NC0004685_Permit Issuance_20081013

Michael F. Easley
Governor
William G. Ross, Jr., Secretary
North Carolina Department of Environment and Natural Resources
October 13, 2008
Mr. Timothy G. Mathis
Manufacturing Manager
PPG Industries Fiber Glass Products, Inc.
940 Washburn Road
Shelby, North Carolina 28150
Subject:
Dear Mr. Mathis:
Coleen H. Sullins, Director
Division of Water Quality
Issuance of NPDES Permit NC0004685
Shelby Facility
Cleveland 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 October 15, 2007 (or as subsequently amended).
This final permit includes no major changes from the draft permit sent to you on August 13, 2008.
If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable to
you, you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt of this
letter. This request must be in the form of a written petition, conforming to Chapter 150B of the North Carolina
General Statutes, and fled with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh, North
Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division may require
modification or revocation and reissuance of the permit. This permit does not affect the legal requirements to obtain
other permits which may be required by the Division of Water Quality or permits required by the Division of Land
Resources, the Coastal Area Management Act or any other Federal or Local governmental permit that may be
required. If you have any questions concerning this permit, please contact Sergei Chemikov at telephone number
[phone].
Sincerely`,X
S,
/-)KTColeenl-I.Sullins
cc Central Files
Mooresville Regional Office, Surface Water Protection
EPA Region IV
NPDES Files
N. C. Division of Water Quality I NPDES Unit Phone: [phone]
1617 Mail Service Center, Raleigh, NC 27699-1617 fax: [phone]
Internet: h2o.enr.state.nc.us DENR Customer Service Center. 1800 623-7748

PermitNC0004685
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 provisions of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and the Federal Water Pollution Control Act, as amended,
PPG Industries Fiber Glass Products, Incorporated
is hereby authorized to discharge wastewater and stormwater from a facility located at
Shelby Facility
On NCSR 1313
West of Shelby
Cleveland County
to receiving waters designated as Brushy Creek and Overflow Branch in the Broad River Basin in
accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts
I, II, III, and IV hereof.
The permit shall become effective November 1, 2008.
This permit and the authorization to discharge shall expire at midnight on August 31, 2013.
Signed this day October 13, 2008.
l
Coleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0004685
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked, and as of this 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.
PPG Industries Fiber Glass Products, Incorporated is hereby authorized to:
Continue operation of a 1.3 MGD wastewater treatment facility consisting of.
• an overflow/storage basin;
• bar screen and grinder;
• an influent wet well with lime addition;
• influent pumps;
• a surge tank;
• an equalization tank with aluminum chloride addition;
• a flash mix tank;
• coagulant and polymer addition;
• two primary clarifiers;
• two aeration basins with bentonite clay addition;
• a splitter box and floc tank;
• three secondary clarifiers with ferric chloride addition;
• a sand filter;
• an effluent holding tank;
• a sludge thickener tank; and
• a sludge belt press.
These treatment works are located at PPG's Shelby facility on NCSR 1313, west of Shelby,
Cleveland County and discharge treated process wastewater, stormwater, sanitary sewage,
cooling water, and landfill leachate, at the location specified on the attached map, through
outfall 001 into Brushy Creek, a class C water in the Broad River Basin; and
2. Discharge non -contact cooling water and stormwater through outfall 002, at the location
specified on the attached map, into Overflow Branch, a class C water in the Broad River Basin.

Outfall 001 to Brushy Creek \
Latitude: 35°20'25"
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PPG Industries. - NC0004685
tion
LLFacifity
USGS Quad Name: Shelby SE/SW
Receiving Stream: See Above
Stream in: Br C "
Subbasin: Broad - 030804
Not to SCALE "

Permit NC0004685
A. (1) Effluent Limitations and Monitoring Requirements [001]
Beginning on the effective date of this permit and lasting until permit expiration, the Permittee is
authorized to discharge from Outfan 001. Such discharges shall be limited and monitored by the
Permittee as specified below:
PARAMETER
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
a
Sample
Location'
Flow
1.3 MGD
Continuous
Recording
Influent or
F.i ucnt
BOD, 5-day, 200C (mass)
217.0 pounds/day
pounds.5
weekly
Composite
Effluent
BOD, 5-day, 20-C
(concentration)
20.0 mg/L
30.0 mg/L
Weekly
Composite
Effluent
Total Suspended Solids
20.0 mg/L
146.0 mg/L
Weekly
Composite
Effluent
NH3-N (mass)
65.0
pounds/day
97.5
pounds/day
Weekly
Composite
Effluent
NH3-N (concentration)
6.0 mg/L
9.0 mg/L
Weekly
Composite
Effluent
Dissolved Oxygen
Daily Average z 5.0 mg/L
Daily
Grab
Effluent
Dissolved Oxygen (instream)
Monitor & Report
See Note 1
Grab
U,D
PH
z 6.0 and 5 9.0 standard units
Daily
Grab
Effluent
Temperature, OC
Daily
Grab
Effluent
Temperature, -C (instream)
See Note 1
Grab
U,D
Fecal Coliform
Weekly
Grab
Effluent
Total Nitrogen
Quarterly
Composite
Effluent
Total Phosphorus
Quarterly
Composite
Effluent
Conductivity
See Note 1
Grab
U,D
Oil and Grease
10.0 mg/L
15.0 mg/L
Weekly
Grab
Effluent
Total Lead
Monthly
Composite
Effluent
Fluoride
5.4 mg/L
Weekly
Composite
Effluent
Total Zinc
2/Month
Composite
Effluent
Total Copper
2/Month
Composite
Effluent
Chloride
2/Month
Composite
Effluent
Total Residual Chlorine2
17 µg/L
Weekly
Grab
Effluent
Chronic Toxicity3
Quarterly
Composite
Effluent
NOTES:
1 U: upstream at NCSR 1323. D: downstream at NCSR 1305. Instream samples shall be grab
samples collected three times per week during June, July, August, and September and weekly
during the remainder of the year.
2 The facility shall report all effluent TRC values reported by a NC certified laboratory including field
certified. However, effluent values below 50 pg/L will be treated as zero for compliance purposes.
Monitoring and effluent limitation for TRC apply only if chlorine is added fro disinfection.
3 Chronic Toxicity (Ceriodaphnia) P/F @ 33%; January, April, July, October [see A. (5)].
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE
AMOUNTS.

Permit NC0004685
A. (2) Effluent Limitations and Monitoring Requirements 1002]
Beginning on the effective date of this permit and lasting until permit expiration, the Permittee is authorized to
discharge from Outfall 002. Such discharges shall be limited and monitored by the Permittee as specified below:
PARAMETER
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Averse
Daily
Maximum
Measurement
Frequency
Sample
a
Sample
Location
Flow. (MGD)
Semi -Annually
Estimate
Grab
Effluent
Effluent
Effluent
Effluent
Temperature
...............
See Note 1
Semi -Annually
Total Residual Chlorine2
28 µg/L
Semi -Annually
Grab
PH
> 6.0 and < 9.0 standard units
I Semi -Annually
Grab
NOTES:
1 The temperature of the effluent shall be such as not to cause an increase in the temperature of the
receiving stream of more than 2.8GC and in no case cause the ambient water temperature to exceed
29oC.
2 The facility shall report all effluent TRC values reported by a NC certified laboratory including field
certified. However, effluent values below 50 µg/L will be treated as zero for compliance purposes.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE
AMOUNTS.
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE COOLING WATER.
A. (3) Biocide Condition
The Permittee shall not use any biocides except those approved in conjunction with the
permit application. The Permittee shall notify the Director in writing not later than ninety
(90) days prior to instituting use of any additional biocide used in cooling systems which
may be toxic to aquatic life other than those previously reported to the Division of Water
Quality. Such notification shall include completion of Biocide Worksheet Form 101 and a
map locating the discharge point and receiving stream.
A. (4) Disinfection Condition - Outfall 001
In the event that violations of North Carolina's water quality standards for fecal coliform
occur as a result of this discharge, disinfection will immediately be required and the permit
amended to establish a fecal coliform effluent limitation.

Permit NC0004685
A. (5) Chronic Toxicity Permit Limit (Quarterly) - Outfall 001
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 33%.
The permit holder shall perform at a minimum, guarterlu monitoring using test procedures outlined in the 'North
Carolina C.eriodaphnia Chronic Effluent Bioassay Procedure; Revised February 1998, or subsequent versions or
'North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure' (Revised -February 1998) or subsequent
versions. The tests will be performed during the months of January, April, July and October. Effluent
sampling for this testing shall be performed at the NPDES permitted final effluent discharge below all treatment
processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the
permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the two
following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest
concentration having no detectable impairment of reproduction or survival and the lowest concentration that does
have a detectable impairment of reproduction or survival. The definition of 'detectable impairment," collection
methods, exposure regimes, and further statistical methods are specified in the "North Carolina Phase II Chronic
Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the months in which tests were performed. If reporting pass/fail results using the
parameter code TGP3B, DWQ Form AT-1 (original) is sent to the below address. If reporting Chronic Value
results using the parameter code THP311, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / DWQ / 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, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature.
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 the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be
required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water
Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include
alternate monitoring requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such
monitoring shall be included in the calculation & reporting of the data submitted on the DMR & all AT Forms
submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism
survival, minimum control organism reproduction, 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.

PPG Industries Fiber Glass Products, Inc.,
Timothy G. Mathis
Manufacturing Manager
Fiber Glass Products
September 3, 2008
Sergi Chemikov, PH. D.
Environmental Engineer H
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
940 Washburn Switch Road, Shelby, N.C. 28150
Via Certified Mail — Return Receipt Requested
Re: Draft NPDES Permit— (Permit NC0004685)
13rK61T4nH .T419
704-434-2261
Extension 206
[e-mail]
I 1 '
rl i
_F
SEP 5 20 88
WATER O(IAtITY
In response to your letter dated August 13, 2008 please find below continents of PPG Industries
Fiber Glass Products, Inc. (PPG) on the Draft NPDES Permit NC0004685.
1- SUPPLEMENT TO PERMIT COVER SHEET, Section 1
Aluminum chloride addition occurs in the equalization tank instead of the flash mix tank.
2- A (1.) EFFLUENT LEMTATIONS AND MONITORING REQUIREMENTS, Notes: # 2
Previous Permit — "The limitation for TRC becomes effective 18 months from the effective date
of this permit. Monitoring and effluent limitation for TRC apply only if chlorine is added for
disinfection."
Draft Permit — "The facility shall report all effluent TRC values reported by a NC certified
laboratory including field certified. However, effluent values below 50 ug/I will be treated as
zero for compliance purposes."
The following statement was excluded from the Draft Permit - "Monitoring and effluent
limitation for TRC apply only if chlorine is added for disinfection." This statement is applicable
to our system as no disinfection process exists within the treatment processes.
3- A (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS, Notes: # 2
Previous Permit — "The effluent limitation for chlorine shall become effective 18 months after
the effective date of this permit."

Draft Permit — "The effluent limitation for chlorine shall become effective 18 months after the
effective date of this permit."
The effluent limitation became effective during the Previous Permit. The following statement
would be applicable for a note on this requirement. "Effluent values below 50 ug/l will be treated
as zero for compliance purposes."
PPG requests that these comments prior to issuance of the permit. If you have any question
concerning these comments, please contact Richard Young, Sr. Engineer Associate, at (704) 434-
2261 ext. 359.
SinceTly
Timothy
Manufacturing Manager
Cc: Richard Young
file

THE STAR
August 21, 2008
PUBLIC NOTICE STATE OF NORTH CAROLINA ENVIRONMENTAL
MANAGEMENT COMMISSION/ NPDES UNIT 1617 MAIL
I, Aron Goss, Advertising Director,
at THE PUBLIC NOTICE STATE OF NORTH CAROLINA ENVIRONMENTAL
MANAGEMENT COMMISSION/ NPDES UNIT 1617 MAIL STAR, a newspaper
published in Shelby, N. C., do
solemnly swear that the advertisement
hereto annexed appeared in the
SHELBY STAR, one
successive weeks/days beginning PUBLIC NOTICE
STATE OF NORTH
August 21, 2008 ARC OLINA
ENVIRONMENTAL
MANAGEMENT
COMMISSION/
NPDES UNIT
tLL9._
Advertising Director
Name of Account:
NCDENR/DWQ/NPDES
Order Number: 54407883
Ad Number: 54421241
Sworn to, and subscribed before me this
21 st day of August, 2008.
Notary Public
My Commission Expires
0`1Cudbi
P.ESECCA R. RENKO QYCIIS
Notary Public, North ro fne
Cleveland County
My Commission Expires
September 04. 2008
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
143.215.1 and 15A NCAC
02H.0109 and other lawful
standards and regulations,
the North Carolina Envi-
ronmental Management
Commission proposes to
issue a National Pollutant
Discharge Elimination Sys-
tem (NPDES) wastewater
discharge permit to the
person(s) listed below at-
rective 45 days from the
publish date of this notice.
Written comments regard-
ing the proposed permit will
be accepted until 30 days
after the publish date of this
notice. All comments re-
ceived prior to that date are
considered in the final de-
terminations regarding the
proposed permit. The Di-
rector of the NC Division of
Water Quality may decide
to hold a public meeting for
the proposed permit,
should the Division receive
a significant degree of pub-
lic interest.
Copies of the draft permit
and other supporting infor-
mation on file used to de-
termine conditions present
in the draft permit are aml-
able upon request and pay-
ment of the costs of repro-
duction. Mail comments
and/or requests for infor-
mation to the NC Division
of Water Quality at the
above address or call Dina
Sprinkle [phone]at
the Point Source Branch.
Please include the NPDES
permit number (below) in
any communication. Inter-
ested persons may also
visit the Division of Water
Quality a1512 N. Salisbury
Street, Raleigh, NC
27604-1148 between the
hours of 8:00 a.m. and 5:00
p.m. to review information
on file.
PPG Industries Fiber Glass
Products, Inc. has applied
for renewal of the NPDES
permit for its Shelby facility
(NC0004685). The facility
is permpled to discharge up
to 1.3 MGD of treated ef-
fluent from oudall 001 to
Brushy Creek, and
non -contact cooling water
from oudall 002 to OvarfloW
Branch. Both receiving
streams are class C waters
in the Broad River Basin.
BOD, ammonia, DO, TRC
and fluoride are water qual-
ity limited. This discharge
may impact future alloca-
tion of the receiving
streams.
August 21, 20081tc

re NC0006351 and NC0004685
Subject: re NC0006351 and NC0004685
From: [e-mail]
Date: Thu, 21 Aug 2008 08:38:49 -0400
To: [e-mail]
EPA has no comment on either of these permits. Would you like no
comment letters or will this email suffice?
1 of 1 8/21/2008 8:49 AM

DENR/DWQ FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0004685
1111111ffffacility Information
Applicant Facility Name: PPG Industries Fiber Glass Products, Inc.
Applicant Address:
940 Washburn Switch Road, Shelby, NC
Facility Address:
940 Washburn Switch Road, Shelby, NC
Permitted Flow
1.3 MGD
Type of Waste:
95% Industrial, 5% Domestic
Facility/Permit Status:
Existing renewal without expansion
County:
Cleveland
Stream Characteristics
Receiving Stream
Brushy Creek (001) and Overflow Branch (002)
303(d) Listed?
No
Stream Classification
C
Sub -basin
03-08-04
Drainage Area (mi2):
15.1
Summer 7Q 10 (cfs)
4.0
Winter 7Q10 (cfs):
7.6
Average Flow (cfs):
21.0
IWC (%) @ 3.0 MGD:
33
Miscellaneous
Regional Office:
Mooresville
USGS Topo Quad:
F12SE
Permit Writer:
Sergei Chemikov
Date
August 5, 2008
1.0 Proposed Chances
No changes are proposed.
2.0 Background
PPG Industries Fiber Glass Products, Inc. operates a fiberglass fiber manufacturing facility in
Shelby, NC. The Shelby plant currently concentrates the bulk of its fiberglass manufacturing
on the reinforced plastics market.
Manufacturing begins with glass raw materials including limestone, silica, boron, clay and
fluorspar. These raw materials are blended in powder form and added to melt furnaces. The
batch melt furnaces, operating at 2800°F, transform the batch into molten glass. The molten
glass is then drawn from the furnaces through electrically heated platinum bushings into
continuous fibers. These fibers are gathered into strands and either spooled or chopped into
specified lengths. Water sprays cool the glass and keep strand contact points clean during the
winding process.
A "binder", which is water based, is applied to the individual fibers as they are drawn from the
furnaces before being gathered into strands. The binder is a proprietary mixture of resins, film
formers, lubricants, surfactants and coupling agents emulsified in a water base. The majority of
the wastewater treated by the treatment plant is spray water, lost binder and cleaning water.
Additional wastewater is received from Azdel, Inc. Azdel is a PPG joint venture with GE and
produces a fiber glass reinforced polypropylene sheet material that is sold to molders. This is
considered a plastics laminating process and is cover under 40 CFR 463. The manufacturing
process is dry, so that the wastewater sent to PPG is either cooling water, cleaning water or
domestic wastewater. Therefore, no allocation based on 463 is proposed.
PPG Industries Fact Sheet
NPDES Renewal
Page 1
-J

3. Wasteload Allocation Summa
This permit was first issued on May 31, 1978. The permit was summarily adjudicated. It is not
entirely evident why the permit was adjudicated, however a review of historical files seems to
indicate that the adjudication was filed because of a disagreement with limit development. At
issuance, final effluent limitations were based on 40 CFR 410.32, Subpart C: Textile Dry
Processing. While the permit was being adjudicated, interim limits were established based on
the results of a field calibrated water quality model. Upon resolution of the adjudication (it was
determined that textile guidelines did not apply to PPG's discharge), the permit was reissued in
August of 1979 with water -quality limitations based on the results of the model. This original
series of wasteload allocations was based on a discharge flow of 0.875 MGD.
The permit was renewed in 1985 with a change in allocation, however the reason for the
change is not evidenced in the files. In 1988, Jackie Nowell completed a wasteload allocation
for this facility at an expanded flow of 1.3 MGD. The increase in flow was based on process
modifications in the manufacturing facility. Jackie evaluated PPG's discharge with a level B
model and developed appropriate water quality -based limitations for BODs and NH3-N.
The current effluent limitations for BOD5 and NH3-N are based on the level B model run in
1988, while the current TSS limits are BPJ, apparently based on the BODs limits developed as
resolution to the 1978/79 adjudication.
Extensive research was conducted during the previous renewal process to determine if any
federal guidelines exist for such a manufacturing operation. Lacy Ballard of PPG was contacted
for a detailed description of the manufacturing process and associated end products. Don
Anderson and Hugh Wise were contacted at EPA in D.C. regarding the applicability of textile
and glass guidelines. After conversations with both, it was determined that neither set of
guidelines applies to PPG's process. As stated earlier, PPG does accept wastewater from Azdel,
Inc. Azdel's operation falls under the authority of 40 CFR 463, Plastics Laminating. However,
manufacturing at Azdel is a dry process. Azdel's wastewater is largely cooling water, cleaning
water and domestic wastewater. Therefore, guidelines do not apply to this aspect of PPG's
effluent either.
PPG operates two outfalls, 001 and 002.
Outfall 001
Outfall 001 is the effluent from the wastewater treatment plant and receives the following kinds
of wastewater:
• Sanitary
• Research
• Boilers
• Miscellaneous
• Forming
• Fabrication
• Coating
• Process WW
• Storm drains/garage pads
• Azdel, Inc. W W
Outfall 002
Outfall 002 is a non -contact cooling water outfall and is permitted in accordance with the
general permit for non -contact cooling water.
4.0 Compliance Summary
A review of DMR data has indicated that the facility has a mixed compliance history. During
the period from 01/2004 through 06/2008 four NOVs for violating O&G standard have been
issued on the following dates: 5/ 17/07, 04/24/06, 10/ 18/04, and 9/ 12/04.
PPG Industries Fact Sheet
NPDES' Renewal
Page 2

5 0 Instream Monitoring Requirements
PPG currently monitors dissolved oxygen, fecal coliform, temperature and conductivity
instream. This renewal recommends maintaining instream monitoring for DO, temperature,
and conductivity.
6.0 Reasonabple Potential Analysis (RPAI
Reasonable potential analyses were conducted for lead, copper, zinc, and fluoride for outfall
001. While the maximum predicted concentration for copper and zinc exceeded the allowable
concentration, no limits are proposed as the facility is not experiencing whole effluent toxicity.
7.0 Whole Effluent Toxicity IWET)
Type of Toxicity Test: Chronic P/F
Existing Limit: 001: Chronic P/F @ 33%
Recommended Limit: 001: Chronic P/F @ 33%
Monitoring Schedule: January, April, July, and October
The facility has been consistently passing its WET test.
8.0 Proposed Schedule for Permit Issuance
Draft Permit to Public Notice: August 13, 2008 (est.)
Permit Scheduled to Issue: October 6, 2008 (est.)
9.0 State Contact
If you have any questions regarding any of the above information or the attached permit, please
contact Sergei Chernikov at [phone].
REGIONAL OFFICE COMMENT
PPG Industries Fact Sheet
NPDES Renewal
Page 3

REASONABLE POTENTIAL ANALYSIS
PPG Industries - Shelby
NC0004685
Time Period January 2002 -December 2003
Ow (MGD) 1.3
wW7P Class III
7Q10S (cls) 4
IWC (%) @ 7010S 33.5
7Q10W (ds) 7.6
@ 701OW 20.957
3002 (c/a) 0
@ 3002 NIA
Avg. Swam Flow, CA (c/a) 21
@ QA 8.7552
Rec%dng Stream Brushy Creek
Stream Class C
Outfall 001
Qw=1.3MGD
STANDARDS&
PARAMETER
TYPE
CRITERIA(2)
POL
Units
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
NcwgS/ YFAV/
n 9M MUFad L1r Allowable Cv
(1)
Chronic Acue
Acute: 7
Maintain monitoring at 2/momh. While the Max Predicted
Copper
NC
7 AL 7 3
ug/L
36 36
138.E
is greater man the aAw2bk_no WET is cccudng_thus no
----- --
Chronc 20.9
limit is Proposed------
Acute: N/A
Limit and monitoring remain unchanged.
Fluoride
NC
1,800
ug/L
78 73
6,080.0
_ _ _ _ _ _ _ _ _ _ _ _
___
Chronic: 5,373
Acute: 34
Maintain monitoring at 1/month.
Lead
NC
25 N 33.8
ug/L
32 0 2.5
_ _ _ -
-- _ _ _ _ _ _ _ _ _-_______
___
Chronic 7C6
Acute: 67
Maintain monitoring at ?/month. While the max predicted
Zine
NC
50 AL 67
,,'L
36 36
115.5
no WET is occuring, thus no
is greater than the allo"ble_-- --_---- --
—_---
Chronic 149
---
lproposed.
'Legend. " Freshwater Discharge
C = Carcinogenic
NC = Non -carcinogenic
4685 Ta, rpa
8/6/2008

iMA

To: NPDES Unit
Water Quality Section
Attention: Dina Sprinkle
SOC Priority Project: No
Date: April 11, 2008
NPDES STAFF REPORT AND RECOMMENDATION
County: Cleveland
Permit No. NC0004685
PART I -GENERAL INFORMATION
1. Facility and address: PPG Industries, Inc.
940 Washburn Switch Road
Shelby, North Carolina 28150
2. Date of investigation: March 26, 2008
3. Report prepared by: Samar Bou-Ghazale, Environmental Engineer II
4. Persons contacted and telephone number: Tim Mathis, [phone].
5. Directions to site: From the intersection of US Hwy 74 and SR 1313 (Washburn Switch Road)
just west of the City of Shelby, travel north on SR 1313 approximately 3.0 miles. The PPG plant
is located on the left side of the road.
6. Discharge point(s), list for all discharge points:
Outfall 001:
Latitude: 35° 20' 26" Longitude: 81° 37' 00"
Outfall 002:
Latitude: 35° 19' 28" Longitude: 81° 37' 51"
Attach a USGS map extract and indicate treatment facility site and discharge point on map.
WWTP:
U.S.G.S. Quad No.: F12SW
U.S.G.S. Quad Name: Boiling Springs North, NC
Discharge point:
U.S.G.S. Quad No.: F12SE U.S.G.S. Quad Name: Shelby, NC
7. Site size and expansion area are consistent with application? Yes. There is ample area for
additional WWTP construction, if necessary.

Page Two
8. Topography (relationship to flood plain included): Flat to moderate slopes; the W WTP is not
located within a 100-year flood plain.
9. Location of nearest dwelling: None within 500 feet of the plant
10. Receiving stream or affected surface waters: Brushy Creek (outfall 001), Overflow Branch
(outfall 002)
a. Classification: C (both receiving streams)
b. River Basin and Subbasin No.: Broad 030804
C. Describe receiving stream features and pertinent downstream uses: Brushy Creek is of
moderate size (15-25 feet wide) with a sandy bottom. General "C" classification uses
downstream. Overflow Branch is � 3 - 4 feet wide, and downstream uses are primarily
agricultural in nature.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
a. Volume of wastewater to be permitted: 1.3 MGD (outfall 001), Flow is intermittent at
outfall 002.
b. Current permitted capacity of the wastewater treatment facility: 1.3 MGD
C. Actual treatment capacity of the current facility (current design capacity): 1.3 MGD
d. Date(s) and construction activities allowed by previous Authorizations to Construct
issued in the previous two years: N/A
e. Please provide a description of existing or substantially constructed wastewater treatment
facilities: Existing treatment facilities consists of an influent overflow/storage basin,
influent screening with grinder, wet well with lime addition, a surge tank, an equalization
tank, a flash mix tank for aluminum chloride, coagulant and polymer addition, two (2)
primary clarifiers, two (2) aeration basins with diffused air and bentonite clay addition, a
floc tank with ferric chloride addition, three (3) secondary clarifiers with ferric chloride
addition, a chlorine contact tank being used as an effluent pump tank (no chlorine is
added at this time), traveling bridge sand filter, defoamer addition, gravity sludge
thickener, belt filter press, and an overflow lagoon. Stand-by power is provided for the
industrial process and the WWTP through on -site generators. The permittee has received
approval from the Division to use of bentonite clay for effluent toxicity reduction and the
addition of aluminum chloride as a reactant for fluoride removal, chemical precipitation,
and floc formation. There is no treatment provided at outfall 002.
f. Please provide a description of proposed wastewater treatment facilities: There are no
proposed WWT facilities at this time.

Page Three
g. Possible toxic impacts to surface waters: Information contained in the files of this office
indicates that this facility is in compliance with its toxicity testing requirements.
It. Pretreatment Program (POTWs only): N/A
2. Residuals handling and utilization/disposal scheme: Residuals are currently land filled at the
Cleveland County landfill. PPG has a non -discharge permit for the land application of residuals
(WQ0001055), however, no residuals have ever been applied.
3. Treatment plant classification: Class IV (no change from previous rating)
4. SIC Code(s): 3229 (PPG), 3083 (Azdel)
Wastewater Code(s) Primary: 64 Secondary: 02, 73, 15, 14, 36
Main Treatment Unit Code: 01602
PART IH - OTHER PERTINENT INFORMATION
Is this facility being constructed with Construction Grant Funds or are any public monies involved
(municipals only)? No public monies were involved in the construction of this facility.
2. Special monitoring or limitations (including toxicity) requests: None at this time.
3. Important SOC, JOC or Compliance Schedule dates: N/A
4. Alternative Analysis Evaluation:
Spray Irrigation: Insufficient area
Connection to Regional Sewer System: There is none presently available to serve this site.
Subsurface: Insufficient area
5. Air quality and/or groundwater concerns or hazardous materials utilized at this facility that may
impact water quality, air quality, or groundwater: No GW concerns at this time. The facility has
obtained the necessary air quality permits. There are no known hazardous materials concerns.
PART IV - EVALUATION AND RECOMMENDATIONS
The permittee, PPG Industries, Inc., is requesting permit renewal to discharge wastewater from
their WWT facilities. The WWTP serves the industrial and domestic needs for PPG and a nearby
company; Azdel, Inc. Azdel is located on the PPG property and uses the fiberglass produced at PPG in
part of their industrial process. Azdel contributes approximately 10,000 gpd to the PPG WWTP.
Outfa11001 is the outfall from the WWTP that treats the industrial, domestic, some of the
stormwater from the two sites, and at this time all non -contact cooling wastewater. Outfall 002 consists
of non -contact cooling water and stormwater.

Page Four
PPG Industries, Inc., Is requesting that Fluoride monitoring frequency be reduced from weekly to
monthly based on the fact that the effluent fluoride limit from the facility is 10 to 20% of the permit
limit.
PPG has also obtained coverage under SW general permit number NCG070015, which contains
outfalls, 003, 004, 005, 006, 007, and 008. During the previous renewal, this office recommended that
the Stormwater permit be combined with the NPDES permit. However, since the stormwater permit
requirements evolved to new directions from previous years, we recommend that the stormwater permit
be a standalone permit and be distinct from the wastewater permit.
Pending review and approval by the P & E, it is recommended that the permit be renewed with the
above changes..
Signature of report preparer Date
Water Quality Regional Supervisor ate

PPG Industries Fiber Glass Products, Inc.
Timothy G. Mathis
Manufacturing Manager
Fiber Glass Products
February 25, 2008
Mrs. Valery Stephens
NC DENR
Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
12
940 Washburn Switch Road Shelby, N.C. 28150
SENT VIA CERTIFIED MAIL — RETURN RECEIPT REQUESTED
Re: Renewal of NPDES Permit NC0004685
PPG Industries Fiber Glass Products, Inc., Shelby, N.C. Facility
Dear Mrs. Stephens:
704-434-2261
Extension 206
[e-mail]
We are pleased to enclose an original, signed NPDES Permit Renewal Application package
along with the two required photo copies. This is for the PPG Industries Fiber Glass Products,
Inc. facility in Shelby, NC. We are requesting the re -issuance of NPDES Permit No.
NC0004685. The primary SIC Code for facility operations is 3229-Pressed and Blown Glass -
not elsewhere classified. Approximately one percent of the waste load is from Azdel, Inc. sheet
laminate facility (SIC 3083). The wastewater oufall, Outfall 001, is located at latitude 35
degrees, 20 minutes, 26 seconds, by longitude 81 degrees, 37 minutes, 0 seconds with the
receiving water being Brushy Creek.
There have not been any changes to the facility since the previous permit renewal. There is a
fluoride limit and weekly fluoride monitoring included in our permit. However, over the last
several years our fluoride has been significantly reduced. Typically the effluent fluoride level is

10 to 20 percent of the limit. We are requesting as part of our renewal that the monitoring
YJ
frequency for fluoride be reduced to monthly monitoring.
We request that all NPDES Permit questions and issues be directed to Mr. Richard Young, Sr.
Engineer Associate, Environmental.
As part of this permit renewal package, we have included:
1. Cover letter;
2. Introduction;
3. EPA Form 1;
4. EPA Form 2C;
5. Narrative description of the sludge management plan; and
6. Analytical data.
The data presented in Form 2C Section V is based on plant operating data for the period August
2006 to July 2007 and special analysis conducted by Pace Analytical Services Inc. Copies of the
Pace reports on the special analysis have been provided in the package (Tab G). The plant
operating data is from monthly DMR submittals.
Please feel free to contact me if you need any additional information or if you have any questions
regarding this submittal.
Sincerely,
Timothy G. Mathis
Manufacturing Manager
Attachment
Cc: Richard Young
File

Certification
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing: tm0 AX 6, M4 ,
Title: �w kl"1n r NIG�10.C,L° r
r�
(Signature of Applicant)
North Carolina General Statute 143-215.6 b (i) provides that:
(Date Signed)
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan or
other document filed or required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with or knowingly renders inaccurate any recording or monitoring device or
method required to be operated or maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $25,000, or by imprisonment not to
exceed six months, or by both. (16 U.S.C. Section 1001 provides a punishment by a fine of not more than $25,000 or imprisonment
not more than 5 years, or both, for a similar offense.)

INTRODUCTION
PPG Industries Fiber Glass Products, Inc. (PPG) operates a Fiber Glass manufacturing facility in
Shelby, North Carolina. This facility operates under the existing NPDES Wastewater Permit
Number NC0004685 which expires on August 31, 2008. This permit allows the facility to
discharge treated wastewater at 1.3 million gallons/day to outfall 001 and to discharge non -
contact cooling water to outfall 002. In addition to PPG's Fiber Glass Manufacturing operation,
an Azdel, Inc. sheet laminate manufacturing facility is located adjacent to the PPG site and
discharges approximately 10,000 gallons per day to the PPG wastewater treatment plant for
treatment. Wastewater from PPG and Azdel operations are sent to PPG's wastewater plant for
treatment and both operations are covered under the existing permit. Additional details and
clarification for several items relevant to this permit application are highlighted below.
1. SIC Codes and Outfall 001 Testing
The SIC code for the Azdel, Inc. (sheet laminate facility) is 3083. The Azdel site
discharges 10,000 gallons wastewater per day to the PPG wastewater treatment plant for
treatment. This discharge makes up approximately 1/100a' of PPG's wastewater flow.
Therefore, as required for the 3083 SIC code, PPG performed volatile compound testing
on Outfall 001. Results from this testing are incorporated into Form 2C of this
application.
2. Outfall (002) Testing
Outfall 002, the primary stormwater outfall, is currently permitted for the discharge of
non -contact cooling water. Therefore, PPG conducted the testing as set forth in Form 2C.
This testing also included the required volatile compounds for SIC codes 3083.
3. Wet Weather Only Outfalls
Outfalls 003, 004, 005, 006, 007 and 008 are covered under the General Stormwater
Permit #NCG070000, Certificate of Coverage # NCG070015. These outfalls are wet
weather outfalls only and would contain little, if any, drainage from industrial areas. For
this renewal, testing was not conducted on these wet -weather outfalls.
4. Sample Reporting and Averaging
Sample reporting and averaging was provided in Form 2C as per NC DENR DWQ's
"Directions for Completing Monthly Monitoring Reports" dated September 1, 2000.
These instructions provide guidelines with respect to rules for reporting and averaging
less than detectable "<" values. (e.g., a sample result with a value of less than the
detectable limit is considered to equal "zero" when calculating monthly and long-term
arithmetic averages). Also per NC DENR DMR reporting guidelines, fecal coliform
monthly and long-term averages were calculated using a geometric mean.
5. Signature Authority
There will be no change requested in signature authority for monthly monitoring report
requirements. Signature authority for monthly monitoring reports as a "Duly Authorized
Representative" per 15A NCAC 2B.0506(b)(2)(D), will remain unchanged and is
delegated to the person holding the title of Maintenance Manager.

SLUDGE MANAGEMENT PLAN
The wastewater treatment plant (WWTP) sludge generated by the Shelby facility is a mixture of
both primary and secondary sludges. The primary sludge is the result of clarification using lime,
aluminum chloride, polymers and coagulants to achieve floc formation and settling. The
secondary sludge is waste activated sludge from the biological treatment system. The secondary
sludge also contains bentonite clay and a small amount of ferric chloride.
Both sludges are combined in a sludge thickener/storage tank prior to dewatering. Polymer
addition and mechanical mixing, along with dilution water, are required to prepare the sludge for
the belt press. The sludge is then pumped to the belt press for dewatering.
The belt press has both a gravity drain section and a pressure section where the water is removed.
Typically, the solids are increased from 4-5% as it leaves the storage tank, to 25-30% solids as
discharged from the belt press. The dewatered sludge is transported via screw conveyors to a
roll -off box. The water is routed back to the head of the WWTP.
Before the roll -off box is picked up for disposal, a paint filter test is conducted on the sludge to
ensure that free liquids are not present. The dewatered sludge is then taken to a permitted, lined
landfill for disposal.

EPA FORM 2C SECTION II.A.
OUTFALL 003. 004, 005. 006, 007 1008 SCHEMATIC
PPG INDUSTRIES FIBER GLASS PRODUCTS, INC.
Stormwater
Stormwater
Stormwater
[-Stormwaterl
I Stormwater
Stormwater
30 8 acres
3.1 acres
2.7 acres
9.0 acres
33.8 acres
2.6 acres
Outfall
Outfall
Outfall
Outfail
Outfall l l
#004
#005#006
#007
nut.f#003
Peak flow
Peak flow
Peak flow
Peak flow
Peak flow
Peak flow
12.9 cfs
2.3 cfs
1.3 cfs
2.8 cfs
12.2 cfs
0.9 cfs
Discharges from OutNfls #003, #004, #005, #006. #007 8 #008 are covered under the General Stormwater Discharge Perni
#NC070000, COC #:NCG070015.
These areas contain limited drainage from industrial areas of the property. Outfall 002 is the primary stornvrater discharge point
of the industrial portions of the property.
Peak flows were calculated using the Rational Method (Q = CiA) where:
0 = peak flow (cfs)
C = runoff coefficient (where: .9 = impermeable, 8 = graveled, .3 = grassed, .1 = wooded)
i = intensity
A = area (acres)
note: the above peak flows were calculated using an intensity of 1 "rhr. See table below for runoff coefficient calculations.
RUNOFF COEFFICIENT CALCULATIONS
OUTFALL
C
003
0.42
20% industrial (.9), 80%grassed (.3)
004
0.75
90% paved parking lot (.9) and 10% grassed (.3)
005
0.48
30% paved parking lot (.9) and 70% grassed (.3)
006
0.31
95% lawn (.3), 2.5% wooded (.1), 2.5% graveled (.8)
007
0.36
10% industrial (.9) and 90% grassed (.3)
008
0.36
10% industrial (.9) and 90% grassed (.3)

EPA FORM 2C SECTION IIA.
OUTFALL 001 SCHEMATIC
PPG INDUSTRIES FIBER GLASS PRODUCTS, INC.
Supply
1,500,000 gpd
,search I IMisc. I I Sanitary I I boners rvnsc rwuess rauncduun
1,000 3,000 60.000 43,000 Water 15,000 850,000
gpd gpd gpd gpd 75,000 gpd gpd gpd
Evaporation
335,000
gpd
I I u I Prodct
Stormwater 11 1, 00
du
Garage/Pads gpd
(185.000 gpd)
1" rainfall
AZDEL SIC VVIM�P
CODE L03083
—10,000 gpd (see wNTP Schematic)
Dewatering
33.250 gpd
OUTFALL
#001
up to 1.3
MGD

EPA FORM 2C SECTION II.A.
OUTFALL 002 SCHEMATIC
PPG INDUSTRIES FIBER GLASS PRODUCTS, INC.
up to 150,000 gpd
+ stormwater
ouVall for the
discharges from Ibis oudall are permthed under NPOES permit NCOD046BS
Discharges are covered under the General Stormwaler Discharge Permit ANC070000. COC eNCG07001S
Rormwater Peak flow was calculated using the Rational Method (0 w CIA) where:
- peak Clow (cfs)
= mmly coefficient (where:.9 = impermeable..6 = graveled. 3 = grassed..t = wooded)
= intensity
I - area (acres)
: the above peak flow far stormwater was calculated using an intensity of 1'rhr.
mrwR coaMciem (C) used was 0.76 based on the followbg estimate: 80% industrial (.9). 10% grassed (.3). 10%
led (.1)

EPA FORM 2C SECTION U.S.
WWTP TREATMENT I OUTFALL 001 SCHEMATIG
PPG INDUSTRIES FIBER GLASS PRODUCTS, INC.
NPDES PERMIT N00004605 RENEWAL APPLICATION
Process Water- 0.8 MGD)
Sanita - 0.06 MGDEk
BAR
SCREEN
Stormweter 0.12 MGD V. 1-T
OUTFALL
#001
4-A
RECYCLE/
COOLMM.
WATER
4-C
SLUDGE PROCESS SCHEMATIC
GRAVITY
THICKENER
5-L
5-E, 1.0. 5-C
Water
valor sludge to
to head or LondW
WWTp 5-0
4-c ) (
FLOW I I LOAD
EQUALIZATION EQUALIZATION
Ume
FILTRATION
AICb
sludge to
thickener
TANK �--i� CLARIFIERS
I. 1-G. 2-C I I 1-U
CLARIFIERS (3)
2-C, 1-U
FeCb Lhns
Anbnlc 1pW
Polymer �—
RAS to
Aonlion
sludge 10
Ihkkener
TANKS (2)
3-A
I reaunCm l uuea Uavu nu111 I Cum u-r
1-G
Flocculation
1-L
Grinding(Comminutors)
1-O
Mixing
1-T
Screening
1-U
Sedimentation (Settling)
1-V
Sand Filtration
2•C
Chemical Precipitation
2-D
Coagulation
3-A
Activated Sludge
4-A
Discharge to Surface Water
4-C
Re -Use I Recycle of Effluent
5-C
Belt Filtration
5•E
Chemical Conditioning
5-L
Gravity Thickening
5-Q
Landfill
Bentonde Ctay