STATEMENT OF QUALIFICATIONS

Foundry Industry SOQ

TRCcompanies.com Foundry Industry SOQ

About TRC The world is advancing. We’re advancing how it gets planned and engineered. TRC is a global consulting firm providing environmentally advanced and technology‐powered solutions for industry and government. From solid waste, pipelines to power plants, roadways to reservoirs, schoolyards to security solutions, clients look to TRC for breakthrough thinking backed by the innovative follow‐ through of a 50‐year industry leader.

The demands and challenges in industry and government are growing every day. TRC is your partner in providing breakthrough solutions that navigate the evolving market and regulatory environment, while providing dependable, safe service to our customers. We provide end‐to‐end solutions for environmental management.

Throughout the decades, the company has been a leader in setting industry standards and establishing innovative program models. TRC was the first company to conduct a major indoor air study related to outdoor air quality standards. We also developed innovative measurements standards for fugitive emissions and ventilation standards for schools and hospitals in the 1960s; managed the monitoring program and sampled for pollutants at EPA’s Love Canal Project in the 1970s; developed the basis for many EPA air and hazardous waste regulations in the 1980s; pioneered guaranteed fixed‐price remediation in the 1990s; and earned an ENERGY STAR Partner of the Year Award for outstanding energy efficiency program services provided to the New York State Energy Research and Development Authority in the 2000s.

We are proud to have developed scientific and engineering methodologies that are used in the environmental business today—helping to balance environmental challenges with economic growth. The unparalleled strength of our diverse staff and firm commitment to solving our clients’ toughest challenges has made TRC a trusted advisor. We not only share our clients’ goals, we take responsibility for reaching them.

TRC has more than 5,000 employees in over 140 offices throughout the United States, the UK, and China. TRC is ranked #20 on ENR’s list of the Top 500 Design Firms in the United States.

Results You Can Rely On TRC has provided consulting services to the Foundry Industry since 1977. Our staff has a wide range of expertise, which is tailored to handle the challenging issues associated with industry. In addition to our strong technical capabilities, TRC has distinguished itself by providing superior project management and coordination capabilities on industrial projects. Our project management staff understands the business issues that are unique to the Foundry Industry. Our goal is to deliver our technical services to you, the client, in a manner that helps bring bottom‐line results.

TRC’s Guiding Principles

Our Mission We understand our clients’ goals, and embrace them as our own, applying creativity, experience, integrity, and dedication to deliver superior solutions to the world’s energy, environment, and infrastructure challenges.

Our Vision We will solve the challenges of making the Earth a better place to live—community by community and project by project.

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Our Values We commit to these values to guide our decisions and our behaviors:

Safety We create a working environment that promotes safe performance.

Quality We always strive for excellence in the services we provide and in the results we produce for our clients.

Integrity We are committed to the highest ethical standards.

Creativity We believe in looking at challenges and opportunities from new angles and in exercising our curiosity.

Accountability We take responsibility for all of our decisions and actions.

Teamwork We work together to succeed.

Passion We deliver superior results because we care deeply about what we do.

TRC has provided construction management oversight and self‐performed environmental remediation at multiple locations throughout the United States. With over 140 office locations and TRC’s dedicated staff, we are well positioned to support our customers’ construction needs.

A Safety First Culture TRC’s commitment to safety is not lip service. Safety is embedded in our culture and integral to how we conduct our business. Our executive safety council provides leadership for safety initiatives that protect not only our employees, but the work sites they frequent. The council and our safety team work tirelessly to develop strategies that target hazards across all business sectors in an effort to reduce risk.

TRC’s corporate health and safety program is administered and maintained by Mike Glenn, National Safety Director, and a safety structure of over 50 staff providing support throughout the country. TRC’s commitment to health and safety is reflected in our Total Recordable Incident Rate (TRIR) of 0.29 and Experience Modification Rate (EMR) of 0.82 for 2019.

Quality We believe that quality does not come by chance. Quality is a responsibility that we all share. Our focus on quality requires accountability across all business sectors. This isn’t just about meeting expectations. It’s about becoming a trusted partner for our customers.

A Commitment to Our Communities As a firm with strong ties to the environmental movement of the 1970s, sustainability is etched in our DNA. For the past five decades, TRC has committed to solving client challenges in a way that makes the earth a better place to live—community by community and project by project.

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There has never been a more important time to find the right balance between pursuing economic growth and protecting the environment for future generations. We collaborate with our clients to design tangible solutions that provide real, quantifiable results and ongoing benefits—long after a project’s completion. Partnership with the Foundry Industry TRC has a unique partnership with the Foundry Industry. Many of our engineers and scientists came from various foundry industries or have conducted industry‐sponsored research, so they have an in‐ depth understanding of industry issues. In addition, our staff continues to stay involved with the industry and share environmental information through trade associations, special research projects, and presentations.

Our knowledge of the challenges associated with hazardous waste management led TRC to develop proprietary processes to treat wastes containing metals that render the wastes nonhazardous. Companies that use this technology have saved hundreds of thousands of dollars in hazardous waste treatment and disposal costs.

TRC’s knowledge of residuals generated by the Foundry Industry and how they act in the environment has encouraged the beneficial reuse of these materials that, in the past, have been destined for land disposal. TRC assisted industry trade groups on the state level to advocate beneficial reuse regulations in a number of states. As a result of these regulations, the Foundry Industry has been able to save millions of dollars by constructively reusing their by‐products in a manner that is also environmentally sound. Many tons of materials that normally would be filling our precious landfill space have thus been put to good use, which also minimizes the need for scarce natural resources.

As TRC has grown, so have many of our clients. To assist our clients with plant expansions, plant upgrades, or process changes, TRC features a diverse group of civil, electrical, mechanical, and process engineers. Our engineering staff can handle an entire project, from design and testing to construction and startup. In addition, our staff considers the environmental effects of production changes and can develop solutions that minimize waste generation, air emissions, and water discharges. As partners with our clients, we can avoid some of the environmental pitfalls that have historically plagued the industry.

Membership in Trade Organizations TRC's commitment to the Foundry Industry includes active participation in trade associations. Because our clients have contributed so much to the success of TRC, we believe that by contributing our time, our talent, and our money to these trade organizations, we can give something back to the industry. TRC has been active in the following trade associations:

Foundry Industry . The American Foundry Society . The Non Ferrous Founders Society . State Cast Metals Associations (California, Illinois, Indiana, Ohio, Wisconsin, Texas, Pennsylvania, and Michigan) . The North American Die Casting Association

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Steel Industry EXPERT: TRC has a long The Steel Manufacturers Association history as expert problem solvers. Beyond activity at the corporate level, many TRC members serve in key roles on technical committees within these organizations. In addition to serving as members on these committees, staff have also

functioned as officers, providing overall leadership of the technical committees. CREATIVE: We excel in constructing creative options In addition to holding national memberships, TRC is also active at the state and chapter levels of many to find the optimal solution of these associations across the United States. Our involvement in these organizations includes for our clients. preparing and presenting technical papers, attending chapter meetings, and participating in committee activities. TRC's routine participation in these industry activities gives our staff a keen understanding of the myriad of financial, production, and environmental challenges facing metals DEDICATED: We are facilities today. This helps us better serve our clients as they aggressively meet the challenges of dedicated to helping our everyday business. clients reach their ultimate goals. Industry Research and Development TRC staff have dedicated substantial resources toward the advancement of the industry's environmental management alternatives. These efforts include the following: . Research and development of four proprietary treatment technologies for metal‐containing waste and soil . Research and development of field methods for on‐site analysis of compositional and leachable lead . Research for the American Foundry Society on the nature and characterization of leachate from foundry waste . Development of guidelines for the location, design, operation, and monitoring of foundry waste landfills for the American Foundry Society . Extensive research on the comparison between laboratory leachate of foundry sand and soil . Research on the beneficial and constructive reuse of foundry sand . Development and support for industry positions on rulemaking for the treatment and management of solid waste, and the management of water and air quality . Research for a cast metals association on process‐specific emission measurements for benzene and formaldehyde for eight foundries. Developed benzene and formaldehyde emission rates for pouring, cooling, and shakeout operations for green sand, no‐bake, and shell foundries . Developed laboratory data review and emission testing procedures for the Casting Emission Reduction Program. TRC authored a document detailing what factors may influence hazardous air pollutant emissions from gray iron pouring, cooling and shakeout operations. . Providing assistance to the American Foundry Society regarding the resolution of technical issues during the development of the Iron and Steel Foundry MACT and Area Source Rules. . Served as primary technical consultant and foundry expert for the CCMA Engineering Group by assisting in the development of their ventilation controls report and interactive CD‐ROM. This interactive CD‐ROM spawned from the 2‐year Group Study and was developed to be a single source for assessing ventilation controls at a foundry, a complete resource guide for ventilation control publications and studies, and a launching pad for developing ventilation controls at one’s facility.

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Solid Waste Management Effective management of solid waste, including innovative waste minimization, and constructive reuse and disposal alternatives, enhances a facility's ability to focus on production. TRC provides the following solid waste management services: . Waste minimization . Waste characterization and analysis . Beneficial/Constructive reuse . Landfill site selection, design, and permitting . Stability analysis and geotechnical design . Leachate treatment design . Closure and final use planning . Construction quality assurance . Construction management . Regulatory and public liaison

Air Pollution Control TRC's air specialists have been working with foundries, steel mills, and metal recyclers to prepare them for new permitting and control requirements. We are a key contributor at American Foundry Society air quality committee which helps us stay aware of and help comment on key air regulatory issues for the foundry industry. We are air experts for the foundry industry. Our staff of air specialists is prepared to assist you with the following: . Air toxics evaluation . Ambient air quality monitoring . Clean Air Act: Title I, III, and V assistance . Compliance assessment and feasibility analysis . Control equipment selection and design . Dispersion modeling . Emission characterization and annual emissions reporting . Emission reduction . Emission testing and stack sampling . Fugitive emission monitoring . Permit acquisition, applicability determinations, and new source review . Property line sampling . SARA Title III auditing and reporting assistance

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Industrial Ventilation TRC provides a comprehensive mix of environmental compliance expertise, process engineering knowledge and construction project management capabilities to help industry meet chemical, industrial, mechanical and environmental process challenges. TRC’s process and air pollution control engineering services include: industrial ventilation system assessments and engineering; air pollution control system design and engineering; pollution control equipment assessments and troubleshooting; manufacturing process design improvement; incineration, combustion, and thermal systems design and engineering; energy recovery assessments and system engineering; industrial hygiene assessments and design of engineering controls; and turnkey project design and implementation.

TRC has traditionally taken a “systems approach” to industrial ventilation that integrates regulatory compliance, emission control, and process improvements. Experienced in the evaluation of existing operations and the design of new systems, our team of industrial ventilation specialists offers a range of capabilities beyond those typically provided by general environmental consultants or sheet metal design and contracting firms. Our staff literally wrote the manual on foundry ventilation (Managing the Foundry Indoor Air Environment). Our industrial ventilation staff provide the following services: . Ventilation system evaluation . Troubleshooting and problem solving . Building/Plant differential pressure evaluations . Conceptual and detailed ventilation design . Hood and enclosure design . Predictive ventilation modeling . Air pollution control system design . Startup and operator training . Testing and balancing . Turnkey design/build

Industrial Hygiene TRC is committed to helping clients reap the benefits of an effective industrial hygiene program. We understand that companies need to be profitable, to fuel growth and to maintain a qualified work force. The costs associated with work place injuries and illnesses can negatively impact each of these goals. The burden of workers’ compensation claims including lost productivity, retraining, and accommodation for injured employees can slowly eat away at the bottom line. Lack of attention to industrial hygiene can also impact worker morale, corporate image, and community relations.

We strive to help our clients attain their risk management, cost containment, as well Occupational Safety and Health Administration (OSHA) compliance goals. TRC is well versed in the foundry operations and understands your operations, workforce relations, monetary constraints, and priorities. We assign trained staff who bring foundry regulatory experience and industry knowledge to customize solutions for your facility. We operate as part of your team and develop long‐term partnerships that bring both business results and professional growth.

Our industrial hygienists work hand in hand with our ventilation engineers to provide cost effective engineered solutions. TRC provides expertise in industrial hygiene through: . Industrial hygiene program evaluation and development — Evaluate and develop programs for hazard communication, respiratory protection, hearing conservation, confined space entry, silica, lockout/tagout, hexavalent chromium, lead, and PPE. — Review material usages and identify chemicals of concern to be monitored.

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 Job hazard surveys — Focuses on identifying and controlling high hazard processes and areas as a priority to improving safety — Leads to the development of safe work practices and procedures

 Industrial hygiene assessments/exposure monitoring — Characterize worker exposures to silica, fumes, vapors, gases, heat, noise, etc. — Utilize real‐time instrumentation to identify root causes of employee exposures. — Address controls through engineering design, administrative change, and the use of personal protective equipment (PPE)

Environmental, Health, and Safety Management Services Today's foundries face a myriad of economic, regulatory, environmental, legal, and public relations challenges. Many large manufacturers have mandated that preferred suppliers receive ISO 14001 certification. Even if certification is not a requirement, an effective environmental health and safety management system is critical to ensure bottom‐line profitability. TRC is positioned to assist industry every step of the way with our extensive experience in the following: . ISO 14001 program facilitation and pre‐registration review . Retained liability management . Compliance audit programs . Management systems’ audits . Compliance program design and implementation . Compliance monitoring . Air and noise monitoring . Employee training . Engineering controls . Hazard communication . Health and safety plans . Personal protective equipment programs . Information management . Outsourcing of staff . Process safety management and risk management . Environmental permitting . Sustainability advisory services

Hazardous Waste Management Metals facilities are continually striving to reduce hazardous waste treatment and disposal costs. TRC provides innovative, project‐specific solutions to your hazardous waste challenges, including the following: . Waste minimization/Pollution prevention . Closure plans . RCRA hazardous waste monitoring, assessment, and corrective action . Hazardous waste treatment . New facility siting studies . Hazardous waste facility permitting 7 Foundry Industry SOQ

. RCRA compliance . RCRA facility investigations . Waste characterization

Environmental Liability Management Effective management of environmental liability is essential if industry is to be competitive in today’s economy. TRC’s team of risk management specialists has built a reputation for finding the most cost‐ effective way to limit your exposure from existing environmental liabilities. Our environmental liability reduction services include the following: . Merger and acquisition/due diligence . Divestitures . Order negotiations . Retained liability management . Risk management . Risk communications/community relations . Permit transferability . Regulatory liability management

Remediation Services The remediation of past disposal sites and spills has been a challenge for many companies in the Foundry Industry. TRC has spent years developing cost‐effective means for rendering metals nonhazardous. This research has resulted in a number of patented products that have been widely applied to metal remediation sites across the country. This type of knowledge of fate and transport of metals, as well as remedial action know‐how, separates TRC staff from the competition. TRC’s range of remediation services includes the following: . Site investigations . Geophysical surveys . Feasibility studies/remedial action plans When TRC created the Exit Strategy Program, The . CERCLA: RI/FS, ARARs review, and RD/RA Wall Street Journal . Risk‐based closures praised it as a “radical . Ecological assessments experiment” to end the “tangle of litigation . Human health risk assessments around U.S. Superfund . Toxicity assessments law.” Today, it is a proven . Turnkey remedial design and construction success with several major projects completed and . Brownfield redevelopment over 40 others under way. . Remediation through natural attenuation . Bioremediation . Sediment remediation . Operations and maintenance of remediation systems . Construction management

Exit Strategy® and Liability Management TRC pioneered the concept of creating and implementing innovative fixed‐price solutions for the resolution of environmental cleanup obligations for individual sites and/or portfolios of properties,

8 Foundry Industry SOQ including brownfi eld sites, distressed assets, bankrupt facilities, discontinued industrial operations, operating assets, and multi‐party Superfund sites. By transferring cleanup liability for a contaminated site (or portfolio of sites) to TRC, clients can reduce costs and expedite site restoration. With Exit Strategy, we guarantee absolute cost certainty, cleanup liability relief, and definition of long‐term financial obligations. Exit Strategy is a flexible program that TRC can tailor to ensure the resolution of our clients’ remediation needs.

Wastewater Treatment and Water Quality It may be necessary for industry to retrofit scrubbers and wastewater equipment to meet the upcoming standards, which will impose more stringent guidelines. TRC's wastewater treatment and water quality services include the following: . Clean Water Act permitting . Construction and operation services . Pilot plant design . Remediation services . Storm water characterization and pollution prevention plan development . Treatability testing . Waste characterization and analysis . Wastewater treatment design

Facility and Process Design Environmentally designed facilities and processes will be a key factor as metals facilities position themselves for tomorrow's competitive markets. TRC's unique expertise in both facility and process design and environmental management allows industry to cost‐effectively prepare for compliance, focus on production, and minimize long‐term involvement in regulatory issues. Our facility and process design capabilities include the following: . Civil, structural, mechanical, electrical, and control system design . Process and facility design . Cost estimating . Process safety management . Fire radiation analysis . Risk analysis . Waste minimization/Pollution prevention

TRC Staff

TRC Staffing and Organization TRC has a long history of providing high‐quality environmental, health, and safety (EHS) compliance, sustainability, and transactional consulting services to the Foundry Industry. Our staff of over 5,000 professionals are uniquely qualified to understanding your business processes and objectives, and to creating solutions that match innovation with practicality.

The TRC staff highlighted below have extensive foundry experience. Copies of their resumes are available upon request.

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Michael J. Amstadt, P.E. A Principal Project Manager in TRC’s Madison office, Mr. Amstadt has nearly 30 years of experience of permitting, design, and construction experience with solid waste management, environmental, and remediation projects. His experience includes technical coordinator, lead engineer, designer, and project/client manager. He is a register PE in sixteen states and knows how to work across states. Mr. Amstadt has also served as the department manager for our solid waste management team, providing leadership for project managers and mentoring junior staff. Mike is an experienced project and client manager and has served as the client manager for multiple larger accounts. As client manager, he coordinates all of the project work for these clients, managing project teams and budgets and making sure that client needs, and expectations are understood and met. Examples include General Motors Company, Dalton, Waupaca, Waste Management, Enbridge, and Norfolk Southern.

Howard J. Zwirn, J.D. A Senior Project Manager in TRC’s Chicago office, Mr. Zwirn is responsible for leading transactional due diligence; EHS compliance; auditing; and management system implementation projects. His experience includes ten years working in manufacturing and eight years in environmental consulting. Projects have been conducted in 40 of the United States and in 20 countries around the world.

Robert C. Scholz, P.E. Mr. Scholz has over 40 years of experience in air pollution control engineering, industrial ventilation engineering, and industrial hygiene. These projects involved many manufacturing areas, with a focus on the foundry industry and ventilation control of hot processes. In recent years, his focus turned more to minimizing ventilation energy consumption while satisfying regulatory air requirements. The Environmental, Safety, and Health Division of the American Foundry Society (AFS) recognized Bob with the prestigious Loebler‐Childress Lifetime Service Award.

Martin J. Stromberger, P.E. Mr. Stromberger has over 30 years of experience in environmental engineering and regulatory affairs at a range of foundries and smelters. He focuses on air quality permitting and air pollution control, odor assessments, and regulatory liaison activities, using his in‐depth understanding of foundry operations to advocate for the best regulatory outcomes for foundry clients.

Melissa Hart Ms. Hart has over 30 years of experience in private industry and consulting. Her focus is on air permitting and regulatory compliance, Emergency Planning and Community Right‐to‐Know Act (EPCRA) reporting and auditing, due diligence, civil penalty calculations, compliance with Homeland Security Chemical Facility Anti‐Terrorism Standards (CFATS), and air regulatory and legislative policy development. Ms. Hart has provided environmental support for numerous foundries and iron and steel manufacturing facilities, including permitting at one of the largest smelters in the U.S.

Stephen B. Ellingson, Ph.D., CGWP Dr. Ellingson has over 30 years of experience working in environmental consulting, for private industry and for a state regulatory agency. He has a strong value‐creation focus, is highly successful at integrating technical/compliance opportunities into cost‐effective business solutions, and excels at bringing together diverse stakeholders to build sustainable solutions for new and challenging issues. He has directed investigations, risk assessments, and remedial actions at a range of foundries, smelters, and iron and steel manufacturing facilities.

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Domestic Project Experience TRC has over 140 offices across the U.S. These offices are well aligned with many of our client’s facilities. This close proximity results in quick response times for local TRC staff and low or no travel costs to reach these facilities. Finally, these near‐by TRC staff have a wealth of local regulatory knowledge and strong working relationships with the regulatory agencies.

Global Project Experience TRC delivers consistent and high‐quality services to global clients throughout the world. Because we believe local regulatory knowledge is critical to project success, TRC has established a Global Partner Network, aligning ourselves with local subject matter experts around the world. We are able to quickly assemble the most qualified team to assist you by combining our domestic project managers with in‐country experts. Through TRC's global strategy, our multinational clients are able to: . Gain cost‐effective access to our extended network of highly qualified professionals with technical fluency in multiple languages, in‐country experience, and a global perspective. . Learn applicable legislation, regulatory practices, business culture, and country‐specific political and social circumstances—and how these factors impact global programs. . Rapidly achieve improved performance and measurable business results.

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Representative Client List Iron and Steel Foundries D&L Foundry and Supply Rexroth Corp Aarrowcast Inc Dalton Foundries Inc ITT Industries Inc Accurate Castings Inc Dana Corp Jahn Foundry Corp Accurate Specialties Inc Decatur Foundry Inc John Deere Foundry ‐ Waterloo Acme Foundry Inc DeZURIK Johnstown Corp Advanced Cast Products Inc Durametal Corp Kirsh Foundry Inc AFK Corp East Jordan Iron Works Kramer International Inc Ahlstrom Pumps LLC EBAA Iron Inc Kurdziel Industries Inc Alexander City Casting Co ECS Corp Lake City Forge Allied Products Corp Eljer Manufacturing Inc Lake Shore Inc AlliedSignal Automotive Eljer Plumbingware Lemfco Foundry Inc American Foundry Society Esco Corp Lodge Manufacturing Co American Roller Co Excelsior Foundry Co Inc Lyons Iron Castings American Steel Foundries Falk Corp (The) Madison‐Kipp Corp Arneson Foundry Inc Ferro Corp Magottaeux Atchison Casting Corp Flowserve Corp Manitowoc Grey Iron Foundry Baker Manufacturing Co Ford Motor Co Mansfield Foundry Corp Beloit Corp Foundry Systems International Margate Industries Inc Beloit/J&L Product Center G&C Foundry Maynard Steel Castings Co Benton Foundry Inc General Casting Co McWane Brainerd Industries Georgia Iron Works Industries Inc Micron Technologies Inc Briggs & Stratton Corp Globe Iron Foundry Inc Mid‐City Foundry Co Brillion Iron Works Inc GMC Powertrain Group Midwest Metallurgical Laboratory Buck Co (The) GMD Engineered Systems Inc Milwaukee Malleable & Grey Iron Works Buckeye Steel Castings Co GNB Technologies Inc Mueller Co Burnham Corp Foundry Div Golden Castings Murray Machinery Inc Calhoun Foundry Co Inc Great Lakes Castings Corp NACO Inc California Cast Metals Association Grede Foundries Inc National Castings Inc Case Corp Grede‐Pryor Inc Navistar International Transportation Cast Metals Services Inc Griffin Pipe Products Co Neenah Foundry Co Castalloy Corp Gulf Coast Machine & Supply Co New Haven Foundry Cast‐Fab Technologies Inc Gunite Corp NIBCO Inc Caterpillar Inc Hale Products Inc Noblesville Casting Inc Champion Steel Co Harrison Steel Casting Co Ohio Aluminum Industries Inc Charlotte Pipe & Foundry Co Harvard Industries Inc Ohio Cast Metals Association Chicago‐Dubuque Foundry Hayes Lemmerz International Ohio Cast Products Inc Chrysler Corp Hiler Industries Oldenburg Group Companies (The) Citation Corp Hitachi Magnetics Corp Osco Industries Inc Clow Water Systems Co Honda Anna Engine Plant OZ Gedney Co CMI Cadillac Inc Illinois Cast Metals Association Pearce Foundry West Inc CMI Cast Parts Inc Integra Castings USA Pearle Pump Supply Inc Col‐Pump Co Inc Intermet Foundries Inc Pelton Casteel Inc Commercial Intertech Corp Ironton Iron Inc PREDCO Inc

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Representative Client List Quakertown Foundry Nonferrous Foundries Schlumberger Ltd Quality Castings Corp AE Goetze North America Sall‐Eclipse Inc Quanex Corp American Precision Castings Inc Sloan Valve Co Richland Center Foundry Co Ampco Metal Inc Speakman Co Rockwell Automation Barry Bronze Co Tool Products Roloff Manufacturing Corp Berntsen Foundry Twin City Die Castings Co Ross Metals Cast Metals Technology United Brass Works Inc SanCast Inc Castalloy Corp US Filter/Castalloy Inc Sandusky International Inc Celina Aluminum Precision Technology Wisconsin Precision Casting Corp Sawbrook Steel Casting Co (The) CMI Precision Mold Inc Wolverine Brass Inc Shelmet Precision Casting Co Colonial Guild Ltd York Group Inc SKF USA Inc Country Cast Products Yotec SMI Steel Cryovac Div Scrap Sparta Manufacturing Co ECK Industries Inc Connell Limited Partnership St Marys Foundry Inc Eljer Manufacturing Inc General Iron Industries Inc Sterling Castings Corp Elkhart Brass Manufacturing Co Jackson Iron & Metal Co Stockham Valves & Fittings Inc Evans Rule Co Inc Louisville Scrap Materials Supreme Casting Inc Federal‐Mogul Corp Luria Brothers T & B Foundry Co Fresno Valve & Castings M&M Metals International Inc Tamsa Foundry Ford Meter Box Oy AEM Technocast Inc General Aluminum Manufacturing Co Steel Texas Steel Co Inc Gibbs‐Texas Die Casting Corp American Steel Foundries Transmission Technologies Corp Globe Valve Corp AmeriSteel Tree Island Industries Gorham Bronze Bayou Steel Corp Tyler Pipe Indiana Precision Technology Inc Bethlehem Steel Corp Urick Foundry Co Intermet Foundries Inc Buckeye Steel Castings Co US Filter/Castalloy Inc Inverness Castings Group Inc Callahan Steel US Lock & Hardware Kohler Castalloy, Inc US Pipe & Foundry Co Lakeland Mold Co Chaparral Steel Vermont Castings Inc Le Sueur Inc Charter Steel Viking Pump Inc M&M Metals International Inc Columbus Steel Castings Co Wagner Castings Co Milwaukee Valve Co Edgewater Steel Washburn Iron Works Niagara Bronze Ltd Fisher Cast Steel Waunakee Alloy Casting Corp NIBCO Inc Florida Steel Corp Waupaca Foundry Northern Diecast Corp Franklin Steel Co Weil‐McLain Ohio Aluminum Industries Inc Georgetown Steel Corp Wheland Foundry Pearle Pump Supply Inc Gerdau Ameristeel Wisconsin Cast Metals Association Precision Basic Industries GST Steel Co Wisconsin Centrifugal Inc Ravenna Aluminum Industries Inc Harrison Steel Wisconsin Investcast Ryobi Die Casting USA Xenia Foundry & Machine Co

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Representative Client List Inland Steel Smelting Macalloy Corp IPSCO Steel AEM Ltd Outokumpu Copper Kenosha Inc Kentucky Electric Steel, Inc American Chrome & Chemicals Inc Oy Aem Kenwal Steel Corp Ampco Metal Inc Pechiney Rolled Products LLC Keystone Steel & Wire Co Carolmet Inc Phelps Dodge Magnet Wire Co LTV Steel Corp CDS Precise Hard Chrome Maynard Steel Castings Corp Century Aluminum Co Precision Basic Industries Missouri Steel Co Doe Run Co Progressive Metal Recyclers National Castings, Inc Eckhart Aluminum LP Ravenna Aluminum Industries Inc Nucor Steel ECS Corp Ravenswood Aluminum Corp Sawbrook Steel Castings Co Edw C Levy Co Recycling Industries of Wisconsin SMI Steel Elementis Chromium LP Refined Metals Corp Structural Metals Inc Encycle/Texas Inc RSR Corp Superior Forge and Steel Corp Gaston Copper Recycling Corp Southwire Co Tamco Steel GNB Technologies Inc Sulpaco West Texas Steel Partners, Inc Horsehead Resource Development Co US Reduction Co Trico Steel Co Johnson Controls Inc Vulcan Lead Products Co Inc TXI (Chaparral Steel) Kobe Copper Products Wabash Alloys US Steel Inc Lone Star Lead Construction Zinc Corporation of America USS/Kobe Steel Co Wausau Steel

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Project Experience

Air Pollution Control Client/Location Project Description

Cast Iron Foundry ‐ WI PSD Permit and Air Toxics Assisted in the preparation of a Prevention of Significant Deterioration (PSD) permit application and supporting materials. Conducted an ambient air quality impact analysis for ozone and a Best Available Control Technology (BACT) analysis for VOC capture and control systems, and prepared the final permit application for submittal to the state regulatory agency. The permit was approved without any additional pollution control investment. Also estimated the actual and allowable emission rates of air contaminants from three of their facilities. Reviewed available production data, material safety data sheet information, material usage data, and stack test results. Identified substances regulated under state air toxics regulations and estimated actual and allowable emissions from the following sources: cupola melting, mold pouring and cooling, casting shakeout, casting cleaning and finishing, core making, and other foundry processes. TRC prepared the plan to achieve compliance with the state air toxics regulation and represented the foundry in liaison with the regulatory agency.

Steel Mill Facility ‐ SC Particulate Matter Study Assisted the client with obtaining regulatory approval to increase the billet production at the facility. Conducted a study to determine the overall particulate matter (PM) emission rate, both point‐source and fugitive. Evaluated fugitive dust pick‐up equipment, baghouse capacity, volumetric flow rate, and operational considerations. Also evaluated lime‐handling systems, scrap pile operation and management, slag pile operation and management, screening operations, and all of the traffic pattern, paving, water truck, and chemical treatment programs. The study showed that the client could increase their overall billet steel production rate by 25 percent. The study also demonstrated that major process improvements and management techniques have resulted in a 17 percent net reduction in the facility PM emission rate at the increased production level. As a result, the regulatory agency granted the requested increase in billet production.

Nonferrous Foundry ‐ IN Multi‐Facility Air Emission Inventories, Title V Operating Permit Applications Client operates secondary aluminum smelting facilities in 11 locations throughout the U.S. TRC has provided air permitting assistance at nine of these facilities. Main processes include scrap drying, crushing, aluminum melting, demagging, degassing and fluxing, pouring and cooling of ingots and sows, ladle heating, and dross cooling and processing. TRC's first assignment was to prepare detailed air emission inventories with a regulatory analysis to assist the client in its Title V strategy. Following the inventory, TRC was retained to prepare the Operating Permit Application for applicable facilities required under Title V of the federal Clean Air Act Amendments of 1990. In addition, TRC conducted additional services to address items of concern identified in the Air Emission Inventory Reports. All permit applications were prepared and submitted prior to their respective deadlines. (#2195)

Ductile Iron Foundry ‐ OK Title V Operating Permit Application Developed an emission inventory in preparation for a Title V Operating Permit application. Estimated

historical emissions as well as projected emissions; prepared process and material flow diagrams; and identified appropriate monitoring, record keeping, and reporting procedures. Prepared a report summarizing estimated plant‐wide and process‐by‐process emission estimates for criteria and hazardous air pollutants with supporting documentation. The client will use the emission estimates and TRC's regulatory analysis to prepare their Title V permit application.

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Client/Location Project Description

Metal‐Finishing Facility ‐ Dispersion Modeling SC Investigated the impact of nitric and phosphoric acid bath emissions on the ambient fluoride monitors. Used Gaussian dispersion models to verify the location of ambient fluoride monitors and a

meteorological station. Installed, calibrated, and maintained the monitoring network for 1 year. Also performed building downwash studies using weather balloons and flares to verify the dispersion model results. Tested process emissions in the field and in TRC's laboratory to determine the impact on the fluoride ambient monitors. Concluded that the physical layout of the facility increases the fluoride impact at the monitoring site and that the scrubber exhaust stack height should be increased for maximum dispersion.

Small Engine Air Quality Services Manufacturer ‐ WI Provided a number of air quality services for this facility, which includes a grey iron foundry, a lost foam foundry, an aluminum die casting operation, heat treating and plating, and final assembly and

painting. Conducted source testing for air toxics for the lost foam casting line, and acted as regulatory liaison with the Wisconsin Department of Natural Resources concerning remedial actions to comply with air toxic emission limits. TRC prepared a compliance plan, and the client submitted it to the Wisconsin Department of Natural Resources describing plans to achieve compliance with the state air toxics regulation.

Ductile and Malleable Title I VOC RACT Plan Iron Foundry ‐ PA Prepared a VOC RACT Plan in accordance with Clean Air Act Title I requirements. Performed a plant survey of emission sources and determined VOC emissions. The survey included the identification

and quantification of all emission sources. Survey findings indicated that the facility was a “major source” as defined by the Clean Air Act. Reviewed applicable emission control technologies and their associated costs. Prepared a RACT proposal for submittal to state and federal regulatory agencies, which included recommendations for the most cost‐effective control technologies. The RACT Plan was completed under budget and within the scheduled time frame. The client was able to rely on TRC staff to interpret the dynamic regulations, recommend appropriate technologies, and thereby minimize the client's involvement in nonproduction issues.

Solid Waste Management Client/Location Project Description

Automotive Brake Shoe Asbestos Landfill Design, Permitting, Expansion, Closure/Post‐Closure Plans, and Remedial Action Manufacturer ‐ TN This client owns and operates an off‐site Class II industrial landfill for the disposal of waste friction materials, including asbestos wastes. The disposal facility (Phase I) was originally designed by TRC in 1981 and included a clay‐type liner for leachate migration control. Phases II and III were in use, but would need to be closed in the future according to new regulations for disposal facilities built under previous standards. TRC was retained to design a landfill expansion (Phase IV) consistent with the new solid waste regulations, which cost‐effectively utilized in‐place structures and maximized current disposal practices. TRC also provided remedial action and permitting services, and prepared a closure plan and schedules for the active landfill. (#436)

16 Foundry Industry SOQ

Client/Location Project Description

Grey Iron Foundry ‐ AL Landfill Vertical Expansion Designed a phased vertical expansion of an existing 20‐acre landfill considering waste characteristics,

slope stability, and general site conditions. The vertical expansion will provide approximately 24 years of additional capacity for waste disposal. The design included adherence to current regulatory permit requirements; horizontal expansion of the existing landfill boundary, including successful permitting to fill a small isolated wetlands area; and vertical expansion and a final cap consisting of waste material, including a final cover of select foundry waste sand and topsoil. Also outlined landfill operating procedures, on the basis of waste characteristics and current regulatory requirements.

Battery Manufacturer ‐ Surface Impoundment Characterization and Closure TN The client disposed of waste electrolytic manganese dioxide sludge, a major component of dry storage batteries, in on‐site surface impoundments. This practice ended in 1983 when the client

began sending the waste sludge to a sanitary landfill. TRC was retained by the client and the client's legal counsel to characterize the waste sludge material in the impoundments using the Toxicity Characteristic Leaching Procedure (TCLP) and to observe and document closure. Results indicated that the sludge is classified as nonhazardous and is consistent in chemical composition throughout the impoundments. A detailed impoundment closure plan was developed, submitted to Tennessee regulators, and approved for field implementation. The closure was completed by TRC to the State's satisfaction. (#733)

Iron Foundry ‐ WI Comprehensive Landfill Services and Constructive Reuse of Foundry Sand Provided comprehensive solid waste management services, including waste characterization and analysis, landfill siting, landfill design, landfill permitting, groundwater monitoring system design, operating plan development, regulatory liaison, construction document preparation, and on‐site observation and documentation of construction. The client is using the landfill as permitted; and TRC continues to assist the client with long‐term groundwater monitoring, regulatory liaison, and other services as needed. TRC also assisted the client in obtaining a constructive reuse variance from the Wisconsin Department of Natural Resources to substitute foundry sand for clay and topsoil as final capping material.

Grey and Nodular Iron Landfill Horizontal Expansion Foundry ‐ OH Designed a 26‐acre horizontal expansion coupled with a 64‐acre vertical expansion constructed over an existing on‐site 130‐acre disposal area. Over 350,000 cubic yards of waste are disposed in the facility every year. A new clay‐lined cell was successfully constructed over existing sludge deposits on a fast‐track schedule. The new cell provided additional disposal capacity while the permit application preparation and negotiations continued. Currently preparing final revisions to the permit application documents for a vertical and horizontal expansion that will gain 30 years of disposal capacity. The site expansion is designed to maximize the beneficial use of waste materials, which will result in substantial cost savings over having to bring materials from off‐site for berm construction and drainage layers, and to bring in clay for cover.

Nonferrous Foundry ‐ TN Landfill Site Suitability Study and Hydrogeologic Investigation The client located a new foundry plant site in Tennessee and contracted TRC to assist in evaluating a

site for development of a landfill to support the new plant. TRC provided a phased approach to investigate the site for suitability for landfill development prior to developing the hydrogeologic investigation portion of the Part II permit application. The hydrogeologic investigation portion of the Tennessee Part II permit application was submitted and determined to be a complete permit application. (#70820)

17 Foundry Industry SOQ

Client/Location Project Description

Secondary Aluminum Landfill Closure and Landfill Design Melting Facility ‐ IN Assisted with the closure of an existing solid waste landfill, including construction observation and documentation, preparation of plans and specifications, and industrial hygiene air monitoring.

Performed a hydrogeologic investigation of groundwater impacts and are currently preparing a remediation workplan with the proposed solution centered on natural attenuation and long‐term monitoring.

Also developed a new 24‐acre industrial landfill for process waste disposal with a life of 12 years. Evaluated compliance with local zoning rules and state regulations, and performed a waste characterization and analysis and a subsurface investigation. Landfill design included a clay and geomembrane double‐composite liner and a passive gas collection and venting system in the cap. Performed clay liner and geomembrane compatibility studies using hydraulic conductivity tests to determine the impact of exposure to synthetic leachate generated from the waste. Prepared new landfill operating procedures and evaluated landfill slope stability using geotechnical stability computer programs. Prepared landfill construction plans and served as agent for client to construct and close Phase I, and construct Phase II. Providing assistance to maximize efficiency of landfill operation. Conducted certification training for client’s landfill operation.

Ductile and Grey Iron Landfill Design and Construction Foundry ‐ WI Provided comprehensive landfill services for the construction of a new foundry waste landfill. Services included site selection/ documentation, landfill design, wetland management, regulatory

liaison, and construction services. Construction services included preparation of plans and specifications, bid review and assistance, full‐time construction observation, and submittal of a construction documentation report to the regulatory agency. Also held public meetings and managed the complicated permitting process. The landfill was successfully permitted and constructed according to the schedule.

Grey Iron Foundry ‐ MI Landfill Closure Designed a closure plan to cap a 20‐acre foundry waste landfill under Michigan Acts 641 and 307.

Services included waste characterization and analysis of nineteen waste streams, treatability studies, waste treatment, geophysical analysis, groundwater monitoring, and design of the cap and runoff controls. Demonstrated through waste testing that inert waste materials from the foundry could be used as capping material. This work will allow the client to extend the landfill life by 2 years and will eliminate the need to dig and haul the waste at a cost of $30 million. Used TRC's proprietary treatment process for stabilizing lead‐impacted wastes and rendering them nonhazardous. This treatment process saved the client approximately $200/yard in hazardous waste disposal costs. Performed regulatory liaison services during intense negotiations with the Michigan Department of Natural Resources and the USEPA.

Secondary Aluminum Landfill Feasibility Study Recycling Facility ‐ Performed a landfill feasibility study to identify the best possible location for a nonhazardous solid Midwest, Multi‐State waste landfill with a 30‐year disposal capacity. Investigations covered a seven‐state area and Area included a permitability evaluation for each state, regulatory review, regional siting studies, and an analysis of suitable land parcels within targeted areas. TRC prepared a summary of the study results,

including recommendations, to expedite the client's decision‐making process.

18 Foundry Industry SOQ

HAZARDOUS WASTE MANAGEMENT Client/Location Project Description

Allied Products Corp., Remedial Design, Remedial Action for an NPL Site White New Idea (Grey A former sand and gravel quarry was used for over ten years as a disposal site for foundry wastes. In Iron Foundry) ‐ IA 1988 the USEPA conducted a preliminary assessment and seceded in 1990 to place the site on the National Priorities List (NPL). The Remedial Investigation / Feasibility Study performed on this site identified benzene and lead contamination, which posed risks for ingestion of contaminated groundwater and direct contact with the landfill material. Faced with a projected cost of $2 million to cover the foundry landfill, TRC was retained to provide and effective and economical cover solution. TRC conducted a very limited investigation of the site, which showed that the foundry materials were relatively impermeable and potentially suitable for use in construction of a final cover. Also, TRC found that the single hit of benzene in the groundwater was not due to the foundry materials and was not present beyond the boundary of waste disposal. As a result of these findings, TRC was able to negotiate a change to the Record of Decision (ROD) that allowed select foundry process materials to be used to cover the landfill and was successful in convincing the agency that not groundwater pump and treat system would need to be installed to protect groundwater. The foundry sand cap was never installed because the foundry ceased operations prior to implementation of the remedy. However, the changes negotiated successfully by TRC helped save the client over $1 million as compared with the cost of implementation of the original ROD.

Secondary Aluminum RCRA Closure Melting Facility ‐ OH Observed and documented the RCRA closure of a concrete pad used as a temporary storage area for dust from a rotary kiln. Remained on‐site for the duration of closure activities, which included the

removal and disposal of 2,100 tons of waste, decontamination of the concrete pad, and soil sampling. The primary contaminants of concern were lead and cadmium. Prepared a detailed report documenting the closure. Performed Phase I and II subsurface soil investigations to determine if any hazardous constituents had been released from the waste pile. Performed a neutron activation analysis with University of Wisconsin‐Madison nuclear reactors to show that certain constituents found in soil samples were not present in the waste pile and, therefore, most likely came from old waste disposed on‐site by a previous owner.

Automotive Parts Closure of RCRA Hazardous Waste Management Units Foundry ‐ Midwest TRC acted as the client’s agent to perform in‐situ treatment of approximately 69,000 cubic yards of cadmium‐ and lead‐contaminated waste that were present in several RCRA hazardous waste units,

according to the approved closure plan. An additional 16,000 cubic yards of impacted, but nonhazardous, soil were also excavated. The waste also contained low levels of oils and PCBs. The treated waste and the impacted material from the RCRA hazardous waste units were excavated and placed on the existing on‐site landfill, which was then capped and closed. TRC also prepared a clean closure documentation report for the former RCRA units, and a landfill closure construction documentation report. The use of TRC’s innovative heavy metals treatment additives for in‐situ treatment of the waste and on‐site disposal saved the client the considerable expenses of transporting and disposing the waste off‐site, and eliminated the liability associated with disposing hazardous waste off‐site. TRC successfully negotiated for beneficial reuse of foundry slag to fill the area left by the excavation, and saved the client $100,000. Overall, TRC saved the client more than $1 million. The area previously occupied with waste piles is now an attractive lawn. (#1468)

19 Foundry Industry SOQ

Client/Location Project Description

Brass Foundry ‐ IN Waste Characterization and Analysis and Waste Minimization/Treatment Analyzed waste streams and evaluated the technical and economic feasibility of alternative waste

management procedures. Sampling and analysis of waste generation sources indicated that certain wastes were nonhazardous and could be disposed in a solid waste landfill. This reduced long‐term liability and disposal costs for the client.

After evaluating alternative treatment options for the remaining hazardous waste, TRC determined that a combination of waste treatment and sand reclamation was the best overall waste management alternative for the client. Found that the waste could be treated and rendered nonhazardous with the addition of a treatment material. Also worked with the client and equipment vendors to identify appropriate sand reclamation equipment to recycle waste process molding and core sand. TRC assisted the client in obtaining regulatory approval to construct and operate the exempted treatment/reclamation system that had less than a 2‐year payback, and further reduced the client's long‐term liability and disposal costs. As a result of the research in waste treatment methods, TRC received an Engineering Excellence Award from the American Council of Engineering Companies‐Wisconsin.

Machining Facility ‐ OH Equipment Decontamination and Removal The client retained TRC to remove and decontaminate a TCE degreaser tank during a weekend, so as

not to interfere with plant production. Developed specifications for removal and decontamination of a TCE degreaser tank approximately 40 feet long by 20 feet wide. During the removal, TRC provided on‐site coordination and documentation that the tank was clean. The scrap was cut up and sorted in various roll‐offs (i.e., stainless steel, mild steel). TRC successfully removed and decontaminated the degreaser tank without any interference to plant production at half of the client's anticipated cost.

Iron and Steel Foundry ‐ Waste Characterization and Analysis, Waste Minimization, and Hazardous Waste Lagoon Closure MN Worked with the client to identify and remove the hazardous constituents in the waste stream, thereby rendering the stream nonhazardous and reducing the client's long‐term liability and disposal costs. Accomplished this by evaluating the foundry's process waste using both USEPA EP‐Toxicity and ASTM water tests. The tests were performed to assess whether any of the wastes met the characteristics of a hazardous waste and also to determine characteristics of the nonhazardous wastes.

Also investigated the existing lagoon that had accepted the client's hazardous waste, and assessed environmental effects using a waste sampling and groundwater monitoring program. Because the lagoon contained hazardous waste, the client was required to submit a closure plan for the facility under USEPA interim status guidelines. TRC prepared plans and specifications for the closure of the lagoon, and the MPCA approved the closure plan. Closure activities were completed on schedule. In addition, incorporated the closed lagoon into a closure plan for the surrounding landfill with the final site being used as a city park. Residential housing around the landfill is booming, with extensive use of the park's baseball and soccer fields.

20 Foundry Industry SOQ

Client/Location Project Description

Electroplating Facility ‐ Clean Closure TX Negotiated standards with the Texas Water Commission to be used to identify hazardous wastes in the facility's landfill during closure and remediation. Conducted a preliminary assessment and site

inspection at the facility to develop information for a sampling plan. Sampled and analyzed the new electroplating sludge, and successfully determined that the waste was nonhazardous and amenable to disposal in a municipal landfill. Two waste piles containing old sludge were spread across the project zone to allow representative sampling using a three‐dimensional grid system. The old sludge was characterized as nonhazardous and was disposed in a municipal landfill. Filed a closure plan amendment and received approval from the Texas Water Commission for in‐situ treatment of the cyanides using destructive chlorination under alkaline conditions. This allowed the facility to certify clean closure, thus eliminating the need for post‐closure care.

Grey and Nodular Iron Hazardous Waste Surface Impoundment Remediation Foundry ‐ OH Provided engineering and consulting services to “clean‐close” a RCRA‐regulated, 17.5‐acre basin that contained approximately 300,000 cubic yards of EP‐Toxic sludge. The basin is about one‐third mile long and several hundred feet wide. Collected and analyzed sludge samples from the basin, assisted the client in notifying the agency of the EP‐Toxic sludge and in negotiating a consent agreement for remediation of the sludge, performed bench‐scale treatability testing, developed engineering designs and remediation costs for several treatment options, and designed and developed a closure plan. Prepared plans, specifications, and contract documents. Installed an in‐line wastewater treatment system upstream from the basin to treat incoming solids and successfully prevented the generation of new hazardous sludge during treatment.

The closure plan was approved by the USEPA and the Ohio EPA, and a continuous hydraulic dredging system with in‐line addition of treatment chemicals was successfully developed by TRC and implemented by the client. Sampling results indicate that the clean‐closure performance standards have been satisfied. Closure activities were designed to allow continued use of the basin, which allowed the client to realize savings up to $100 million compared to other remediation and disposal options.

REMEDIATION Client/Location Project Description

Fabricator ‐ OH Facility Demolition As part of this client’s effort to optimize operations at 15 plastics plants, TRC assisted in enhancing

the marketability of an idled plant, while minimizing environmental costs. TRC completed a lump‐ sum demolition and asbestos removal effort that saved the client significant costs through reductions in annual insurance premiums and the elimination of a full‐time site security service. The successful completion of this project also prepared the site for redevelopment. (#4752)

21 Foundry Industry SOQ

Client/Location Project Description

Fabricator ‐ Mideast Remediation and Long‐Term Monitoring for State Superfund Site TCE from an industrial manufacturing operation was discharged to an on‐site septic system. As a result, a significant number of private wells were impacted with varying levels of TCE contamination. TRC was retained by the client to conduct the RD/RA for the site. The remedy for the site included the extension of public water supply to serve all potentially affected residents, the construction of a groundwater extraction and treatment system, the evaluation of remedial measures to clean up the off‐site plume, long‐term groundwater monitoring, and the development of institutional controls. A critical facet of this project was the need to interact with the public in a way that would minimize exposure to the client. The client also requested TRC to assist them in negotiations with a second PRP. As a result of the negotiations, the client will receive 50 percent of the present worth of costs for the complete remedy. The project team completed the final design of a $1.8 million groundwater extraction and treatment system for the site. (#70924)

Ductile Iron Foundry ‐ OH RCRA Corrective Action and RCRA Closure Implemented a RCRA facility investigation of soil, sediment, waste materials, and groundwater at the facility. Workplan and QAPP approvals were obtained from the USEPA, and the RFI report is under review.

Also designed and implemented a RCRA closure plan for a 6‐acre surface impoundment containing 160,000 cubic yards of emission control sludge. Services involved the excavation of hazardous sludge and contaminated underlying soil. A new composite‐lined landfill will be constructed in the excavated area that is to be used for future disposal of sludge and foundry waste. Provided final design and construction assistance.

Iron and Steel Foundry ‐ Waste Removal and Remediation TX This Fort Worth foundry produced ash and other materials that were impounded in an on‐site pit. Developed a method for cleaning the pit and transporting the contaminated ash to a secure landfill.

Developed a program to remediate the site with minimal cost. Removed 6,000 yards of ash from the site, and cleaned approximately 10 acres of property for productive use.

Automotive Parts Groundwater Remediation Foundry ‐ IN Designed and constructed a recovery and treatment system for groundwater containing trichloroethylene (TCE). The site posed unique challenges because the TCE was migrating through

permeable sand and gravel lenses that were contained within a tighter glacial till to depths of 30 feet below grade. Hydrogeologic investigations and evaluations of alternative recovery and treatment methods showed that conventional pumping wells could not effectively recover TCE. TRC developed an innovative “deep trenching” technique for groundwater collection and reduced the volume of contaminated soil cuttings that may have required off‐site management as a hazardous waste. TRC also prepared construction plans and specifications covering civil, electrical, and mechanical components of the work. Managed the construction effort, including subcontracting, field engineering, and start‐up services. The completed system effectively intercepted groundwater flow and reversed hydraulic gradients for up to several hundred feet. Total construction costs for the system were approximately $250,000, and the client realized over $300,000 savings in soil disposal costs.

22 Foundry Industry SOQ

Client/Location Project Description

Battery Manufacturer Waste Treatment and Stabilization and Recycler ‐ IL Treated and stabilized over 30,000 tons of lead‐impacted soil using a combination of ex‐situ and in‐ situ treatment methods. The stabilized soil satisfied the TCLP criteria and the drinking water

standards. Both ex‐situ and in‐situ treatment processes were conducted using TRC's innovative proprietary treatment additive. This allowed the client to realize a 20 to 40 percent cost savings and to minimize the long‐term liability associated with the management of a hazardous waste. The client saved over $500,000 in disposal costs. TRC also constructed a storm water retention berm from stabilized soil, which will prevent storm water from coming on to the site, and which will also allow for potential building expansion.

Battery Manufacturing Groundwater Remediation Facility ‐ WI Designed and implemented a system to remediate contaminated groundwater caused by a sudden release of 3,800 gallons of magnesium perchlorate solution from an aboveground tank that had a transfer pipe break. Installed groundwater monitoring wells and collected groundwater samples to determine the vertical extent of contamination. Installed centrifugal pumps to control the migration of contaminants until a long‐term, full‐scale remedial system could be installed. Performed a remedial options analysis for recovery of the released magnesium perchlorate and found that a large‐ diameter extraction well was suited for product recovery. Negotiated with the state regulatory agency and the city to allow discharge of the contaminated groundwater to the sanitary sewer. Also coordinated a proactive public communication program in conjunction with the client, regulatory agency, media, and local officials. The site was remediated in 14 months, and the regulatory agency approved closure of the remediation system and monitoring wells.

Battery Reclamation Remedial Investigation and Feasibility Study Facility ‐ TX Completed a Remedial Investigation and Feasibility Study (RI/FS) for this site, which was utilized for the reclamation of batteries. The RI identified lead as the only contaminant of concern and

established that the lead contamination was limited to the surficial soil and the sediment associated with off‐site drainage ditches and an off‐site pond. A Baseline Risk Assessment was conducted from the analytical data and identified potential exposure pathways and estimated lead intakes under five exposure scenarios. The Feasibility Study included the identification of 13 potential remedial technologies and over 35 process options. The screening process resulted in six remedial action alternatives that were subjected to a detailed evaluation. These included combinations of treatment technologies, containment technologies, and off‐site disposal. TRC exceeded the client's expectations by performing the project on schedule and under budget.

Brass Foundry ‐ NY Ex‐Situ and In‐Situ Treatment of Lead and Cadmium During 47 years of operation, lead and cadmium from this brass foundry had impacted soil and

sediment surrounding the plant, which included a baseball diamond and park in the area, and an off‐ site ditch that bordered an inactive railroad track. TRC’s investigation convinced the NYSDEC that contaminants were limited to lead and cadmium, and that groundwater was not affected. This reduced costs for subsequent investigations. TRC managed all remediation activities and the disposal of impacted soil and sediment. (#2778)

23 Foundry Industry SOQ

Client/Location Project Description

Aluminum Manufacturer Sediment Evaluation ‐ TX Evaluated the impact of dredging and disposal activities of mercury‐contaminated sediment from the client's industrial shipping canal. Reviewed data collected by the Texas Water Commission, the Texas

Department of Health, and the client to establish statistical trends. Also analyzed the data for bioavailability, sediment distribution, pathways of movement between trophic levels, and evidence of bioaccumulation in the ecosystem. Analysis indicated that dredging and deposition of the sediment on the island effectively removed the mercury from the ecosystem. Therefore, the client could continue dredging activities and avoid any interruptions in production.

Automotive Parts Facility In‐Situ Treatment of Chromium‐Impacted Soil ‐ Midwest The client operated a chromium plating facility from the early 1940s to the early 1990s. During this period, leaks from various processes in the plant permeated the plant floor and reached underlying

soil. Significant groundwater contamination resulted. The impacted groundwater was recovered via several pumping wells designed to contain the plume of chromium‐impacted groundwater on the site. The recovered groundwater was treated using an ion exchange system. The regenerant from the ion exchange system is a liquid containing high concentrations of chromium, which must be disposed as a hazardous waste at a significant cost. The client retained TRC to chemically remediate the impacted soil that was the source of the groundwater impacts. The client will realize cost savings of approximately $100,000 per year once the ion exchange system is decommissioned, and will be able to make real‐time decisions regarding the investigation through use of the field‐screening. By using the technical assessments and the in‐situ treatment/ stabilization process, TRC was able to negotiate a corrective action plan that reduced overall remediation costs by $500,000 compared to traditional excavation (dig and haul) alternatives. (#80089)

Metal Stamping Facility ‐ Remedial Investigation/Feasibility Study OH Assessed the nature and extent of a trichloroethene (TCE) spill on a State of Ohio Superfund site. Prepared the workplan to be followed during implementation of the Remedial Investigation and

Feasibility Study. Conducted a Remedial Investigation that was approved by the Ohio EPA, and began work on the Feasibility Study. Recommended pumping groundwater and soil vacuum extraction (SVE) to remediate the site. Performed a SVE Pilot Test to assess the effectiveness of the system. The Remedial Investigation concluded that constituents in groundwater have migrated off‐site. The results of the Baseline Risk Assessment concluded that the site needed to be remediated due to the potential risk posed to human receptors. The Remedial Investigation was approved by the Ohio EPA, and the Feasibility Study was submitted to the agency.

24 Foundry Industry SOQ

Industrial Ventilation Client/Location Project Description

Large Foundry Melting Industrial Hygiene and Ventilation Study Facility ‐ IA Elevated levels of respirable particulate in this facility’s melt area were causing concerns from both the industrial hygiene and business perspectives. Although silica was the primary problem, the melting area produced respirable particulate from a variety of sources and in several forms, including dust, fume, smoke, and possibly mist. After identifying a solution that required building a floor to ceiling wall for the full length of the melt oven to separate various sources areas, facility managers still could not confidently predict that it would work. Relying on TRC’s unique ability to provide a model that would accurately predict system performance, facility managers asked TRC to proceed with a four‐ phase program. It would include reviewing available data, developing an approach to completing an emission source assessment, identifying and evaluating control alternatives, and demonstrating through modeling or simulation that the recommended approach would work. As a result of TRC’s analyses, it was determined that physical barriers, such as the wall that was originally proposed, would have actually worsened conditions in the facility. (#4422)

Cast Iron Pump Ventilation System Modifications Manufacturer ‐ IA Evaluated the dust collection systems for possible improvements and developed a preliminary opinion of cost to implement the improvements. Observed processes and operations to identify

obvious deficiencies in hood design, and measured airflow rates at selected locations in the exhaust system. Interviewed foundry personnel about the history of the systems, their operating problems, and their future plans for the addition of equipment that may need exhaust ventilation and dust collection. Recommended that a backup system for one of the dust collectors be implemented, so that exhaust air could be recirculated. Compared estimates of exhaust airflow rates with existing airflow rates to determine if projected airflow needs could be met by the existing dust collector capacity or if additional dust collectors were needed. Developed a line drawing that showed modified ductwork routing for suggested modifications to the exhaust ventilation system. In addition, developed a cost estimate to design and install those modifications.

Foundry Addition ‐ Industrial Ventilation Service Canada This foundry produces a variety of highly specialized parts made from various metals, such as beryllium, bronze, brass, stainless steel, and aluminum. A new green sand addition was planned that would increase the production capacity of the foundry significantly. Special care was needed in designing the ventilation systems for the new addition due largely to the presence of beryllium in the foundry operations. Beryllium dust and fume are hazardous from an industrial hygiene viewpoint. TRC designed make‐up air and dust collection systems for the new addition that met OSHA Permissible Exposure Level (PEL) standards for lead and beryllium. The ventilation system design included special features to protect workers from breathing in beryllium and the foundry from discharging unclean emissions. (#4681)

Brass Foundry ‐ IL Ventilation System Design and Industrial Hygiene Survey Performed an industrial hygiene survey, including employee exposure monitoring for lead. Evaluated

the existing ventilation system and designed a new system to reduce employee exposure. Based on the survey results, TRC designed a 50,000‐cfm exhaust ventilation and makeup air system, including exhaust hoods for pouring, shakeout, and cooling processes. System evaluations after installation indicated that employee exposures to lead were less than the OSHA‐Permissible Exposure Limit. By using a computer‐aided design system to calculate system pressure drop, fan pressures, and motor horsepower, TRC was able to substantially reduce the project costs.

25 Foundry Industry SOQ

Client/Location Project Description

Ferrosilicon Production Conceptual Engineering Evaluation and Ventilation Design Facility ‐ WV Prepared a conceptual engineering analysis of the options available to control particulate emissions generated by repouring operations and high‐purity ferro‐silicon casting. In addition, developed a conceptual plan for a ventilation system to control emissions. Reviewed the existing information on particulate emission sources at the facility, conducted a site visit to observe processes and operations, review the physical layout of the production area, and interview plant personnel. Prepared and submitted a report providing the results of the study and incorporating the outputs of the conceptual planning work, including preliminary conceptual ductwork and hood configuration drawings, exhaust airflow rates, and opinions‐of‐cost. Continue to assist this client by preparing final plans and construction specifications for a ventilation system to control particulate emissions from repouring operations. Will provide ongoing assistance to the client during construction of the above‐ mentioned system and during final design and construction of a second repouring ventilation system and a ventilation system to serve the high‐purity silicon casting area.

Battery Manufacturer ‐ Ventilation System Design Mexico This client wanted to redesign an existing building make‐up air ventilation system, and to design new lead‐acid battery manufacturing process exhaust systems to be installed within the existing building. The systems had to meet stringent indoor worker health standards and community air emission standards. TRC provided detailed design services for multiple systems. TRC also provided construction management assistance to the client and to their local construction teams. The ventilation system designs have been successfully implemented, and the new production facility is in full operation. (#3351)

Ferrous Foundry ‐ WI Industrial Ventilation Services TRC was contracted to provide ventilation engineering design and bid specifications covering four areas of the facility. In the bronze foundry, TRC designed and prototyped a mobile push‐pull furnace hood for a lead‐bronze melting operation. Special consideration had to be given to clearances required for charging and slagging operations, and fume capture through the full 95‐degree tilt of the furnace during tapping and slagging. Maintenance access to all furnace components needed to be ensured as well. The added challenge to this project centered on the fact that designs for all four project elements were produced simultaneously. This program provides testimony to the diversity and complexity of projects handled by TRC’s ventilation design team. (#3019)

Brass Foundry ‐ IN Design, Construction Observation, and Startup for a New Melting Operation Ventilation System This client produces brass parts for the automotive and electronics industries from coil stock. A new facility will supply these two plants with the coiled brass raw material. This new plant was designed initially with two production lines, each consisting of a melting furnace, holding furnace, and coil processing equipment. The facility will eventually be expanded to contain eight complete lines. The melting and slagging operations from the two new lines were to be ventilated to a spark arrestor and a pair of baghouses. It was critical that the design allow the baghouses to be maintained without interruption to the process operations. TRC’s ventilation engineering assistance included mechanical design, bidding assistance, construction management, and startup for the new melting department ventilation system. The project enabled the client to run the new production lines without interruption during baghouse maintenance activities. The system has met permitted particulate emission requirements and performs very well in capturing fumes from the melting furnaces, holding furnaces, and slagging operations. (#4185)

26 Foundry Industry SOQ

Environmental, Health, and Safety Management Client/Location Project Description

Industrial Pump Environmental Due Diligence Investigation Manufacturer ‐ North TRC was retained by this client to perform a multi‐site environmental due diligence investigation at and South America, 26 sites in Europe, the United Kingdom, North America, and South America as part of an acquisition. United Kingdom, and The investigation was composed of an ESA Phase I and a Limited Compliance Assessment at all 26 Europe sites and a Limited Phase II ESA at 11 of the sites. The facilities were used to produce and repair pumps for all types of industrial applications, including the petrochemical and mining industries, and shipped their products world‐wide. TRC was selected for this work because of our knowledge of environmental regulations, and of the foundry, metal fabricating, and machining industry, and because of TRC’s experience in international investigations and in interacting with regulators on the behalf of clients. The investigation report for each site presented the Recognized Environmental Conditions (REC) and Compliance issues. TRC proceeded to provide the client with a cost estimate for remediating the significant RECs and addressing the compliance issues. The client was able to use this information to negotiate the final purchase price. (#2139)

International ISO 14001 Implementation at Multiple Sites Manufacturer of Roller This client needed to mobilize quickly when its parent company mandated that ISO 14001 processes Bearings and Seals ‐ NY be implemented and certified immediately. With 18 manufacturing facilities, a technical center, and four warehouses in the U.S. developing and documenting the 17 different elements covered within

an ISO 14001 certified system posed a challenge. Since the company would be applying for “group” certification, the ISO 14001 registrar would select several facilities randomly for audit. If any of the audited facilities failed the audit, the entire company would be denied ISO 14001 certification. When management determined they simply did not have the staff time or resources needed to accomplish the goal within the time available, TRC was asked to assist staff with self‐assessments, preparing procedures and work instructions, and documenting the Environmental Management Systems at facilities. The client achieved ISO 14001 certification within the specified time frame. (#4436)

Steel Foundry ‐ WI Managing Day‐to‐Day Compliance This client’s management team set out to improve the efficiency of environmental compliance

activities at its steel mini‐mill. Tired of dealing with compliance “problems,” the company committed to developing an environmental management system that could meet the ISO 14001 standard and bring value to the company’s bottom line. They asked TRC to assist in designing a system that could do the following: (1) provide for workable day‐to‐day compliance management, (2) reduce long‐term environmental risk, (3) gain third‐party ISO certification, (4) accommodate the client’s corporate culture, and (5) identify ways to increase operational efficiency. TRC developed a custom management system more quickly and for a lower cost than could have been achieved with in‐house staff, allowing the client to maintain focus on important production issues. (#4633)

Nonferrous Foundry ‐ IN Multiple Environmental Compliance Audits The client wanted to acquire six facilities, and needed assistance in evaluating their potential and

actual liability exposure associated with the acquisition. TRC expedited the completion of environmental compliance audits, and Phase I and Phase II environmental site assessments of six secondary aluminum smelting operations located in the United States. A TRC team of 15 senior staff provided the client with a comprehensive assessment of the technical issues as well as a thorough understanding of the financial and business implications associated with the business transaction. (#4704)

27 Foundry Industry SOQ

Client/Location Project Description

Automotive Parts Pre‐Acquisition Site Assessments Manufacturer ‐ TRC was retained to perform pre‐acquisition site assessments for the acquisition of a rubber hose and Southeast gasket manufacturer with multiple manufacturing facilities in the southeastern United States. Based on preliminary findings, TRC was subsequently retained to assist with enrolling the sites in Tennessee’s Voluntary Cleanup Oversight and Assistance Program (VOAP), to investigate the nature and extent of contamination at several of the facilities, and to develop remediation plans and budgetary estimates. None of the manufacturing sites had been investigated by the USEPA or state agencies, nor were the sites listed by these agencies as sites where assessments are desired or scheduled. At the client’s request, TRC presented the investigation findings and conclusions to the appropriate state agencies. TRC also presented proposed actions to remedy contaminated media where remediation was warranted. TRC is implementing remedial actions to be taken by the client where needed. TRC is also coordinating communication between the current and former owners and the state agencies. (#70356)

Nonferrous Foundry ‐ SC Environmental and Safety and Health Services TRC has been providing environmental and safety and health services to this metals client since 1994.

Our services were initially provided to supplement existing staff. For the past 3 years, TRC has essentially provided full services. The plant formerly was a secondary copper refinery performing scrap handling, wire chopping, lead sweating, copper smelting, electrolytic refining of copper, and casting of commercial rod. The finished material is used in wire manufacturing. Accomplishments included completion of air permitting, storm water permit renewal, closure of RCRA units, and potable water system evaluations. TRC essentially provided two full‐time equivalents, but in practice, this was a shared responsibility among up to 10 TRC professionals at any time. (#70022)

Battery Manufacturing Industrial Hygiene Audits Facility ‐ WI Performed a multi‐facility industrial hygiene audit of nine Wisconsin facilities to identify potential employee overexposure areas for air contaminants and noise. Conducted air and noise sampling,

measured airflow rates in exhaust ventilation systems, and recommended corrective actions for improving the performance of the hoods. Reviewed written company programs for hearing conservation and respiratory protection for consistency with OSHA. Also evaluated protective procedures and equipment used by plant personnel. Prepared a written report summarizing test results, findings and conclusions, recommendations, and cost estimates for further improvements.

Metal Casting Facility ‐ Industrial Hygiene and Environmental Audit CA Conducted a comprehensive industrial hygiene audit, including air sampling for organic compounds and metals. Also conducted a comprehensive environmental audit of the facility's operation.

Reviewed applicable environmental regulations, conducted interviews with facility staff, and reviewed files to identify areas of potential noncompliance with applicable regulations. Prepared a comprehensive report that outlined the facility's compliance status and discussed available options to improve environmental management. Findings included the identification of a recycling option for metal‐containing process waste and the selection of a biological off‐gas treatment system for the control of ethanol emissions from the facility. The client implemented measures in response to the audit's findings.

28 Foundry Industry SOQ

Client/Location Project Description

Industrial Pump Industrial Hygiene and Safety Program Manufacturer and Developed a comprehensive industrial hygiene and safety program during construction and startup of Associated Foundry ‐ SC the facility. Developed an industrial hygiene and safety program manual, conducted health and safety training, and conducted personal exposure monitoring to evaluate employee exposures to

chemicals used in those operations and to assess compliance with OSHA. Also assisted with the SARA release reporting. Developed an environmental management manual that includes a facility emergency response plan and a best management practices plan for spill control and management. The environmental plan included the identification of hazardous wastes, disposal plans for solid waste, air permit applications, and wastewater discharge requests. The operating staff are currently using the manual, which includes step‐by‐step instructions to assist in complying with environmental regulations.

Grey Iron Foundry ‐ KS Industrial Hygiene Audit Conducted a plant‐wide industrial hygiene audit, including air sampling for organic compounds and

metals. The audit included a review of MSDSs for chemicals used and a study of employee work habits. Prepared a report that discusses results of all air monitoring, as they relate to the OSHA and ACGIH limits. The client implemented TRC's recommendations for improving airflow patterns in one area, for changing employee work habits, and for improving employee personal protection.

Wastewater Treatment and Water Quality Client/Location Project Description

Battery Recycling Facility Wastewater Treatment System Optimization/Design ‐ CA TRC was retained to optimize the existing wastewater treatment system for treatment cost and performance. Regulatory issues warranted a new location for the system, and a decision was made to expand the existing area. This required transition to a new system while the existing system was still operational. The client retained TRC to perform the conceptual analysis and design and to oversee the detailed design of the $1.5 million system. TRC staff provided oversight for detailed design, permitting assistance, construction oversight, and startup/training. (#90170)

Grey Iron Foundry ‐ IL Wastewater Treatment Plant Modifications This ongoing project involves wastewater treatment modifications to convert a once‐through wet

dust collection system to a recycle system. Conducted a review of an existing waste treatment and dust collection system and made recommendations for system improvements. Preliminary piping design engineering was completed. A pilot plant treatment system was also performed.

Secondary Copper Storm Water Management Collection and Treatment Design Manufacturer ‐ TRC was hired to provide engineering and technical services to provide the client with a storm water Southeast management program for metals discharged in the runoff from the site. TRC evaluated the required level of storm water control and the control options to be used to meet zero‐discharge requirements,

and then provided preliminary design engineering for the construction of the storm water collection system. (#70497)

Metal‐Finishing Facility ‐ Process Engineering and Pumping System Design SC Provided process engineering design, including the piping, pumping, electrical, and instrumentation necessary to convert an existing wastewater lagoon to an automated equalization basin with a 1

million‐gallon capacity. In addition, designed a pumping system to remove the equalized wastewater from the basin and discharge it to a municipal sewer.

29 Foundry Industry SOQ

Client/Location Project Description

Metal Plating Facility ‐ TX Treatment System Design and Materials Flow Optimization This Texas‐based manufacturer of pressure vessels finishes and plates a variety of large industrial

parts. TRC developed a system of continuous treatment of normal wastewaters and batch treatment of specific concentrated wastewaters. In addition, TRC improved the process for removing nickel salts. Worked with the owner to improve the overall management of water within the system as well as optimized the materials flow process.

Metal Finishing Facility – Treatment System Design RI, CT Conducted an in‐plant investigation of all plating and metal‐finishing streams and developed a mass balance of the process. Investigated and defined treatment systems for handling a variety of metals.

The selected process included recycling approximately 50 percent of the water in the initial stage of design. Thereafter, developed treatment of the remaining wastewaters. An additional 50 percent of the remaining water from the wastewater plant could be used for plant purposes. The overall discharge to the local sewer system was reduced to approximately 25 percent of the original flow, with no metals being present above allowable concentrations. Technology employed included ion exchange and precipitation.

Ordnance and System Mass Balance Ammunitions Reviewed a variety of metal finishing operations, most notably a shot tower, where significant Manufacturer ‐ CT quantities of lead were collected. Developed an overall mass balance of the system. Proposed a number of schemes for water reuse and recycling that were ultimately implemented. Developed a

scheme for water reuse through the shot tower.

Battery Recycling Facility Storm Water Pond Treatment/Dewatering ‐ GA TRC was retained to dewater a 1.6 million‐gallon storm water pond for the purpose of installing a liner. Three million gallons of storm water needed to be treated and discharged in a matter of days

to ensure accomplishing the liner installation during the dry season. Three million gallons of storm water was successfully treated and discharged in less than a week while meeting permit conditions. The liner was successfully installed. (#70868)

Metal Plating Facility ‐ Treatment System Design GA Managed the development and design of a waste treatment system that discharged 1 million gallons per day. Activities included a treatability study, process design, detailed design, and the coordination

during construction of a physical/chemical treatment system. Unit processes included hexavalent chrome pretreatment, lime precipitation of metals, sludge dewatering, and disposal.

Galvanizing and Wire Treatment System Design and Construction Facility ‐ GA Engineered/Managed the treatability study, the process design, the construction, and the startup of a facility treating 2 million gallons per day of wire drawing and galvanizing mill wastewater. Activities

included the treatability study, the process design, and the detailed design of a physical/chemical treatment system, including neutralization, caustic precipitation, sludge dewatering, etc. Wastewater was discharged to the City of Atlanta wastewater system.

Battery Manufacturing Wastewater Reuse System/Zero Discharge Facility ‐ MS TRC was retained to eliminate the discharge from a small facility manufacturing raw materials for use in battery manufacturing. The project will result in substantial savings to the client by eliminating the

need for a wastewater treatment system and will provide significant public relations benefits. The system has been approved and sanctioned, and is in the equipment procurement stage. TRC will provided installation and startup services. (#70803)

30 Foundry Industry SOQ

Client/Location Project Description

Wire Extruding Facility ‐ Treatment System Design and Construction RI Engineered/Managed the treatability, the process design, and the detailed design of a wastewater treatment system that discharged 1 million gallons per day. The system consisted of neutralization

and primary settling and included oily waste pretreatment and chrome waste pretreatment prior to combining with other streams.

Facility and Process Design Client/Location Project Description

Metal Plating Facility ‐ NJ Capture System Design This facility plates steel and stainless‐steel wire with tin, nickel, and silver. TRC designed capture systems for the aqueous/metal emissions from each of their plating lines. In addition, assisted with the permitting of each line. Surveyed all of the heating systems within the two plants for an inventory of NOx and CO emissions. These modifications assisted the client in maintaining state regulatory compliance.

Aluminum Processing Boiler System Design Facility ‐ NJ This facility fine‐grinds aluminum to produce a powder for aluminum paints. Stearic acid and mineral spirits are used as grinding lubricants during the process and are then filtered to separate the powder from the liquid. The filtrate is then boiled to recover the mineral spirits, and the remaining stearic acid is stored in 55‐gallon steel drums. TRC provided the engineering design for a new boiler system that reused this stearic acid as a fuel in the boiler. In addition, we designed an air pollution control system consisting of a pulse‐jet baghouse and an I.D. Fan. Supplied the complete engineering package, including a process flow diagram, a process and instrumentation diagram, equipment specifications, and specifications for a CEM to monitor CO and O2. Also assisted in obtaining an air pollution control permit for the new equipment. The new system allowed the client to reuse a former waste as a valuable plant resource, reduced the amount of fuel oil required for operations, and reduced the amount of waste generated at the facility.

Rare Metals Recovery Incineration and Air Pollution Control System Design Facility ‐ NJ This plant recovers rare metals, primarily silver from X‐ray film. The recovery process utilizes an incineration process operating at reduced atmospheres. Designed and specified the complete

incineration and air pollution control system for the facility. Also assisted the client with obtaining state air permit applications. The new incinerator allowed the client to recover more silver from the process.

Battery Recycling Facility Facility Design, Air Pollution Control, and Wastewater Treatment System Design ‐ Southeast U.S. Designed this battery recycler's air pollution control and wastewater treatment systems. The facility will recycle approximately 50,000 batteries per day and will remelt the lead to be sold as pure lead or

lead alloys. TRC performed the conceptual and preliminary design of the air pollution control system, including 16 baghouses. In addition, performed the conceptual and preliminary design of a wastewater collection and treatment system that will treat approximately 200,000 gallons a day. The wastewater system is designed to dewater process sludges in a filter press and to recycle them into the operation's smelting furnace. Also designed the two buildings that enclose the control systems and will perform the detailed engineering for both facilities. Capital cost estimates and backup documentation provided by TRC assisted the client in the preparation of required permits and allowed the project to proceed toward the scheduled startup date in 1996.

31 Foundry Industry SOQ

Client/Location Project Description

Aluminum Reclamation Reclamation Furnace Modifications Facility ‐ WV This client reclaims aluminum from beverage cans. Paint on the cans was causing stack emissions to exceed state regulatory limits. TRC modified and improved the reclamation furnace controls and

ductwork to bring the system into compliance with state regulatory limits.

Automotive Trial Burn Plan Manufacturer ‐ TN This client installed a new waste incinerator for their new manufacturing plant. The unit consists of a rotary kiln and a secondary chamber with a waste heat boiler and a baghouse collector. The client later decided to burn characteristic hazardous waste in the unit and permitted the facility as a RCRA incinerator. TRC prepared the required trial burn plan and assisted the client in regulatory negotiations.

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