NC0028169_Permit (Issuance)_20050908

NPDES DOCUMENT SCANNING COVER SHEET
NPDES Permit:
NC0028169
Aquadale Quarry
Document Type:
Permit Issuance�`1
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Correspondence
Speculative Limits
Instream Assessment
(67b)
Environmental Assessment (EA)
Permit
History
Document Date:
September 8, 2005
This document is printed on reuse paper - ignore any
content on the reYerse side

NCDENR
Jeff Lamm
Manager of Environmental and Land Resources
BV Hedrick Gravel and Sand Go.
7 Yorkshire Street, # 102
Asheville, North Carolina 28803
Dear Mr. Lamm:
Michael F. Easley
Governor
William G. Ross, Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
September 8, 2005
Subject: Issuance of NPDES Permit NC0028169
BV Hedrick Gravel and Sand Co.
Stanly 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 May9, 1994 (or as subsequently amended).
This final permit includes no major changes from the draft permit sent to you on July 6, 2005.
If anyparts, measurement frequencies or sampling requirements contained in this pennit are unacceptable to
you, you have the right to an adjudicatoryhearing upon written request within thirty (30) clays 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 maybe required bythe Division of Water Quality or permits required bythe Division of 1. end
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 Sergei Chernikov at telephone number
[phone], extension 594.
cc: Central Files
NPDES Permit File
Mooresville Regional Office/Surface Water Protection
Aquatic Toxicology Unit
N. C. Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
Internet: h2o.enr.state.nc.us
Sincerely,
ORIGINAL SIGNED BY
SAi� A.ime WILSGI4
P.E. an W l
Phone: [phone]
fax: [phone]
DENR Customer Service Center..1 800 623-7748

Permit NC0028169
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,
BV Hedrick Gravel and Sand Company
is hereby authorized to discharge wastewater from a facility located at
Aquadale Quarry
NCSR 2029
West of Aquadale
Stanly County
to receiving waters designated as Long Branch 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 October 1, 2005.
This permit and authorization to discharge shall expire at midnight on February 28, 2009.
Signed this day September 8, 2005.
ORIGINAL SIONEO ISY
SUSAN A. WILSON
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0028169
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.
BV Hedrick Gravel and Sand Company is hereby authorized to:
1. Continue operation of an existing quarry dewatering system, and a kiln rock wash system
located at the Aquadale Quarry site [off NCSR 2029 west of Aquadale] in Stanly County.
2. Discharge from said treatment works at the location specified on the attached map
through outfall 002 to Long Branch (formerly the Treatment Works Pond), currently
classified C waters in the Yadkin -Pee Dee River Basin.

Facility Information
Latitude: 35°13'38" Sub -Basin: 03-07-13
Longitude: 80°14'53"
Quad#: G18NW
Stream Class: C
Receiving Stream: Long Branch
Permitted Flow: N/A
Faci
lity
Loca
tion
North
Aoki"
BV Hedrick Gravel and Sand Co
NC0028169

Permit NC0028169
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on October 1, 2005 and lasting until expiration, the Permittee is authorized
to discharge from outfall 002. Such discharges shall be limited and monitored by the Permittee as
specified below:
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Flow
Weekly
Instantaneous
Effluent
Total Suspended Solids
30.0 mg/L
45.0 mg/L
2/Month
Grab
Effluent
Oil and Grease
30.0 mg/L
60.0 mg/L
2/Month
Grab
Effluent
Lead
2/Month
Grab
Effluent
Chromium
21Month
Grab
Effluent
Manganese
Monthly
Grab
Effluent
Acute Toxicity 2
Quarterly
Grab
Effluent
Turbidity3
50 NTU
2/Month
Grab
Effluent, U, D
Temperature, °C4
2/Month
Grab
Effluent, U, D
pH
' 2/Month
Grab
U, D
pH
> 6.0 and < 9.0 standard units
2/Month
Grab
Effluent
Footnotes:
1. U: upstream 200 feet from the outfall. D: downstream 200 feet from the outfall.
2. Acute Toxicity (Fathead Minnow) See Part I A(2.).
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 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.
BMP Conditions
1. The permittee shall operate the facilities in a manner, which will minimize the impact on the
receiving water.
2. The permittee shall utilize sound management practices to ensure that contaminants do not enter the
surface waters as a result of blasting at the site.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Definitions:
Mg/L — milligrams per liter
NTU - Nephelometric Turbidity Units
C — Celsius

z
Permit NC0028169
A. (2.) ACUTE TOXICITY MONITORING (QUARTERLY)
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" (Revised -July, 1992 or subsequent versions). The monitoring shall be performed as a Fathead
Minnow (Pimephales promelas) 24 hour static test. The effluent concentration at which there may be at no time
significant acute mortality is 90% (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 February, May, August and November.
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 Quality
Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30
days after the end of the reporting period for which 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 (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 comment area of the form. The report shall be submitted to the Environmental Sciences Section 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 permittee 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 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 follow-
up testing to be completed no later than the last day of the month following the month of the initial monitoring.

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0028169
Facility Information
Applicant/Facility Name:
BV Hedrick Gravel and Sand Co.
Applicant Address:
P.O. Box 987, Albemarle, NC 28002
Facility Address:
NCSR 2029, West of Aquadale
Permitted Flow
N/A
Type of Waste:
Quarry dewatering, rock washing
Facility/Permit Status:
Renewal
County:
Stanly
Miscellaneous
Receiving Stream:
Long Branch
Regional Office:
Mooresville
Stream Classification:
C
USGS Topo Quad:
G 18NW
303(d) Listed?:
No
Permit Writer:
Sergei Chernikov
Subbasin:
03-07-13
Date:
June 16, 2005
Drainage Area (mi2):
Summer 7Q10 (cfs)
0
Winter 7Q10 (cfs):
Average Flow (cfs):
IWC (%):
100%
Primary SIC Code:
3295
SUMMARY
BV Hedrick operates a lightweight aggregate (LWA) manufacturing facility on an approximate
689-acre parcel of land in Norwood North Carolina. The facility may be subdivided into a
quarrying operation where the raw material used to make LWA is mined, a raw material
department where rock is processed (crushed and sized through screens), the kiln department
where the LWA is produced, and a finish department where LWA is crushed, sized, and placed
in storage for future sale. Solite Corporation was the previous owner, the site changed ownership
in 2005. The site has a General Stormwater Permit.
Process water for most operations at the site comes from the Treatment Works Pond (TWP), after
being used at the plant for various purposes (see below), process wastewater is discharged back
into the TWP. Therefore, process water is being recycled at the site. Originally, the company was
permitted to discharge water through Outfall 002 into Long Branch, which is a class C water in
the Yadkin -Pee Dee River Basin. Outfall 002 was located below the dam, which separates the
TWP from Long Branch. Discharges occurred only intermittently, after significant storm events.
In the fall 2001 Mooresville Regional Office conducted an inspection of the site and
determination was made that the TWP is "waters of the state". Solite Corporation (owner at that
time) disagreed with the determination. However, the new owner (BV Hedrick) did not dispute
it, and agreed to the relocation of the Outfall 002 to the former TWP. Sampling will be
conducted at the point where all process wastewater is being discharged into the TWP.
The wastewater generated on -site comes from the following sources: mine dewatering (main
source of water), water from a rock wash screening system, dust suppression, and a small amount
of cooling water (discharged only during heavy rainfall). Cooling water is being used to cool
LWA immediately after its release from the kilns. LWA is dumped into a large depression that
contains approximately 1,000 gallons of water (BPJ). The depression itself is located in a very
low-lying area, hence release of this cooling water is very unlikely and may occur during very
heavy rainfalls. In addition, a significant portion of the water is evaporated during the cooling
process.
Fact Sheet
NPDES Renewal
Page 1

TOXICITY TESTING:
Type of Toxicity Test:
Existing Limit:
Recommended Limit:
Monitoring Schedule:
Fathead minnow, Acute P/F
002: Acute P/F, Annual
002: Acute P/F, Quarterly
February, May, August and November.
COMPLIANCE SUMMARY:
No compliance problem for the limited number of discharges over the past four years.
PROPOSED CHANGES:
• Monitoring Frequencies: Whole effluent toxicity testing has been changed to quarterly
based on the recommendation of the Aquatic Toxicology Unit.
• Limits: Limits for chromium and lead have been removed from the permit based on the
review of DMRs. All samples were below detection level.
• The Outfall 002 has been changed from the Long Branch to the Treatment Works Pond. New
outfall coordinates are 35° 13' 38" N, 80° 14' 53" W.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE:
Draft Permit to Public Notice: July 6, 2005 (est.)
Permit Scheduled to Issue: August 29, 2005 (est.)
STATE CONTACT:
If you have any questions on any of the above information or on the attached permit, please
contact Sergei Chernikov at [phone] ext. 594.
REGIONAL OFFICE COMMENT:
NAME: DATE:
Fact Sheet
NPDES Renewal
Pag 2

imap://[e-mail]:143/f...
Subject: Draft Permit Reviews (4)
From: John Giorgino <[e-mail]>
Date: Fri, 29 Jul 2005 15:09:39 -0400
To: sergei chernikov <[e-mail]>
Sergei, I have reviewed the following:
NC0000311
NC0000337
NCO028169
NCO033227
I have no
John
M-B Industries
Agfa
BV Hedrick
Tyco
comments. Thanks for forwarding them.
John Giorgino
Environmental Biologist
North Carolina Division of Water Quality
Environmental Sciences Section
Aquatic Toxicology Unit
Mailing Address:
1621 MSC
Raleigh, NC 27699-1621
Office: 919 733-2136
Fax: [phone]
Email: [e-mail]
Web Page: http://www.esb.enr.state.nc.us
1 of 1
8/2/2005 8:35 AM

The Stari!y News & Press
P.C. Box 488
Albemarle NC 28002
[phone]
AFFIDAVIT OF INSERTION /'tDDa00
DATE: 05/1 1 /06
STARTDATE CLASS DESCRIPTION WORDS INS CHG
02100838-000
NCDENR/DWO/NPDES
1617 MAIL SERVICE CENTER
RALEIGH NC 27699-1617
07/1 0/2005 355 PUBLIC NOTICE STATE OF 322 1 90.16
NORTH CAROLINA, STANLY COUN
MAY 2 2 2006
AFFIDAVIT OF PUBLICATION
DENR - WATER QUALITY
Before the undersigned, a Notary Publ G-o .. ai "+T SOURCE BRANCH
County and State, duly commissioned, qualified,
and authorized by law to administer oaths,
personally appeared: REX MAYNOR, who being first
duly sworn, deposes and says: that he is
Publisher of a newspaper known as THE STANLY
NEWS AND PRESS, published, issued, and entered
as second class mail in the City of Albemarle, in
said County and State; that he is authorized to
make this affidavit and sworn statement; that the
notice or other legal advertisement, a true copy of
which is attached hereto, was published in THE
STANLY NEWS AND PRESS on the dates specified on
the copy attached and that the said newspaper in
which such notice, paper, document or legal
advertisement was published was, at the time of
each and every such publication, a newspaper
meeting all of the requirements and qualifications of
Section 1-597 of the General Statures of North
Carolina and was a qualified newspaper within the
meaning of Section 1-597 of the General Statures
of North Carolina.
7/4,
REX MAYNOR
Publisher
Sworn to and subscribed to before me this
11 th day of May, 2006
Y\DENNIS, Notary Public
My commission expires January 17, 2007

1
Neon tie/It-II
Public Notice
PUBLIC NOTICE
STATE OF NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT
COMMISSION/NPDES UNIT
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT TO ISSUE
A NPDES WASTEWATER PERMIT
On the basis of thorough staff review
and application of NC General, Statute
143.21. Public law 92-500 and other
lawful standards and regulations, the
North Carolina Environmental Manage-
ment Commission proposes to issue a
National Pollutant Discharge Elimina-
tion System (NPDES) wastewater dis-
. charge permit to the person(s) listed
below effective 45 days from the pub-
lish date of this notice.
Written comments regarding the pro-
posed permit will be accepted until 30
days after the publish date of this no-
tice. All comments received prior to that
date are considered in the final determi-
nations regarding the proposed permit.
The Director of the NC Division of Wa-
ter Quality may decide to hold a public
meeting for the proposed permit should
the Division receive a significant degree
of public interest.
Copies of the draft permit and other
supporting information on file u to
determine conditions present ind the
draft permit are available upon request
and payment of the costs of reproduc-
tion. Mail comments and/or requests for
information to the NC Division of Water
Quality at the above address or call the
Point Source Branch at [phone],
extension 520. Please include the
NPDES permit number (attached) in
any communication. Interested persons
may also visit the Division of Water
Quality at 512 N. Salisbury Street, Ra-
leigh. NC 27604-1148 between the
hours of 8:00 a.m. and 5:00 p.m. to re-
view information on file.
The BV Hedrick Gravel and Sand Co.
(7 Yorkshire Street, #102, Asheville, NC
28803) has applied for renewal of
NPDES permit NC002811 for the facili-
ty in Stanly County. This permitted fa-
cility discharges industrial process
wastewater to the Long Branch in the
Yadkin Pee-Deo Basin. Currently oil
and grease, TSS, and turbidity are wa-
ter quality limited. This discharge rnor
affect future allocations in this portion of
the Yadkin Pee -Dee River -Basin
N..0, 2005

{
North Carolina ) ss
Mecklenburg County)
The Knight Publishing Co., Inc.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
NCDENR/DWQ/NPDES
CAROLYN BRYANT
1617 MAIL SERVICE CTR
RALEIGH NC 27699-1617
REFERENCE: 30045571
5478360 Nat'l Pollutant Disc
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of the Knight Publishing Company a
corporation organized and doing business under the
laws of the State of Delaware, and publishing a
newspaper known as The Charlotte Observer in the
city of Charlotte, County of Mecklenburg and State
of North Carolina and that as such he/she is
familiar with the books, records, files and
business of said Corporation and by reference to
the files of
the attached
following is
files of the
Publication.
said publication
advertisement was inserted. The
correctly copied from the books and
aforesaid Corporation and
PUBLISHED ON: 07/09
AD SPACE: 162 LINE
FILED ON: /07/13/05
NAME:
TITLE:
DATE:
_ PUBLIC NOTICE.:
STATE OF NORTH CAROLINA -
ENVIRONMENTAL MANAGEMENT COMMISSION/NPDES UNIT
• 1617 MAIL SERVICE CENTER •
RALEIGH, NC 27699-1617 '
NOTIFICATION OF INTENT TO ISSUE •
•. A NPDES WASTEWATER PERMIT. -
On the basis 'of thorough staff review and a pA Iiditi NNO General
Statute 14321. Public Law 92500 and other lawful standards and reg.
ulations: the North Carolina Environmental Management Commission
props to issue a National Pollutant Discharge Elimination System
(NPDES) wastewater discharge permiteo the person(s) listed below
effective 45 ddys from the publish date of this notice. •
Written comments rel wing the proposed permit. will be accepted
until 30 alter t b9sh date of this notice. • AO comments
received prior to that date are considered in the.8nal determinations
regarding, the proposed permit. The Director: of the NC Division of
Water may decide to hold a public meeting for the proposed
• permit d the Divisbn receive a significant degree of p!rblic
esl
Copies of the•draft :permit'and other "supporting information on tote
used to determine conditions present in the draft permit are available
upon request and payment_ of the costs of reproduction. Mali com-
ments andlor requests for tntorrnation to the NC Division of Water
Quality at the above address or call the Point Source Branch at (919)
733-5083 extension 520. Please include the'NPDES permit number-
a(ttached)) tn•any coamunkatton. Interested persons may also visit
tie Division of Water Duality at 512 N. Salisbury Street. Raleigh. NC
: 27604-1148 between the hours of 8:00 a.m. and 5:00 p.m. to review
Information on tie.
The Ctty" of Gastonia (P.O. Box 1748, Gastonia, NC 28053) has epplled
for renewal of NPDES_permit NC0020184 for the Long Creak WWIP
in Gaston County.This permttted facility discharges 16.0 MGD of
treated to Long - Creek in the Catawba River Basin.,
Currently BCD, ammonia nitrogen; total nitrogen, total phosphonis,
nickel and total residual chlorine are water quality limited. This dis-
charge may affect tut= allocations in this portion of the Catawba
River Baslrh.- , • _.. -. - •
The Town of Dallas (210 North Hotand Street Dallas, NC 28034) has
applied for renewal"of permit NC0068888 for its WWTP in Gaston
County.This permitted facility discharges treated domestic waste -
the Catawba River
Basin. Currently unnamed
ammonia secLong Creek s coliform and total
residual chlorine ere water quality limited. This discharge ,may affect
tuturealoc aeons in tits portion of Long Creek. ' "
Plantation Pipa tine Company has applied for renewal of NPDES per-
mit NC0084280 for Its groundwater remediation site In Mecklenburg
County: This permitted facility discharges remediated groundwater to
an unnamed tributary to the Catawba River In the Catawba
Basin. Currently -manganese is water quality limited. This dscdharge
may impact future allocations to this portion of the watershed.
Unocal • Corpdratton has applied for renewal of NPDES permit
N00085057 for- its Orr Road, - groundwater remedietion site In
Meddenburg..Co.- This permitted facility. discharges remediated
groundwater to an unnamed tributary to Bder Creek in the
River Been. Currently,'tromiurn and nickel are water -quality
This discharge may impact future allocations in this portion of the
Kinder Morgan Southwest Terminals, Litt has app• lied for renewal of
NPDES • permit NC0032891 tor its Charlotte Terminal 1 site in
Meddler County. This permitted facility discharges storm e�
from secooccontainment areas to an' unnamed tributary
Branch In the wba River Basin.' Currently turbidity is water auatity
limited. This discharge may irrmpac t future allbcatiorrs to Ns portion of
the. watershed. t• • .
The BV, Hedrick Gravel and Sand Co. -(7 Yoikshire Street, #102,
Asheville, NC 28803) has ,applied for renewal of NPDES permit
N900281169 for the Witty In Stanly County. This permitted facility
Industrial process wastewater to the Long Branch in the
Yadkin• Dee River Basin. Current oil and grease, TSS, and Wr-
bidtty are water quality limited. This discharge may affect future allo-
cations In this porton of the Yadkin -Pee Dee River Basin. •
• L.P'Y5478380
•
dzor4hi Qier,
7-1,Y1JJ
In Testimony Whereof I have hereunto set my hand and affixed my seal, the
day and year aforesaid. _ •
Co nmission Expires May 27, 20 b
Notar
ommi ss i on Expires: _/_/__

imap://[e-mail]:143/f...
Subject: Solite Corp
From: John Giorgino <[e-mail]>
Date: Thu, 23 Jun 2005 09:20:12 -0400
To: sergei chemikov <[e-mail]>
Sergei, I spoke with Matt and he suggested a quarterly fathead acute pass/fail limit.
John Giorgino
Environmental Biologist
North Carolina Division of Water Quality
Environmental Sciences Section
Aquatic Toxicology Unit
Mailing Address:
1621 MSC
Raleigh, NC 27699-1621
Office: 919 733-2136
Fax: [phone]
Email: [e-mail]
Web Page: http://www.esb.enr.state.nc.us
1 of 1
6/23/2005 9:43 AM

imap://sergei.chemikov%40dwq. [e-mail]:143/f...
Subject: RE: permit renewal information
From: "Jeff Lamm" <[e-mail]>
Date: Wed, 22 Jun 2005 11:19:11 -0400
To: "'Sergei Chernikov"' <sergei.chemikov®ncmail.net>
Sergei,
As we discussed by telephone, the nature of the cooling water that you referred to is simply the small area of water
located at the end of the kilns that the hot aggregate drops into. Typically this water would not discharge due to rapid
evaporation unless it commingled with storm water during a storm event. Let me know if you have any further
questions. Thanks.
(Telif
Original Message
From: Sergei Chernikov [mailto:[e-mail]]
Sent: Friday, June 17, 2005 10:41 AM
To: Jeff Lamm
Subject: Re: permit renewal information
Jeff,
Thank you for information! I have been reviewing permit file of Solite Corporation and found a
report that was mailed to DWQ on April 1, 2002. This report contained information on process
water and stormwater discharges on the facility site. According to this report, there are 4 discharges
to Ponds 1, 2, and 3. Unfortunately, I have only one copy of this report, but hopefully you have a
copy in your file, or you can obtain one from Solite (if you can't, let me know and I will make you a
copy). I think it would be very useful for you to review this report. I have identified several issues
that have to be addressed before we can issue the permit:
1) Are all these outfalls identified in the Solite report still exist ?
2) Is the composition and origin of the water being discharged through these outfall remained the
same since Solite report was mailed?
3) During our meeting at the site you have mentioned that Treatment Works Pond (also known as
Pond #3) receives wash water, quarry dewatering water, and cooling water. What is the nature of
this cooling water? I need to know if it's non -contact cooling water being used to cool the kiln, or
it's a contact cooling water that is sprayed on the aggregates after they have been removed from the
kiln.
If you have any questions please contact me.
Thank you!
Sergei
Jeff Lamm wrote:
Outfall is 35 13'38" N, 80 14'53" W . Water usage is 346,000 gallons per
day average. This is water that is pumped from the pit (pit dewatering) to
the treatment pond and then water needed at the plant is pumped from the
pond to the plant.
Jeff Lamm
1 of 3 6/22/2005 12:06 PM

imap://[e-mail]:143/f...
Subject: RE: permit renewal information
From: "Jeff Lamm" <[e-mail]>
Date: Tue, 14 Jun 2005 09:27:41 -0400
To: "'Sergei Chernikov"' <[e-mail]>
Outfall is 35 13'38" N, 80 14'53" W . Water usage is 346,000 gallons per
day average. This is water that is pumped from the pit (pit dewatering) to
the treatment pond and then water needed at the plant is pumped from the
pond to the plant.
Jeff Lamm
Original Message
From: Sergei Chernikov
Sent: Monday, June 13,
To: Jeff Lamm
Subject: permit renewal
Jeff,
[mailto:[e-mail]]
2005 12:52 PM
information
Last week you have mentioned that you will e-mail me latitude and
longitude of the new outfall and flow estimate. Please let me know when
you expect to have this information.
Thank you!
Sergei
Jeff Lamm wrote:
US 1 south to 15/501 south to west on 24/27 to Albemarle. In Albemarle
turn
left on 138 south to aquadale, turn right on Old Aquadale road and entrance
road to plant is about 1 mile on left. You will see sign that says Hedrick
Industries/Carolina Stalite. My cell is 828-712-9730. The plant number is
704-474-3165. See you on June 1st.
Jeff Lamm
Original Message
From: Sergei Chernikov[mailto:[e-mail]]
Sent: Thursday, May 19, 2005 9:03 AM
To: jlamm
Subject: permit application
Jeff,
Recently your permit application have been re -assigned to me and I would
like to schedule a site visit before permit is drafted. I have tried to
call you but the phone number on the Name/Ownership Change Form that you
have submitted seems to be incorrect. Please e-mail me your phone number
and I will give a you a call to schedule a site visit.
Thank you!
Sergei
Sergei Chernikov, Ph.D.
Environmental Engineer
1 of 2 6/14/2005 11:25 AM

1504 Santa Rosa Road
Suite 200
Richmond, VA 23229
[phone]
[phone] (Toll Free)
[phone] (Fax)
Corporate
PO Box K-28
Richmond, VA 23288
[phone] (Toll Free)
[phone] (Fax)
AF Old Division
PO Box 68
Arvonia, VA 23004
[phone] (Toll Free)
[phone] (Fax)
Virginia Solite Division
Route 1, Box 101
Cascade, VA 24069
[phone] (Toll Free)
[phone] (Fax)
Carolina Solite Division
PO Box 987
Albermarle, NC 28001
[phone] (Toll Free)
[phone] (Fax)
September 2, 2003 FEDERAL EXPRESS
OBTAIN DELIVERY SIGNATURE
Mr. Bill Reid, Director
Point Sources Branch
Division of Water Quality
North Carolina Department of Environment,
and Natural Resources
1617 Mail Service Center
Raleigh, NC 27699-1617
RE: Solite Corporation, Carolina Solite Division
Norwood, North Carolina
Permit Renewal and Modification Request
NPDES Permit NC0028169
Dear Mr. Reid:
Please find enclosed the NPDES permit application for renewal and modification of the
facility. The facility proposes the following modifications:
1. Addition of a kiln rock wash system (wet screening system).
2. The relocation of the raw material department and the rock wash screening
system.
3. Elimination of the chemical/physical treatment process and waive Operator
requirements;
J �
4. Add a new discharge monitoring point, referenced as 003; and
5. Eliminate process and quarry dewatering discharge into the treatment works
pond (currently regulated under NCDENR non -discharge permit
WQ0003150).
If you have any questions or require additional information, please contact Mrs.
Casandra Ruff at [phone] or myself at [phone].
Sincerely,
Cecil Hopper
Corporate Manager, Environmental Affairs
cc w/att:
Mr. Charles Weaver, NCDENR, DWQ, M oresville Regional Office
Stephen Holt, Solite Corporation
Casandra Ruff, Sol ite Corporation
Cecil Hopper, Solite Corporation
l
SFp - 3 2003

1. APPLICATION SUMMARY:
Solite Corporation, Carolina Solite Division (herein, Solite), operating under
North Carolina Department of Water Quality Permit No. NC0028169, is submitting a
permit application renewal request for the facility. The mining operation proposes the
following operational changes:
o The addition of a kiln rock wash screen, the relocation of an existing rock wash
system (herein, wet screening operation), and the raw material department as shown
in Figure No. 2. The purpose of the new kiln feed rock wash system is to remove
fines from the feed to prevent kiln ring formation, an improvement to stabilize kiln
operation. The raw material department and rock wash screen are planned to be
relocated as part of a modernization project, and will allow the discharge water from
these processes to be directed into the quarry. The proposed operation will add
process water to the quarry dewatering and increase the number of pumping cycles to
discharge from quarry water. An additional outfall will be established, referenced as
discharge point 003. The new outfall will discharge directly into the lower lake
reservoir. Refererence Figure No. 3
o The current permit allows for an intermittent or seasonal discharge for mine
d_ erin _from outfa11002. Currently Solite directs its discharge (process and quarry
dewatering) into the treatment works pond under NCDENR non -discharge permit
(WQ0003150). Solite request to be allowed to redirect its discharge from the
treatment works pond to the new outfall 003. The mining operation proposes to
discharge intermittently into Lower Long Branch, from outfall no 003.
o The mining operation no longer utilizes the chemical/physical waste water treatment
facility (referenced as SWMU no. 9) at its Norwood, North Carolina facility;
therefore Solite is proposing to eliminate the wastewater treatment requirements,
p P g
including operator requirements.
P-21 2Ai'UjvV NN
av
(NPDES Permit 2003.doc) 4

o The Process water and quarry dewatering will no longer be directed into the treatment
works pond. Storm water runoff from the stockpiled finished product will continue to
discharge into the treatment works pond, however, Solite proposes to incorporate the
treatment works pond area into the General Permit NCG 070006.
A general facility description is provided in Section II of this document. Section III of
this modification request provides a detailed summary of the proposed equipment
additions/modifications and operating scenarios and Section IV addresses potential
contaminants associated with facility process water. Section V consists of
engineering alternatives analysis.
Permit application Short Form C is attached in Appendix A.
2. FACILITY BACKGROUND:
Solite Corporation (Solite) operates a lightweight aggregate manufacturing
facility on an approximate 689-acre parcel of land in Norwood, North Carolina (Stanly
County). A map detailing the facility location using 7.5-minute series quadrangles is
provided as Figure 1 of this submittal. The facility may be subdivided into a quarrying
operation where the raw material used to make lightweight aggregate (LWA) is mined, a
raw material department where rock is processed (crushed and sized through screens), the
kiln department where the LWA is produced and a finish department where the LWA is
crushed, sized, and placed in storage for future sale. The quarrying operation consists of
mobile rock moving equipment such as front-end loaders, haul trucks and track hoes.
The raw material department consists of a series of conveyors, crushers, screens, storage
silos, and stock piles used to manage the raw materials prior to being used in the kilns to
make LWA or being sold as raw rock. The kiln department consists of four lightweight
aggregate rotary expansion kilns (20 tons per hour each of crushed argillite maximum
permitted capacity) that may be fired with coal, No. 2 fuel oil including recycled No. 2
fuel oil, natural gas, or non-RCRA regulated waste fuel. Emissions from these kilns are
controlled using dust collectors (Baghouse 7B and Baghous 8B), and using dry lime
\` /
(NPDES Permit 2003.doc) 5

injection as a means to control SO2 emissions. In the finish department the expanded
shale (clinker) is processed into various construction products on -site through additional
crushing and screening operations. Lightweight Aggregate Kiln Dust (LAKD) is
captured in the kiln baghouses (Baghouse 7B and Baghouse 8B) and transferred to the
facility dust silo where it is either mixed with the finished products, sold for other
purposes, or stored onsite.
Other activities present at the Solite facility include a maintenance shop located
on the northern portion of the facility and various buildings/sheds used to store facility
equipment and maintenance materials. Vehicle maintenance is performed inside the
maintenance shop building to prevent potential contact with storm water run-on and run-
off. The maintenance area includes several outdoor above ground storage tanks used to
store petroleum products such as diesel fuel, gasoline, used oil, and lube oils of various
weights. All tanks are located within secondary containment to minimize contact with
storm water run-off. The maintenance facility consumes less than 55-gallons of motor oil
per month.
Process water is generated from water sprays used to control fugitive dust
emissions and to remove material fines from the raw material and finish product. These
water sprays are located throughout the plant in both the raw material and finished
product departments above or on conveyor transfer points, screens and material crushers,
at conveyor transfer points, screens and material crushers.
The bulk of the process water comes from the raw material rock wash screen and
the kiln rock wash screen. The raw material rock wash screen (200 gpm — maximum)
operates intermittently and is used to size raw rock that may be used in septic tank fields,
driveways, and so forth. The kiln rock wash screen also operates at a maximum of 200
gallons per minute. An explanation as to the purpose of the kiln rock wash screen is
provided in Section 1.
(NPDES Permit 2003.doc)

2000 0 1000 2000
`MEi illild
SCALE 1" = 2000'
1\ engineering & surveying, p.c.
19810-A West Catawba Avenue
Cornelius, N.C. 28031
704-655-7290 704-655-7291 (fax)
MADE
Gunn=LL
SOLITE CORPORATION
REFt USGS 7 1/2 MIN. QUAD
AQUADALE
NPDES DISCHARGE
FIG. NO. 1
MGES PROD, ND, 671.20 l

3. PROPOSED OPERATIONS MODIFICATIONS
3.1. Treatment Works Pond (Background)
In February 1990 Solite Corporation submitted a non -discharge permit application
to operate a "Treatment Works Pond" at their Aquadale, North Carolina facility.
Subsequently, Solite was issued water quality permit WQ0003150 for the operation of
the treatment works pond. This permit is currently in effect.
Subsequently, NCDENR, Division of Water Quality (herein, DWQ) conducted
an inspection of the Solite facility and the operations subject to WQ0003150 (fall 2001).
Following this inspection, the DWQ issued an October 19, 2001 letter, that states:
"Based on 15A NCAC 02B.0228..., the Division has determined that the pond
(TWP) is located in -stream and has determined that the ponds are "waters of the
state." Thus, the "WQ" permit is not appropriate and an NPDES permit will be
required."
The October 19, 2001, letter also requested that a meeting be held between Solite and
DWQ to discuss options available concerning the re -permitting of the discharges to the
TWP under an NPDES system. That meeting was held on November 27, 2001. During
the meeting, the DWQ indicated that its goal was to issue an NPDES permit for the
discharges to the facility TWP. Without agreeing with the DWQ on their interpretation
as to the TWP's status, Solite agreed to perform a draft assessment of the facility's
discharges to the TWP. The report was to include the following:
1. An identification of all discharges to the TWP and associated channel.
2. Classification of the discharges as process vs. stormwater,
3. Identification of industrial activities associated with process water,
4. Delineation of the runoff area associated with the TWP,
5. Pollution control measures that could be implemented to minimize pollutant run-
off to the TWP.
(NPDES Permit 2003.doc) 8

This report was submitted to the Department on April 1, 2002 (See Appendix E). To
date, the DWQ has not responded to this report either in writing or otherwise. As a
result, we are including proposed facility modifications and controls with this NPDES
permit modification to address the Department's concerns.
The water channel subject to the DWQ's October 21, 2001 letter consists of one pond
located north of the railroad tracks (herein, Pond 1), the existing Treatment Works Pond
(Pond 3), and a marsh area (Pond 2) located between the two ponds, south of the railroad
tracks. To date no outfall from the TWP has been constructed. Nor does the TWP have a
discharge. Water from the TWP is transferred from the pond by groundwater migration.
In addition, there is a water channel (Upper Long Branch) that flows south from the
reclaimed mining overburden area into the Long Branch Creek. The water source for this
channel consists of groundwater seepage. The facility is currently permitted to discharge
water from a quarry dewatering operation into Upper Long Branch under a NPDES
Permit (Permit No. NCO028169) or to the existing TWP under NC DENR non -discharge
permit WQ0003150.
3.2. Relocation of Rock Wash and Raw Material
Solite is proposing to operate a wet screening operation to remove fines from the
kiln feed produced at the Norwood, NC facility. The system consists of a 5' x 16' double
deck screen with spray bars on both decks, and an under screen discharge hopper. Table
1 provides a description of each individual piece of equipment associated with the kiln
rock wash system.
Table 1:
h Dual Screen Equipment Specifications
^Equipment Type
Equipment Dimensions
Throughput Capacity
Screen (2)
5' x 16'
250 ton/hour
Under Screen
Hopper/Reject Grid
5' x 16'
250 ton/hour
Spray Bars
16' in length w/nozzles
spaced @ 15" apart
200 gpm
(NPDES Permit 2003.doc)
9

A drawing illustrating the proposed location of this piece of equipment (along
with the other facility modifications) is included as Appendix B of this submittal. This is
the only new piece of equipment that is to be included as part of this NPDES permit
modification request. The new kiln feed rock wash screen will be in operation anytime
the kilns are in continued operation. As a result, this piece of equipment may potentially
discharge up to 288,000 gallons of water per day. The kiln feed silos afford the capacity
such that the rock wash screen may be shut down temporarily while the kilns are in
operation. Nonetheless, we anticipate that it will not be uncommon for this piece of
equipment to operate 24 hours per day. The process water from the kiln rock screener
will be directed to the quarry to allow sedimentation.
3.3. Chemical/Physical Treatment
Section C.(1.) of the current NPDES permit requires that Solite employ an
operator in responsible charge at the certification grade equivalent to or greater than the
classification assigned. Formerly (Pre-1993), Carolina Solite utilized wet scrubbers as a
means of SO2 emissions control. Solite had a wastewater neutralization plant to
neutralize the scrubber water before it was discharged. As a result, the facility was
categorized as a physical/chemical WWTP and thus, a requirement was imposed to have
a physical/chemical operator onsite. The practice of using a wet scrubber for emissions
control was discontinued in 1992 (Solite implemented a dry lime injection system as a
means of SO2 reduction at this time). The neutralization plant has been closed since that
time. The only sources of wastewater from the plant are process water from plant rock
washes and water sprays and water from the dewatering of the quarry. As a result, with
this submittal we are requesting that our certification grade be changed to a level
applicable to our facility, as it currently exists.
3.4. Stormwater Drainage
Solite is preparing to relocate the plant raw department to an area that will result
in drainage from this department being directed into the quarry and away from the TWP.
This project is scheduled to begin in 2004. The raw materials department consists of
(NPDES Permit 2003.doc) 10

several belt conveyors, two crushers and two screens along with their associated water
sprays. The facility drawing provided in Appendix B illustrates the future location of the
plant raw material department.
Solite operates a rock wash screening system that consists of a hopper, several
belts and a multi -deck screen. The screen is equipped with spray bars whose purpose is
to remove the fines from the rock such that the rock is sized to particular specifications.
Currently, this equipment is located such that the drainage from it is directed to the TWP
via a canal located along the railroad tracks. Process water from the stone washing
system amounts to approximately 26,880 gallons per day. This equipment will be
relocated to an area near the future location of the raw material department (see drawing
provided in Appendix C) in 2003 or 2004 pending budgetary constraints.
The majority of the water discharged from the plant is from quarry dewatering.
Currently this water is directed to the TWP. This discharge amounts to approximately
432,000 gallons per day (average). This water is largely unaffected by the operation of
the plant and has very little sediment loading. We propose to relocate the quarry
discharge point, which will be inclusive of the water from the raw department, kiln raw
feed material screening operation and rock wash screening operation to a location east of
the quarry. The new outfall will be located such that the discharge will be directed into a
pond whose effluent enters Lower Long Branch and ultimately Rocky River Springs.
The facility drawing, referenced as Figure No. 3 is provided in Appendix C and illustrates
the proposed location of this outfall. The relocation of the quarry discharge may be
established within two months of receiving approval from NCDENR for this permit
modification request.
The proposed NPDES discharge 003 will include two water collection sump basins
located within the quarry pit. The initial sump basin, number 1, will receive process water
from the rock wash screen area. The water will gravity flow across the mine pit to a final
collection sump (no. 2). A 1,500 gpm pump will discharge to points 002 and/or 003. A
slab -type catch basin will be installed at the end of the pipe for energy dissipation.
(NPDES Permit 2003.doc) 11

Once these modifications are made the remaining discharge to the TWP (Pond 3)
will be from water sprays from the finish department at a rate of approximately 11,520
gallons per day. The TWP also receives storm water during a rain event from the portion
of the plant located south of the railroad tracks that transect it
Storm water runoff generated within the plant boundaries is directed to either
Pond No. 1 or the TWP (Pond 3) as a result of a railroad track that subdivides the facility.
Currently, storm water drainage that originates from the part of the plant located north of
the railroad tracks is directed to Pond 1 (as previously described). Facilities in this area
of the plant include the plant offices, maintenance shop and fuel storage tanks. Outfall
PS-001 (Permit WQ0003 150) contains both process water discharged from the trailer
wash station and storm water run-off from the area located north of the railroad tracks,
including the office area, maintenance shop, GRR facility, and facility storage sheds.
The potential for excessive storm water loading from this portion is minimized due to the
lack of industrial activity on the northern portion of the facility, and the use of concrete
secondary containment surrounding all petroleum and non -hazardous waste storage tanks.
In addition, the trailer washing station is designed only to rinse residual inert materials
from equipment and customer material transport trailers to prevent product contamination
(e.g. - mixing aggregate materials of different gradations). Therefore, Solite anticipates
that the only significant pollutant associated with this process would be the suspended
sediment. However, the trailer washing station is located over 200' from outfall PS-001
and the wash water flow to the outfall consists of primarily overland flow. Therefore, a
significant amount of natural settling occurs before the material migrates to the outfall. In
addition, an initial inspection of the outfall did not reveal any evidence of significant
solids loading at this outfall. Accordingly, Solite believes that the installation of
sediment traps at strategic locations in the outfall channel will be sufficient to control any
residual solid materials in the process/storm water discharge.
The majority of the storm and process water drainage from the plant that
originates south of the railroad tracks is directed to the TWP (portion to the quarry). This
(NPDES Permit 2003.doc) 12

area of the plant includes the finish and raw materials department, the rock wash
screening equipment, the LWA kilns and product storage silos and piles. Once the rock
wash screening equipment and the raw materials department has been relocated from this
area, the only sources of process water will be the water sprays associated with fugitive
dust suppression. These water sprays do not result in significant levels of runoff from the
plant. As a result, once the specified facility equipment has been removed from this area
we do not feel that significant facility modifications will be necessary due to small
amount of water generated by the water sprays.
4. WASTEWATER CHARACTERISTICS
The only sources of wastewater generated at the facility result from either quarry _ _ ____
de -watering, storm water or water geiiiiitesil from fines screening, vehicle washing or
fugitive dust suppression. Regardless as to its source the potential pollutant encountered
is primarily suspended sediment. This facility does. not._process or manage industrial
chemicals. All of the fuel storage tanks are located within secondary containment that is
maintained as part of a facility Spill Prevention, Control and Countermeasures Plan.
Raw material and product storage piles are located south of the railroad tracks that
subdivide the facility. Lightweight aggregate kiln dust (LWAKD) is managed and stored
on -site. The LWAKD storage pile borders the production facility on the western side of
the plant and is located between Pond 1 (as previously described) and the TWP (Pond 3).
The TWP is located down gradient from the raw material, product and LWAKD storage
piles. The TWP is sampled three times per year as part of NC DWQ non -discharge
permit WQ0003150. Results from the previous year's analyses are included in Appendix
D of this submittal. The results of these analyses form the basis for our entries in Section
V of Form 2C.
(NPDES Permit 2003.doc) 13

5. ENGINEERING ALTERNATIVES ANALYSIS
5.1. General Information
The facility name, address and telephone number, as well as the county in which
it is located in is included in the information provided in Short Form C which is located
in Appendix A. Requisite information regarding the preparer of this EAA is as follows:
Cecil Hopper
Manger of Corporate Environmental Compliance
320 D Midland Parkway
Summerville, SC 29485
Phone: [phone]
A detailed description of the project is provided in Section 3 of this submittal.
Portions of the existing facility that will be included in this project are also described in
detail in Section 3 of this submittal. An overall water use drawing is provided with Form
2C in Appendix A of this submittal.
5.2. Evaluation of Alternatives
Process water for the plant is pumped out of the pond that borders the eastern side
of the quarry and forms a portion of Lower Long Brach. Solite proposes to relocate the
primary facility outfall (future 003) to discharge into this pond. The discharge point will
be located upstream of the water intake for the plant. Locating the discharge point in this
manner will result in a looped type arrangement where the water that is discharged will
be reused by the plant. This will result in the net effect of reducing the outfall discharge
rate.
Plant process water will not require pretreatment prior to being discharged from
the plant.
(NPDES Permit 2003.doc) 14

The reuse of plant process water is the most feasible alternative to discharging the
process water into Lower Long Branch without regard to water use management. Other
forms of management were evaluated and determined to either not apply to our plant
(e.g., there is no publicly or privately owned treatment works in proximity to our plant) or
to be a lesser alternative when compared to water reuse. This manner of storm/process
water management has also been formulated in consideration of the reclassification of the
TWP (Pond 3) by the State and the elimination of the TWP as being the primary receiver
of process water and quarry dewatering from the plant.
(NPDES Permit 2003.doc) 15

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 NCO() 28169
Please print or type
1. Applicant and facility producing discharge
A. Name Solite Corporation, Carolina Solite Division
B. Mailing address of applicant:
Street address P. O. Box 987
City Albemarle County Stanley
State North Carolina Zip Code 28002
Telephone Number
Fax Number
e-mail address
C. Location of facility:
Contact Person Casandra Ruff
( 704) 474-3165
( 704) 474-4074
rgardener(d giantcement. com
Street 12423 Old Aquadale Road
City Norwood County Stanley
State North Carolina Zip Code 28128
Telephone Number ( 704 ) 474-3165
2. Standard Industrial Classification (SIC) code(s): 3295
3. Number of employees: 40
4. Principal product(s) produced: Lightweight Aggregate
Principal raw material(s) consumed: Shale Rock
5. Principal process(es) Crushing, grinding. Kiln firing, screening & sizing
6. Amount of principal product produced (or raw material consumed)
List saecific amounts consumed and/or units of production
Product Produced or Raw Material Consumed
(AVERAGE)
Product Produced or Raw Material Consumed
(PEAK)
per Day
340
670
per Month
8,750
13,400
per Year
105,000
160,800
7. Check here if discharge occurs all year ®, or
Circle the month(s) in which discharge occurs: January February March April
May June July August September October November December
Page 1 of 2
Version —11/2000

NPDES PERMIT APPLICATION - SHORT FORM C
For manufacturing or commercial facilities with a discharge <1 MGD (or WTPs)
Days per week discharge occurs:
NOTE: If the facility has separate discharge points (outfalls) or multiple industrial processes, include a schematic diagram
of wastewater flow at the facility.
5
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
0
Cooling water, etc. - daily average
0
0
Process water - daily average
525,000
0
Maximum per operating day for
total discharge (all types)
2,160,000
0
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 0 gpd
D. Evaporation lagoon or pond 0 qpd
E. Other, specify 0 gpd
10. Number of separate discharge points: 2
11. Name of receiving stream(s): Lower Long Branch
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.
Richard A. Familia VP Environmental Affairs
Print a - of Person Signing
Title
Sig ture of Applicant Date
North Carolina General Statute 143-215.6E (i) provides that Any person who knowingly makes any false statement representation, or certification in any application, record,
report, plan, or other document files or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or
who falsifies, tampers with, or knowingly renders inaccurate any recording or monitoring device or method required to be operated or maintained under Article 21 or
regulations of the Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $10,000, or by
imprisonment not to exceed six months, or by both.
(18 U.S.C. Section 1001 provides a punishment by a fine of not more than $10,000 or imprisonment not more than 5 years, or both, for a similar offense.)
Page 2 of 2 Version -11/2000

1.0 INTRODUCTION
As required by the State of North Carolina Department of Environment and Natural resources,
Division of Water Quality (NCDENR-DWQ), Carolina Solite Corporation is authorized to
discharge stormwater under the National Pollutant Discharge Elimination System (NPDES),
General Permit Stormwater Permit No. NCG070006 and an Individual Permit NC0028169.
Part II, Section A of the permit requires Carolina Solite Corporation to develop a Stormwater
Pollution Prevention Plan (Plan). The purpose of the Plan is to identify potential pollutant
sources which may be expected to contribute to contamination of stormwater discharges and to
minimize the impact of any potential release of pollutants to State waterways via stormwater
discharges from the Carolina Solite facility in Norwood, North Carolina (Stanly County). This
Plan is developed in accordance with the content outlined in Part II, Section A of the Permit.
Carolina Solite operates a lightweight aggregate facility on an approximate 690 acre facility in
Aquadale, North Carolina. Shale is mined at the property and combusted at high temperatures in
rotary kilns to produce the lightweight aggregate. Stormwater, associated with the NPDES
Permit No. NCG070000 and covered by this Plan, consist of discharges from the face of an
overburden pile on the western portion of the facility and stormwater from the portion of the
facility east of the kilns near the control room and coal shed.. Stormwater from the kiln and tank
farm areas of the facility is covered by NCDENR-DWQ Non -discharge Permit No. WQ0003150
and is therefore not included in this plan.
The Plan outlines information regarding monitoring, controls, inspections, and limitations for
permitted stormwater discharges at the Carolina Solite facility. Also included within the Plan is
a list of team members responsible for its implementation. The Plan will be maintained on -site
and will include all subsequent modifications made to the Plan. Inspection and maintenance
records will be documented on the appropriate records and will be maintained on file for a
minimum of three (3) years.
REMAINDER OF PAGE INTENTIONALLY LEFT BLANK

3.0 SITE PLAN
The site plan shall provide a description of the physical facility and the potential pollutant
sources which may be expected to contribute contamination of stormwater discharges.
REMAINDER OF PAGE INTENTIONALLY LEFT BLANK

3.2 DESCRIPTION OF POTENTIAL POLLUTANT SOURCES
The initial stormwater pollution prevention plan (SPPP) was initially prepared for the Carolina
Solite facility on December 1994. During the inspection, the Carolina Solite facility was
inspected to identify possible sources of stormwater pollution. There is one stormwater outfall
which is subject to NPDES Permit No. NCG070006. The outfall is a perennial stream.
Stormwater applicable to this Plan drains to this stream from the overburden pile located in the
western portion of the facility and from the portion of the facility east of the kilns. The
following potential sources of pollution were identified and are further described in this Plan:
Overburden is stripped from the quarry area prior to blasting. The resulting soil/rock is placed in
the western portion of the facility. Stormwater run-off from the top of this pile drains back to the
quarry. Run-off from the Northwestern face of the pile, however, discharges to a tributary of the
Long Branch Creek. The only pollutant identified from this source is sediment run-off. A
sediment trap is installed below the overburden fact to control run-off from the area. As required
by Carolina Solite's mining permit (PERMIT No. 84-01), the face of the overburden is being
graded to reduce stormwater erosion. A copy of the sediment and erosion control measures for
this project is included as Appendix B of this Plan.
A coal pile is located on the southern portion of the facility. A roof has been constructed to
provided coverage over the pile; however, not all of the coal is located under this roof.

3.4 LIST OF SIGNIFICANT SPILLS OR LEAKS
There have been no significant spills or leaks of toxic or hazardous pollutant in these areas in the
three years prior to the effective date of this permit. See Table 3.
3.5 CERTIFICATION OF STORMWATER OUTFALLS
NON-STORMWATER DISCHARGE ASSESSSMENT AND CERTIFICATION OUTFALL
INSPECTIONS:
The following inspections were performed of the stormwater outfall to identify the presence of
the non-stormwater discharges. The inspections were visual inspections conducted during the
dry weather period. Worksheet No.5, which follows this section, further documents the
inspections performed.
Date: 10/21/94
Comments: Inspected the site area and outfall. The outfall is perennial stream. The outfall
was clear and flow moderate. There was no indication of a non-stormwater discharge present.
Date: 6/21/94
Comments: Inspected the site area and outfall. The outfall is perennial stream. The outfall
was clear and flow moderate. There was no indication of a non-stormwater discharge present.
Date: 1/26/94
Comments: Inspected the site area and outfall. The outfall is perennial stream. The outfall
was clear and flow normal. There was no indication of a non-stormwater discharge present
REMAINDER OF PAGE INTENTIONALLY LEFT BLANK

4.0 STORMWATER MANAGEMENT PLAN
The stormwater management plan shall contain a narrative description of the management
practices employed which control or minimize the exposure of significant materials to
stormwater, including structural and non-structural measures.
See Table I and Table 2 for this section. Table 1, Material Inventory, lists the applicable
materials used, stored, and produced on -site. The materials have been assessed for their potential
to contribute pollutants to stormwater run-off. Table 2, Description of Exposed Material,
outlines the significant materials were exposed to stormwater during the past three years and/or
currently exposed.
4.1 FEASIBILTY STUDY
A review of the technical and economic feasibility of changing the methods of operations and/or
storage practices to eliminate or reduce exposure of materials and processes of stormwater was
conducted only for the storage of materials which may have the potential to contribute
contamination to stormwater discharges: the overburden soil and the coal pile.
The sediment trap located below the overburden face controls run-off from this area. As results,
no evidence of sediment loading into the stormwater discharge has been observed based on the
facility's semi-annual inspections. In addition, the following reclamation measures have been
implemented in the overburden disposal area: (1) the top of the overburden pile has been graded
to prevent run-off water running down the face; (2) a berm has been placed at the edge of the
overburden pile; (3) the face of the pile has been planted with black locusts and will be
hydroseeded. In the future, if Carolina Solite chooses to place overburden on top of the pile, the
face will be benched back and the pile will be placed at the slope to the required maximum 2:1
grade. Any overburden placed on the current overburden pile will also be placed at a slope to the
required maximum 2:1 grade. The reclamation measures are consistent with the July 25, 1995
letter (Eure, Solite to Cook, DLQ). [See Attachment in Appendix C]. These measure were
determined after an inspection determined that the area had been stabilized and that disturbing
the face wold not be necessary. Based on the fact that materials and personnel are readily
available for future reclamation activities and that the current reclamation measures are
consistent with an agreement between the State and the facility, it is determined that these
measures, described above, are the most technically and economically feasible methods, and
there is no need to change current methods of operations or storage practices.
The coal pile is stored beneath a roof structure, although not all of the coal is covered by the
roof. Based on a review of the semi-annual inspections, there has been no visible sheen or
floating solids observed in the stormwater discharge. Consideration has been given to extending

the existing roof structure. However, a review of technical feasibility indicates that an extension
of the roof structure may inhibit the movement of heavy equipment used to transport the coal to
the kiln area. Coal is transferred to this area, beneath the roof, from the coal (railcar) unloading
area where it is stored until it is used as a fuel source in the combustion process. A gravel berm
will be installed surrounding the coal pile to minimize coal particles run-off.
4.2 SECONDARY CONTAINMNET SCHEDULE
A schedule to provide secondary containment for bulk storage of liquid materials, storage of
Section 313 if the Title III Superfund Amendments and Reauthorization Act (SARA) water
priority chemicals or storage of hazardous substances to prevent leaks and spills from containing
stormwater runoff is not applicable. Secondary containment structures already exist for the
storage of these materials
4.3 BEST MANAGEMENT PRACTICES (BMP) SUMMARY
See Tables 4, 5, and 6, for this section. Table 4 identifies water pollution sources and describes
the existing management practices that address these sources. This table also describes
additional BMP options that will be incorporated in the Plan. Table 5 describes the BMP
included in this Plan to prevent stormwater contamination from plant activities. Table 6
develops the schedule for implementing each BMP identified and lists personnel responsible for
their implementation. Several BMP's listed have been implemented and are ongoing practices
and therefore have no completion dates.
5.0 SPILL PREVENTION AND RESPOSNE PLAN (SPRP)
The facility maintains a Spill Prevention and Control and Countermeasures (SPCC) Plan for the
storage of bulk liquids. This Plan sufficiently addresses operations that may have the potential to
contaminate stormwater runoff through spills or exposure of materials associated with the facility
operations. Therefore, the common elements of the SPCC are incorporated by reference into this
Plan, as provided in Appendix D. A list of responsible persons is provided in Section 8.0 of this
Plan.

In addition, all other bulk storage of materials are contained within concrete secondary
containment structure in accordance with the RCRA regulations. Responses to any spills from
this area will be handled in accordance with the Carolina Solite SPCC Plan. ,
6.0 PREVENTATIVE MAINTENANCE AND GOOD HOUSEKEEPING PROGRAM
A preventative maintenance and good housekeeping program already exist for the facility in
accordance with various requirements outlined in the SPCC Plan. Applicable pages from these
documents will be incorporated by reference into his Plan, as provided in Appendix E.
7.0 EMPLOYEE TRAINING
Facility personnel shall be instructed in the use and maintenance of all spill response equipment
as well as emergency notification procedures and applicable spill prevention regulations. See
Table 7for this section. Table 7 describes the employee training program for the Carolina Solite
facility. The program addressees spill prevention and response, good housekeeping, and material
management practices.

8.0 RESPONSIBLE PARTY
Leader:
POLLUTION PREVENTION PLAN
TEAM MEMBER ROSTER
Richard Gardner Title: Plant Manager
Responsibilities: Coordinate Pollution Prevention Team, meetings, and actions to assure
compliance with the storm water regulations. Monitor environmental and
operational activities as related to storm water discharges.
Members:
(1) Ben Edidns Title: Fuels Manager
Responsibilities: Monitor environmental and operational activities as related to storm water
discharges.
Casandra Ruff Title: Env. Affairs Coordinator
(2)
Responsibilities: Coordinate development and implementation of Storm Water Pollution
Prevention Plan. Monitor plant activities for potential environmental
implications relating to storm water discharges.
(3)
Tom Ferguson Title: Burning Manager
Responsibilities: Monitor environmental and operational activities as related to storm water
discharges.
(4)
Benny Mabry Title: Maintenance Manager
Responsibilities: Monitor environmental and operational activities as related to storm water
discharges.
(5)
Jeff Holshouser Title: Technical Equipment Coordinator
Responsibilities: Monitor environmental and operational activities as related to storm water
discharges.

9.0 PLAN AMENDMENT
The permittee shall amend the Plan whenever there is a change in design, construction,
operation, or maintenance, which has a significant effect of the potential for the discharge of
pollutants to surface waters. The Stormwater Pollution Prevention Plan shall be reviewed and
updated on an annual basis.
REMAINDER OF PAGE INTENTIONALLY LEFT BLANK

10.0 FACILITY INSPECTION PROGRAM
Facilities are required to inspect all stormwater systems on at least a semiannual schedule, once
in the fall (September —November) and once during the spring (April -June). The inspection and
any subsequent maintenance activities performed shall be documented, recording date and time
of the inspection, individual(s) conducting the inspection and a narrative description of the
facility's stormwater control systems, plant equipment and systems. Records of these inspections
shall be incorporated into the Stormwater Pollution Prevention Plan.
10.1 STORMWATER SAMPLING, MONITORING, AND REPORTING
There is no sampling required to be conducted as part of the NPDES Permit No. NCG070000.
Therefore, there is no sampling schedule or protocol associated with this Plan. Any storm water
sampling on -site will be performed in accordance with the requirements of Section C of General
Permit Number NCG070000 to discharge stormwater, in the event the facility uses more than 55
gallons of new motor oil per month when averaged over a CY, shall perform storm water
sampling during a representative storm event.
10.2 SEMI-ANNUAL INSPECTION PLAN FOR SEDIMENT AND EROSION
CONTROL
A minimum of two visual inspections of the overburden sediment trap and the property outfall
will be conducted each year. Records of each inspection will include the date and time of the
inspection, the person conducting the inspection, and any comments or observations made. Any
maintenance performed as a result of an inspection will be documented also. Sample inspection
forms are included in Appendix A.
10.3 COMPREHENSIVE SITE COMPLIANCE EVALUATION
An annual site inspection will be performed by the appropriate personnel to verify the accuracy
of this Plan, as it relates to plant operations. The inspection will identify potential pollutant
sources, as well as, the possible need for additional erosion and sedimentation control measures.
The inspection will also review the Plan and its implementation to identify the need for any
additional changes.

Page 1 of 1
Cecil Hopper
From: Cassandra Ruff
Sent: Friday, August 29, 2003 1:09 PM
To: Cecil Hopper
Subject: SWPPP comments
Cecil, I believe any discussion of haz waste and VVVVTP should removed form the plan.
Also, the Certificate of Coverage should be changed to Solite Corporation as the owner.
All other comments are in the attachment..
8/29/2003

S)\-)3\Y
Discharge Locations
Solite
Corporation
Norwood, NC
Outfall 002-quarry discharge water -
bypasses lake reservoir
Outfall 003-quarry discharge water -
make up water for reservoir
M=OG=
GUfll=LL
engineering & surveying, p.c.

1504 Santa Rosa Road
Suite 200
Richmond, VA 23229
[phone]
[phone] (Toll Free)
[phone] (Fax)
Corporate
320-D Midland Parkway
Summerville, SC 29485
[phone] (Toll Free)
[phone] (Fax)
AF Old Division
PO Box 68
Arvonia, VA 23004
[phone]
[phone] (Fax)
Virginia Solite Division
Route 1, Box 101
Cascade, VA 24069
[phone]
[phone] (Fax)
Carolina Solite Division
PO Box 987
Albermarle, NC 28001
[phone]
[phone] (Fax)
March 5, 2003
VIA FASCIMILIE & CERTIFIED
MAIL
Mr. Mark McIntire, P.E.
Point Sources Branch
Division of Water Quality
North Carolina Department of Environment,
and Natural Resources
1617 Mail Service Center
Raleigh, NC 27699-1617
RE: Solite Corporation, Norwood, North Carolina
Permit Modification Request
Recycle System Permit WQ0003150
°BAR 11 2003
Dear Mr. McIntire:
We certainly appreciate the opportunity afforded by you and the other members of the
NC DENR Division of Water Quality Staff in meeting with us at the plant and taking
the opportunity to see the facility first hand and to discuss aspects of water quality
permitting applicable to our plant. We believe our meeting was beneficial for both
DENR and the facility.
The purpose of this correspondence is to request that Solite Corporation be allowed to
continue to operate under the provisions of our Recycle System Permit (WQ0003150)
until our existing NPDES permit has been modified to incorporate process and quarry
dewatering discharges (expiration date of WQ0003150 permit is April 20, 2003) and to
request approval for the installation a rock wash screening system in our aggregate
manufacturing operation. We request that the kiln rock wash screening system be
governed under the provisions of Recycle Permit WQ0003150 until modification and
renewal of our exiting NPDES permit can be made to incorporate this source of process
water.
Background:
The purpose of the kiln wet screening operation is to remove fines from the kiln feed to,
prevent kiln ring formation. Fines in the raw material result in ring formation which
leads to unstable kiln operation and increased production downtime. The addition of
this system will result in more efficient kiln operation, benefiting the plant and the
environment (i.e., air emissions -eliminate kiln malfunctions). The system will consist
of a 5' x 16' double deck screen with spray bars on both decks, and an under screen
discharge hopper. A drawing illustrating the location of this piece of equipment is
included as an attachment to this submittal. The maximum water discharge rate will be
approximately 200 gallons per minute. The kiln feed screening process will result in
the discharge of water and fines from the quarried rock that is being processed. Fines
will accumulate underneath the screen (and removed by front-end loader and placed in
a storage pile to be sold); the rock will pass though to the silo conveyor and the water

Page 2 of 3,
Hopper to McIntire,
March 5, 2003.
will be discharged to the quarry. The new kiln feed rock wash screen will be in
operation as necessary to fill the raw material storage silos. The silos are capable of
containing approximately 4 hours of feed with both kilns operating. No additional
pollutants or significant increase in pollutant loading is anticipated as a result of the
addition of this piece of equipment.
NPDES Permit Renewal:
As we discussed during our meeting of Tuesday, March 4, 2003, our intentions are to
request a modification of our NPDES permit (No NC 0028169) in association with the
renewal process. Several existing sources will be relocated to redirect our quarry and
process water discharges away from the pond designated as waters of the state by NC
DENR DWQ with their October 19, 2001, letter. Our understanding is that the State
prefers our establishing an NPDES permitted outfall for our quarry dewatering and
process water discharges in lieu of the discharge to the treatment works pond.
We certainly appreciate your time and consideration in this matter. If you have any
questions or require additional information, please do not hesitate to contact either Mrs.
Casandra Ruff at [phone] or myself at [phone].
W. Cecil Hopper
Corporate Manager, Environmental Affairs
cc w/att: Mr. Charles Weaver, NCDENR, DWQ, Raleigh Office
Stephen Holt, Solite Corporation
Casandra Ruff, Solite Corporation
Cecil Hopper, Solite Corporation

Mr. Mark McIntire
March 5, 2003
Page 3
be w/o att: i R. Familia
M. Kirlin
R. Gardener
•

RCS20 RCS19 RCS18
S29I
RCS30
RC 27/ IRCS
RCS28
RCSe
RCS14
RCS26
RCSS
RCS24
Cefi
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ire
RCS34
RCS3S RCS7S
RCS4S:=•\
RCS4 \RCs,'O �RC:S.6
t RCS15
RCS10
RCCS3 \ It
RCSSS RCS6S
RCS11
RCS17
RCS21
RCS1S
RCS1
RCS2S
RCS11 36' x 54' Jaw Crusher
RCS21 4 1/4' Cone Crusher
RCS31 4 1/4' Cone Crusher
RCS41 6' x 16' Multiple Deck Screener
RCS51 6' x 16' Multiple Deck Screener
RCS6! 24' Conveyor
RCS71 24' Conveyor.
RCSB! 24' Conveyor
RCS91 24' Conveyor
RCS101 30' Conveyor
RCS111 30' Conveyor
RCS121 30' Conveyor
RCS131 30' Conveyor
RCS14: 30' Conveyor
RCS151 36' Conveyor
RCS161 36' Conveyor
RCS171 42' Conveyor
RCS181 600 Ton Silo
RCS191 600 Ton Sllo
RCS201 600 Ton Silo
RCS211 50 Ton Feed Hopper
RCS221 36' Conveyor.
RCS23-30i Eight (8) 24' Conveyors
RCS311 30' Conveyor
RCS1S-7S! Seven (7) Mist Water Sprays
RCS341 Kiln Feed Wet Screener
CAROLI\A SOLITE
Raw Material Processing. Area
Notes!
!. Drawing not to scale
2. Drawing represents flow
only and does not represent 12 / 2 0 / 2 0 0 2
costructlon or actunl :locations.
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320-D MIDLAND PARKWAY • SUMMERVILLE • SOUTH CAROLINA 29485
PHONE [phone] • FAX [phone]
April 1, 2002
Mr. Michael Myers
North Carolina DENR
Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
Re: Solite Corporation
Carolina Solite Division
Treatment Works Pond
Permit No. WQ0003150
Via Federal Express
Obtain Delivery Signature
Dear Mr. Myers:
As requested during our November 27, 2001 meeting, Solite Corporation performed an
initial assessment of the process water and stormwater discharges to the existing
Treatment Works Pond (TWP) at its Carolina Solite facility, located in Aquadale, North
Carolina.
Attached please find a draft copy of the initial assessment information. It is our
understanding that once the Division of Water Quality has reviewed the attached
information, it will contact Solite to discuss any potential permitting requirements for the
TWP and associated discharges.
If you have any questions or require additional information, please contact Ms. Casandra
Ruff at 704-474-3165 or me at 804-673-8625.
Sincerely,
Michael T.1?leyo
on behalf of Solite Corporation
md:laquadal elwaterlt wpass-sub.doc
cc: Stephen Holt
Casandra Ruff

Division of Water Quality
MEMO From: (.Q.ram'c f�c�vt Date: 4/4010
To: P' Subject:
Led Row))
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71u� a.� 7)A9L, 4-0 tie (,o co_.�c., k�
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ern
NCDENR
North Carolina Department of Environment and Natural Resources
PO Box 29535, Raleigh, North Carolina 27626-0535 / Phone: [phone]

1.0 EXECUTIVE SUMMARY:
On February 20, 1990 Solite Corporation, Carolina Solite Division (herein, Solite), submitted a
non -discharge permit application to operate a "Treatment Works Pond" at the Aquadale, North
Carolina facility. Subsequently, Solite was issued water quality permit WQ0003150 for the
operation of the treatment works pond (TWP), which included the operation of a rock
washing/recycle system. North Carolina water quality permit WQ0003150 was most recently re-
issued to Solite Corporation on June 25, 1999.
The treatment works pond presently receives water discharges from the following facility
sources:
• Process water from the raw material rock washing system (wet screener operation),
• Process water discharges from various facility water sprays being used for dust suppression,
and
• Stormwater run-off from the active portion of the facility.
• Quarry de -watering activities under NPDES Permit NC0028169
The North Carolina Department of Environment and Natural Resources, Division of Water
Quality (herein, DWQ), performed an inspection of the Solite facility and the operations subject
to permit WQ0003150 in the fall of 2001. As a result of this inspection, the DWQ issued an
October 19, 2001 letter that states, in part:
"Based on 15A NCAC 02B .0228..., the Division has determined that the pond [TWP] is
located in -stream and has determined that the ponds are 'waters of the state." Thus, the
"WQ" permit is not appropriate and a NPDES discharge permit will be required."
The letter also requested that Solite meet with the DWQ so that the DWQ and Solite could
discuss the options available to re -permit the pond system under the NPDES system. On
November 27, 2001, representatives of Solite met with the DWQ.
During the meeting, the DWQ indicated that its goal was to issue an NPDES permit for the
discharges to the facility pond. Without agreeing to the DWQ's interpretation of the pond's
status under the NPDES system, Solite agreed to perform an assessment of the facility discharges
to the existing pond and provide a draft report to the DWQ, by April 1, 2002. The report was to
included the following information:
1. An identification of all discharges to the TWP and associated channel,
2. Classification of these discharges as process water or stormwater,
3. Identification of all industrial activities associated with each discharge, and
4. Delineation of the run-off area associated with each discharge.
In addition, the DWQ also requested that if by April 1, 2002, the facility was aware of any types
of control measures or facility modifications that it may implement to minimize pollutant run-off
to the ponds and/or channel, to include such information in the draft report.
1

Accordingly, Solite is submitting the following draft "Assessment of Stormwater and Process
Water Discharges and Potential Control Measures" to the DWQ by April 1, 2002. The draft
report is being submitted for discussion purposes with the DWQ and is not intended to represent
an agreement of the regulatory status of the pond system.
Section 2.0 of this report provides a description of the Solite facility and lightweight aggregate
manufacturing operations. Section 3.0 provides an overview of the project description and
Section 4.0 provides a detailed listing of the process water discharges and potential sources of
stormwater pollutants. Finally, Section 5.0 provides a listing of potential control measures
and/or facility modifications that are being considered for implementation at the Solite facility.
2

2.0 FACILITY DESCRIPTION:
Solite Corporation, Carolina Solite Division (herein, Solite), operates a lightweight aggregate
manufacturing facility on an approximate 689-acre parcel of land in Aquadale, North Carolina.
At the facility, raw materials (shale/slate) are mined, crushed and screened in the facility raw
material processing equipment, and fed into the upper (cold) end of one of three rotary kilns
where the material is heated to temperatures of approximately 1800 —2000° F. At these elevated
temperatures, the raw material expands, or "bloats," to form lightweight aggregate clinker. The
lightweight clinker, which exits at the lower (hot) end of the kiln, is then crushed and screened in
the facility's finished material processing equipment to produce various sized finished materials
for use in construction applications.
In addition to the production of lightweight aggregate, the facility also processes and sells raw
material aggregate for construction, roadbed, and other commercial/private purposes.
Located contiguous to, and wholly within the Solite facility property boundary, is a separate
company, Giant Resource Recovery, Inc. (GRR). GRR operates a non -hazardous waste fuel
storage and blending facility and supplies Solite Corporation with non-RCRA regulated waste
fuel to fire its rotary kilns. The GRR facility consists of six aboveground storage tanks ranging
in size from 10,000 to 20,000 gallons. All tanks are located within secondary containment with
sufficient capacity to hold the contents of the largest tank within the containment, as well as
sufficient freeboard to contain rainwater from a 24-hour, 25-year storm event. In addition, the
tank farm is covered with a freestanding roof that minimizes the accumulation of rainwater
within the containment. The GRR facility consists of a truck loading/unloading pad, also located
within containment and covered by a roof, and a railcar unloading facility.
In addition to the non-RCRA regulated waste fuel, Solite also fires its rotary kilns with
conventional fuels including coal and no. 2 fuel oil. Therefore, the facility maintains a coal
storage area located on the eastern side of the active portion of the facility and a no. 2 fuel oil
storage tank located within containment adjacent to Kiln No. 8.
Other activities present at the Solite facility include a maintenance shop located on the northern
portion of the facility and various buildings/sheds used to store facility equipment and
maintenance materials. Vehicle maintenance is performed inside the maintenance shop building
to prevent potential contact with stormwater run-on and run-off. The maintenance area includes
several outdoor above ground storage tanks used to store petroleum products such as diesel fuel,
gasoline, used oil, and lube oils of various weights. All tanks are located within secondary
containment to minimize contact with stormwater run-off.
Figure 1 of this report provides a layout drawing of the Solite and GRR facilities. Section 4.0 of
this report provides a detailed listing of the process water discharges and potential sources of
stormwater pollutants.
3

3.0 PROJECT DESCRIPTION / SCOPE:
The water channel subject to the DWQ's October 21, 2001 letter consists of one pond located
north of the railroad tracks (herein, Pond 1), the existing Treatment Works Pond (herein, Pond
2), and a marsh area located between Ponds 1 and 2, south of the railroad tracks. No outfall from
the TWP is constructed.
In addition, a water channel (Upper Long Branch) flows south from the reclaimed mining
overburden area into the Long Branch Creek. The water source for this channel consists of
groundwater seepage. The facility is currently permitted to discharge water from a quarry de -
watering operation into Upper Long Branch or to the existing TWP (Pond 2) under NPDES
Permit No. NC0028169.
For purposes of this report, Solite Corporation has assessed all point source discharges of process
water and stormwater into the area located from Pond 1 through Pond 2. The assessment
consists of the following:
1. An identification of all discharges to the TWP and associated channel,
2. Classification of these discharges as process water or stormwater,
3. Identification of all industrial activities associated with each discharge, and
4. Delineation of the run-off area associated with each discharge.
Detailed information for items 1-4 above are provided in Section 4.0 of this report.
In addition, the facility has assessed the feasibility of various potential control measures and
facility modifications that may be implemented to improve the water quality of the above
referenced discharges to the facility channel. Information on these modifications/control
measures is provided in Section 5.0 of this report.
5

4.0 IDENTIFICATION OF WATER DISCHARGES:
Presently, there are four point source discharges to the water channel identified as the
area from Pond 1 through Pond 2. Three of the discharges (herein referred to as PS-001,
PS-002, and PS-003) consist of both process water and stormwater runoff. One outfall
(herein, P-004) consists of a quarry water discharge. The following paragraphs provide
the detailed assessment of each outfall:
4.1 Outfall PS-001:
Outfall Location:
Outfall PS-001 discharges to Pond 1 at a location north of, and
adjacent to, the railroad tracks that traverse the Solite property.
Figure 1 details the location of outfall PS-001.
Outfall Description: Earthen conveyance (vegetated).
Discharge Contents: Process water from a trailer washing station located to the south of
the facility shop.
Stormwater run-off (drainage area detailed below)
Stormwater
Drainage Area:
The drainage area for outfall PS-001 consists of the office, parking
areas, GRR facility, maintenance shop area, brick shed, and
material storage shed. Figure 2 details the approximate drainage
area for this outfall.
Pollutant Sources: Potential pollutant sources for outfall PS-001 include:
Outfall Flow Rate:
• Petroleum storage tank loading areas
• Trailer washing station
• Parking areas
Flow is intermittent and is primarily impacted by stormwater
activity. Flow measurements will be performed during application
process, if necessary.
4.2 Outfall PS-002:
Outfall Location:
Outfall PS-002 discharges to the marsh area between Ponds 1 and
2, south of the railroad tracks. Figure 1 details the location of
outfall PS-002.
Outfall Description: Earthen/stone conveyance (non -vegetated).
6

Discharge Contents: Process water from the facility stone washing system.
Stormwater
Drainage Area:
Pollutant Sources:
Outfall Flow Rate:
Stormwater run-off (drainage area detailed below)
The drainage area for outfall PS-002 consists of the raw material
storage area located west of the raw material crushing and
screening operations, and south of the railroad tracks. Figure 2
details the approximate drainage area for this outfall.
Potential pollutant sources for outfall PS-002 include:
• Rock washing system
• Raw material storage piles
Flow is intermittent and is primarily impacted by the stone
washing system. Water flow rates from the stone washing system
range from zero to approximately 26,880 gallons per day.
Stormwater flow rates will be determined during the permitting
process, if necessary.
4.3 Outfall PS-003:
Outfall Location:
Outfall Description:
Discharge Contents:
Stormwater
Drainage Area:
Outfall PS-003 discharges to the marsh area between Ponds 1 and
2 at a location north of, and adjacent to, the access road to Pond 2.
Figure 1 details the location of outfall PS-003.
Earthen/stone conveyance (non -vegetated), with a portion of the
discharge conveyed via piping under the facility access road.
Process water from dust suppression water sprays in the raw
material and finished material crushing and screening operations
and process water from water tank overflow.
Stormwater run-off (drainage area detailed below).
The drainage area for outfall PS-003 consists of the kiln, raw
material, and finished material departments, as well as a portion of
the raw material storage area located west of the raw material
crushing and screening departments. Figure 2 details the
approximate drainage area for this outfall.
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Pollutant Sources: Pollutant sources for outfall PS-003 include:
• Raw and Finished Material Storage Piles
• Raw and Finished Material Crushing, Screening, and
Conveying Operation
Outfall Flow Rate: Flow is intermittent and is primarily impacted by the dust
suppression water usage. Flow measurements will be performed
during application process, if necessary.
4.3 Outfall P-004:
Outfall Location: Outfall P-004 discharges to Ponds 2. Figure 1 details the
approximate location of outfall P-004.
Outfall Description: Pipe.
Discharge Contents: Process water from quarry de -watering authorized under NPDES
Permit No. NC0028169.
Stormwater
Drainage Area: N/A.
Pollutant Sources: Pollutant sources for outfall P-004 include:
• Quarrying activities
Outfall Flow Rate:
Flow is intermittent and is equivalent to the quarry de -watering
rate. Flow rates range from zero to approximately 396,000 gallons
per day.
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5.0 POTENTIAL CONTROL MEASURES / FACILITY MODIFICATIONS:
As detailed above, Pond 2 is currently operated as a treatment works pond subject to water
quality permit WQ0003150. As such, uncontrolled process water and stormwater run-off is
discharged to the system at four locations, outfalls PS-001, PS-002, PS-003, and P-004. The
DWQ has indicated that based on 15A NCAC 02B .0228, each of these outfalls will now be
regulated as discharges to "waters of the State" and consequently, may potentially be subject to
individual inspection and monitoring requirements as well as discharge limitations.
To comply with these requirements and limitations, Solite anticipates that it may need to
implement control measures and/or operational modifications to either improve the water quality
of point source discharges PS-001, PS-002, and/or PS-003, or eliminate one or more of these
point source discharges completely. Outfall P-004 consists of quarry water only and therefore, it
is not anticipated that any control measures or facility modifications would be necessary for this
outfall. However, as part of this assessment, Solite personnel have indicated that they may
request that this discharge authorized under North Carolina Permit No. NC0028169 be permitted
to discharge to a third location at the facility. A further discussion of this issue is provided in
Section 5.4 of this report.
As part of this draft Assessment, Solite Corporation has identified a preliminary list of
operational modifications and control measures that may be implemented as part of the permit
application process for outfalls PS-001, PS-002, and PS-003. A listing of these potential
modifications/control measures is provided in Table 1. However, as discussed during the
November 27, 2001 meeting, the facility will continue to assess and/or modify the potential
control options as the permitting process continues. The information in this section is being
provided at this time for discussion purposes only.
Sections 5.1 through 5.3 provide a further discussion of the control options for each outfall.
Table 1: Potential Facility Modifications for Each Outfall/Discharge
Outfall
Type of Facility Modification
(control measure or
operational modification)
Description
Estimated
Completion Time
PS-001
Control Measure
Sediment trap(s) installed in outfall channel
1 month
PS-002
Operational Modification
Re -location of rock washing system to
eliminate outfall PS-002. Drain wash water
into quarry for settling.*
1 year
Control Measure
Installation of run-off berms around raw
material storage piles (control sheet flow
from storage piles)
3 months
PS-003
Operational Modification
Installation of overflow shut-off switch for
pump servicing raw material water tank
3 months
Control Measure
Re -locate outfall to discharge to Pond 2 on
south side of pond access road and install
sediment trap in outfall channel
6 months
The quarry would act as a settling basin and the water, after adequate settling, would be discharged under
NPDES Permit NC0028169. Therefore, a modification to permit NC0028169 may be required.
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5.1 Outfall PS-001:
As detailed in Section 4.0, outfall PS-001 contains both process water discharge from the trailer
wash station and stormwater run-off from the area located north of the railroad tracks, including
the office area, maintenance shop, GRR facility, and facility storage sheds.
Due to the lack of industrial activity on the northern portion of the facility, and the use of
concrete secondary containment surrounding all petroleum and non -hazardous waste storage
tanks, the potential for excessive stormwater loading is minimized. In addition, the trailer
washing station is designed only to rinse residual inert materials from the trailers of material
transportation vehicles to prevent product contamination (e.g. - mixing aggregate materials of
different gradations).
Therefore, Solite anticipates that the only significant pollutant associated with this process would
be the solids loading. However, the trailer washing station is located over 200' from outfall PS-
001 and the wash water flow to the outfall consists of primarily overland flow. Therefore, a
significant amount of natural settling occurs before the material migrates to the outfall. In
addition, an initial inspection of the outfall did not reveal any evidence of significant solids
loading at this outfall.
Accordingly, Solite believes that the installation of sediment traps in the outfall channel will be
sufficient to control any residual solid materials in the process/stormwater discharge.
5.2 Outfall PS-002:
Outfall PS-002 discharges washwater from the rock washing system detailed in the existing
permit WQ0003150. Consequently, the outfall PS-002 discharge contains significant solids
loading that would need to be treated prior to the washwater being discharged to "waters of the
State." As an open conveyance, this outfall also contains stormwater from the surrounding raw
material storage areas.
Potential options for the control of these discharges include the construction of a non -discharge
sedimentation basin equipped with a recycle system or a sedimentation basin designed with an
outfall to the existing water channel. However, each of these options would incur significant
capital and/or operational costs such as periodic dredging and power costs associated with a
recycle pump system.
Therefore, the facility has opted to re -locate the rock washing system to an area adjacent to the
existing quarry. Water from the rock washing system will discharge to the quarry, which will act
as a settling basin. After adequate settling has occurred, the water would then be discharged
under the existing NPDES permit NC0028169.
With the re -location of the rock washing system, the facility will be able to eliminate the outfall
conveyance and therefore, eliminate point source outfall PS-002.
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5.3 Outfall PS-003:
Outfall PS-003 presently discharges process water (water used for dust suppression) and
stormwater run-off from the raw material, finished material, and kiln processing areas of the
facility to the marsh area between Ponds 1 and 2. Located on the northern side of the Pond 2
access road, the outfall ditch also collects and discharges stormwater from a portion of the raw
material storage area.
A potential control option identified for outfall PS-003 included the elimination of the process
water discharge by re -directing the process water to the existing quarry basin. After adequate
settling, the water could then be discharged in the same manner as detailed under outfall PS-002
above. However, an inspection of outfall PS-003 reveals that the process water discharge
typically contains very little solids loading which could be controlled by installing a
sedimentation trap in the outfall ditch. In addition, re -directing the water would incur significant
capital cost associated with the construction of a collection sump and pumping system.
Therefore, re -directing the process water is not deemed necessary at this time.
However, additional solids also appear to be entering the existing outfall in the stormwater from
the raw material storage area. Therefore, to minimize the stormwater loading from the raw
material storage area, Solite has opted to relocate the process water outfall ditch to the south side
of the Pond 2 access road. To control any solids loading from the process water flows; a
sedimentation trap will be constructed in the relocated outfall. The relocated outfall would then
discharge directly to Pond 2.
5.3 Outfall P-004:
As noted above, outfall P-004 presently discharges quarry process water to Pond 2 under an
existing NPDES permit. Therefore, there are no control measures or facility modifications that
are being proposed as part of this assessment. However, as part of the potential permitting
process, the facility is interested in obtaining authorization to discharge this quarry water to the
intermittent stream and pond system located on the eastern portion of the Solite facility (Lower
Long Branch). Lower Long Branch merges with the Upper Long Branch, eventually discharging
to the Rocky River.
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