AQ_F_0400005_20121107_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Bonsal American
NC Facility ID 0400005
Inspection Report County/FIPS: Anson/007
Date: 11/08/2012
Facility Data Compliance Data
Bonsal American Inspection Date 11/07/2012
351 Hailey's Ferry Road Inspector's Name Robert Hayden
Lilesville,NC 28091 Operating Status Operating
Lat: 34d 57.5360m Long:79d 57.4490m Compliance Code Compliance-inspection
SIC: 3272/Concrete Products,Nec Action Code FCE
NAICS: 32739/Other Concrete Product Manufacturing On-Site Inspection Result Compliance
Contact Data Permit Data
Facility Contact Authorized Contact Technical Contact Permit 01759/R20
Charles Knight Jeff Horne Ronald Grover Issued 3/8/2012
Maintenance Supervisor Plant Manager Engineer Expires 2/28/2017
[phone] [phone] [phone] Classification Synthetic Minor
Permit Status Active
Inspector's Signature ` Comments:
Date of Signature: t 5 N;0V \
MACT/GACT Applicability: None. There are no emergency generators on site.
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 1/2
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 slipperier than expected
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 3
August 2012 until 28 February 2017. Cindy Grimes conducted the last compliance inspection on 30
November 2011.
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 2010
Employees: 26 (including drivers) (21 in 2009)
Hours: 6AM—2:30PM Mon-Fri, 40 hrs/wk, 52 wks/yr(same in 2009)
Material received: Portland Cement 24,015,2601bs (23,156,7501bs in 2009)
Masonry 4,574,860 (4,136,754 lbs in 2009)
Fly Ash 662,280 (4,056,782 lbs in 2009)
Units Produced: 2.2 million bags in 2011)
b) Permitted Sources
Emission Emission Source Control r Control System
Source ID �T Description System ID I 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)
Production Line 1,consisting of:
SF22 (Portland cement silo,Line 1 BH22 JBagfilter(156 square feet of filter area)
SF23 (Recycled cement silo Line 1 I BH23 Bagfilter(156 square feet of filter area)
SF24 (Fly ash silo,Line 1 BH24 Bagfilter(156 square feet of filter area)
SF25 Nor ..x cement silo,Line 1 BH25 Bagfilter(156 square feet of filter area)
ES03 Rock and sand bucket conveyor BH1A ;Bagfilter(3,825 square feet of filter area)
operation including a rock silo and a
sand silo '
i
ESO1 Cement handling operation (bagging, BHO1 !Bagfilter(3,840 square feet of filter area)
weighing, mixing),Line 1 j
Production Line 2,consisting of: I
SF40 Portland cement silo,Line 2 BH40 Bagfilter(156 square feet of filter area)
SF41 ock silo,Line 2 i BH41 r agfilter(156 square feet of filter area)
SF42 Sand silo split,Line 2 BH42 Bagfilter(156 square feet of filter area)
SF43 Fly ash silo,Line 2 BH43 Bagfilter(156 square feet of filter area)
SF44 (Type S cement silo, Line 2 BH44 Bagfilter(156 square feet of filter area)
SF52 ecycled cement silo, Line 2 BH52 Bagfilter(156 square feet of filter area) i
ES18 (Rock screen from sand,Line 2 BH13 Bagfilter(1,200 square feet of filter area)
ES02 Cement handling operation(bagging, BH02 Bagfilter(1,900 square feet of filter are)
weighing, mixing),Line 2 j
3) Inspection Conference
On 7 November 2012, I, Robert Hayden met with Charles Knight, maintenance supervisor; we discussed
the following:

a) Verified the FACFINDER information.
b) There have been no changes since last year's compliance inspection. Mr. Taylor told me there have
been no problems with any of the permitted equipment.
c) I inspected the logbooks, of which separate ones are kept for each bagfilter. The lead maintenance
technician or Mr. Knight 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 used to be done weekly but are now done every 3 weeks.There is also an annual inspection
done on the system, usually toward the beginning of each year. This year's was performed in January.
4) Inspection Summary
At my initial arrival time, everybody (management) was at lunch, but I observed the emission points and saw
no VE. I believe both lines were operating (bagging)but not the sand dryer. No silos were being filled. After
lunch, Mr. Knight led me on an inspection of the facility, which had just ceased 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 not 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.
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.
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.
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.
In Compliance— All visible emissions observed were 0% in opacity. Dryer not observed operating.
d) A.7 2D .0540 FUGITIVE CONTROL REQUIREMENT-The Permittee shall not allow fugitive
non-process dust emissions to contribute to substantive complaints.

In Compliance—I saw no excess fugitive dust emissions during my inspection. The haul roads are
gravel/sand, and Mr. Knight 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 BAGFILT.ER REQUIREMENTS—Particulate matter emissions shall be controlled
by the permitted equipment list, with periodic/annual inspections performed and records kept in a
logbook.
In Compliance—Separate logbooks are kept for each bagfilter, and regular and annual inspection
records are kept current.The last record for all controls was 17 August 2012.
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.
8) DAQ Compliance History
a) 9 November 2005 —NOV/NRE for B6, Improper Operation and Maintenance and 2D.0535, Failure to
Report Malfunction.
b) 30 September 2003 —NOV/NRE for 2D .0521,Excessive Visible Emissions.
c) 6 September 2000—NOV/NRE for Operating Without an Air Permit and B6, Improper Operation
and Maintenance
d) 15 June 1999 - Warning Letter, excess dust from play sand silo.
9) Comments and Compliance Statement
Note: The rotary sand dryer was installed in the 1950's, thus predating the NSPS (after 23 April 1986).
Bonsal American appeared to be in compliance on 7 November 2012.