AQ_F_0400005_20140311_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Bonsal American
NC Facility ID 0400005
Inspection Report County/FIPS:Anson/007
Date: 03/12/2014
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
NAICS: 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 03/11/2014
Inspector's Name Mike Thomas
Inspector's Signa ure: Operating Status Operating
/ Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: 3 On-Site Inspection Result Compliance
(Z /Ll
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(in pounds)
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 FRO,take Hwy 401 South to Wagram.Turn right onto Old Wire Road(Hwy 144)and go— 11 %miles
to Laurel Hill. Turn right onto US 74 West and continue for—25 miles until you enter Anson County,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.Robert Hayden conducted the last compliance inspection on 7 November 2012.
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 2013
Employees: 20 (including drivers)(26 in 2011)
Hours: 6AM—2:30PM Mon-Fri,40 hrs/wk, 52 wks/yr(same in 2011)
Material received: Portland Cement 19,429,6721bs(24,015,260 lbs in 2011)
Mason 5,017,514(4,574,860 lbs in 2011)
Fly Ash 4,574,860(662,280 lbs in 2011)
Units Produced: _2.2 million bags
b) Permitted Sources
' Emission ( Emission Source Control Control System
Source ID Description System ID Description
Drying Operation,consisting of:
ES30 Natural 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
maximum capacity)
Operating with 0%VE j
Production Line 1,consisting of:
SFr 22 Portland cement silo,Line 1 BH12 Bagfilter(156 square feet of filter area)
—)Operating with 0%VE
j SF23 Recycled cement silo,Line 1 B1423 Bagfilter(156 square feet of filter area)
Operating with 0%VE
SF24 IFly ash silo,Line 1 BH24 Bagfilter(156 square feet of filter area)
_._,Operating with 0%VE
��SF25 Nomix 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)

Em�issio Emission ource yontrol ControlSSystem
Source ID Description S stem lD Descn lion
j operation including a rock silo and a
sand silo
Operating with 0%VE
ESO—Cement handling operation(bagging,
BHOl Bagfilter(3,840 square feet of filter area)
weighing,mixing),Line 1
Operating with 0%VE
r Production Line 2,consisting of:
SF40 lPortland cement silo,Line 2 BH40 Bagfilter(156 square Peet of filter area)
Operating with 0%VE
SF41 Ropck silo,Line 2 BH41 Bagfilter(156 square feet of filter area)
O erati
-- ng with 0%VE
_
SF42 Sand silo split,Line 2 BH42 Bagfilter(156 square feet of filter area)
Operating with 0%VE
SF4�Fly ash silo,Line 2 ' BH43 Bagfilter(156 square feet of filter area)
Operating with 0%VE ;�—
„ _._ _
SF44 T e S cegment silo,Line 2 BH44 Bagfilter(156 square feet of filter area)
O eratin with 0%VE
SF52 i Recycled cement silo,Line 2 BH52 Bagfilter(156 square feet of filter area)
Operating with 0%VE
ES18 Rock screen from sand Line 2 BH13 Bagfilter(1,200 square feet of filter area)
1 Operating with 5%VE
i
ES02 Cement handling operation(bagging, BH02 Bagfilter(1,900 square feet of filter are)
weighing,mixing),Line 2
Operating with 0%VE _
3) Inspection Conference
On 11 March 2014 I Mike Thomas of FRO DAQ met with Bryan Barber,Maintenance Manager;we
discussed the following:
a) Verified the FACFINDER information. Brian Barber has replaced Charles Knight as Maintenance
Manager and Mr.Kevin Tucker has replaced Jeff Horne as Plant Manager. Mr.Barber also informed
me that the name of the company has changed from Bonsal, Oldcastle to Adams, Oldcastle. I will
email him the name change form.
b) Mr.Barber said that when he and Mr.Tucker arrived at the facility in November 2013 there were a lot
of maintenance issues with the dust collections system. They began a systematic effort to clean out
duct work and vents resulting in greatly reducing VE at the plant.
c) I inspected the logbooks, of which separate ones are kept 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.These inspections are now
done monthly. There is also an annual inspection done on the system,which is scheduled for two weeks
from the date of my inspection.
4) Inspection Summary
Mr.Barber led me on an inspection of the facility,which was operating.The results are as follows:

a) During silo filling, drivers are told to unload at 10-15 psi,with their trucks being set at the maximum
pressure of 15 psi before a relief valve activates.
b) SF-22,23,24,25,40,41,42,43,44,and 52(all silos): I observed no excess build up of materials on any of
the silos.
c) ES-03 (rock& sand conveyor operation),ES-18(rock screen from sand): All conveyors and screens
appeared to be operating properly.
d) ES-01,ES-02(cement handling operations):Both of these lines operate inside a warehouse and appeared
to be working properly.
e) ES-30 (sand and gravel dryer): Even though this dryer is old, it appears to function well.The input
temperature range for the sand is usually between 300-325 degrees F, and for the gravel,225-250
degrees F. The dryer was operating. 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.
Mr.Barber said that they had recently replaced the drum on the dryer with an identical unit due to the age
of the existing drum.
f) I saw no excess dust from any trucks or roads while entering or leaving the facility.
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.He uses water from
a watering truck if dust becomes a problem during a dry spell.
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 I I2R.

7) DAQ Compliance History
None the past 5 years
9) Comments and Compliance Statement
Bonsal American appeared to be in compliance on I 1 March 2014.