NCS000324_COMPLIANCE_20081210 (2)

STORMWATER DIVISION CODING SHEET
NCS PERMITS
PERMIT NO.
�C.S dno 32c�
DOC TYPE
❑ FINAL PERMIT
-❑-MONITORING REPORTS-- - -- -- ----- --
❑ APPLICATION
I COMPLIANCE
❑ OTHER
DOC DATE
❑ 20
YYYYM M DD

NCS000324
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
STAFF REVIEW AND EVALUATION
NPDES Stormwater Permit
Coleen H. Sullins Director
Division of Water Quality
Facility Name:.
Consolidated Metco Inc.
i
NPDES Permit Number:
NCS000324
Facility Location:
780 Patton Ave., Monroe, NC (Union County)
Type of Activity:
Aluminum Foundries
SIC Code:
3365
Receiving Streams:
See Figure I j
River Basin:
Yadkin Pee -Dee River Basin, Sub -basin 03-07-14
Stream Classification:
WS-III
Proposed Permit Requirements:
See attached draft
permit.
Monitoring Data:
See Table 1
Response Requested by (Date):
Central Office Staff Contact:
Return to: Brian Lowther, [phone]
Special Issues:
Issue -'-
Rating Scale: ](easy) to 10 hard
Compliance historyj
1
Benchmark exceedance
1�
Location (TMDL, T&E
species, etc)j
4-
Other Challenges:
3
i
Difficult Rating:
9/40
i
Description of Onsite Activities:
Aluminum casting for the trucking industry. Machine and assembly.
Documents Reviewed:
• NPDES Stormwater Permit Application Materials
• National Heritage Program (NHP) Threatened and Endangered Species Database
• SPU File
• Central Files
• 2008 EPA Sector -Specific Permit,'Sector F `Primary Uletals"
• 303(d) List, 2008 draft, 2006 final
• 2008 (draft) Yadkin Pee -Dee Basinwide Plan
Page I of 7

NCS000324
History: I
• November 1, 1995: permit first issued. Analytical monitoring included pH on an annual basis.
• May 1, 2002: permit re -issued. No analytical monitoring.
• November 21, 2006: Date permittee submitted renewal application.
Page 2 oV

NCS000324
Figure 1: Map of Facility
24 ff
MIT
f
% A
rZ[r
Fm
Jo9 -
1%, e, — � . , ,ti , 15 r, 1
NO "r.A. . �,l
1',
Al
V
AW
A .;ede
T�
-1
121'�
Y,
Zonschdaied Matco inc,
Q
A
1 M
fit - 2 IKA V
IN
w,
�r/� �1��p..✓✓��sa: wit �� �r--�,7f '->v �ca�_ � ���P�i; � 4�, '. �- _ T
IND
NCS000324
Consolidated Metco
Inc.
Lab hide: 341159'52" N
Longitude: 80cl 33' 12" W
County: L-hion
7 ��i
Recei vng Stream: UT tD Stewarts
Steam Class: WS-111
Creek
Sub -basin: 03-07-14 (Yadkin
Pee -Dee River Basin)
Fa ci I i ty Loca tion
MIP Scc9le P249,000
Page 3 of, 7

NCS000324
Central Office Review Summary:
1. Owner's Other Pen -nits:
• Air Quality — CCA 3717900036
2. General Observations: Consolidated Metco (ConMet), a subsidiary of Amsted Industries, is a manufacturer of
aluminum components for a variety of heavy-duty commercial and off -highway vehicles. The company's products
include standard and preset wheel hubs and brake drums.
3. Impairment: Stewarts Creek is not on the 2006 303(d) but is in the draft from 2008 for ecological/biological
integrity and benthos. The 2003 Yadkin Basinwide Plan does not mention Stewarts Creek but it does mention
Richardson Creek which is downstream and impaired for biological integrity and turbidity.
The 1998 basin plan discusses naturally low dissolved oxygen, excess nutrients and sedimentation in
Richardson Creek. Recommendations are that no new discharges of oxygen consuming wastes be permitted
above the Monroe WWTP discharge. The plan also states that further investigation into the causes and sources
of water quality impacts is needed before more specific recommendations to improve water quality can be
made. Although the stream remains Impaired below the Monroe WWTP, the benthic macroinvertebrate
community is steadily improving. Between 1990 and�2001, the EPT abundance increased from 16 to 46,
suggesting real change in water quality. Local actions are needed to reduce nutrients from all sources
(agriculture, wastewater infrastructure and storniwate�r runoff) in the Richardson Creek watershed above SR
1649 and Salem Creek.
4. Threatened and Endangered: No protected species within 2 miles based on the Natural.l-leritage Virtual
Workroom.
5. Location: WS-11I
6. Industrial Changes Since Previous Permit: Since the time of the last permit reissuance, there has been
completion of significant expansion of the production facilities which necessitated a major building expansion.
In the course of this expansion, there has been an increase in the building area and the amount of impervious
surface area which drains to stormwater outfall (001)1 These expansion activities were nearing completion at
the time of the last permit reissuance and were included in the information submitted at that time.
There has been an increase in the amount of impervious surfaces as a consequence of the paving of some .
parking areas that were formerly gravel. This is reflected in the updated site plan.
With the exception of the above described improvements, manufacturing materials and practices have remained
relatively the same.
7. Analytical Monitoring Notes: There is no analytical monitoring onitoring in the previous pen -nit.
In the 2008 EPA Multi -Sector General Pert -nit Sector F, the subsector Nonferrous Foundries recommends
monitoring for Total Cu and Total Zn. This site's primary process' is aluminum.
S. Qualitative Monitoring Notes: Visual monitoring was done ten times from 05/04/02 to 10/18/06. The data
shows little signs of pollution. However, the color ranges from clear to one event being med. Grey. Many of
the events are light grey in color.
TSS was added to the pen -nit because the visual monitoring shows a light grey color for many observations.
Page 4 of

NCS000324
Revised Permit Recommendations: Analytical Monitoring:
1. Adding TSS and Aluminum to the renewed pen -nit.
2. pH has been added to the analytical monitoring requirements.
3. All analytical monitoring has been set to semi-annually during a representative storm event as defined in Part II
Section B. The permittee must also document the total precipitation for each event. If no discharge occurs
during the sampling period, the permittee must submit a monitoring report indicating "No Flow" within 30 days
of the end of the six-month sampling period. Additionally, samples must be taken a minimum of 60 days apart,
as specified in Table 2.
4. Benchmarks for analytical monitoring have been add d to this draft -permit. Exceedances of benchmark values
require the permittee to increase monitoring, 4increase management actions, increase record keeping, and/or
install stormwater Best Management Practices (BMPs) in a tiered program. If the sampling results are above a
benchmark value, or outside of the benchmark range, for any parameter at any outfall then the facility shall
follow the Tier.1 guidelines which require a facility inspection within two weeks and implementation of a
mitigation plan within two months. If during the tend of this permit, the sampling results are above the
benchmark values, or outside of the benchmark range, for any specific parameter at a specific discharge outfall
two times in a row (consecutive), then the facility shall follow the Tier 2 guidelines which require a repetition
of the steps listed for Tier 1 and also immediately institute monthly monitoring for all parameters at every
outfall where a sampling result exceeded the benchmark value for two consecutive samples.
5. The permittee is required to collect all of the analytical and qualitative monitoring samples during
representative storm events as defined in Part II Section B. Qualitative monitoring is required regardless of
representative outfall status.
The permittee is responsible for all monitoring until
4, and 5.
The flow reporting requirement has been removed pi
this permit, however.)
Vehicle maintenance monitoring has been revised to
qualitative monitoring.
Other Proposed Changes to the Previous Permit:
Additional guidance is provided about the Site Plan r
receiving stream is impaired and if it has a TMDL es
outfall. The map requirements are stated more explic
spills that have occurred in -the past three years and a.
ensure that they do not contain non-stormwater disch
Section A.
renewal pen -nit is issued. See Footnote 1 of Tables 1,
DWQ revised strategy. (The total rainfall parameter is in
i-annually in order to coincide with analytical and
quirements. The site map must now identify if the
blished. It must also describe potential pollutants in each
ly. And, the site plan must contain a list of significant
o must certify that the outfalls have been inspected to
rges. Additional information is provided in Part II
2. Additional requirements for the Stormwater Management Plan have been specified in Part 11 Section A. More
details regarding secondary containment are provided.
3. Additional requirements for the Stormwater Pollution Prevention Plan have been specified in Part II Section A.
The plan must also be updated annually to include a list of significant spills and to certify that the outfalls do
not contain non-stonmwater discharges.
4. The facility must now implement a semi-annual Facility Inspection Program of the site's stormwater
management controls as specified in Part 11 Section f
Information regarding the No Exposure Exclusion he
and activities are not exposed to precipitatioq or run(
qualify for a No Exposure Exclusion from NPDES si
information is provided in Part I Section A.
been added to this draft permit. If industrial materials
Tas described in 40 CFR §122.2G(g), the facility may
�rmwater discharge permit requirements. Additional
Pagel 5 of 7

NCS000324
Discussions with permittee: Wayne Duncan, 704 289 +
Permit Contact: Rick Linville 704 226 5319— 12/4/08
1. General description of industrial activities? Aluminu►;
assembly.
2. Have there been any changes since filing the applicat
3. What chemicals or materials are stored outside? Cast
propane with secondary containment. Storage trailer
4. Do you do vehicle maintenance onsite? No
5. What is you SIC code? 3365
Follow up questions:
6. Do you only do aluminum casting? Yes
7. The visual monitoring shows light grey as the water c
do the monitoring, Thurman Horne.
Talked with Turman Horne on 12/8/08, 704 788 4455,
The light grey color he said was almost clear and comma
a little bit of suspended solids in the water.
1, 12/2/08 referred me to Rick Linville
casting for the trucking industry. Machine and
DO No. The site has scaled back some.
ig, used/spare equipment, and wood pallets. Diesel and
. Sand used in the casting is not stored outside.
multiple times. Why? Referred me to the engineer
turn call was from 704 720 0728
with storm water discharges. He thinks it might be from
Page 6 o