AQ_F_0400005_20100729_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Fayetteville Regional Office
AIR QUALITY Bonsal American
NC Facility ID 0400005
Inspection Report County/FIPS:Anson/007
Date: 07/30/2010
Facility Data Compliance Data
Bonsal American Inspection Date 07/29/2010
351 Hailey's Ferry Road Inspector's Name Cindy Grimes
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
NAILS: 32739/Other Concrete Product Manufacturing On-Site Inspection Result Compliance
Contact Data Permit Data
I
Facility Contact Authorized Contact Technical Contact permit 01759/R19
Issued 10/3/2007
Charles Knight Frank Ketchum Ken Brown Expires 3/31/2012
Safety and Environmental Regional Plant Manager EHS Director Classification Synthetic Minor
Manager [phone] [phone] permit Status Active
[phone]
Inspector's Signature: Comments:
Date of Signature: 81 - lJ l it
J
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
approximately 11 '/z miles to Laurel Hill. Turn right onto US 74 West and continue for about 25 miles,until
you enter Anson County,just after crossing the Pee Dee River. Go approximately 5 more miles to Pit Road
(SR 1801),where there are crossroads and a large antique cart in a yard on the right.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:Safety shoes,safety glasses,and hardhat.Earplugs are optional.Watch for forklifts and
truck traffic during inspection.
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. 1759R19, effective from 3 October
2007 until 31 March 2012. Cindy Grimes conducted the last compliance inspection on 20 August 2009.
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 2009
Employees: 21 (including drivers) (same in 2008)
Hours: 6AM—3:30PM Mon-Fri,40 hrs/wk, 52 wks/yr(7:OOAM-4:OOPM in 2008)
Material received: Portland Cement 23,156,750 lbs (11,0007.95 tons in 2008)
Masonry 4,136,754 lbs (1,783.33 tons in 2008)
Fly Ash 4,056,7821bs (1,817.13 tons in 2008)
Units Produced: 1,967,691 Bags (1,360,222 bags in 2008)
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)
Production Line 1,consisting of:
SF22 Portland cement silo,Line 1 BH22 Bagfilter(156 square feet of filter area)
SF23 Recycled cement silo,Line 1 BH23 Bagfilter(156 square feet of filter area)
SF24 Fly ash silo,Line 1 BH24 Bagfilter(156 square feet of filter area)
SF25 Nomix 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
ES01 Cement handling operation(bagging, BH01 Bagfilter(3,840 square feet of filter area)
weighing,mixing),Line 1
Production Line 2,consisting of:
SF40 Portland cement silo,Line 2 BH40 Bagfilter(156 square feet of filter area)
SF41 Rock silo,Line 2 BH41 Bagfilter(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 Recycled cement silo,Line 2 BH52 Bagfilter(156 square feet of filter area)
ES18 Rock screen from sand,Line 2 BH13 Bagfilter(1,200 square feet of filter area)
ES02 Cement handling operation(bagging, 131­102 Bagfilter(1,900 square feet of filter are)
weighing,mixing),Line 2
3) Inspection Conference
On 29 July 2010,I(Cindy Grimes)met with Frank Ketchum(Authorized and Facility Contact),Charles
Knight(Safety and Environmental Manager) and Jeff Horne (Asst. Plant Manager) at Bonsal. We
discussed the following:
a) Verified the FACFINDER information. Mr. Ketchum wants Charles Knight to be the new Facility
Contact, replacing him, since he might not be here at all times. All other contacts remain the same.

b) There have been no changes in equipment since a new baghouse was installed to replace the existing
one back in 2007.Mr.Ketchum told me there have been no problems. This newer baghouse is pulse jet
versus a shaker that was on the older house.
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 observing any 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
Mr.Ketchum,Mr.Knight,and Mr.Home led me on an inspection of their facility. The facility was operating at
the time, and the results were as follows:
a) There was no unloading that occurred during the inspection. 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 on the trucks is kicked off.
During my inspection last year,there was a problem with excess VE during the opening of a relief valve on
a truck after unloading Portland cement at BH-40 (the driver told us at the time that he usually doesn't see
any dust during this procedure).Mr. Ketchum said that he has not noticed any more problems since then.
b) I observed no excess build up of materials on any of the silos,which might indicate any compromises.
c) I saw no excess dust from any trucks entering or leaving the facility.
d) I observed 0%VE from all other emission sources.
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.
b) AA 2D .0516 SULFUR DIOXIDE CONTROL REQUIREMENT—SO2 emissions from the combustion
sources shall not exceed 2.3 Ibs/mm BTU.
In Compliance—The AP-42 emissions factor for No. 2 fuel oil is 0.507 Ibs/mmBtu; natural gas is
0.001 lbs/mmBtu.Facility is only burning natural gas at this time.
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 seen were 0%opacity.
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. Ketchum 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.
In Compliance—Separate logbooks are kept for each bagfilter, and regular and annual inspection
records are kept current.
6) Reporting Requirements
There are no reporting requirements for this facility in their current permit.

7) 112R Status
Based on the facility's current inventory, it was decided that they are not subject to 112R requirements.
8) 5 Year Compliance History
a) 9 November 2005—NOV/NRE for B6, Improper Operation and Maintenance and 2D.0535,Failure to
Report Malfunction..
b) 30 August 2003—NOV/NRE for 2D .0521, Excessive Visible Emissions.
9) Comments and Compliance Statement
This facility was operating during my inspection,but I saw no trucks unloading any products while I was oil
site.During a previous inspection,there was a problem of excess dust VE during the unloading of a product;
Mr. Ketchum told me that he has reiterated the procedure policy to drivers and has seen no problems since.
The question came up if this facility is subject to NSPS Subpart UUU(Standards of Performance for Calciners
and Dryers in Mineral Industries); On 30 August 2010,Robert Hayden and Cindy Grimes called Frank
Ketchum of Bonsal American to get information concerning the rotary sand dryer. This dryer was installed in
the 1950's, thus predating the requirements of this subpart(installation date must be after 23 April 1986 to be
subject).
Bonsal American appeared to be in compliance on 29 July 2010.
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