NC0083801_Complete File - Historical_20171231

Mid -At
Associates, P.
1310 H corporation. Parkway . Raleigh, INC 27610 [phone]
R,C, Box 43 183 . Raleigh, NC 2'7629 FAX [phone]
December 19, 1996
Mr. D. Rex Gleason, P.E.
Water Quality Regional Supervisor
North Carolina Department of Environment,
Health and Natural Resources
Water Quality Section
919 North Main Street
Mooresville, North Carolina 28115
I'T OF
FINVIROMM. ENT, HEALTr7
NA-I'()RAI. HrrRC?UriITS
DEC 2 3 1996
Subject: RESPONSE TO NOTICE OF RECOMMENDATION FOR ENFORCEMENT
NOTICE OF VIOLATION
UNICON CONCRETE PRODUCTS, INC. (FORMERLY AMERICAN
CONCRETE PRODUCTS, INC.)
NEWTON, NORTH CAROLINA
NPDES GENERAL PERMIT NO. NCG140000
Dear Mr. Gleason:
On behalf of Unicon Concrete, Inc. (formerly American Concrete Products, Inc.), Mid -
Atlantic Associates would like to respond to the Notice of Recommendation for
Enforcement, Notice of Violation dated December 11, 1996. This notice indicated
that the facility was in violation of it's NPDES permit and NCGS 143.215.1(a)(6)
based on the following conditions:
The effluent discharged from the facility had a pH value in violation of
the permit limits (cut-off concentrations);
The discharge of this effluent into McLin Creek resulted in violation of
the stream's water quality standard for pH; and
It appeared that concrete slurry was being discharged into the creek.
Mid -Atlantic visited the subject site on December 1 7, 1996 and met with Mr. Andy
Stankwytch of Unicon to discuss potential reasons for these violations and
practices/processes which may be implemented to lower the pH and total volume of
the effluent discharged from the site, Mr. Stankwytch indicated that during the time
period in question, wet concrete was being dumped on the ground at the site instead
of into the sedimentation basin. Heavy rainfalls during this time appeared to wash
some concrete slurry into the roadside ditch adjacent to the site. Based on the
discussions during our site visit, Unicon agreed to implement the following best
management practices (BMPs) at the site in an attempt to lower the pH and total
volume of the effluent discharged from the site:
Effective immediately, concrete trucks returning to the site will dump
excess concrete directly into the sedimentation basin.

Response to Notice of Recommendation for Enforcement
Unicon Concrete, 'Inc. (Formerly American Concrete...),
Newton Facility
December 19, 1996
Page 2 _
• Effective immediately, Unicon will implement a water recycling program
at the sedimentation basin for truck wash -out operations. This recycling
program will reduce the amount of water used at and discharged from
the sedimentation basin' during. truck wash -out - operations , by
approximately 1,000 to 1,500-gallons per day.
• The sedimentation basin will be regularly inspected and cleaned out
when half -full. -The basin will be cleaned out only during dry periods
when the sediment/slurry will have time to set-up prior to anticipated
rainfall 'events. -
• Within 90 days, Unicon will construct ad additional'sedimentation basin
and implement a water recycling program for truck rinsing and concrete
batching operations. By using recycled water in .the batching process,
up, to 3,000-gallons of:water per day will be eliminated from the site's
effluent stream. This additional sedimentation basin will also provide
additional space and time for the settlement of suspended solids prior to
discharging off site. This basin will also be'cleaned out only during dry.
periods ,when the sediment/slurry will have_ time to set-up prior to
anticipated rainfall events. • -
• In accordance with their present Stormwater Pollution Prevention Plan
(SWPPP), Unicon will continue to maintain the straw bale and -silt screen
.barriers at the 'feeder ditch to McLin Creek. •
Upon, implementation of the above practices, Unicon will evaluate their effectiveness
and determine the potential need for additional measures.' If necessary, additional
BMPs, operational changes and/or processes will be investigated. If you have any
questions concerning the contents of this letter, please feel free contact me at 919-
250-9918 or Mr. Andy Stankwytchi-of Unicon at 704-872-9566.
Sincerely,
MID -ATLANTIC ASSOCIATES, P.A.
• Darin M. McClure, P.E.
Senior Engineer -
DMMfbro
cc: Mr. Andy Stankwytch, Unicon Concrete, Inc.
Mr. Kenneth.Combs, Unicon Concrete, Inc.

5083.
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 21, 1994
Mr. David P. Boden
Engineering and Environmental Consulting
3680 Lakeview Drive
Pfafftown, NC 27040
Subject: NPDES Permit Application Return
NC0083801
American Concrete Prod. - Newton
Catawba County
Dear Mr. Boden:
On October 5, 1993 the Division of Environmental Management received your
application for the discharge of wastewater from the Newton facility. The Division is
returning your application based on your letter dated November 21, 1993. Unfortunately,
the application fee cannot be held until you submit a recycling permit application. The
subject application is enclosed and the $400.00 fee will be returned under a separate cover.
If in the future, you determine that you wish to have a discharge, you must first
apply for and receive a new NPDES permit. Discharging without a valid NPDES permit it
subject the discharger to a civil penalty of up to $10,000 per day.
If you have any question regarding this matter please contact Jay Lucas at (919) 733-
P.E.
Enclosure
P.Q. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

BODEN
ENGINEER
i0.1114iET
°MULLING
Mr. Jay Lucas
NCDEHNR
P.E. Box 29535
Raleigh
NC 27626-0535
Application No.
Application No. NCO683780 :Hickory Facility, American Concrete Products,
N r' rsj°x�T r
pplat INT,
NOV 2 4 1993
E"Ir'rONM tiTA1. Y ud
%Yi11E RECICWI C,RCE
3680 LAKEVIEW DRIVE
PFAFFTOWN, N.C. 27040 U.S.A.
PHONE: [phone]
FAX: [phone]
November 21. 1993,
Dear Mr, Lucas:
fte
I am writing to advise you of some decisions taken recently in respect to the referenced
NPDES permit applications.
During a recent review of process and storm water discharges at the Hickory and Newton.
facilities conducted with Mr. Michael Parker of the Mooresville Regional Office it was
agreed that a more appropriate course of action would be to separate the process and
storm water discharges and recycle the process water so that the discharge will be
eliminated. Conceptual plans for the engineering work to accomplish this were reviewed
with Mr. Parker on November 17th and it was agreed that these were appropriate to
accomplish the desired objective.
The proposed solution is to separate process and storm water by constructing a series of
berms to deflect storm water around those areas where process water is discharged, and to
construct retention and recycling systems for the process water, which will then be reused
in the concrete manufacturing process. In this way all discharges of process water to the
surface waters will be eliminated. Consequently the requirement to obtain NPDES permits
for the discharge of process water will be voided.
As you willnote from Application No.. NC0083780, the Hickory facility already operates
a recycle system that is permitted under Permit No. WQ0004266, therefore only the
Newton facility will require a new recycling system.
We respectfully request that you:
1, Void the NPDES permit application lbr the Hickory
application fee to the undersigned.
a
y and refund the

2. Void the NPDES permit application for the Newton facility and credit the
application fee towards our application for a recycle facility. The permit application is
currently being prepared and will be forwarded to you in due course,
I trust that you will agree that this is a preferable course of action for American Concrete
Products, Inc. since it will entirely eliminate process water discharges from the two plants.
If you have any questions or comments concerning this letter please contact the
undersigned.
Y©sincerely,
Dr. David P. Baden.
cc. Mr. Michael. Parker, NCDEHNR Mooresville Regional Office /
Mr. Andy Stankwytch, American Concrete Products, Inc.

NG AND E
0N5Uti1N6
Mr. Michael Parker
NCDEHNR
919 North Main Street.
Mooresville
North Carolina 28115.
Dear Mr. Parker:
3680 IAKEV1EW DRIVE
PFAFFTOWN, N.E. 27040 U.S.A.
PHONE: [phone]
FAX: [phone]
November 9, 1993
I am writing to outline in concept form our plans for the separation of process water and
storm water at the Hickory ants. ° .;pants of American Concrete Products, Inc. At
both of these plants there is some mixing of process and storm water which, on occasion
results in discharges to the local surface waters. The discharge of storm water will be
regulated by the General Permit for our industry group and we were in the process of
making an application for a permit to discharge process water from both plants
(Application Nos, NC0083801 and NC0083780), At the recent meeting with Mr, Andy
Stankwytch you requested that we draw up plans to separate storm water from process
water and recycle the process water so that process water permits would not be required.
We agreed to study this and, following our investigation, we believe that your suggestion
is feasible. We, therefore, would like you to review the following conceptual plans. If
these meet with your approval we will proceed to draw up full engineering plans.
1. Hickory:
Please see attached concept sketch,
There are three sources of process water at the site. These are:
- the concrete manufacturing plant
the truck bowl cleaning operation
- the concrete reclamation facility.
Water from these sources is collected in, a retention pond for recycling.
The topography of the plant is such that storm water flows through the concrete
manufacturing plant and also across the plant yard into the retention ponds, During
periods of heavy rain, this storm water causes the retention ponds to overflow resulting in
discharges of mixed storm water and process water to Lyle Creek.

Our plan is to construct berms around the concrete manufacturing plant and the concrete
reclamation plant to divert the storm water away from the sources of process water. Truck
washing will be conducted inside the berm that surrounds the retention pond so that all
run-off from this operation will be trapped in the ponds. Process water from the concrete
plant will be prevented from coming into contact with storm water by being captured by
the berm and directed to an underground drain that will convey it to the retention pond. In
this way all process water will be collected in the retention pond, from which it will be
recycled into the concrete manufacturing process, Storm water from the plant yard will be
diverted around the retention pond by a second system of berms and will be channeled
directly into the feeder to Lyle Creek.
In this way the mixing of storm and process waters will be eliminated, storm water will be
directed into the Lyle Creek feeder and process water will be recycled into the concrete
plant.
The storm water will be regulated by the General Industry NPDES Storm Water Permit
and, since there will be no discharge of process water, a NPDES Process Water Permit
should not be required.
2. Newton
Please see attached concept sketches.
There are two sources of process water at the site. These are:
- the concrete manufacturing plant
- the truck bowl cleaning operation.
Water from the concrete plant flows through a concreted channel into a retention system
for clarification and, from there into McLin Creek. Water from the truck bowl cleaning
operation is collected in a retention pond where the solids are allowed to settle before they
are pumped out and stored on the site for future use as landfill.
The topography of the site is such that during heavy rain storm water flows into the
concreted channel where it is mixed with the process water and is subsequently discharged
into McLin Creek. Storm water also flows into the truck wash retention pond which
causes it to overflow into the creek,

Truck cleaning to remove residual concrete will be discontinued at this site and will be
transferred to the Hickory facility. This will eliminate one of the sources of process water.
A berm will be constructed along the concreted channel to divert storm water run-off from
the plant yard away from the process water. A. new retention pond system will be
constructed alongside the existing process water drain to trap and clarify process water for
recycling into the concrete manufacturing process. This will be achieved by increasing the
height of the concrete retaining wall along the existing drain and excavating new
settlement ponds parallel to the drain. We estimate that the new retention system will be
approximately 15 feet wide by 25 feet long. It will be composed of two chambers, the
primary chamber being 10 feet long and 6 feet deep, and the secondary chamber being 15
feet long and decreasing in depth from 6 feet to ground level. Water from the secondary
chamber will be pumped to the concrete plant for re -use.
We believe that these changes will effectively separate process water and storm water. All
storm water will be discharged into McLin Creek while all process water will be recycled,
The storm water discharge will be regulated by the General Industry NPDES Storm Water
Permit and, since there will be no discharge of process water, a NPDES Process Water
Permit should not be required.
We would like to meet with you to review these concepts to ensure that they satisfy your
requirements, If you approve them, we will proceed to prepare full engineering plans.
I would like to assure you that American Concrete Products, Inc. wishes to work with you
in a timely manner to resolve this situation.
Yours ncerely,
Dr, David P. Boden

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