WQ0001122_Final Permit_20090515

CDEN
North Carolina Department of Environment and Natural Resources
Division of Wate- Quality
Beverly Eaves Perdue Coleen H. Sullins
Governor Director
May 15, 2009
CATHY CURTIS — OWNER
CURTIS INSULATION CO. INC.
10150 WEST HIGHWAY 97
MIDDLESEX, NORTH CAROLINA 27557
Dear Ms. Curtis:
Dee Freeman
Secretary
Subject: Permit No. WQ0001122
Curtis Insulation
Closed -Loop Recycle System
Nash County
In accordance with your change of ownership request received April 24, 2009, we are forwarding
herewith Permit No. WQ0001122, dated May 15, 2009, to Curtis Insulation Co. Inc. for the continued
operation of the subject closed -loop wastewater recycle facilities.
This permit shall be effective from the date of issuance until April 30, 2010, shall void Permit No.
WQ0001122 issued May 6, 2005, and shall be subject to the conditions and limitations as specified
therein. Please pay particular attention to the monitoring requirements in this permit. Failure to establish
an adequate system for collecting and maintaining the required operational information will result in
future compliance problems.
Please note the Division has created a new permit shell since the last permit issuance.
Accordingly, the following conditions are new to your permit and require your attention:
Condition I.1. — This condition requires the Permittee to install a gauge to monitor waste
levels in the settling lagoon within 60 days of permit issuance or facility reactivation.
2. Condition III.3. — This condition requires the Permittee to prevent public access to any
portion of the closed -loop recycle system.
Condition 111.7. — This condition describes where and how the settling lagoon waste level
gauge shall be installed.
4. Condition 111.8. — This condition requires the Permittee to establish and maintain a protective
vegetative cover on the embankments of the settling lagoon.
5. Condition IV 2. — This condition requires all laboratory analyses for effluent, groundwater, or
surface waters be made by a Division certified laboratory.
6. Condition IV.3. — This condition requires the Permittee to weekly record the settling lagoon
freeboard and to maintain these records at the facility for a minimum of five years.
AQUIFER PROTECI0!1 SECTO'
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Locatic 272& Capi;u' Boulevard• Ralei.^', i40r:n Carolina 27c14
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Ms. Cathy Curtis
May 15, 2009
Page 1 of 2
7. Condition IV A. — This condition requires the Permittee to keep a record of all residuals
removed from the facility.
8. Condition VI.7. — This condition requires the Permittee to maintain this permit until all
permitted facilities are properly closed or permitted under another permit issued by an
appropriate permitting authority.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the
right to request an adjudicatory hearing upon written request within thirty (30) days following receipt of
this permit. 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, NC 27699-6714. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Nathaniel Thornburg at
[phone] or [e-mail].
Sincerely,
Stl. /CollH. Sullins
cc: Nash County Health Department
Raleigh Regional Office, Aquifer Protection Section
APS Central Files
LAU Files

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
CLOSED -LOOP RECYCLE SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
PERMISSION 1S HEREBY GRANTED TO
Curtis Insulation Co. Inc.
Nash County
FOR THE
continued operation of a 900 gallon per minute (GPM) closed -loop recycle system consisting of: a 2.15
million gallon settling lagoon with recycle of wastewater back into the manufacturing facility
to serve Curtis Insulation Co. Inc., with no discharge of wastes to the surface waters, pursuant to the
application received April 24, 2009, and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment and Natural
Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until April 30, 2010, shall void Permit No.
WQ0001122 issued May 6, 2005, and shall be subject to the following specified conditions and
limitations:
I, SCHEDULES
L If not already installed, a waste -level gauge to monitor waste levels in the settling lagoon shall be
installed within 60 days of issuance of this permit or prior to facility reactivation. Caution shall be
taken not to damage the integrity of the liner (if provided) when installing the gauge.
2. Within sixty (60) days of reactivation of this facility, all water supply wells within the compliance
boundary shall be permanently abandoned. Within thirty (30) days of abandonment, a Well
Abandonment Record (GW-30 form) that lists this permit number and the appropriate monitoring
well identification number shall be completed for each well abandoned and mailed to N.C. Division
of Water Quality, Aquifer Protection Section, 1636 Mail Service Center, Raleigh, N.C. 27699-1636.
The well(s) shall be abandoned by a North Carolina Certified Well Contractor according to the North
Carolina Well Construction Standards (15A NCAC 02C .0113) and local county rules.
No later than six months prior to the expiration of this permit, the Permittee shall request renewal of
this permit on official Division forms. Upon receipt of the request, the Division will review the
adequacy of the facilities described therein, and if warranted, will renew the permit for such period of
time and under such conditions and limitations as it may deem appropriate. Please note that Rule 15A
NCAC 02T .0105(d) requires an updated site map to be submitted with the permit renewal
application.
WQ0001122 Version 2.1 Shell Version 090415 Page 1 of 6

II. PERFORMANCE STANDARDS
The closed -loop recycle system shall be effectively maintained and operated at all times so that there
is no discharge to the surface waters, nor any contravention of groundwater or surface water
standards. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions due to improper operation and maintenance, the Permittee shall take immediate
corrective actions including those actions that may be required by the Division, such as the
construction of additional or replacement wastewater treatment, recycle, or disposal facilities.
2. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to ground
or surface waters resulting from the operation of this facility.
The compliance boundary for the closed -loop recycle system is specified by rules in 15A NCAC 02L
.0100, Groundwater Classifications and Standards. This closed -loop recycle system was individually
permitted prior to December 30, 1983; therefore, the compliance boundary is established at either 500
feet from the settling lagoon, or at the property boundary, whichever is closest to the settling lagoon.
An exceedance of groundwater standards at or beyond the compliance boundary is subject to
remediation action according to 15A NCAC 02L .0106(d)(2) as well as enforcement actions in
accordance with North Carolina General Statute 143-215.6A through 143-215.6C.
4. The review boundary is established around the settling lagoon midway between the compliance
boundary and the perimeter of the settling lagoon. Any exceedance of standards at the review
boundary shall require action in accordance with 15A NCAC 02L .0106.
5. The facilities permitted herein must be constructed according to the following setbacks:
a, The setbacks for storage and treatment units permitted prior to September 1, 2006 shall be as
follows (all distances in feet):
i. Surface waters: 50
ii. Any well with the exception of a Division approved groundwater monitoring well: 100
iii. Any property line: 50
M. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintained and operated at all times. The facilities shall be effectively
maintained and operated as a non. -discharge system to prevent the discharge of any wastewater
resulting from the operation of this facility. The Permittee shall maintain an Operation and
Maintenance Plan pursuant to 15A NCAC 02T .1007 including operational functions, maintenance
schedules, safety measures, and a spill response plan.
2. Upon classification of the wastewater treatment and closed -loop recycle facilities by the Water
Pollution Control System Operators Certification. Commission (WPCSOCC), the Permittee shall
designate and employ a certified operator to be in responsible charge (ORC) and one or more certified
operator(s) to be back-up ORC(s) of the facilities in accordance with 15A NCAC 08G .0200. The
ORC shall visit the facilities in accordance with 15A NCAC 08G .0200 or as specified in this permit
and shall comply with all other conditions specified in these rules.
Public access to the wastewater treatment equipment, wastewater storage structure(s), and closed -loop
recycle system shall be controlled.
4. The residuals generated from these treatment facilities must be disposed I utilized in accordance with
15A NCAC 02T .1100. The Permittee shall maintain a residual management plan pursuant to 15A
NCAC 02T .1008.
5. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
WQ0001122 Version 2.1 Shell Version 090415 Page 2 of 6

6. Freeboard in the settling lagoon shall not be less than two (2) feet at any time.
7. A waste -level gauge to monitor waste levels in the settling lagoon shall be provided. This gauge shall
have readily visible permanent markings indicating the maximum liquid level at the top of the
temporary liquid storage volume, minimum liquid level at the bottom of the temporary liquid storage
volume, and the lowest point on top of the dam elevations.
8. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum allowable temporary storage elevation on the inside of the
embankment), berms, pipe runs, erosion control areas, and surface water diversions. Trees, shrubs,
and other woody vegetation shall not be allowed to grow on the earthen basin dikes or embankments.
Earthen basin embankment areas shall be kept mowed or otherwise controlled and accessible.
IV. MONITORING AND REPORTING RE UIREMENTS
Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed
necessary by the Division to ensure surface and ground water protection will be established and an
acceptable sampling reporting schedule shall be followed.
2. All laboratory analyses for effluent, ground waters, or surface waters shall be made by a laboratory
certified by the Division for the required parameters) under 15A NCAC 02H .0800.
3. Freeboard (waste level to the lowest elevation on the top of the embankment) in the settling lagoon
shall be recorded weekly. Freeboard recording results shall be maintained at the facility for a period
of no less than five years, and shall be made available to the Division upon request.
4. A record shall be maintained of all residuals removed from this facility. This record shall include the
name of the hauler, permit authorizing the disposal or a letter from a municipality agreeing to accept
the residuals, date the residuals were hauled, and volume of residuals removed.
Prior to plant reactivation, monitoring wells MW-1, MW-2 and MW-3 shall be inspected every
November to ensure the wells are in compliance with 15A NCAC 02C .0108 Well Construction
Standards. Records of such inspections must be maintained. Each monitoring well must be labeled
as required by 15A NCAC 02C .0108 (c)(11).
6. Upon reactivation of this facility, monitoring wells shall be sampled initially before reactivation and
within 3 months prior to initiating waste disposal operations. Monitoring wells shall be sampled
thereafter at the frequencies and for the parameters specified in Attachment C. All mapping, well
construction forms well abandonment forms and monitoring data shall refer to the permit number
and the well nomenclature as provided in Attachment C and Fi e 1.
7. Two (2) copies of the results of the sampling and analysis must be received on Form GW-59
(Groundwater Quality Monitoring: Compliance Report Form), along with attached copies of
laboratory analyses, by the Division of Water Quality, Information Processing Unit, 1617 Mail
Service Center, Raleigh, North Carolina 27699-1617 on or before the last working day of the month
following the sampling month. Form GW-59 shall include the number of this permit and the
appropriate well identification number. One Form GW-59a certification form shall be provided for
each set of sampling results submitted.
WQ0001122 Version 2.1 Shell Version 090415 Page 3 of 6

8. Noncompliance Notification:
The Permittee shall report by telephone to the Raleigh Regional Office, telephone number (919) 791-
4200, as soon as possible, but in no case more than 24 hours or on the next working day following the
occurrence or first knowledge of the occurrence of any of the following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the
contents of a basin or tank; the known passage of a slug of hazardous substance through the
facility; or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility incapable of
adequate wastewater treatment such as mechanical or electrical failures of pumps, aerators,
compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters.
d. Any time that self -monitoring information indicates that the facility has gone out of compliance
with its permit requirements.
For any emergency that requires immediate reporting (e.g., discharges to surface waters, imminent
failure of a storage structure, etc.) outside normal business hours must be reported to the Division's
Emergency Response personnel at telephone number [phone], [phone], or (919) 733-
3300. Persons reporting such occurrences by telephone shall also file a written report in letter form
within five (5) days following first knowledge of the occurrence. This report must outline the actions
taken or proposed to be taken to ensure that the problem does not recur.
V. INSPECTIONS
1.. Adequate inspection and maintenance shall be provided by the Permittee to ensure proper operation
of the subject facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and recycle facilities to prevent
malfunctions and deterioration, operator errors and discharges which may cause or lead to the release
of wastes to the environment, a threat to human health, or a nuisance. The Permittee shall keep an
inspection log or summary including at least the date and time of inspection, observations made, and
any maintenance, repairs, or corrective actions taken by the Permittee. This log of inspections shall
be maintained by the Permittee for a period of five years from the date of the inspection and shall be
made available upon request to the Division or other permitting authority.
3. Any duly authorized officer, employee, or representative of the Division may, upon presentation of
credentials, enter and inspect any property, premises or place on or related to the disposal site or
facility at any reasonable time for the purpose of determining compliance with this permit; may
inspect or copy any records that must be maintained under the terms and conditions of this permit,
and may obtain samples of groundwater, surface water, or leachate.
WQ0001122 Version 2.1 Sbell Version 090415 Page 4 of 6

VI. GENERAL. CONDITIONS
1. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee
to an enforcement action by the Division in accordance with North Carolina General Statute 143-
215.6A to 143-215.6C.
2. This permit shall become voidable unless the facilities are constructed in accordance with the
conditions of this permit, the approved plans and specifications, and other supporting data..
This permit is effective only with respect to the nature and volume of wastes described in the
application and other supporting data. No variances to applicable rules governing the construction
and / or operation of the permitted facilities are granted unless specifically requested and granted in
this permit.
4. The issuance of this permit does not exempt the Permittee from complying with any and all statutes,
rules, regulations, or ordinances, which may be imposed by other government agencies (local, state,
and federal) that have jurisdiction. Of particular concern to the Division are applicable river buffer
rules in 15A NCAC 02B .0200, erosion and sedimentation control requirements in 15A NCAC
Chapter 4 and under the Division's General Permit NCGO10000, and any requirements pertaining to
wetlands under 15A NCAC 02B .0200 and 02H .0500.
5. In the event there is a desire for the facilities to change ownership, or there is a name change of the
Permittee, a formal permit request must be submitted to the Division on official Division form(s),
documentation from the parties involved, and other supporting materials as may be appropriate. The
approval of this request will be considered on its merits and may or may not be approved. The
Permittee of record shall remain fully responsible for compliance until a permit is issued to the new
owner.
The Permittee shall retain a set of approved plans and specifications for the life of the facilities
permitted herein.
The Permittee shall maintain this permit until all permitted facilities herein are properly closed or
permitted under another permit issued by the appropriate permitting authority.
The Permittee must pay the annual fee within thirty (30)
Failure to pay the fee accordingly may cause the Division
pursuant to 15A NCAC 02T .0105(e).
Permit issued this the 15'' day of May 2009
days after being billed by the Division.
to initiate action to revoke this permit
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
0/61een/lf Sullins, Director
DivisiW of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0001122
WQ0001122 Version 2.1 Sbeli Version 090415 Page 5 of 6

THIS PAGE BLANK
WQ0001122 Version 2,1 She]] Version 090415 Page 6 of 6

ATTACHMENT C — GROUNDWATER MONITORING AND LIMITATIONS
Monitoring wells: MW-1, MW-2 and MW-3
Permit Number: WQ0001122 Version: 2.1
GROUNDWATER CHARACTERISTICS
GROUNDWATER STANDARDS
MONITORING REQUIREMENT'S
Parameter Description - Parameter Code
Daily Maximum
Frequency Measurement
Sample Type
Footnotes
Carbon, Tot Organic (TOC) — 00680
mg/1
Annually
Grab
1,4
pH — 00400
6.5-8.5
S.U.
Annually
Grab
1,2
Water level, distance from measuring point— 82546
11
Annually
Calculated
I, 13
1. Annual monitoring shall be conducted every November.
2. The measurement of water levels shall be made prior to purging the wells. The depth to water in each well shall be measured from the surveyed point on the top of the casing, The measurement
of pl I shall be made after purging and prior to sampling for the remaining parameters.
3. The measuring points (top of well casing) of all monitoring wells shall be surveyed to provide the relative elevation of the measuring point for each monitoring well. The measuring points (top
of casing) of all monitoring wells shall be surveyed relative to a common datum.
4, If TOC concentrations greater than 10 mg/1 are detected in any downgradient monitoring well, additional sampling and analysis must be conducted to identify the individual constituents
comprising this TOC concentration. If the TOC concentration as measured in the background monitor well exceeds 10 mg/I, this concentration will be taken to represent the naturally occurring
TOC concentration. Any exceedances of this naturally occurring TOC concentration in the downgradient wells shall be subject to the additional sampling and analysis as described above.
5. Monitoring wells shall be reported consistent with the nomenclature and location information provided in Figure I and this attachment.
WQ0001122 Version 2.1 Attachment C Page I of I

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Spring Hope, NC 27882
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