WQ0001550_Final Permit_19960131

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
January 31, 1996
Mr. Larry Murphy, Plant Manager
Stone Manufacturing Company
11917 Andrew Jackson Hwy. SW
Fair Bluff, North Carolina 28439
Dear Mr. Murphy:
mink
C)EHNR
Subject: Permit No. WQ0001550
Stone Manufacturing Company, Fair Bluff Plant
Wastewater Treatment & Disposal Facilities
Columbus County
In accordance with your application received August 18, 1995, we are forwarding herewith Permit
No. WQ0001550 dated January 31, 1996, to Stone Manufacturing Company for the continued operation
of the subject wastewater facilities. This permit, as did the previous permit, clearly requires connection to
a municipal or regional sewerage collection system, upon availability. It is understood Stone
Manufacturing Company is currently negotiating for sewer connection to the Town of Fair Bluff. Please
note, this permit is being renewed for one year only to allow the time for Stone Manufacturing Company
to make contractual agreements and obtain any necessary permits for construction and connection to the
Town of Fair Bluffs wastewater collection facilities. The Division does not intend to allow any further
renewal of this permit.
This permit shall be effective from the date of issuance until December 31, 1996, shall void Permit
No, WQ0001550 issued March 11, 1994, and shall be subject to the conditions and limitations as
specified therein. Please pay partcular 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.
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 150E of the
North Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer
27447, Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Mr. John Seymour at
[phone] extension 546.
Sincerely,
X'je
to Howard Jr� P.E.
A. Pres � ,
cc: Columbus County Health Department
Wilmington Regional Office, Water Quality Section
Wilmington Regional Office, Groundwater Section
Bob Cheek, Groundwater Section, Central Office
Training and Certification Unit (no revised rating)
Facilities Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
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NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
INFILTRATION LAGOON 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 IS HEREBY GRANTED TO
Stone Manufacturing Company
Columbus County
FOR THE
continued operation of a 10,000 GPD wastewater treatment facility consisting of extended aeration
package treatment plant with a chlorination facility, a polishing pond/ infiltration evaporation pond with an
approximate volume of 0.19 million gallons, and all associated piping, valves, controls, and
appurtenances to serve Stone Manufacturing Company's Fair Bluff Plant with no discharge of wastes to
the surface waters, pursuant to the application received August 18, 1995, and in conformity with the
project plan, specifications, and other supporting data subsequently filed and approved by the Department
of Environment, Health and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until December 31, 1996, shall void Permit
No. WQ0001550 issued March 11, 1994, and shall be subject to the following specified conditions and
limitations:
1. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective actions, including those
actions that may be required by this Division, such as the construction of additional or
replacement wastewater treatment or disposal facilities.
2. This permit shall become voidable if the soils fail to adequately assimilate the treated
wastewater and may be rescinded unless the facilities are installed, maintained, and
operated in a manner which will protect the assigned water quality standards of the surface
waters and ground waters. The overflow of wastewater from the pond, for any reason,
shall be considered as evidence of failure of the soils to adequately assimilate the
wastewater. Additionally, such failure shall be interpreted as a violation of this permit.
3. The residuals generated from these treatment facilities must be disposed in accordance with
General Statute 143-215.1 and in a manner approved by the North Carolina Division of
Envirohmental Management.
4. Adequate measures shall be taken to divert stormwater from the high rate infiltration area
and to prevent wastewater runoff.
5. Diversion or bypassing of the untreated wastewater from the treatment facilities is
prohibited.
6. The issuance of this permit shall not relieve the Permittee of the responsibility for damages
to surface or groundwaters resulting from the operation of this facility.

II.
7. The freeboard in the polishing/ infiltration pond shall not be less than one (1) foot at any
time.
1. The facilities shall be properly maintained and operated at all times.
2. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class Il, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
3. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater outside of the infiltration disposal area, which
results from the operation of this facility.
4. The screenings removed from the wastewater treatment plant shall be properly disposed of
in a sanitary landfill or by other means which have been approved by this Division.
5. The flow measurement device shall be calibrated annually by a representative of a firm
which is routinely engaged in the calibration of flow measurement devices. Records of this
calibration, including all information pertinent to the calibration, shall be available during
any inspection by Division staff.
6. Diffusers shall be cleaned as needed to ensure that adequate aeration is provided. Records
of this maintenance shall be maintained by the permittee.
7. The chlorine used in the disinfection facility shall be of the kind and type specified in the
plans and specifications approved by the Division.
MONIMUNQ AND REPORTING REQUIREMENTS
Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
2. As an indicator of proper operation and maintenance, the facility shall produce an effluent
in compliance with the following limitations:
Parameter Monthly Averagea Daily Maximumb
Flow 10,000 GPD
BOD5 (5-day, 20°C) 10 mg/l
NH3 as N 4 mg/l
TS S 20 mg/l
Fecal Coliform 14 per 100 ml 43 per 100 ml
a Monthly average shall be the arithmetic mean of all samples collected during the
reporting period.
b Daily maximum shall be the maximum value of all samples collected during the reporting
period.
2

The Influent and/or effluent from the subject facilities shall be monitored, by the Permittee,
at the point prior to discharge to the polishing/ infiltration pond for the following
parameters:
ParaMet�r Sampling Point m lin Frequency T f 1
Flow
Influent or Effluent
monthly
Recording
BOD5 (5-day, 20°C)
Effluent
monthly
Composite
NH3 as N
Effluent
monthly
Composite
TS S
Effluent
monthly
Composite
Fecal Coliform
Effluent
monthly
Grab
Settleable Matter
Effluent
Daily
Grab
Residual Chlorine
Effluent
Daily
Grab
NO3
Effluent
*Triannually
Grab
TDS
Effluent
**Triannually
Grab
TOC
Effluent
**Triannually
Grab
Chloride
Effluent
**Triannually
Grab
The effluent pH shall not be less than 6.0 standard units nor greater than 9.0 standard
units.
** Triannually sampling shall be conducted during March, July, and November.
If Groundwater sampling indicates or predicts problems with compliance with of the
Groundwater Standards, this permit will be modified to include additional and/or more
restrictive limitations.
3. Three (3) copies of all effluent monitoring data (as specified in condition III 2) on Form
NDMR-1 shall be submitted on or before the last day of April, August, and December. All
information shall be submitted to the following address:
NC Division of Environmental Management
Water Quality Section
Facility Assessment Unit
Post Office Box 29535
Raleigh, N.C. 27626-0535
4. A record shall be maintained of all residuals removed from this facility. The record shall
include the name of the hauler, the permit authorizing the disposal or a letter from a
municipality agreeing to accept the residuals, the date the residuals were hauled, and the
volume of residuals removed.
5. A maintenance log shall be maintained at this facility including, but not limited to, the
following items:
a. Daily sampling results including residual chlorine, settleable matter, and dissolved
oxygen in the aeration basin and at the clarifier weir;
b. Visual observations of the plant and plant site;
c. Record of preventative maintenance (changing of filters, adjusting belt tensions, alarm
testing, diffuser inspections and cleaning, etc.);
d. Date of calibration of flow measurement device; and
e. Date and results of power interruption testing on alternate power supply.

6. Noncompliance Notification:
The Permittee shall report by telephone to the Wilmington Regional Office, telephone
number 910/ 395-3900 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 renders 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
of all or any portion of the influent to such station or facility; or
d . Any time that self -monitoring information indicates that the facility is not in compliance
with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form. within 15 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.
I V . GROUNDWATER REQUIREMENTS
1. The three (3) existing monitor wells (MW-1, MW-2, and MW-3) shall be sampled every
March, July, and November for the following parameters:
NO3 Ammonia Nitrogen
TDS TOC
pH Water Level
Chloride Fecal Coliforms
Total Phosphorus
Volatile Organic Compounds - In November only (by Method 1 below)
Method 1: Method 6230D (Capillary - Column), "Standard Methods For The
Examination of Water and Wastewater", 17th ed., 1989
The measurement of water levels must be made prior to sampling for the remaining
parameters. The depth to water in each well shall be measured from the surveyed point on
the top of the casing.
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.
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 rngl 1, 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.
4

If any volatile organic compounds are detected by Method 6230D, or the equivalent Method
502.2, then the Wilmington Regional Office Groundwater Supervisor, telephone number
9101 395-3900 must be contacted immediately for further instructions regarding any
additional follow-up analyses required. The results of all initial and follow-up analyses
must be submitted simultaneously.
The results of the sampling and analysis shall be sent to the Groundwater Section, Permits
and Compliance Unit, P.O. Box 29578 Raleigh, N.C. 27626-0578 on Form GW-59
[Compliance Monitoring Report Form] every April, August, and December.
2. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall
be provided.
3. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in
15A NCAC 2L, Groundwater Classifications and Standards. The Compliance Boundary
for the disposal system constructed prior to December 31, 1983 is established at either (1)
500 feet from the waste disposal area, or (2) at the property boundary, whichever is closest
to the waste disposal area. An exceedance of Groundwater Quality Standards at or beyond
the Compliance Boundary is subject to immediate remediation action in addition to the
penalty provisions applicable under General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the
disposal systems midway between the Compliance Boundary and the perimeter of the
waste disposal area. Any exceedance of standards at the Review Boundary shall require
remediation action on the part of the permittee.
V . INSPECTIONS
1. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
2. The Permittee or his designee shall inspect the wastewater treatment and disposal 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 maintain 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 Perrittee for a
period of three years from the date of the inspection and shall be made available to the
Division of Environmental Management or other permitting authority, upon request.
3. Any duly authorized officer, employee, or representative of the Division of Environmental
Management 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.
VI. GENERAL CONDITIONS
1. 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.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.

3. This permit is not transferable. 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 of Environmental Management accompanied by an application
fee, 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.
4. The subject wastewater treatment and disposal facilities shall be connected to an operational
publicly owned wastewater collection system within 180 days of its availability to the
subject facilities, in accordance with the terms and conditions of this non -discharge permit
and the governing statutes and regulations. Prior to the initiation of these connection
activities, appropriate approval must be received from this Division.
5. The annual administering and compliance fee must be paid by the Permittee within thirty
(30) days after being billed by the Division. Failure to pay the fee accordingly may cause
the Division to initiate action to revoke this permit as specified by 15A NCAC 2H .0205
(c)(4).
6. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6(a) to 143-215.6(c).
7. The issuance of this permit does not preclude 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) which have jurisdiction.
8. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
9. The Permittee, at least six (6) months prior to the expiration of this permit, shall inform the
Division of it's status for the connection of the subject treatment facilities to the available
Town of Fair Bluff sewer collection system. If connection to avail-I)le sewer is not
possible, the Permittee will inform the Division and provide acceptable justification as to
why it is not possible. This will not exempt the Permittee from any possible enforcement
actions for failure to connect, nor does it mean the Division will allow a permit renewal.
Permit issued this the 31st day of January, 1996
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
A, Preston ward, Jr., P. ., Director
Division of vironmental Management
By Authority of the Environmental Management Commission
Permit Number WQ0001550