AQ_F_1400196_20200824_CMPL_CAV-Rpt

NORTH CAROLINA DIVISION OF Asheville Regional Office
AIR QUALITY Kerr's Hickory Ready-Mixed Concrete Co.,Inc.
NC Facility ID 1400196
Inspection Report County/FIPS:Caldwell/027
Date: 08/24/2020
Facility Data Permit Data
Kerr's Hickory Ready-Mixed Concrete Co.,Inc. Permit n/a
1190 Bradford Mountain Road Issued n/a
Lenoir,NC 28645 Expires n/a
Lat: 35d 53.1840m Long: 8Id 33.6550m Class/Status 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
Robert Kerr Robert Kerr Robert Kerr
Vice President Vice President Vice President
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 08/24/2020
Inspector's Name Richard Morris
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code PCE
Date of Signature: `Q� y� On-Site Inspection Result Compliance
Total Actual emissions in TONS//YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2012 1.12 --- --- --- --- 0.3300 0.1000
2008 3.26 --- --- --- --- 0.9800 0.2803
*Highest HAP Emitted(in pounds)
Five Year Violation History:None
Date Letter Type Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:None
Date Test Results Test Method(s) Source(s)Tested
CAV Inspection Report:
1) Location: Kerr's Hickory Ready-Mixed Concrete Co., Inc. is located at 2701 Morganton
Blvd. in Lenoir,NC. Caldwell County.

Directions: From Morganton take Hwy 18 to Southwest Blvd. (just before Lenoir) and
turn right. The facility will be on the left just past the Virginia Street overpass.
2) Description: Kerr's Hickory Ready-Mixed Concrete Co., Inc. is a batch concrete plant that
produces concrete for the construction industry. This facility is now permit exempt effective
date February 23, 2017. This company has been bought by Southern Concrete but is still DBA
Kerr.`s. Last compliance inspection conducted on August 7, 2019 by Richard Morris.
Current throughputs: 2020
Hours: 2-3 days/week
Production: —1,800 cubic yards. Jan 2020-Aug 2020
Permitted Sources are:
Emission Emission Source Control Control System
Emission
ID J Description__ __System ID Description
one truck mix concrete batch plant(maximum concrete process rate of 125 cubic yards per hour)consisting
i of the following: i
one split cement-flyash one bagfilter(225 square
j ':i storage silo-cement side I feet of filter area, cement
ESl 1
(100 tons of cement CD- side)
!storage capacity) j
jone split cement-flyash one bagfilter(225 square
ES2 storage silo-flyash side CD-2 feet of filter area,flyash
(50 tons of flyash storage side)
capacity
one cement flyash weigh one bagfilter(16 square feet
�ES3 hopper(5 tons of holding CD-3 of filter area)
capacity)
ES4 �II one concrete truck load out N/A N/A
operation
Insignificant/Exempt Activities
Source Date of Exem tion Source of Source of Title
Application Regulation TAPS? V Pollutants?
I 1 -Sand and aggregate delivery to ground
storage,transfer to conveyor,transfer to N/A !F2)Q.0102 No �Yeselevated storage,and weigh hopper (2)(E)(i) y L J
3) Pre-inspection Conference: On August 24, 2020, I,Richard Morris with DAQ called and
spoke with Michael Calloway, plant operator with Kerr Concrete. Based on my conversation
with him, we discussed the following:

a) Verified the contacts based on FACFINDER printout. Robert Kerr is now
signature authority (James Kerr died two years ago).
b) I informed Mr. Calloway that because of COVID-19 pandemic,NCDAQ is not
physically inspecting facilities. We are conducting Partial Compliance Evaluations
remotely to fulfill our compliance commitments. I requested he answer some
questions about production and record keeping which he was glad to answer.
c) I asked for the most recent bag filter logbook entries that is kept in the dispatchers
control room. They keep a very good log with recent entries of maintenance and bag
change out. Last annual inspection for all control devices was performed on
8/04/2020. All bags were checked and an air valve for the compressor was replaced.
d) The facility was not operating at the time of my call.
4) Process Description: (AP-42)
Concrete is composed essentially of water, cement, sand(fine aggregate), and coarse aggregate.
Coarse aggregate may consist of gravel, crushed stone, or iron blast furnace slag. Some specialty
aggregate products could be either heavyweight aggregate (of barite, magnetite, limonite,
ilmenite, iron, or steel) or lightweight aggregate (with sintered clay, shale, slate, diatomaceous
shale, perlite, vermiculite, slag, pumice, cinders, or sintered fly ash). Concrete batching plants
store, convey, measure, and discharge these constituents into trucks for transport to a job site. In
some cases, concrete is prepared at a building construction site or for the manufacture of
concrete products such as pipes and prefabricated construction parts. The raw materials can be
delivered to a plant by rail, truck, or barge. The cement is transferred to elevated storage silos
pneumatically or by bucket elevator. The sand and coarse aggregate are transferred to elevated
bins by front end loader, clam shell crane, belt conveyor, or bucket elevator. From these
elevated bins,the constituents are fed by gravity or screw conveyor to weigh hoppers,which
combine the proper amounts of each material. Truck mixed(transit mixed) concrete involves
approximately 75 percent of U. S. concrete batching plants. At these plants, sand, aggregate,
cement, and water are all gravity fed from the weigh hopper into the mixer trucks. The concrete
is mixed on the way to the site where the concrete is to be poured. Central mix facilities
(including shrink mixed) constitute the other one-fourth of the industry. With these, concrete is
mixed and then transferred to either an open bed dump truck or an agitator truck for transport to
the job site. Shrink mixed concrete is concrete that is partially mixed at the central mix plant and
then completely mixed in a truck mixer on the way to the job site. Dry batching, with concrete
mixed and hauled to the construction site in dry form, is seldom, if ever, used.
5) Inspection: No on-site inspection was conducted.
a. ES4 Truck load out: Not observed.
b. ES1 cement silo: Not observed.
c. ES2 flyash and ES-3 weigh hopper: Not observed.

6) Regulatory Review:
2D.0515 —Particulate Control (process weight). In compliance. Bagfilter control.
2D.0521 —Visible Emissions. Not observed. Facility not operating.
2D.0540—Fugitive Dust Control. Not observed. No fugitive dust observed.
7) Reporting requirements:
There are no reporting requirements in the current permit.
8) 112R Status: Based on the facility's inventory, it was decided that they are not subject to
112R reporting requirements.
9) Comments and Compliance Statement:
Based on review of records and discussions with facility contact,this facility appeared to
be in compliance with the Air Quality standards and regulations at the time of this
inspection.
10) 5 Year Compliance History:
No violations in past 5 years.