AQ_F_1000101_20210120_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Wilmington Regional Office
AIR QUALITY Ready Mixed Concrete Company- Shallotte
NC Facility ID 1000101
Inspection Report County/FIPS: Brunswick/019
Date: 01/20/2021
Facility Data Permit Data
Ready Mixed Concrete Company- Shallotte Permit n/a
4987 Industrial Drive Issued n/a
Shallotte,NC 28470 Expires n/a
Lat: 33d 59.9760m Long: 78d 27.1580m Classification Permit Exempt
SIC: 3273/Ready-Mixed Concrete Permit Status Inactive
NAICS: 32732/Ready-Mix Concrete Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Duron Shaw Steve Simonsen Steve Simonsen
Plant Supervisor Environmental Manager Environmental Manager
[phone] [phone] [phone]
Compliance Data
Comments: Inspect facility as scheduled.
Inspection Date 1 1/1 112 02 1
Inspector's Name Scott Sanders
Inspector's Signature: Scott Sanders Operating Status Operating
Compliance Code Compliance- inspection
Action Code FCE
Date of Signature: 1/20/21 On-Site Inspection Result Compliance
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 * HAP
* 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
Directions to the facility are as follows: From Wilmington, take the US-17 /Shallotte /Myrtle
Beach exit onto Ocean Hwy. E (US-17 S). Go 31.2 miles and take the ramp toward NC-130/
Shallotte/Whiteville. Turn left onto Whiteville Rd. NW(NC-130). Go 3 miles and turn right onto
Industrial Drive. The facility is at the end of the road to the left.

Ready Mixed Concrete Company—Shallotte
January 20,2021
1. Contact was made onsite with Duron Shaw, Plant Supervisor, and Sam Owens, Wilmington
Area Operations Manager, to conduct a compliance assurance visit. Mr. Owens oversees
operations at four concrete plant locations (this location— Shallotte, Leland, Sunnyvale Road
—Wilmington, and Scotts Hill). Mr. Owens has an office at the Scotts Hill facility.
2. This plant was closed from December 9, 2015 to May 21, 2019. 4,484 yards of concrete were
produced here in CY 2015. 6,900 yards were produced in CY 2020. The Wilmington Division
of Ready Mixed Concrete recently took back the oversight of this plant in 2019. The Myrtle
Beach Division of Ready Mixed Concrete has had oversight of this plant for the seven to eight
years before that.
3. Ready Mixed Concrete Company — Shallotte operates a concrete batch plant that consists of
one split storage silo (60% cement and 40% flyash), one weigh hopper, and one truck loading
operation. A central ground level dust collector is present.
4. The following equipment was contained in Air Permit No. 08859R06:
Emission Emission Source Control Control System
Source ID FDescription System ID I Description
One Concrete Batch Plant-Truck Mix-with 110 cubic yard/hour maximum capacity
ES-1 one split storage silo with CD-1 one ground level central dust
60%cement collector(1,433 square feet of
surface area); closed-loop
system with emissions
returned to the flyash silo
ES-2 one split storage silo with CD-1 one ground level central dust
40 % flyash collector (1,433 square feet of
surface area); closed-loop
system with emissions
returned to the flyash silo
ES-3 one weigh hopper CD-1 one ground level central dust
collector(1,433 square feet of
surface area); closed-loop
system with emissions
returned to the flyash silo
ES-4 one truck-loading CD-1 one ground level central dust
operation collector(1,433 square feet of
surface area); closed-loop
system with emissions
returned to the flyash silo
5. Applicable regulations for Ready Mixed Concrete Company—Shallotte are as follows:
2D .0202 "Permit Renewal and Emission Inventory Requirement"
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Ready Mixed Concrete Company—Shallotte
January 20,2021
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 "Monitoring Emissions from Other Sources (Fabric Filter
Requirements)'
2Q .0711 "Emission Rates Requiring a Permit"
6. An air permit modification was done on March 16, 2010 that added a ground level central dust
collector replacing four p g separate
p ate bagfilters at this facility. This project was part of an overall
Green Star Program. The goals of this program included energy conservation and recycling
efforts. The new ground level central dust collector began operating on April 19, 2010.
Air permit renewal done on November 20, 2014 was requested and processed with no changes
to the permit.
On August 16, 2016, this facility requested rescission of the current air permit under the new
2Q .0102(d) exemption. Since the 2013 CY emissions did not exceed 5 tons per year each for
PM10, S02, CO, NOx, VOC, HAP, or TAP and aggregate total emissions did not exceed 10
tons per year, the facility qualified for exemption from permitting under 2Q .0102(d). The
rescission request was granted by WiRO DAQ on September 9, 2016. This associated
paperwork was attached to a previous inspection report for reference.
7. This facility operates five(5)days per week, fifty-two(52)weeks per year. Fugitive emissions
from the plant grounds are kept to a minimal due to water spray that is applied to the property
by mixer truck or loader as needed. Gravel has been placed on the haul roads to decrease
fugitive emissions. Fugitive emissions from the haul roads were very minimal during the
inspection. This plant is in a rural, commercial area with no nearby surrounding residences.
8. The current loading rate for the site is approximately thirty (30)to forty (40)yards of concrete
per day. Three (3) mixer trucks are currently run out of this site.
9. The facility receives approximately one(1)load of cement every two weeks and approximately
one (1) load of slag per month with an average process rate of twenty-five (25) tons per load
per hour. Loading time is usually one hour. Ready Mixed Concrete Company has replaced
flyash with a product called slag due to the overall scarcity of flyash. Slag is mixed with
cement in the same manner as flyash was. No silo loading of cement or slag was occurring
during the inspection. Plant personnel indicated that a load of cement and a load of slag were
each received early this morning before the inspection.
10. The ground level central dust collector controls the particulate emissions generated during
cement and slag loading, during the transfer of cement and slag into the weigh hopper, and
during the transfer of sand, aggregates, cement and slag from the weigh hopper and conveyor
discharge area into the mixer truck.
11. Cement and slag are transferred from the split storage silo to the weigh hopper as a conveyor
transfers sand and aggregates into a discharge area located below the weigh hopper. This
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Ready Mixed Concrete Company—Shallotte
January 20,2021
discharge area is equipped with a flexible boot (hose or chute) that transfers the ingredients
into the truck mixer. Fugitive emissions can be generated as sand and aggregates are conveyed
from storage into transit-mix trucks and as cement and slag are transferred from silo to the
weigh hopper into transit-mix trucks. Visible emissions can be excessive unless the loadout
area is equipped with a hooded or partial enclosure of some type with a vacuum point, which
is the case for this plant. This facility has an enclosure, which partially covers the truck mixer
when loading sand, aggregates, cement, and slag. This enclosure appears to be adequately
designed and is equipped with two vacuum lines that vent to the central dust collector. This
results in higher control efficiency for collecting the fugitive dust generated during truck load-
out activities. Mix trucks were observed being loaded during the inspection with minimal
fugitive emissions coming from the truck load-out area. Mr. Owens, Operations Manager,
indicated during the inspection that the facility will make the partial enclosure(shroud) larger,
particularly on the back side of it. This measure will help to further reduce fugitive emissions
generated at the truck load-out area.
12. Maintenance is performed on the central dust collector on a regular basis. Maintenance records
are kept on site for reference. The baghouse contains 72 total bags. During loading of the
silos,delivery pressure from the truck should be kept at a minimum to avoid bag failure. Ready
Mixed Concrete operates their trucks at a delivery pressure no greater than ten(10)pounds per
square inch. An increase in pressure above this limit could cause a bag failure. All the bags
in the central dust collector were last changed out back on September 7, 2015. This was the
first time the bags in the dust collector needed changing out since it was installed in April of
2010. This plant has operated very little since then. A company named Filter Kleen does all
of the scheduled baghouse and ductwork maintenance for Ready Mixed Concrete Company.
Plant personnel logs a daily reading of the magnahelic gauge associated with the dust collector
to ensure proper pressure is maintained in the unit. A reading between 2 and 4 indicates good
pressure. The magnahelic had a reading of 2.0 during the inspection. Plant personnel also log
daily visual inspections as to whether the unit is dusting or not. Plant personnel indicated that
that the belts in the dust collector were changed one month ago.
13. 5-year compliance history— No NOD's, NOV's, or NRE's have been issued to this facility
during this time period.
14. Ready Mixed Concrete Company—Shallotte appeared to be operating in compliance with Air
Quality regulations during the inspection.
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