AQ_F_0400005_20150820_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Bonsal American
NC Facility ID 0400005
Inspection Report County/FIPS: Anson/007
Date: 09/09/2015
Facility Data Permit Data
Bonsal American Permit 01759/R20
351 Hailey's Ferry Road Issued 3/8/2012
Lilesville,NC 28091 Expires 2/28/2017
Lat: 34d 57.5360m Long: 79d 57.4490m Classification Synthetic Minor
SIC: 3272/Concrete Products,Nec Permit Status Active
NAILS: 32739/Other Concrete Product Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Bryan Barber Kevin Tucker Ronald Grover
Maintenance Manager Plant Manager Engineer
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 08/20/2015
Inspector's Name Mike Thomas
Inspector's Signature: Operating Status Operating
W,/ Compliance Code Compliance-inspection
Action Code FCE
Date 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 Type Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested
1) Location
Bonsal American is located at 351 Hailey's Ferry Road, outside of Lilesville,NC,Anson County.

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 1801),where there is a large antique cart in a yard on the right and a
sign for Welika Fish Camp on the left.Turn left, go almost .2 mile, and then just before the railroad tracks,
take a left onto facility's dirt drive.Main office is on the right.
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
2) Facility and Process Description
W R.Bonsal,Inc. 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. This facility is permitted under Air Permit No. 1759R20,effective from 8
May 2012 until 28 February 2017. Mike Thomas conducted the last compliance inspection on 11 March
2014.
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.
a) Current Throughputs for 2014
Employees: 20 (including drivers same in 2013)
Hours: 6AM—2:30PM Mon-Fri,40 hrs/wk, 52 wks/yr(same in 2013)
Material received: Portland Cement 24,015,260 lbs(19,429,6721bs in 2013)
Mason 4,574,860 (5,017,514 lbs in 2011)
Fly Ash 662,280 (4,574,860 lbs in 2013)
Units Produced: 2.2 million bags
b) Permitted Sources
j Emission
— Emission Source Control Control System
Source ID Description System ID Description
Drying Operation,consisting of:
ES30 1INatural gas/No.2 fuel oil-fired(15 BH1A Bagfilter(3,825 square feet of filter area)
mmBtu max heat input)sand and
gravel dryer(50 tons per hour
in capacity)
Operating with 0%VE _
Production Line 1,consisting of:
j SF22 JPortland cement silo,Line 1 BH22 Bagfilter(156 square feet of filter area)
Operating with 0%VE
- - _ -- -
SF23 Recycled cement silo,Line 1 BH23 filter(156 square feet of filter area)
Bag
Operating with 0%VE ��
SF24 Fly ash silo,Line 1 BH24 Bagfilter(156 square feet of filter area)
Operating with 0%VE
SF25 IN cement silo,Line 1 BH25 Bagfilter(156 square feet of filter area)
Operating with 0%VE ,
ES03 Rock and sand bucket conveyor BH1A Bagfilter(3,825 square feet of filter area)

mission Source ntrol Control System
Emission Co
Source ED Description System ID Description
operation including a rock silo and a sand silo
a sand silo
Operating
�era nj
perating with 0% VE
ESol IlCement handling operation BHO I agfilter(3,840 square feet of filter area)
(bagging,weighing,mixing),Line
Operating with 0% VE
S Production Line 2,consisting of:
agfilter(156 square feet of filter area)
F4 Portland cement silo,Line 2
[Operating with 0% VE
SF41 IRock silo,Line 2 B i4l Bagfilter(156 square feet of filter area)
Operating with 0% VE
SF42 Sand silo split,Line 2 BH42 Bagfilter(156 square feet of filter area)
Operating with 0%VESF43 jFly ash silo,Line 2 BH43 Bagfilter(156 square feet of filter area)
Operating with 0%VE—
IType S cement silo,Line 2 BHA4 Bagfilter(156 square feet of filter area)
11Operating with 0% VIE
F
SF52 Recycled cement silo,Line 2 BH52 Bagfillter(156 square feet of filter area)
Operating with 0% VE
ES 18 IlRock screen from sand,Line 2 BH13 113aglifter(1,200 square feet of filter area)
jOperating with 5% VE
----ES02 ,lCement handling operation(bagging BH02 0 square feet of filter are)
weighing,mixing),Line 2
1Operating with 0% VE
3) Inspection Conference
On 20 August 2015 1 Mike Thomas of FRO DAQ met with Bryan Barber,Maintenance Manager;we
discussed the following:
a) Verified the FACFJNDER information.No changes required.
b) The facility maintains separate logbooks for each bagfilter.The lead maintenance
technician usually performs the inspections,which includes inspections of the bags,blower, ductwork,
and observation of visible emissions. The results are all noted in the logbooks.
4) Inspection Summary
Mr. Barber led me on a tour of the facility which was operating. We started at the storage silos(SF-22,23,24,
25,40,41,42,43,44,and 52). The facility keeps the fill access to each of the silos locked so that drivers have
to check in before silo filling can take place. Drivers are instructed to fill silos at 10 to 12 psi to avoid
exceeding the rate of the bagfilters. Each system has an over pressure valve that is triggered if the fill pressure
exceeds 15 psi.
I observed the rock and sand conveyor operation and the screening operation(ES-03 and ES-18). Both
appeared to be in good operational order. I saw only very slight and infrequent emissions of fugitive dust in
these areas.

Mr.Barber showed me ES-01,ES-02 (cement handling operations): Both of these lines operate inside a
warehouse and appeared to be working properly.I observed no emissions coming from inside the building.
I observed ES-30(sand and gravel dryer). The input temperature range for the sand is usually between 300-
325 degrees F, and for the gravel,225-250 degrees F. There is a pressure gage to monitor the various drops of
pressure within the bag house. Maintenance checks the gage regularly and then records results into the
logbooks.
5) Permit Stipulations
a) A.3 2D .0515 PARTICULATE CONTROL REQUIREMENT—Particulate matter emissions from
sources shall not exceed the allowable rates.
Appears to be in compliance—Latest permit review indicates compliance. Operating bag houses assures
compliance.
b) A.4 2D .0516 SULFUR DIOXIDE CONTROL REQUIREMENT—SO2 emissions from the
combustion sources shall not exceed 2.3 lbs/mm BTU.
Appears to be in compliance—The AP-42 emissions factor for No. 2 fuel oil is 0.507 lbs/mmBtu;
natural gas is 0.001 lbs/mmBtu.Facility is only burning natural gas.
c) A.5 2D .0521 VISIBLE EMISSIONS CONTROL REQUIREMENT—Visible emissions from the
emission sources shall not exceed 20%opacity.
Appears to be in compliance—All visible emissions observed were 0% in opacity.
d) A.7 2D .0540 FUGITIVE CONTROL REQUIREMENT-The Permittee shall not allow fugitive
non-process dust emissions to contribute to substantive complaints.
Appears to be in compliance—I saw no excess fugitive dust emissions during my inspection. The
haul roads are gravel/sand,and Mr. Barber said that he has not received any complaints.
e) A.8 2D .0611 BAGFILTER REQUIREMENTS—Particulate matter emissions shall be controlled
by the permitted equipment list,with periodic/annual inspections performed and records kept in a
logbook.
Appears to be in compliance—Separate logbooks are kept for each bagfilter,and regular and annual
inspection records are kept current.
6) 112R Status
This facility neither uses nor stores chemical compounds that require a written risk management plan
under the Clean Air Act, Section 112R.
7) Non-compliance History Since 2010
None.
9) Comments and Compliance Statement
Bonsal American appeared to be in compliance on 20 August 2015.
Pink Sheet: No comments.
/mst