NC0080586_Permit (Issuance)_20040213

NPDES DOCUHENT ! CANNINO COVER SHEET
NC0080586
Carolina Stalite
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Renewal Application
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
February 13, 2004
This document printed oa reuse paper - ignore any
content on the reYerse side

Michael F. Easley, Governor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
February 13, 2004
Mr. Tim Agner
Carolina Stalite
P.O. Box 1037
Salisbury, North Carolina 28145-1037
Subject: Issuance of NPDES Permit NC0080586
Carolina Stalite
Rowan County
Dear Mr. Agner:
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).
This final permit includes no major changes from the draft permit sent to you on December 17,
2003.
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 (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such
demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division
may require modification or revocation and reissuance of the permit. This permit does not affect the
legal requirements to obtain other permits which may be required by the Division of Water Quality or
permits required by the Division of Land Resources, the 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 Toya Fields at telephone number [phone], extension 551.
Sincerely,
ORIGINAL SIGNED BY
Tom Behnick
Alan W. Klimek, P.E.
cc: Central Files
Mooresville Regional Office/Water Quality Section
NPDES Unit
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
toya.fieldsabncmail.net - [phone] x551
FAX [phone]
On the Internet at http://h2o.enr.state.nc.us/

Permit: NC0080586
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
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,
Carolina Stalite Company
is hereby authorized to discharge wastewater from a facility located at
Carolina Stalite
Old Beatty Ford Road
South of Gold Hill
Rowan County
to receiving waters designated as an Unnamed Tributary to Long Creek in the Yadkin -Pee Dee
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 March 1, 2004.
This permit and authorization to discharge shall expire at midnight on February 28, 2009.
Signed this day February 13, 2004.
ORIGINAL SIGNED BY
Tom Belnick
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit: NC0080586
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked. As of this permit issuance, any previously issued permit bearing this number is no longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the
permit conditions, requirements, terms, and provisions included herein.
Carolina Stalite Company is hereby authorized to:
1. Continue to operate an existing wastewater treatment system consisting of the
following treatment units:
• Three stormwater catchbasins
• Four settling basins with solids storage
The facility is located at the Carolina Stalite Company on Old Beatty Ford Road,
South of Gold Hill in Rowan County.
2. Discharge treated wastewater from said treatment works at the location specified on
the attached map through outfall 001 into an unnamed tributary to Long Creek
which is classified C waters in the Yadkin -Pee Dee River Basin.

Latitude:
Longitude:
Quad #:
Stream Class:
Receiving Stream:
Permitted Flow:
Facility Information
35°30'10" Sub -Basin: 03-07-13
80°19'42"
E 17 SE
C
Unnamed Tributary to Long Creek
N/A

Permit: NC0080586
A. {1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date to the permit and lasting until expiration, the Permittee
is authorized to discharge treated wastewater from outfall(s) 001. Such discharges shall be limited and
monitored by the Permittee as specified below:
ARAC. .J R TIC
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Flow
2/Month
Instantaneous
E
Temperature, °C2
2/Month
Grab
E
Settleable Solids
0.1 ml/L
0.2 ml/L
2/Month
Grab
E
Turbidity3
2/Month
Grab
U, D
pH4
_
2/Month
Grab
E
Footnotes:
1. Sample Location: E - Effluent, U -Upstream, D - Downstream
2. The temperature of the effluent shall not 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.
3. The effluent shall not cause the turbidity of the receiving stream to exceed 50 NTU. If natural
background conditions in the receiving stream (upstream) are greater than 50 NTUs then the effluent
shall not cause an increase in the turbidity of the receiving stream.
4. The pH of the effluent shall be with the range of 6.0 to 9.0 on the standard pH scale.
There shall be no discharge of floating solids or foam visible in other than trace amounts.

SOC PRIORITY PROJECT: Yes_ No X
To: Permits and Engineering Unit
Water Quality Section
Attention: Valery Stephens
Date: February 9, 2004
NPDES STAFF REPORT AND RECOMMENDATION
County: Rowan
MRO# 03-95
Permit No. NC0080586
PART I - GENERAL INFORMATION
1. Facility and address: Carolina Stalite Company
Post Office Box 1037.
Salisbury, North Carolina 28145-1037
E 3 1 6 2004
2. Date of investigation: February 5, 2004
3. Report prepared by: Samar Bou-Ghazale, Env. Engineer.I
4. Persons contacted and telephone number: Mr. Tim Agner, Manager Engineering Services; Tel#
704/279-2166.
5. Directions to site: From the intersection of US Hwy 52 and SR 1221 (Old Beatties Ford
Road), travel west on SR 1221 approximately 0.7 mile. The Carolina Stalite Company is
located on the south (left) side of SR 1221.
6. Discharge point(s). List for all discharge points:
Latitude: 35° 30' 10" Longitude: 80° 19' 42"
Attach a U.S.G.S. map extract and indicate treatment facility site and discharge point on map.
USGS Quad No.: E 17 SE USGS Name: Gold Hill, NC
7. Site size and expansion area consistent with application?
Yes X No_ If No, explain:
8. Topography (relationship to flood plain included): Flat to moderate slopes; the treatment
facilities are not located within the 100 year flood plain.
9. Location of nearest dwelling: None within 500 feet of the treatment facilities.

10. Receiving stream or affected surface waters: UT to Long Creek
a. Classification: C
b. River Basin and Subbasin No.: Yadkin -Pee Dee & 03-07-13
c. Describe receiving stream features and pertinent downstream uses: Discharge enters a
small wet -weather drainage ditch. Downstream uses are typical for class C waters.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted: Intermittent, dependent on rainfall
b. What is the current permitted capacity of the wastewater treatment facility? N/A
c. Actual treatment capacity of the current facility (current design capacity)? N/A
d. Date(s) and construction activities allowed by previous Authorizations to Construct
issued in the previous two years: N/A.
e. Please provide a description of existing or substantially constructed wastewater
treatment facilities: The existing facilities consist of three (3) stormwater catch basins,
and four (4) settling ponds placed in series. Wastewater is generated from dust
control, crushing and screening operation.
f. Please provide a description of proposed wastewater treatment facilities: N/A.
g. Possible toxic impacts to surface waters: None that we are aware.
h. Pretreatment Program (POTWs only): N/A.
2. Residuals handling and utilization/disposal scheme: Tailing are used onsite as fill or mixed
into the product.
3. Treatment plant classification : N/A
4. SIC Code(s): 3295
Primary: 41 Secondary: 73,15,14,42
Main Treatment Unit Code: 50011
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? N/A.
Page 2

2. Special monitoring or limitations (including toxicity) requests: None.
3. Important SOC, JOC or Compliance Schedule dates: N/A
4. Alternative Analysis Evaluation: (Has the facility evaluated all of the non -discharge options
available. Please provide regional perspective for each option evaluated): N/A
5. Air quality and/or groundwater concerns or hazardous materials utilized at this facility that
may impact water quality, air quality or groundwater? The facility holds one air quality
permit. The facility was permitted by the Groundwater Section for remediation of
petroleum contaminated soils; the remediation was completed in 1992 according to Tim
Agner, Manager Engineering Services with Carolina Stalite Company. No known air
quality, groundwater or hazardous materials concerns at this time.
PART IV - EVALUATION AND RECOMMENDATIONS
The Permittee, Carolina Stalite has applied for permit renewal for its facility. Carolina
Stalite produces lightweight aggregate materials for use in the building industry. Coal is the main
fuel used in the operation of the kilns. Carolina Stalite ceased the burnings of petroleum
contaminated soil in the kilns. Water is pumped from one of the settling pond and used for the
crushing and screening operation. The wastewater treatment facility was in good operating
condition at the time of the inspection.
Pending review and approval by P&E, it is recommended that the permit be renewed as
requested.
Signature of Report ' eparer
Water Q
2-
Date
Regional Supervisor
Page 3

Try
•
L1 1 ' ~ No. 50002
.' PUBLIC NOTICE
"7` State of North Carolina
J h N - 2 004 ? -� , ENVIRONMENTAL
liL Salisbury
+�MANAGEMENT
YK n O� COMMISSION/ NIT
NPDES UNIT
t
1617 Mail Service Center
L�;'.Nil•1,h ATEi? C-,�-.' 1 Y AFFIDAVIT OF PUBLICATION Raleigh, NC 27699-1617
Notification of Intent to
• Issue a NPDES
• Wastewater Permit .
On the basis of thorough
staff review and applipa-
NCDENR/DWQ/NPDES lion of NC General Statue
143.21, Public law 92-500
Attn: Valery Stephens and other lawful standards
1617 Mail Service Center and regulations, the North
Carolina Environmental
Raleigh, NC 27699-1617 Management Commission
proposes to issue a Na'-
tional Pollutant Discharge
#50002 Elimination System
(NPDES) wastewater dis-
_ charge permit to the per -
Due: $75.42 Y son(s) listed below effec-
t five 45 days from the pub
ea)
= fish date of this notice..
Written .comments regard-
ing the 'proposed permit
will be accepted until 30
days after the publish date
of this notice. All com-
ments received prior to
ithat date are considered in
the final determinations re-
garding the proposed per-
mit. The. Director of the NC
Before the undersigned a Notary Public of said County and State, duly commissioned, qualified, and authorized by law Division 'of Water Quality
administer oaths, personally appeared WINFRED MENTION, who being first duly sworn, deposes and says that he is -may decide to hold a pub -
ASSISTANT ADVERTISING DIRECTOR of the Salisbury Post, published, issued and entered as second class mail in thtlic meeting for the pro -
City of Salisbury, in said County and State, that he is authorized to make this affidavit and sworn statement, that the poste permit should the
notice or other legal advertisement a true copyof which is attached hereto, waspublished in the SalisburyPost, on the cant de reo of p a signfi-
g degree of public inter -
following dates: est.
Copies of the draft permit
and other supporting infor-
mation on file used to de-
termine conditions present
and that the said newspaper in which such notice, paper document or legal advertisement was published was, at the In the draft permit are
time of each and every such publication, a newspaper meeting all of the requirements and qualifications of Section 1- available upon request
of the General Statutes of North Carolina and was a qualified newspaper within the meaning of Section 1-597 of the and payment of the costs
General Statutes of North Carolina. of reproduction. Mail com-
ments and/or requests for
information to the NC Divi-
sion of Water Quality at
the •above address or call
} Ms. Valery Stephens at
'�J✓ ��Io. [phone], extension
520. Please include the
NPDES permit number (at-
tached) in any communi-
Sworn and subscribed before me carton. Interested personn
may tals0 visit the Division
This 30th day of December, 2003 of Water Quality at 512 N.
Salisbury Street, Raleigh,
NC 27604-1148 between
the hours of 8:00 a.m. and
December 19, 2003
NORTH CAROLINA
ROWAN COUNTY
My Commission Expires
4
NOTARY PUB
a a9-
5:00 p.m. to review Infor-
mation on file..
Carolina Stalite, Old Beat-
ty Ford Rd., Gold Hill, NC,
28071, Rowan County,
has applied for renewal of
NPDES permit
NC0080586 discharging to
an unnamed tributary to
Long Creek In the Yadkin
Pee Dee River Basin. No
parameters are currently
water quality limited. How-
ever, this discharge may
impact future allocation of
this resource.
PO Box 4639 Salisbury, NC 28145-4639
[phone]

SHIPPING POINT —GOLD HILL, N. C.
y (1 vim
I STALITE'
[AROIiNA STALITE COMPANY
MANUFACTURERS OF LIGHTWEIGHT AGGREGATE "STALITE"
PHONE [phone] FAX [phone]
DRAWER 1037 SALISBURY, N.C. 28145-1037
August 23, 2003
Mrs. Valery Stephens
NC DENR
Division of Water Quality
1641 Mail Service Center
Raleigh NC 27699-1642
IECLEOVs
I SEP - 8 2003
DENR-WATER QUALITY
POINT SOURCE BRANCH
Subject: NPDES Permit NC0080586 Renewal
Carolina Stalite Company, Rowan County
Dear Mrs. Stephens,
Carolina Stalite Company formally requests the renewal of NPDES Permit
NC0080586 for our facility in Gold Hill, NC. The facility has remained
unchanged during the past permit cycle with no planned changes to any of the
existing facilities. The average daily Discharge for the past 12 months was
.4550 MGD and this number is directly influenced by rain events.
Please find the required permit application, and the required copies for your
office to process our application. If you have any questions please do not
hesitate to call me at 704-279-2166.
Sincerely,
Tim Agner
Manager of Engineering Services
enclosures

Carolina Stalite Company
Rowan County
NPDES Permit NC0080586
Supplemental Permit Information
System Description
Carolina Stalite operates a lightweight aggregate facility in Gold Hill, North
Carolina. We use a series of settling ponds to allow sedimentation to occur.
These ponds receive all of the storm water and discharges are determined by
rain events and not by plant use. The average flow over the past 12 months
was .4550 MGD. All of Carolina Stalite's storm water flows through our
settling ponds and out our single discharge. Water is taken from the ponds
to provide the necessary water to operate the facility. Stalite's plant use is
approximately 600,000 gallons per day. This water is recirculated to the
settling ponds for reuse.
Sludge Management Plan
Carolina Stalite does not produce sludge, but sedimentation occurs that is
addressed as needed. Three concrete catch basins are cleaned daily and this
material is blended back with our product to recycle it. As the settling ponds
require they are dipped out and all of the material that is removed from the
ponds is allowed to dry and then blended with material for reuse.
NPDES Permit Application Question 12 Clarification
Oil and Grease ***
Carolina Stalite operates and loads material onto rolling equipment that may
allow oil and grease to come into contact with the ground which may impact
storm water. Oil and grease was highlighted to account for this possibility.

NPDES PERMIT APPLICATION - SHORT FORM C
For manufacturing 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: Caroline Staljte Company
B. Mailing address of applicant:
Street address PO B9x 1037
City Salisbury
State NC
NCOO 80586
County Rowan
Zip Code 28145-1037
Telephone Number ( 704 ) 279-2166
Fax Number ( 704 ) 279-7317
e-mail address [e-mail]
C. Location of facility:
Contact Person Tim N. Agner
Street 18815 Old Beatty Ford Road
City Gold Hill County Rogan
State NC Zip Code 28071
Telephone Number (704 ) 279-2168
2. Standard Industrial Classification (SIC) code(s): 3281
3. Number of employees: 90
4. Principal product(s) produced: Lightweight ight Aggregate
Principal raw material(s) consumed: Crushed Slate
5. Principal process(es): Coal fired rotary kilns expand slate to produce light weight aggregate.
crushing and screening to size the final product.
6. Amount of principal product produced (or raw material consumed)
List specific amounts consumed and/or units of production
Product Produced or Raw Material Consumed
(AVERAGE)
Product Produced or Raw Material Consumed
(PEAK)
per Day
2160 tons
3,312 tons (Theoretical Max.)
per Month
64,800 tons
99,360 tons (Theoretical Max.)
per Year
777,600 tons
1,192,320 (Theoretical Max.)
7. Check here if discharge occurs all year El, or
Circle the month(s) in which discharge occurs: January February March April
May June July August September October November December
vereinn _44f?NV)
aortas lnf7

Manager of Engineering Services
Title
D Z$/e.
Signature of Applicant3 Date
North Carolina General Statute 143-215.68 (i) provides that Any person who knowingly makes any false statement representation, or certification in any application, record,
report, plan, or other document tiles or required to be maintained tmder Article 21 or regulations of the Environmental Management Commission Implementing that Article, or
who falsifies, tampers with, or knowingly renders inaccurate any recording or monitoring device or method required to be operated or maintained under Article 21 or
regulations of the Environmental Management Commission Implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $10,000, or by
imprisonment not to exceed six months, or by both.
(18 U.S.C. Section 1001 provides a punishment by a fine of not more than $10,000 or imprisonment not more than 5 years. or both, fora similar offense.)
NPDES PERMIT APPLICATION - SHORT FORM C
For manufacturing or commercial facilities with a discharge <1 MOD (or WTPs)
Days per week discharge occurs: 7 Seasonal due to rain and storm water
NOTE: if the facility has separate discharge points (outfalis) or multiple industrial processes, include a schematic
diagram of wastewater flow at the facility.
8. Types of wastewater discharged to surface waters only (check as applicable).
Discharge per operating day
Flow
(GALLONS PER OPERATING DAY)
Volume treated before discharging
(PERCENT)
Sanitary - daily average
0
Cooling water, etc. - daily average
100,000
100
Process water - daily average
500,000
100
Maximum per operating day for
total discharge (all types)
600,000
100
9. If any of the types of wastewater identified in item 8 (either treated or untreated) are discharged to places
other than surface waters, record the amount(s) discharged below:
A. Municipal sewer system 0 gpd
B. Underground well 0 _gpd
C. Septic tank 1000 gpd
D. Evaporation lagoon or pond 0 gpd
E. Other, specify 0 gpd
10. Number of separate discharge points; 1
11. Name of receiving stream(s): Unnamed tributary to Long Creek in Yadkin Pee -Dee basin
12. Does your discharge contain or is it possible for your discharge to contain one or more of the following
substances added as a result of your operations, activities, or processes? Circle all that apply:
aluminum ammonia beryllium cadmium chromium chlorine (residual)
copper cyanide lead mercury nickel oil and grease*"
phenols selenium zinc 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.
Tim N. Agner
Printed name of Person Signing
Conn 9 of 9 t/o,rtnn_14P)MA

FACT SHEET FOR EXPEDITED RENEWAL
Permit Number
A/coo 2OSe6
Facility Name
Caro l« S'1 ‘ ;fie
Reviewer
M AM
Basin/Sub-basin
boo 7i?
Receiving Stream
(.4.4 6..e."4
Is the stream impaired (listed on 303(d))?
M
Is stream monitoring required?
. 6v,
yet _i./7
• Do they need NH3 limit(s)?
/VD -
Do they need TRC limit(s)?
N v
Do they have whole -effluent toxicity testing?
N0
Are there special conditions?
No
Any obvious compliance concerns?
4
Existing Expiration Date
7/29.1 o ¢
Proposed Expiration Date
7—/a/0 9
Miscellaneous Comments:
Circle one:
DO NOT EXPEDITE
If expedited, is this a simpler permit or a more difficult one?