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Home My WebLink AboutAQ_F_1000098_20201130_CMPL_InspRpt NORTH CAROLINA DIVISION OF Wilmington Regional Office AIR QUALITY S & W Ready Mix Concrete—Supply plant NC Facility ID 1000098 Inspection Report County/FIPS: Brunswick/019 Date: 11/30/2020 Facility Data Permit Data S & W Ready Mix Concrete—Supply Plant Permit 08825/R03 150 Land Fill Road NE Issued 8/12/2015 Bolivia,NC 28422 Expires 7/31/2023 Lat: 34d 2.5895m Long: 78d 15.2082m Classification Small SIC: 3273/Ready-Mixed Concrete Permit Status Active NAILS: 32732/Ready-Mix Concrete Manufacturing Current Permit Application(s)None Contact Data Program Applicability Facility Contact Authorized Contact Technical Contact SIP Hank Gay Hank Gay Hank Gay Environmental Manager Environmental Manager Environmental Manager (910)253-7588 (910)284-2664 (910)284-2664 Compliance Data Comments: Inspect facility as scheduled. Inspection Date 11/17/2020 Inspector's Name Scott Sanders Inspector's Signature: Scott Sanders Operating Status Operating Compliance Code Compliance- inspection Action Code FCE Date of Signature: 11/30/20 ,may,, On-Site Inspection Result Compliance Total Actual emissions in TONS/YEAR: ,J'I TSP S02 NOX VOC CO PM10 *HAP 2014 3.63 --- --- --- 1.10 --- 2009 0.1400 --- --- --- --- 0.0700 --- Highest HAP Emitted inpounds) Five Year Violation History: None Date Letter Tvae Rule Violated Violation Resolution Date Performed Stack Tests since last FCE: None Date Test Results Test Method(s) Source(s)Tested S&W Ready Mix Concrete—Supply Plant November 30,2020 Directions to the site are as follows: From Wilmington, take the US-17/Shallotte/Myrtle Beach exit onto Ocean Hwy. E (US-17 S). Go 20.6 miles. Take a right onto Galloway Road NE. Go for 380 feet and bear left onto Land Fill Road NE. S&W Ready Mix Concrete is down on the right approximately one-half mile. 1. Contact was made with Hank Gay, Environmental Manager, to perform a DAQ compliance inspection. 2. S&W Ready Mix Concrete— Supply is a concrete batch plant that consists of one cement storage silo, one flyash silo, and one weigh hopper/batcher which supply cement and flyash to ready mix trucks for delivery. Fabric filters are installed on each silo. Also existing at the facility are several associated storage piles for sand and crushed aggregates. 3. The following equipment contained in Permit No. 08825R03: One Concrete Batch Plant with a maximum rated capacity of 60-80 cubic yards per hour,with the following emissions points and control devices: Emission Emission Source Control Control System Source ID Description System ID Description ES-1 one cement storage CD-1 Farea) gfilter(195 silo feet of filter ES-2 one flyash storage CD 2 one bagfilter(195 silo square feet of filter area) ES-3a one weigh CD-3 one weigh hopper hopper/batcher bagfilter with 38 square feet of filter area 4. Applicable regulations for S&W Ready Mix Concrete—Supply are as follows: 2D. 0202 "Permit Renewal and Emission Inventory Requirement' 2D. 0515 "Particulates from Miscellaneous Industrial Processes" 2D. 0521 "Control of Visible Emissions" 2D. 0535 "Excess Emissions Reporting and Malfunctions" 2D. 0540 "Particulates from Fugitive Dust Emission Sources" 2D. 0611 "Bagfilter Requirements" 5. The normal loading rate for the site is approximately one hundred (100) yards of cement per day when the plant is operating. This facility is currently only operating one (1) day per week. It can run three (3)to six (6)delivery trucks out of this site. The Southport plant is currently picking up most of the work in this area. This plant was not operating during the inspection. Page 2 of 4 S&W Ready Mix Concrete—Supply Plant November 30,2020 6. Neither the cement or flyash silo was being filled at the time of the inspection. This facility currently receives approximately two (2) loads of cement per month and approximately two (2) loads of flyash every other month with an average process rate of twenty-five (25) tons per load per hour. 7. Maintenance is performed on the baghouses once a month. Maintenance records are kept on site for reference. All the bagfilters in the cement silo and all the bagfilters in the flyash silo were changed out on January 31,2017 during the annual inspection. All the bagfilters in the weigh hopper were last changed out on March 11, 2014. There are 16 bags in each of the silos and 5 small bags in the weigh hopper. The door seal on the flyash baghouse was repaired on May 11, 2017. All of the bagfilters in the cement silo were again changed out on February 14, 2018. All of the bagfilters in the cement silo were again changed out in November 2018. On March 18,2019,the bags in the cement silo were shook and cleaned out. Recent records indicate that 2 bags were replaced in the flyash silo on August 7, 2020. All of the bagfilters in the cement silo (16 total) were replaced on September 17,2020. The door seals on the cement and the flyash silo were replaced on October 28,2020. A copy of these most recent maintenance records are attached for reference. 8. This plant is one of only three (3) batch mix plants out of 28 total the company owns that does not use a central dust collector to control particulate emissions from silo loading and truck loadout activities. The other two plants without a central dust collector are in Whiteville and Clinton. A central dust collector is more efficient and easier to maintain. This plant would benefit from having one. The bagfilters are taking longer to make. Hank Gay indicated that S&W might install a central dust collector at this location in the future. 9. The pneumatic pressure from the truck to the silos should be kept between eight(8) to twelve (12) pounds per square inch (psi). This amount of pressure will ensure that the bags in the baghouse will not burst due to a high delivery pressure from the truck. This facility operates their loading trucks at a delivery pressure no greater than nine (9)psi. 10. Fugitive dust from the premise and access roads is not a problem with this plant. The plant is in a very rural area and near the county landfill. The plant entrance is covered with rock and part of the premise is paved with concrete. The facility recently put down some fresh 57 stone at the entrance and exit of the plant grounds. This has helped with the fugitive dust. 57 stone is much less dustier than crush and run. Trucks are cleaned with water as well. The property is sprayed with water by using mix trucks or the loader as needed. 11. Facility Total CY 2014 Emission Summary is as follows: PM (TSP) 3.63 Tons PM10 1.10 Tons The facility produced 17,257 cubic yards of concrete in CY 2014. Page 3 of 4 I S&W Ready Mix Concrete—Supply Plant November 30,2020 12. This facility produced 19,202 cubic yards of concrete in CY 2016, 27,759 cubic yards of concrete in CY 2017, 23,815 cubic yards of concrete in CY 2018, 21,476 cubic yards of concrete in CY 2019, and YTD 2020 this plant has produced 23,325 cubic yards of concrete. 13. 5 year compliance history—This facility has been in compliance with Air Quality regulations during this time period. There have been no (zero) notices of deficiencies or notices of violations issued to this facility during the past five (5) years. 14. S&W Ready Mix Concrete — Supply Plant was operating in compliance with Air Quality regulations at the time of the inspection. Page 4 of 4 S&W READY MIX CONCRETE CO 'pANy _ CORPORATE ENVIRONMENTAL' S p��# ® I PROGRAM �. Qp9LIIT Monthly Plant Inspection [n$pectio n PERFORMED BY: . Date: $- 7- ad .INSPECTED ITEMS 'SILO#1 SILO SILO #3 SILO#4 CEMENT FLY AS O CEMENT FLYASH QK REPAIRED DOOR SEAL OK REP I RED OK REPAIRED OK REPAIRED O'er BAGS r-0R BUILD UP A �— CIEAN INSIDE BAG HOUSE l ECK PRESSURE RE IFFE VALVE �. CkEOCVENT OPENINGS I CHECKSHAI�RR CHEOKALL V-BELTS BAG HOLDING BRACKETS OVERALL.INTEGRITY OF HOUSE it VLsual Leaksfrom Tanis Leah min YES NO 0 YES ONO All Tanks are clear) labeled YES N01 YES NO YES NO ContainmentVelvelocked YES NO NO YFS NO CracksorDamagetoimpoundmentwalls YFS NO NO , YFS NO Rainwaterinsideimpoundment NO NO, YES NO Visible sheen on water YFS NO NO ES NO l Ratnwater Released(clear nlnuftl YES NO 6, NO YES NO NO NO YES NO { AP roxNumberofGallonsReleased Fuel Story a(rvosmalfigstgn and fveemnguidiv) YES NO ' Fuel story a nolev,Fr signs vfSPN) ES NO l ' Storm water plan.onstte Water cling m Working properly NO Emergen s III kit onsite NO Returned concrete arffi maintained dal NO h' FS NO COMMENTS ABOUT DEFICIENCIES: Co ,fir . ' 1 i SERRVICE S&WREADYMIX CONCRETE Co -PANY ._ CORPORATE ENVIRONMENTAL%SAF PROGRAM PLANT# S I QUAldr MornhlY Plant Inspection I nsp e cti o n II PERFORMED BY:e�12j)_,r Date: INSPECTED ITEMS 'SILO#1 SILO SILO#3 SILO#4 CEMENT FLY A$ OK REPAIRED CEMENT FLY ASH DOOR SEAL. OK R� IRED OK REPAIRED OK REPAIRED CHECK BAGS FOR BUILD Up �I CLEAN INSIDE BAG HOUSE CHECK PRESSURE RELIEFE VALVE ECKVENTOPENINGS t QjECKSHAKER ' CHECKALL-BELTS BAG HOLDING BRACKETS �I OVERALL INTEGRIry OF HOUSE Visual Leaks from Tanks Leaky iping YES 01 DYES O YES NO All Tanks arecleari labeled YES Ol 0 YES NO Containment Valve locked NOI NO E$ NO Cracks•or Dama etoim oundmentwalls NOI NO. YES NO Rainwaterinside im oundment. 0 YES 0 YES NO I Visible sheen on water NOI E$ O YES NO YES Rainwater Released(clear run O ES. NO YES NO NOI ES NO YES NO A pro)L Number of Gallons Released � Fuel Storage(N0s Wnyalyn Wd)T eeWnye$hv) FS NO , Fuel storage no%oft si s f nsosp/ �NO Storm water plan oresite YES NO Water clingem workin properly YES NO Eme enV spill kit onsfte NO Returned concrete area maintained daily NO-1 COMWNTS ABOUT DEFICIENCIE$: C� I S. 2 C . . I ' 1 OSIER S&W READY MIX CONCRETE COMPANY ® CORPORATE ENVIRONMENTAL/SAFETY PROGRAM Monthly Plant Inspection Inspection A6ttY — _ PERFORMED BY: Danny Register Date: 10-28-2020 Blower and Fan Inspect belts for proper tension and excessive wear. X❑ Blower Fan Inspect for excessive vibration, looking for build-up on front and backside of the fan. X❑ Solenoid Ins ect for roper ulsing. X❑ Drain Header Inspect for excessive moisture. X❑ Recycle System Inspect for proper discharge and tight seal. X❑ Air Pressure Regulator Confirm pressure is between 80 and 100. X❑ Filter Media Condition Check Photohelic or Magnehilic gauge reading.(Normal reading is 2 to 6 X❑ Inlet filter for Return Blower Inspect for Cleanliness. XEI Automatic Recycle System Inspect for Proper Operation. X❑ Vacuum Lines for Gauge Check for Disconnections between the Collector and the ❑ Gauge or Weather Dema e X Visual Leaks from Tanks YES X NO YES X NO YES O Leak i in YES X NO YES X NO YES O All Tanks are clear) labeled X YES O X YES NO YES NO Containment Valve locked X YES NO X YES NO YES NO Cracks or Dama a to im oundment walls YES X NO YES X NO YES NO Rainwater inside impoundment X YES NO YES X NO YES NO Visible sheen on water X YES NO YES X NO YES NO Rainwater Released iclear runoff) X YES NO rjYvc X NO YES NO Approx.Number of Gallons Released 24 Fuel SIorB a Nosmokin signondfimexlin isker X YES NO Fuel storage no leaks,si ns o s ill X YES NO Storrs water plan onsite X YES NO Water rec clin s stem workin to erl X YES NO Emergency r-meEgency spill kit onsite X YES NO Returned concrete area maintained daily X YES NO COMMENTS ABOUT DEFICIENCIES: Replaced door seals on fly ash and cement bag house.