AQ_F_0400005_20170110_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Adams an Old Castle Company-Lilesville
NC Facility ID 0400005
Inspection Report County/FIPS: Anson/007
Date: 01/18/2017
Facility Data Permit Data
Adams an Old Castle Company-Lilesville Permit 01759/R21
351 Hailey's Ferry Road Issued 5/9/2016
Lilesville,NC 28091 Expires 4/28/2017
Lat:34d 57.5360m Long: 79d 57.4490m Classification Synthetic Minor
SIC: 3272/Concrete Products,Nec Permit Status Active
NAICS: 32739/Other Concrete Product Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Kevin Tucker Colin Clampett Doug Fouts
Plant Manager President EH&S Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 01/10/2017
Inspector's Name Mike Thomas
Inspector's Signature:
Operating Status Operating
�TitC Compliance Code Compliance-inspection
Action Code FCE
Dat6 of Signature: On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2010 0.4400 0.0100 0.8800 0.0500 0.7400 0.2300 31.49
2005 1.40 -- 0.1300 0.0100 0.1100 0.4800 4.85
'Highest HAP Emitted(inpounds)
Five Year Violation History:None
Date Letter Tvoe Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested
1) Directions
From Wadesboro,take US 74 West until just after crossing the Pee Dee River. Go-5 more miles to
Hailey's Ferry Road(crossroads SR I801),where there is a large antique cart in a yard on the right and a
sign for Welika Fish Camp on the left.Tura left,go almost 0.2 miles,and thenjust before the railroad

tracks,take a left onto facility's dirt drive. Proceed around the truck loading area to the parking lot. Main
office is directly in front of the parking lot and there is visitor parking to the right of the entrance.
2) Safety Considerations
Standard DAQ safety equipment,including vest. Watch for forklifts and truck traffic throughout the
whole facility during inspection. Stairs and ladders are slippery because of cement dust
3) Facility and Process Description
Adams is a mineral mixing and packaging facility that primarily manufactures bagged concrete. It also
produces play sand,all-purpose sand,and mortar. The processing plant is on contiguous property with the W.
R.Bonsal mine. Raw materials are delivered on site,processed and dried through the sand and gravel dryer
and stored in designated silos. They are then blended and packaged/bagged according to the specified
concrete mix and customer. The company has 20 employees(including drivers)and operates 6AM—2:30PM
Mon-Fri,40 hrs/wk, 52 wks/yr. This facility is permitted under Air Permit No. 01759R21,effective from 9
May 2016 until 28 April 2017.Daniel Thoma conducted the last compliance inspection on 16 June 2016.
4) Permitted Emission Sources
sron �', Emission Source Control Control System Emrs ,-
L Source ID Description System ID Descriptio
Drying 6foration,consisting of:
FNawralMo.2 fuel oil-firedmax heat input)sandBagfiher
ES30ryer(50 tons per hour BHIA (3,825 square feet of filter area)
mum capacity)
ing with 0/VE
Production Line 1,consisting of:
Portland cement silo,Line 1 Bagfilter
SF22 Operating with 0%VE BH22 (156 square feet of filter area)
SF23 Recycled cement silo,Line 1 BH23 Bagfilter
Operating with 0%VE (156 square feet of filter area)
Fly ash silo,Line 1 Bagfilter
SF24 Operating with 0% BH24 (156 square feet toof filter area)
SF25 No-mix cement silo,Line 1 BH25 Bagfdter
Operating with 0%VE F (156 square feet of filter area)
Rock and sand bucket conveyor
operation including a rock silo and Bagfiher
ES03 a sand silo BHIA (3,825 square feet of filter area)
Operating with 0%VE
Cement handling operation
Esol (bagging,weighing,mixing),Line B1401 Bagfilter
1 (3,840 square feet of filter area)
Operating with 0%VE
Production Line 2,consisting of:
40-ton capacity Portland cement Bagfiher
Operating
SF40 s with 0%VE!to,Line 2 BH40 (156 square feet of filter area)
80-ton capacity Portland cement Bagfilter
SF80 silo,Line 2 BV80 (264 square feet of filter area)
Not installed

Emission - Emission Source Control Control System
Description SystemED Description
145-ton cam pacity Portland cement
SF145 silo, Line 2 BVI45 Bagfilter
Not installed (264 square feet offilter area)
SF41 Rock silo,Line 2 BH41 Bagfilter
Operating with 0%VE [(156 square feet offil[er area)
SF42 Send silo split,Line 2 BH42 Bagfilter
Operating with 0%VE (156 square feet of filter area)
SF43 Fly ash silo,Line 2 BH43 Bagfilter
Operating with 0%VE (156 square feet of filter area)
SF44 Type S cement silo,Line 2 BH44 Bagfilter
Operating with 0%VE (156 square feet of filter area)
SF52 Recycledcementsilo,Lin e2 BH52 Bagfilter
Operating with 0%VE F (156 square feet offilter area)
ES 18 Rock screen from sand,Line 2 BH13 Bagfilter
Not operating F (1,200 square feet of filter area)
Cement handling operation
ES02 (bagging,weighing,mixing),Line B1102 Bagfilter
2 r(190
0 square feet offilter are)
Operating with 0%VE
5) Inspection Conference
On 10 January 2017,I Mike Thomas of FRO DAQ,conducted a compliance evaluation inspection of
the Adams Old Castle Company—Lilesville facility. I met with Kevin Tucker,Plant Manager for the
facility. We discussed the following:
a) Verified the FACFINDR information:no changes are required.
b) I reminded Mr. Tucker about the facility's upcoming deadline for emissions inventory and
permit renewal. He stated that he was aware of the deadline and that the company had
decided to use an outside contractor to handle it this time.
c) Production:
2016 52,416,000 3,4070,000 - 18,000,000
2015 25,138,000 - 8,176,000 7,442,000
20% 24,015,260 4,574,860 - 662,280
20 P 19,429,672 - - -
2012 - -
2011 - 5,017,514 - -
6) Inspection Tour
Mr.Tucker led me on a tour of the facility which was operating. I observed the interior location
where the final product is bagged and loaded onto pallets for distribution. Mr.Tucker informed me

that the facility had been allocated money from the corporate office to put in a Hi Vac system to assist
with clean up in the bagging area. He went on to say that the system would have 4 to 6 drops where
spilled product can be collected and recycled back into their process. I informed him that the system
would need to be evaluated to determine if permitting would be required for the unit. (I later
discussed the project with Greg Reeves,who recommended I provide Mr.Tucker with the form to do
a 2Q .318 Modification).
I observed all of the bagftlters and transfer points outside of the building and observed no issues with
any of them. I observed the drum dryer to be in good condition,with no leaks or holes.
I asked Mr.Tucker what their procedure was for receiving dry material into the silos. He stated that drivers
are instructed to fill silos at 10 to 12 psi to avoid exceeding the rate of the bagfilters-Trailers have over
pressure valve that is triggered if the fill pressure exceeds 15 psi.
7) Permit Stipulations
a) A.2 15A NCAC 2D .0202&2Q.0304-PERMIT RENEWAL AND EMISSION
INVENTORY REQUIREMENT-The facility shall submit a permit renewal request and a
completed air emissions inventory at least 90 days prior to permit expiration.
APPEARED IN COMPLIANCE— The facility currently has a deadline of 28 January 2017 for
emissions inventory and permit renewal. I confirmed that Mr.Tucker was aware of the deadline
and he emailed a reminder to the consultant while I was conducting the inspection.
b) A.3 15A NCAC 2D .0515 PARTICULATE CONTROL REQUIREMENT—Particulate
matter emissions from sources shall not exceed the allowable rates as defined in the permit.
APPEARED IN COMPLIANCE—Compliance was determined during the most recent permit review
based on operating the source as described in the permit conditions. No changes have been made to
operations since that determination.
c) AA 15A NCAC 2D.0516 SULFUR DIOXIDE CONTROL REQUIREMENT—SO2
emissions from the combustion sources shall not exceed 2.3 Ibs/mm BTU.
APPEARED IN COMPLLANCE—The AP42 emissions factor for No.2 fuel oil is 0.507 lbs/mmBtu;
natural gas is 0.001 Ibs/mmBtu. Facility is only burning natural gas.
d) A.5 15A NCAC 2D.0521 VISIBLE EMISSIONS CONTROL REQUIREMENT—Visible
emissions from the emission sources shall not exceed 20%opacity.
APPEARED IN COMPLIANCE—No VE observed from any sources during the inspection.
e) A.6 15A NCAC 2D.0535"NOTIFICATION REQUIREMENT"—The facility shall notify the
DAQ if there are excess emissions that last for more than four hours due to malfunction,
breakdown of equipment,or other abnormal conditions.
APPEARED IN COMPLIANCE—Mr.Tucker stated that there have been no instances of excess
emissions during the past year. Visual observations and records reviewed support that statement.
f) A.7 15A NCAC 2D .0540 FUGITIVE DUST CONTROL REQUIREMENT- "Particulates
from Fugitive Dust Emission Sources," the Permittee shall not cause or allow fugitive dust
emissions to cause or contribute to substantive complaints or excess visible emissions beyond the
property boundary.
APPEARED IN COMPLIANCE—We saw no excess fugitive dust emissions during our inspection. The
roads are gravel/sand. Mr.Tucker stated that he has not received any dust complaints.
g) A.815A NCAC 2D.0611 BAGFD.TERREQUIREMENTS—particulate matter emissions
shall be controlled as described in the permitted equipment list, the pemrittee shall perform,at a

minimum,an annual internal inspection of each particulate collection system. The permittee shall
also perform periodic inspections and maintenance as recommended by the equipment
manufacturer. The results of all inspections maintenance activities shall be recorded in the
logbook and kept onsite.
APPEARED IN COMPLIANCE—Separate logbooks are kept for each bagfilter system. Facility
personnel perform monthly internal inspections. All entries were up to date and complete.Bagfilter
BH1A had full bag replacement and internal inspection on 22 October 2016.All of the bagfilters
associated with Production Line I had bag replacements and internal inspections on 30 October 2016.
The bagfilters associated with production Line 2 were inspected internally on 30 October 2016. No bags
were replaced during this inspection.
h) A.9 15A NCAC 2Q.0315 LIMITATION TO AVOID 15A NCAC 2Q.0501(Title V)-
Pursuant to 15A NCAC 2Q .0315 "Synthetic Minor Facilities,'facility-wide PMm emissions
shall be less than 100 tons per consecutive 12-month period. Facility complies with this
limitation by properly operating and maintaining their bagfilters and record keeping in
accordance with 15A NCAC 2D .0611 BAGFILTER REQUIREMENTS.
APPEARED IN COMPLIANCE— Facility met the requirements by performing the required
inspections, maintenance, and record keeping as prescribed in 15A NCAC 2D .0611 BAGFILTER
REQUIREMENTS. See A.8 above.
8) Non-compliance History Since 2010
Jan. 2012-NOD Failure to renew Air Permit
9) 112RStatus
This facility does not store chemical compounds that require a written risk management plan
under the Clean Air Act, Section 112R.
9) Compliance Statement and Recommendations
Adams an Old Castle Company—Lilesville appeared to be in compliance with the conditions in their
current air permit on 10 January 2017.
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