. contains different conditions or is otherwise more
stringent than any effluent limitation in the permit; or
2. controls any pollutant not limited in the permit.
114

Part I11 Continued
Permit No. NC0048712
F. Toxicity Reopener
This permit shall be modified, or revoked and reissued to
incorporate toxicity limitations and monitoring requirements in the
event toxicity testing or other studies conducted on the effluent
or receiving stream indicate that detrimental effects may be
expected in the receiving stream as a result of this discharge.
G. The permittee shall not use any biocides except these approved in
conjunction with the permit application. The permittee shall
notify the Director in writing not later than ninety (90) days
prior to instituting use of any additional biocide used in cooling
systems which may be toxic to aquatic life other than those
previously reported to the Division of Environmental Management.
Such notification shall include completion of Biocide Worksheet
Form 101 and a map locating the discharge point and receiving
stream.

Permit No. NC0048712
STATE OF NORTH CAROL NA
DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT
DIVISION OF ENVIRONMENTAL MANAGEMENT
P E RMT
To Discharge Wastewater Under The
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions 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,
Alumax Extrusions, Inc.
is hereby authorized to discharge wastewater from a facility located
off of NCSR 1931
Catawba County
to receiving waters designated as an unnamed tributary to Terrapin
Creek in the Catawba River Basin
in accordance with effluent limitations, monitor
other conditions set forth in Parts I, II, and I
This permit shall be effective
requirements, and
hereof.
This permit and the authorization to discharge shall expire at
midnight on
Signed this day of
R. Paul Wilms, Director
Division of Environmental Management
By Authority of the Environmental.
Management Commission

Permit N. NC0048712
SUPPLEMENT TO PERMIT COVER SHEET
Alumax Extrusions, Inc.
hereby authorized to:
1. Continue to discharge non -contact cooling water from a
facility
l
o
cated at Alumax Extruninnb* Inc. in Catawba
County into an unnamed tributary to Terrapin Creek
which is classified Class "C" waters in the Catawba
River Basin (See Part 111 of this Permit).

A. EFFLUENT LIMITATION AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration,
the permittee is authorized to discharge from outfall(s) serial number(s) 001.
Such discharges shall be limited and monitored by the permittee as specified below:
uent Characteristics Discharge Limitations
kg/day ( day) Other Units (Specify)
Daily Avg. Daily Max. Daily Avg. Daily Max.
Flow
Tempera
re
'Residual Chlorine
THERE SHALL BE NO CHROMIUM ZINC, OR COPPER ADDED TO THE COOLING WATER
Sample locations:
Effluent, U - Upstream, D - Downstream
Monitoring Requirements
Measurement
Frequency
Sample *Sample
Type Location
Monthly instantaneous E
Monthly Grab E,U,D
Grab E
Monthly
**The temperature of the effluent shall be such as not to cause an increase in the temperature of the
receiving stream of more than 2.8°C and in no case cause the ambient water temperature to exceed 32 C
***Monitoring requirements only apply if chlorine is added to the cooling water.
The permittee shall obtain authorization from the Division of Environmental Management prior
to utilizing any biocide in the cooling water (See Part III of this Permit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be
monitored monthly at the effluent by grab samples
There shall be no discharge of floating solids or visible foam in other than trace amounts.

014
Part III Continued
Permit No. NC0048712
F. Toxicity Reopener
This permit shall be modified, or revoked and reissued to
incorporate toxicity limitations and monitoring requirements in the
event toxicity testing or other studies conducted on the effluent
or receiving stream indicate that detrimental effects may be
expected in the receiving stream as a result of this discharge.
The permittee sha11 not use any biocides except these approved in
conjunction with the permit application. The permittee shall
notify the Director in writing not later than ninety (90) days
prior to instituting use of any additional biocide used in cooling
systems which may be toxic to aquatic life other than those
previously reported to the Division of Environmental Management.
Such notification shall include completion of Biocide Worksheet
Form 101 and a map locating the discharge point and receiving
stream.

Ja7r1e-s, B.
rGo,ierror
Larry Teague
Alumax Extrusions, Inc.
P. 0. Box 100
Catawba, NC 28609
Dear r. Teague:
North care ina Departmenof Naturat
Resources &community Development
SeL l;ary
January 4, 1984
Subject: Mod ification'to 1 PDES
Permit No. NC0048712
Alumax Extrusions, Inc.
T
DiVfSiON OF
FNVE'RONMENTAL
MANAGEMENT'
Rohm. F, Hems
D irect 7r
33 7O 5
In accordance with your request for Permit modification received December
21, 1983, we are forwarding herewith modifications to the subject permit.
These modifications delete the upstrea and downstream self --monitoring from
the NPDES Permit. All other terms and conditions contained in the original
permit remain unchanged and in full effect. These modifications are issued pursuant
to the requirements of North Carolina General Statutes 143-215.1 and the Memorandum
of Agreement between North Carolina and the U. S. Environmental Protection Agency.
If any parts, requirements, or limitations contained in these modifications
are unacceptable to you, you have the right to an adjudicatory hearing before
a hearing officer upon written demand to the Director within 30 days following
receipt of these modifications, identifying the specific issues to be contended.
Unless such demand is made, these modifications shall be final and binding.
If you have any questions concerning these modifications, please contact Ms.
Helen S. Fowler, at telephone number 919/733-5083.
Sincerely yours,
Robert F. Helrns
cc: Mr. Jim Patrick, EPA
Mooresville Regional Office
Mooresville Regional Manager
POLL ITIU_VPREJ'LXTI °PAYS