AQ_F_0400005_20210521_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: 06/03/2021
Facility Data Permit Data
Adams an Old Castle Company-Lilesville Permit 01759/R22
351 Hailey's Ferry Road Issued 3/8/2017
Lilesville,NC 28091 Expires 2/28/2025
Lat: 34d 57.5360m Long: 79d 57.4490m Class/Status 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
Benji Atkinson Mike Poteat Mike Poteat
Maintenance Manager Site Manager Site Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 05/21/2021
Inspector's Name Jeffrey D. Cole
Inspector's Signature: Operating Status Operating
Compliance Status Violation-procedures
Action Code PCE
Date of Signature: ��31 Inspection Result Violation
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2015 3.07 --- 0.7900 0.0400 0.6600 0.9800 28.30
2010 0.4400 0.0100 0.8800 0.0500 0.7400 0.2300 31.49
*Highest HAP Emitted(in pounds)
Five Year Violation History:
Date Letter Type Rule Violated Violation Resolution Date
04/21/2017 NOV/NRE 2D.0521 Control of Visible Emissions 05/05/2017
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested

I. DIRECTIONS:
From FRO,take Hwy 401 South to Wagram. Turn right onto Old Wire Road(Hwy 144)and go— 11
V2 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 0.2 mile, and then just before the railroad tracks,take a left onto
facility's dirt drive.Main office is on the right.
H. 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
III. 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 6:00 AM—2:30 PM Mon-Fri,40 hrs/wk, 52 wks/yr.
IV. FACILITY NON-COMPLIANCE HISTORY
04/21/2017 NOV/NRE for 5 violations of Stipulation A.5 (15A NCAC 2D .0521)"Control
of Visible Emissions." The sources were the top of the rock silo and sand silo,
containing the shaker screen(i.e., Shaker Screen Shed)(Source ID No.ES03)
controlled by Bagfilter(Control Device.ID No.BH1A). This included 2
violations cited for Shaker Screen Shed ES03 and 3 violations cited for Bagfilter
BH1A.
11/09/2005 NOV/NRE for 1 violation of Stipulation B.6"Improper Operation and
Maintenance." The source was the top of the rock silo and sand silo,containing
the shaker screen(i.e., Shaker Screen Shed)(Source ID No.ES03)controlled by
Bagfilter BH1A(which failed at an earlier date due to corrosion).
09/30/2003 NOV/NRE for 3 violations of Stipulation A.5 (15A NCAC 2D .0521)"Control
of Visible Emissions." The source was vibrating rock screen from sand on a split
silo(ID No.ES 18)
V. INSPECTION SUMMARY:
On 21 May 2021,I,Jeffrey Cole of the NC Division of Air Quality,Fayetteville Regional Office,was
in the Lilesville area and drove by the Adams an Old Castle Company—Lilesville facility and
observed what appeared to be excess VE.
At approximately 9:35 AM, as I approached the Adams an Old Castle Company facility and noticed
that the facility was emitting what appeared to be excess dust. I proceeded into the facility grounds
and decided to conduct a Method 9 visible emissions(VE)observation. I was met in the parking lot
of the facility by Mr. Mike Poteat, Site Manager, and informed him of my observation and of my
intent to perform the Method 9 visible emissions(VE)observation. Mr.Poteat stated that he knew
his permit requirements and that he would aide me in my observation if I needed. I chose an
observation position conforming to Method 9 requirements which was located along a haul road to
the aggregate yard at the east end of the facility.

Once in position to observe the emissions,I noted excess dust emitting from 2 sources. The first
source of emissions was a small house-like structure atop what I later identified as their rock silo and
sand silo,containing the shaker screen(i.e., Shaker Screen Shed)(Source ID No. ES03;—112 feet off
the ground). The second source was at the top of the Line 1 product elevator to the right of the
Shaker Screen Shed, also—112 ft off the ground. I looked for any visible emissions from the
associated Bagfilter(CD ID No.BH1A)which exits at—10 feet above the ground and saw none.
I proceeded to conduct a 30-minute visible emissions evaluation(VEE)on both emission points
concurrently. The first 3 to 4 minutes of evaluation resulted in readings above the 20% opacity limit
but the VE at that point started to dissipate. I asked Mr. Poteat if the process had been slowed down
or halted during my observation and he said that it was operating at its normal throughput. Mr. Poteat
noted that the company has an approved plan to replace the Line 1 screen deck, shack covering the
screen deck,Line 1 product elevator and the sand silo beneath the screen deck in 2021. While they
do not have a confirmed date for replacement as of yet some of the replacement parts are already on-
site.
After the VEE was complete,I advised Mr. Poteat that I would have to compute the 6 minute
averages to determine if there had been an emissions violation. Mr.Poteat and I then entered the
facilities offices where he provided me with the status of operations at the facility during my
inspection. The facility was operating as follows:
Production:
—30,000 bags of concrete per day
Overall material processing rate:
—2.1 million lbs per day
Consisting of
—350,000 lbs of cement
—900,000 lbs of sand
—850,000 lbs of rock
Finally, upon my request they also produced a copy of the facility's current air quality permit. I
showed Mr.Poteat the applicable permit stipulation(A.5)and noted that the visible emissions that we
had observed appeared to exceed the opacity standard in their permit. I also stated that the facility
would be contacted about what action would be taken by DEQ.
VI. REGULATORY REVIEW:
The facility's current permit stipulation A.5 (15A NCAC 2D .0521)states,
"... visible emissions from the emission sources, manufactured after July 1, 1971, shall not be more
than 20 percent opacity when averaged over a six-minute period, except that six-minute periods
averaging not more than 87 percent opacity may occur not more than once in any hour nor more than
four times in any 24-hour period."
After returning to the FRO,I ran a calculation of 6-minute averages from the instantaneous readings
every 15 seconds that I had recorded during the two simultaneous VE evaluations. During the
observation from the top of the rock silo and sand silo, containing the shaker screen(i.e., Shaker
Screen Shed),there was only one 6-min average above 20%. During the observation of the top of the
Line 1 product elevator to the right of the Shaker Screen Shed,there was only one 6-min average

above 20%. Allowing for one of the six 6-minute opacity averages each per hour being above 20%
opacity, as stated in the permit,there appeared to be no violations of 15A NCAC 2D .0521.
However,the facility's current permit Stipulation B.6"Improper Operation and Maintenance"states.
"In accordance with G.S. 143-215.108(c)(1), the facility shall he properly operated and maintained at
all times in a manner that will effect an overall reduction in air pollution."
The normal operation of the facility should result in no visible emissions from the areas I observed as
this source(ES03) is supposed to be controlled by the bagfilter(BH1A)with---100% capture
efficiency. Since visible emissions were observed,the source, ductwork and control device are not
being operated as designed and permitted or in a manner that effects an overall reduction in pollution,
and therefore is not meeting the B.6 requirement.
Note that this facility has a history of NOV/NRE's in the past(see Section IV above)with the last
violation of 15A NCAC 2D .0521 being recorded—4 years ago(13 Apr 2017)from some of the same
sources as observed on 21 May 2021.
VII. CONCLUSION:
The Adams an Old Castle Company—Lilesville appeared to be in violation of the general statute
under condition B.6 of their air permit. I recommend sending the facility a Notice of Violation
(NOV)letter citing a stipulation B.6 deviation.
Pink Sheet: I would also recommend more frequent drive by observations in order to ensure that
compliance is maintained.
ENCL: VEE evaluation(readings, calculation of 6-minute averages,map, 1 photo page, Sun Position
GIS)
/j do

VISIBLE FAUSSION OBSERVATION FORM
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l}eicribe EmIsdon Point 2 l
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5 start m Ul arver Dir cticart.P Ol s rver r 14 44
stat End 35V Start. 9 End 15 45
16 46
Describe Emission 17
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Star# ,C.JAff31� 18
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Start *� d Attached ra Detached a lei a20
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Star elitACrY APJ*f f'� .52
gibe:Pl ae.3aclrgrounds 23
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Start ' d' End ��' 2A. 54 ..
Eackgmund Color Sky renditions 25 S
Stab s6 ' End S 4ze End 1 26
Wind S ed wmd Dir fion57
Start l v End !4 Start A W. End trd 7 58
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