490006_Application - 02 design drawings_20240326

Rocky Creek Dairy, Inc.
Ben Shelton
Waste Management System
IREDELL COUNTY, NORTH CAROLINA
ADDRESS & LOCATION: 178 Holstein Lane
Olin, NC 2866
PHONE: [phone] or 704-881-5607
COORDINATES: 035055'07.8"N, 080048'50.0"W
DAIRY SIZE: Maximum Number Cattle in Waste Management System
Milk Cows - 1,295
Dry Cows - 150
Heifers 300-1250 lbs - 1,100
Beef Feedlot, 900 lbs - 60
UPDATED BY: Samuel Bingham, Engineer
APPROVED BY:
DATE: s�
2024 revision is an update of plan approved in 2016. This revision
adds a beef cattle finishing lot and waste pond #7 to the dairy
operation and improves silo leachate treatment at the Henkel Road
Bunker Silos. A concrete chute is also added in waste pond #4 for
transfer of wastewater into the pond.

1 Waste Plan 2024

INDEX
I. Waste Production
II. Waste Management Overview
A. Seven Waste Storage Ponds
B. Tower Tank Alley Flushing
C. Collection Ditches & Pipes @ Milk Herd Facility
D. Collection Ditch at Heifer Facility
E. Sand Settling Lanes & Storage @ Milk Herd
Facility
F. Sand Settling Beach & Storage @ Heifer Facility
G. Manure Transfer Pipes
H. Other Cow Groups on Farm
I. Control of Silo Leachate
J. Clean Water Exclusion
K. Plant Available Nutrients for Waste Utilization
Plan
L. Operation and Maintenance Plan
M. Emergency Action Plan
III. Waste Storage Ponds
IV. Sand Lanes, Beach, and Sand Storage
V. Clean Water Exclusion
A. Diversions & Waterways
B. Guttering
C. Culverts
VI. Waste Nutrients
A. Waste Volumes
B. Nutrient Computations
VII. Operation and Maintenance Plan
Old Design information for existing components located in
file in Iredell County District Field Office. Design
Volumes and Storage Periods updated in this design.
Drawings
Waste Pond Locations
1
of 8
Dairy Plan View
2
of 8
Clean Water Exclusion
3
of 8
Waste Storage Pond #6, Plan View
4
of 8
Waste Pond #7 & Leachate Collection, Plan View
5
of 8
Leachate Collection & Transfer to Pond #7
6
of 8
Plan View - Diversion
7
of 8
Waste Pond #4 Repair - Concrete Chute
8
of 8
1 Waste Plan 2024

WASTE MANAGEMENT SYSTEM
I. Waste Production
A maximum of 1,295 cows will be milked on the Rocky
Creek Dairy farm. The milk herd is confined to freestall
barns. Freestalls are bedded with sand. Manure is scraped
to collection ditch.
A maximum of 150 dry cows and 1100 heifers from 300 to
1250 lbs are housed in freestall barns at farm. Freestall
barns are bedded with sand. The alleys are flushed from
tower tanks to a collection ditch located at lower end of
the facility.
An old feedlot and waste pond on Henkel Road near
entrance to dairy is used for finishing 60 Beef feeders for
slaughter. Waste and wastewater from this facility will be
pumped to the dairy waste pond complex for application on
cropland on the farm.
Manure, runoff and milking parlor wash water are
stored in Seven (7) waste storage ponds. Manure is tank
hauled, hard hose spread or irrigated.
Maximum Number Cattle in Waste Management System
Milk Cows 1,295
Dry Cows - 150
300 to 1,250 lb heifers (-970 lb) - 1,1O0
Beef feeders (-900 lbs) 60
II. Waste Management Overview
The waste management system will economically as
possible handle all the waste production described above in
a manner that does not degrade air, soil or water
resources. The system will prevent discharge of pollutants
to surface and ground water by recycling waste through soil
and plants.
The waste management system includes the following
components:
A. Seven Waste Storage Ponds
Waste ponds #1 and #2 are used primarily for manure
solid storage. Manure solids are trapped in these ponds.
2 Waste Plan 2024

Waste pond #3 is used primarily for liquid storage.
Liquids from ponds #1 and #2 are piped to this pond.
Waste ponds #4 and #5 will be used for liquid storage
and 25 year-24-hour rainfall storage. Liquids in these
ponds are cleaner than other ponds. Liquid in these ponds
is primarily piped to tower tanks and sand lanes.
Wastewater is left in these ponds #4 and #5 during clean
outs to keep liquids in the system. Occasionally when
liquid becomes too dirty, ponds #4 or #5 are land applied
and refilled with liquids from Rocky Creek.
Waste Pond #6 is a satellite pond located on another
farm. Waste from ponds at dairy are pumped to this pond in
an existing pipeline.
Waste pond #7 is a satellite pond located at a feedlot
to finish beef cattle feeders for slaughter. Wastewater is
piped to ponds at dairy and/or direct land applied. If
needed, waste from ponds at dairy can be piped to pond #7
for storage.
The waste storage ponds will store the following
volumes:
1) Manure
2) Milking Parlor Wash Water
3) Runoff from concrete Alleys around freestall
barns
4) Runoff @ Sand Lane, beaches and storage areas
5) Runoff from all vegetated areas that could not be
diverted
6) McLanahan sand conditioner wastewater
7) Dilution Volume pumped from Rocky River when
needed
8) Rainfall minus evaporation on all waste ponds
9) Leachate from bunker silos
10) 25 year - 24-hour runoff from all drainage area
and 25 yr direct rainfall on waste ponds
B. Tower Tank Alley Flushing
Manure and sand are hydraulically flushed from dry
cow/heifer freestall barns. Tower tanks are used to flush
alleys to a collection ditch.
C. Collection Ditches & Pipes @ Milk Herd Facility
At the milk cow freestall barns for milk herd, manure
and sand is scraped to a flush ditch.
3 Waste Plan 2024

All manure and sand collected at milk cow freestall
barns is transferred to sand settling areas and ponds in
collection ditches and pipes.
D. Collection Ditch at Heifer Facility
The manure and sand mixtures collected at heifer
freestall barn will be transferred to sand settling area in
collection ditch. The velocity is planned between 5 to 10
fps to keep the sand/manure mixture agitated and moving to
sand settling beach. The collection ditch diverts water up
a beach to settle sand.
E. Sand Settling Lanes & Storage @ Milk Herd Facility
Sand lanes are designed to settle sand by flowing at
low enough velocity to settle sand.
A sand lane is located at milk herd facilities.
F. Sand Settling Beach & Storage @ Dry Cow/Heifer
Facility
A sand settling beach is located at Dry cow and heifer
facility to settle sand. The collection ditch diverts
wastewater up a beach to settle the sand. Collected sand
is stored at the beach. All runoff from beach and sand
storage area is collected in waste storage ponds.
G. Manure Transfer Pipes
Transfer pipes are used to transfer liquid waste from
waste pond to waste pond. The inlet section is designed
with intake below surface of wastewater. Typically, a
water zone is located above settled solids and below the
floating solids in manure collection pond. Liquids flow
down a concrete channel or drop on concrete slab to protect
clay liners in waste storage ponds.
H. Other Cattle groups on farm
Other cattle groups are housed away from the milk herd
and facilities for dry cows and heifers. This plan only
addresses the confined cattle groups discussed above.
I. Control of Silo Leachate
Leachate from trench silos will flow into a leachate
collection area to be collected and then transferred to a
waste storage pond. Waterway and diversions are located
below the trench silos. Leachate is recognized as a
serious pollutant and is best handled by evaporation and
4 Waste Plan 2024

infiltration or stored in a waste storage pond. Other
runoff from the silos flows to the vegetated filters.
J. Clean Water Exclusion
Clean water will be fully excluded from all waste
storage ponds possible. Diversions, waterways and culverts
are used to divert clean water around waste storage ponds.
Diversions, waterways, guttering and culverts shall have
more than the 25 yr - 24 hr capacity.
K. Plant Available Nutrients for Waste Utilization Plan
Estimate of Plant Available Nitrogen to collect and
spread each year will be determined.
L. Operation and Maintenance Plan
The owner shall be responsible for operating and
maintaining the system. See plan attached.
M. Emergency Action Plan
The emergency action plan describes emergency
conditions and immediate steps to take to gain control.
III. Waste Storage Ponds
Manure and water from sand lanes are diverted into
waste storage ponds #1 and #2 by pipe. One pond will be
filled with manure solids at a time. The liquid waste is
transferred to pond #3 by gravity in transfer pipe. Manure
solids will be pumped to waste storage pond #6, #7, or
spread directly on cropland.
Transfer pipes move liquid from the storage ponds #1
and #2 to the other waste storage ponds. If waste pond #3
is being emptied, liquid can be piped directly to waste
pond #4.
A. Design Volumes
1. Normal Runoff and Rainfall Storage for 6-month period
Use average runoff values in Agricultural Waste
Management Field Manual. The 25 yr rainfall from waste
storage ponds #1, #2, #3 and #4 will be transferred to
waste storage pond #5 at the main farm. Other waste ponds
are at full capacity before liquid is transferred to pond
#5. Waste Storage Ponds #6 and #7 are satellite waste
ponds located at other farms. Since all ponds are operated
5 Waste Plan 2024

as one unit, the normal waste quantities are shown for all
ponds in the computations below.
Drainage areas for design
Concrete around Milk Cow freestall barns, sand lane and
sand
storage - surface - 36,424 sq ft
Around waste ponds - unsurface - 80,924 sq ft
Concrete around Dry Cow/Heifer Facility, sand lane & beach
surface - 16,841 sq ft
Concrete at feed barn on Henkel Road-17,300 sq ft
Unsurfaced area at feed barn on Henkel Road - 4,831 sq ft
Drainage Area = 134,189 sq ft Surface = 70,565 sq ft
Unsurface = 85,755 sq ft
Waste
Storage Pond
#1
Surface
- 31,418 sq
ft
Waste
Storage Pond
#2
surface
- 31,132 sq
ft
Waste
Storage Pond
#3
surface
- 53,896 sq
ft
Waste
Storage Pond
#4
surface
- 44,406 sq
ft
Waste
Storage Pond
#5
surface
- 43,899 sq
ft
Waste
Storage Pond
#6
- surface
- 69,861 sq
ft
Waste
Storage Pond
#7
- Surface
- 23,000 sq
ft
Pond
Surface Area
#1,#2,#3,#4,#5,#6
& #7 = 297,612
sq ft
SURFACE
UNSURFACE
NORMAL
RUNOFF
RUNOFF
MONTH
RAINFALL
o
DEPTH
o DEPTH
NORMAL EVAP.
JAN.
3.70
50
1.85
20 0.74
1.7
FEB.
3.86
56
2.16
25 0.97
1.6
MAR.
4.51
55
2.48
24 1.08
3.1
APR.
3.35
56
1.88
25 0.84
3.8
MAY
3.86
57
2.20
23 0.89
3.9
JUN.
4.19
60
2.51
27 1.13
4.4
JUL.
4.70
60
2.82
26 1.22
4.3
AUG.
4.83
61
2.95
31 1.50
3.9
SEP.
3.82
66
2.52
32 1.22
3.2
OCT.
3.44
62
2.13
30 1.03
2.4
NOV.
2.95
55
1.62
25 0.74
1.7
DEC.
3.80
57
2.17
23 0.87
1.7
Try 6 months: Oct. -Mar.
Surface Runoff Depth = 12.41"
Unsurface Runoff Depth = 5.43"
Surface Runoff = 12.41"* 70,565 sq ft = 72,976 cu ft
12 in/ft
Unsurface Runoff = 5.43"* 85,755 sq ft = 38,804 cu ft
12 in/ft
6 Waste Plan 2024

2. Rainfall minus evaporation of ponds 41,42,#3,#4,45,
#6&#7
22.26 - 12.2 = 10.06" = 0.84 ft/6 months
0.84 ft/6 months x 297,612 sq ft=249,994 cu ft/6 mo.
3. 25 yr - 24 hr runoff on Ponds #1 - #5
CN = (95x53,265 + 60x8O,924)/134,189 = 74
Rainfall = 5.5
Runoff = 2.76"
25yr-24hr runoff = 2.76" * 134,189 sq ft = 30,863 cu ft
12"/ft
4. 25 yr - 24 hr runoff on Pond #7
All the 25-year runoff from feedlot on Henkel Road and
pond surface is stored in pond U .
CN = (95x17,300+ 60x4,831)/22,131 = 87.5
Rainfall = 5.5
Runoff = 4.10"
25yr-24hr runoff 4.10" * 22,131 sq ft = 7,561 cu ft
12"/ft
5. 25 yr - 24 hr rainfall on pond surface #6 and #7
Rainfall = 5.5" = .5 ft
6. 25 yr- 24 hr rainfall from waste ponds #1,#2,#3,#4 &#5
Volume = 5.5 inch/12inch/foot x 204,751 sq ft = 93,844 cu
ft
7. Milking Parlor Wash Water
Volume = 1,295 cows x 5 gal/day/cow * 180 days
7.48 gal/cu ft
= 155,815 cu ft
8. Sand Accumulation
Sand will be removed from sand lanes and beaches. If
any sand escapes, waste ponds #1 and #2 have concrete
bottoms. Sand and manure solids are cleaned out with farm
equipment. No sand storage is needed in waste storage
ponds.
9. Manure
1,295 milk cows, 150 dry cows and 1,100 heifers are in
freestall barn 1000 of the time. 60 beef feeders on lot
7 Waste Plan 2024

300 of the time. Manure in freestall barns is flushed to
sand lanes where sand is settled from waste stream.
Manure and water from sand separation systems are
transferred into waste storage ponds #1 and #2 by pipe.
(See Drawing). One pond will be filled at a time. Once a
pond is full of solids, the waste will be transferred to
the other pond. Manure solids in waste storage ponds will
be applied to cropland or transferred to pond #6.
Transfer pipes move liquid to storage ponds 43, #4 and
#5. All the 25-year storm storage for all the ponds and
runoff areas is stored in waste storage pond #5 at main
dairy.
The Dairy Manure Characteristics table in NRCS
Agricultural Waste Management Field Handbook indicates that
a milk cow producing 100 lb per day of milk will produce
19.5 gal/day/cow of manure and urine. A dry cow will
produce 10.5 gal/day/cow of manure and urine. A 970 lb
heifer will produce 6.5 gal/day/heifer of manure and urine.
An beef finishing animal averaging 900 lb will produce 7.4
gal/day of manure and urine.
Volume =1,295 cows * 19.5 gal/day * 180 days * 100%
7.48 gal/cu ft
607,680 cu ft
Volume =150 cows * 10.5 gal/day * 180 days * 1000
7.48 gal/cu ft
37,901 cu ft
Volume =1,100 heifers * 6.5 gal/day * 180 days * 100%
7.48 gal/cu ft
172,059 cu ft
Volume =60 Beef Finishers * 7.4 gal/day *180 days * 30%
7.48 gal/cu ft
3,205 cu ft
Total Waste = 607,680 + 37,901 + 172,059 + 3,205 = 820,845
cu ft
10. Fresh Water for McLanahan Sand Conditioner
Volume = 5 gal/min x60 min/hr x3 hr/day x 180 days
= 162,000 gal/180 days = 21,658 cu ft/180 days
8 Waste Plan 2024

11. Silo Leachate
Section 5 of the "Ninth Senate Bill (SB) 1217
Interagency Group Guidance Document September 25, 2009"
provides the following guidance for silo leachate control.
"Guidance developed by the SB 1217 Interagency Group
represents guidelines to address questions from technical
specialists and provides uniform interpretations regarding
requirements of animal waste management rules. However, for
areas where no standards exist, DWQ acknowledges these
guidelines as acceptable criteria to base a Certified
Animal Waste Management Plan (CAWMP). Any requested
deviations from this guidance must be considered by DWQ on
a case -by -case basis to ensure that the proposal provides
equal or better protection. These guidelines may also be
incorporated by DWQ as permit conditions for an operation's
individual permit or general permit."
The leachate flow from silos varies during the year
(even year to year). The greatest period of flow is
typically just after harvest and during the early storage
period (i.e., first 3 to 5 days, from NRCS - Agricultural
Waste Management Field Handbook Part 651). Typically, 75%
of leachate is generated during the first 3 weeks of
placing in bunker silos. The silage harvesting period
usually occurs between August 1 and October 1 for corn
silage and sorghum and April 1 and May 1 for small grain
silage.
NRCS reference indicates that "if dry matter content
of the forage placed in the silo is maintained above 30
percent for bunker or trenches then the silage leachate
production will be substantially reduced, if not
eliminated". Optimum dry matter for corn silage is 30 -
50% and optimum moisture content is 50% to 70%. USDA-NRCS
Agricultural Waste Management Field Handbook (AWMFH)
recommends 0.5 cu ft of storage for every ton of silage.
Bunker silos are estimated to contain around 50,000 tons of
silage at full capacity. Chopping silage occurs over a
couple month period, therefore, maximum leachate production
is spread out over a 2-month period.
A leachate collection system is planned at bunker
silos to collect the concentrated leachate from the bunker
silos and store the liquid in a waste storage pond. During
periods when leachate is not present, the rainfall runoff
will be diverted to the vegetated filter area located
downstream of trench silos.
A conservative additional volume to add to the waste
pond volume will be based on the estimated annual runoff
from d concrete surfaced area from the USDA-NRCS AWMFH. In
9 Waste Plan 2024

the Iredell County, NC area, it is estimated that 58% of
the annual rainfall runs off the surfaced areas. It is
also estimated that the first 0.25" of runoff will be
collected in the waste pond from the silo storage area when
leachate is present. It is estimated that 50% of the
total possible runoff will reach a waste pond. The
remainder will flow to the grass filter area when leachate
is not present.
It is estimated that a maximum of 200,000 sq ft of
silo areas drains toward a waste pond. Part of the silo
drainage area flows into clean water areas when plastic
covers the silage.
Estimated leachate and runoff storage volume in the waste
ponds:
Volume = 50,000 tons x 0.5 cu ft/ton or 25,000 cu ft/yr
Runoff = 200,000 sq ft x 47.01"/(12"/ft) x .58% x 50% or
227,215 cu ft/yr
Total Volume = 25,000 + 227,215 cu ft or 252,215 cu ft/year
or 1,887,000 gallons per year = 124,380 cu ft/180 days
B. Summary of Design Volumes for Ponds #1 - #7
a.25-year storage volume required in pond #5 @ main dairy
25 year - 24-hour runoff for pond #5 30,863 cu ft
25 yr - 24 hr rainfall, ponds #1 - #5 93,844 cu ft
Total 124,707 cu ft
See computation below for 25 yr storm in pond #5.
b. 25-year storage volume required in pond #6
25-year rainfall in pond #6 0.5 feet
C. 25-year storage volume required in pond #7
25-year runoff at Pond #7 (7,561 cu ft/20,564 sq ft)
0.4'
25-year rainfall in pond #7 0.5'
TOTAL 0.9 feet
d_ Normal StoracJa Volumes in Waste Ponds - 120 days
10 Waste Plan 2024

a.
Surface Runoff
72,926 cu
ft
b.
Unsurface Runoff
38,804 cu
ft
C.
Rainfall-Evap. in all ponds
249,994 cu
ft
d.
Parlor Water
155,815 cu
ft
e.
Manure Solids and Urine
820,845 cu
ft
f.
McLanahan Sand Conditioner
21,658 cu
ft
g.
Leachate at Silos
124,707 cu
ft
Total
1,484,749 cu
ft
= 11,106,000
gallons/180
days
= 22,520,000
gallons/year
The winter storage period is used in the design to
determine the storage period available. Even with higher
evaporation rates in summer, the summer storage period may
be less due to the amount of water used in freestall barns
for cooling cows; however, less storage period is needed in
summer due to availability of cropland fields to spread
waste.
C. Size of Waste Storage Ponds
Estimate made from "As -Built" information for the
system designed by Bion Technologies, Inc.
a. Waste Storage Pond #1
Dimension at storage depth shown below. Corners of pond
are rounded. Measured area for top surface used in
computation.
1.0'
63' X 223.5'(31,418 sq f
3:1
\ 1 8:1
112' X 130'
Volume = 8.5/6[112 X 130 +31,418 +4(22,989)]
= 195,406 cu ft = 1,462,000 gallons
b. Waste Storage Pond 42
11 Waste Plan 2024

Dimension at storage depth shown below. Corners of pond
are rounded. Measured area for top surface used in
computation.
157' X 210' (31,132 sq ft)
3:1 7.5' 3:1
3:1 8:1
112' X 130'
Volume = 7.5/6[112 X 130 +31,132 +4(22,846)]
= 171,345 cu ft = 1,282,000 gallons
C. Waste Storage Pond #3
OWSIN
49,731 sq ft
3:1 \ 113.0' / 3:1
Triangle Shape Bottom - area = 21,000 sq ft
Volume = 13.0/6[21,000 +49,731 +4(35,365)]
= 459,747 cu ft = 3,439,000 gallons
d. Waste Storage Pond #4
Dimensions were taken from the original waste plan for this
pond.
230' X 200'
2.0'
3:1 \ 110' / 3:1
158' X 128'
Volume = 10.0/6[158 X 128 +218 X 188 +4(188 X 158)]
= 300,040 cu ft = 2,244,000 gallons
e_ Waste Storage Pond 45
12 Waste Plan 2024

Dimensions were taken from the original waste plan for this
pond. 25-year storage level computation shown based on
current drainage areas into ponds.
Freeboard - 2'
25 year - 24-hour runoff 30,863 cu ft
25 yr - 24 hr rainfall #1, #2, #3 & #4 93,844 cu ft
124,707 cu ft
220' X 210'
2.0'
208 x 198
5 yr 3.5'
187 x 177
3:1 9.5' 3:1
130' X 120'
Volume = 3.5/6[187X177+208X198+4(197.5X187.5)]
= 129,738 cu ft OK
The 25-year storage volume marker is 5.5 below the top of
dam.
Available Storage Volume below 25-year storage
Volume = 9.5/6[130 X 120 +187 X 177 +4(158.5 X 148.5)]
= 226,178 cu ft = 1,692,000 gallons
f. Waste Storage Pond #6
25-year storage volume from above - 0.5 feet
319' X 219'
0.5'
310' x 210'
3:1 \ 110.0' / 3:1
250' X 150'
Normal Storage Volume below 25-year storage
Volume = 10/6[250 X 150 +310 X 210 +4(280 X 180)]
= 507,000 cu ft = 3,792,360 gallons
13 Waste Plan 2024

g. Waste Storage Pond 47
Dimensions were taken from Lidar generated contours at the
pond. The top of dam elevation and emergency spillway were
also established based on Lidar data. 25-year storage level
computation shown based on current drainage areas into
pond. Pump out marker was established based on ground
elevation at spillway location.
Freeboard
- 1.0'
25-year runoff at Pond #7 (7,561 cu ft/20,564 sq ft) = 0.4'
25-year direct rainfall in pond #7 0.5'
TOTAL 0.9'
900.6 - 23,000 sq ft
1.0'
899.6 - 21,492 sq ft
0.9'
898.7 - 20,140 sq ft
2:1 8.7' 2:1
midway - 14,739 sq ft
890.0 - 10,690 s f
130' X 120'
Available Storage Volume below 25-year storage
Volume = 8.7/6[10,690+20,140+4(14,739)]
= 130,190 cu ft = 974,000 gallons
The 25-year storage volume marker is 1.9 below the top of
dam and 0.9 feet below the auxiliary spillway.
D. Normal Storage Capacity Available in all Ponds
Waste
Pond
#1
- 195,406
cu
ft =
1,462,000
gallons
Waste
Pond
#2
- 171,345
cu
ft =
1,282,000
gallons
Waste
Pond
#3
- 459,747
cu
ft =
3,439,000
gallons
Waste
Pond
#4
- 300,040
cu
ft =
2,244,000
gallons
Waste
Pond
#5
- 226,178
cu
ft =
1,692,000
gallons
Waste
Pond
#6
- 507,000
cu
ft =
3,792,000
gallons
Waste
Pond
#7
- 130,190
cu
ft =
974,000 gallons
TOTAL
- 1,989,906
cu ft
= 14,885,000 gallons
Note: For 180 days of storage, (1,989,906 cu ft minus
1,484,749 cu ft) or 505,157 cu ft of gray water can be left
in the system at clean out.
14 Waste Plan 2024

E. Dilution Volume for Sand Recovery System
It is not likely that additional water will be needed
in the system to separate sand clean enough to reuse in
freestall barns. Depending on how effectively the settling
waste ponds remove manure solids from the system, it is
estimated that between 35 and 70 gallons per day per cow of
volume will be necessary. 35 gallons per day per mature
cow and 17 gallons per day per -750 heifer will be used as
recommended quantity since it is anticipated this volume
will be effective with the manure settling ponds.
Volume Typically Recommended - 1,445 cows x 35
gal/cow/day / 7.48 gal/ cu ft x 180 days + 1,100 heifers x
17 gal/heifer/day /7.48 gal/ cu ft x 180 days = 1,667,045
cu ft.
The normal storage volume produced is 1,484,749 cu
ft/180 days from the above computations. For a typical
dairy using sand bedding, an additional volume of water is
usually needed in the system to reuse sand (i.e. 1,667,045
- 1,484,749 cu ft or 182,296 cu ft/180 days).
Dr. Shelton indicated he felt they would use less
dilution volume based on their current experience in
collecting clean sand, especially since the McLanahan Sand
Conditioner was added to the system. Based on this dairies
experience, it is felt that leaving the dilution volume in
ponds #4 and #5 during cleanouts will keep enough gray
water in system to clean sand. The volume of dilution
volume left in system after each cleanout will be in ponds
#4 & #5.
a. Waste Pond #4 300,040 cu ft
b. Waste Pond #5 226,178 cu ft
Total 526,218 cu ft
If water is too dirty, waste pond #4 or #5 can be land
applied and filled with fresh water from Rocky Creek.
F. 25-year storage Level in Waste Ponds #5, #6 and #7
See computations above for each pond.
Waste Pond #5 - 5.5 feet below Top of Dam
Waste Pond #6 - 1.5 feet below Top of Dam
Waste Pond #7 - 1.9 feet below Top of Dam
The waste storage ponds should be hauled or irrigated
before the water level reaches the 25 yr - 24 hr storage
volume.
15 Waste Plan 2024

IV. Sand lanes, Beach and Sand Storage
Freestalls are bedded with sand. Manure and sand are
scraped or flushed into concrete collection ditches.
When heifer/dry cow freestall barns are flushed with
tower tanks at 7000 gallons per min per alley. Flush water
is collected in a concrete ditch sloping toward the sand
collection area. The manure -sand mixture will be diverted
onto a beach sloped on 3% grade. Water then will flow back
to the 15' wide sand lane. The slope of channel will be 3"
per 100'. The beach should deaden the manure/sand mixture
and settle the sand. Manure solids and liquid will
continue down the 15' wide lane to waste ponds #1 or #2.
At the milk herd facility, wastewater in waste pond is
pumped to flush collection ditch located at lower end of
freestall barns.
The literature indicates that cows waste about 40 lbs
of sand per day per stall. It is estimated that heifers
will waste about 20 lbs per day.
Sand storage requirement
= (1445 cows @ 40 lbs/cow/day x 60 days + 1100 heifers
@ 20 lbs/heifer x 60 days)/2000 lbs/ton
= 2,394 ton per 60 days
At 100 lbs/cu ft, 47,889 cu ft of storage area will be
needed.
The sand storage area is approximately 50' x 200' x 5' or
50,000 cu ft.
Sand will need to be removed daily from the sand lanes
and beach. Sand in the lower leg should be moved to the
upper leg to rewash. A concrete floor storage area near
the sand lane will be used as a storage area for sand
removed from the channel. Some sand will need to be
removed from settling ponds periodically.
V. Clean Water Exclusion
A. Diversions & Waterways
Clean water diversions are located around the waste
storage ponds and freestall barns. Diversions shall carry
the 25 year - 24-hour runoff plus capacity to store some
sediment. Typical diversion is 1.0 feet deep on 0.5% slope
for small drainage areas.
16 Waste Plan 2024

B. Guttering
Clean water is excluded to the fullest extent possible
by guttering.
C. Culverts
Clean water culverts divert clean water under
driveways, gutter outlets from freestall barns, etc. Pipes
shall carry the 25 year - 24-hour runoff.
17 Waste Plan 2024

VI. Waste Nutrients
A. Waste Volumes
The table below shows the total storage to spread each
year. The estimated storage period is also shown for the
source. Also, the capacity of pond at pump -out level is
shown for each pond.
All the waste storage ponds are combined into one
nutrient source in a waste utilization plan.
Waste
Capacity
Volume to
Estimated
Number
Percent
25
Storage
of Pond
Spread each
Storage
of
Collection
Year
Pond
@ Pump-
Year
Period
Animals
Pump
Out
Gallons/Year
in
Level
Level
Source
Feet
Gallons
Below
Top
of
Dam
Source
22,520,000
1295
100%
1
Volume will be greater
Milk
when ponds #4 or #5 are
Cows
emptied and filled with
150 Dry
100%
water from Rocky Creek.
Cows
1100
100%
Heifers
60 Beef
30%
Feedlot
#1
1,462,000
#1, #2, #3 &
#6
-180 days
42
1,282,000
#3
3,439,000
#4
2,244,300
44 & #5
Dilution
Volume for
System
#5
1,692,000
5.5'
#6
3,792,000
1.5'
#7
974,000
1.9'
Total
Source
21,882,000
1
18 Waste Plan 2024

B. Nutrient computations
Manure application shall be based on actual soil test
and manure analysis.
a. Source 1 - Waste Storage Ponds
The nutrient content per year is shown below for a
broadcast application system. These are the best values to
use for hard hose pull system. Estimates based on data
from 2014 NC Agricultural Chemicals Manual for Dairy
Slurry.
TOTAL NUTRIENTS DISPOSAL LOSSES AVAILABLE
NUTRIENT
(Nutrient availability)
N 290,337 lbs 0.4 116,135 lbs
P2O5 158,207 lbs 1.0 158,207 lbs
K2O 267,735 lbs 1.0 267,735 lbs
5.2 lb N PAN per 1000 gal
NOTE: Nutrient Management Plan for Animal Waste
Utilization last updated in 2024 provides adequate
application fields for waste produced.
VII. Operation and Maintenance Plan
The waste management system will keep pollutants out
of the streams and rivers if the 25 yr -24 hr storage
capacity is maintained in the waste storage ponds and
diversions for clean water and polluted runoff are
maintained around the system.
Before the waste reaches the high-level marks set at
ponds #5, #6 and #7, the storage ponds shall be emptied. A
post will be set with its top at this elevation.
Vegetation around the waste storage pond shall be
mowed annually and eroded areas patched. Fencing shall be
checked and repaired as required.
See Operation and Maintenance Plan and Emergency
Action Plans attached for further detail.
19 Waste Plan 2024

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