AQ_F_1800462_20200113_CMPL_InspRpt

NORTH CAROLINA DIVISION OF Mooresville Regional Office
AIR QUALITY Midstate Contractors,Inc.
NC Facility ID 1800462
Inspection Report County/FIPS: Catawba/035
Date: 01/02/2020
Facility Data Permit Data
Midstate Contractors,Inc. Permit 08115/R08
2260 Indian Trail Issued 8/21/2014
Newton,NC 28658 Expires 7/31/2022
Lat: 35d37.8594m Long: 8ld 12.7206m Class/Status Synthetic Minor
SIC: 2951 /Paving Mixtures and Blocks Permit Status Active
NAICS: 324121 /Asphalt Paving Mixture and Block Manufacturing Current Permit Application(s)None
Contact Data Program Applicability
Facility Contact Authorized Contact Technical Contact SIP
Raymond Lovins ..James Abernethy Raymond Lovins
NSPS`. Subpart I
Plant Manager President Plant Manager
[phone] [phone] [phone]
Compliance Data
Comments:
Inspection Date 01/02/2020
Inspector's Name Jim Vanwormer
Inspector's Signature: ��. - Operating Status Operating
Compliance Code Compliance-inspection
p Action Code . FCE
Date of Signature: � 'J 3 hso t' .11317P On-Site Inspection Result Compliance.
Total Actual emissions in TONS/YEAR:
TSP S02 NOX VOC CO PM10 *HAP
2013 0.8200 --- 0.4800 0.9000 2.47 0.5200 119.00
2008 4.44 2.89 2.17 2.52 7.10 2.30 332.00
*Highest HAP Emitted inpounds)
Five Year Violation History:None
Date Letter Type Rule Violated Violation Resolution Date
Performed Stack Tests since last FCE:
Date Test Results Test Method(s) Source(s)Tested
06/17/2019 Compliance

Midstate Contractors,Inc.
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Page 2
[ETypeAction.: X Full Compliance _Partial Compliance _Complaint Other:
Evaluation Evaluation/Reinspection Investigation
L
Date submitted for initial review 1/2/2020 IBEAM INFO,WARNING/OB,NOD,NOV,NRE
X IBEAM Document
X IB'EAM Inspection,list date inspected X IBEAM LAT/LONG,Facility Locked
X IBEAM Inspection,list date draft is submitted X IBEAM LAT/LONG,Coordinates checked
X IBEAM Inspection,pollutants/programs checked _IBEAM Complaint
X IBEAM Planning,Next Inspection Date 1/l/2021
Directions: From MRO,travel Hwy. 150 west toward Lincolnton. Turn right onto Hwy. 16 north.
Travel approximately 9 miles and turn left onto Smythe Farm Road. Travel approximately 3 miles and
the facility is located on the left.
Safety Equipment. Safety glasses,hardhat and safety shoes are recommended.
Safety Issues: None noted
Lat/Lonz Coordinates: A review of the facility's coordinates on "Maps of DAQ Regulated Facilities"
indicates the facility's latitude and longitude coordinates are accurate.
Email Contacts: IBEAM email contacts were verified
1, The purpose of this site visit was to conduct a routine air quality inspection. This facility is a
drum-mix asphalt plant. The facility is currently operating forty hours per week, with production
of asphalt during approximately 20 hours a week. The facility typically shuts down for 4-6 weeks
between mid-January and mid-March depending on weather conditions. I arrived at the facility at
9:45am and met with Mr. Raymond Lovins, Plant Manager, who accompanied me during this
inspection.
2. Facility Contact Information:
During the inspection,I verified the facility contact information in IBEAM..
3. Compliance history file review:
No problems have been noted in the last five years by DAQ, prior to this inspection. The current
compliance status is discussed in the following sections.
4. Observations of permitted air emission sources and control devices:
Emission Emission Source F Control Control System
Source ID Description System ID Description
ES1 (NSPS) natural gas-fired hot _CD1, CD2 cyclone(112 inches in
drum-mix asphalt/RAPdiameter)and bagfilter
plant(110 million Btu I 1(11,5 81 square feet of 1
per hour maximum heat i Ifilter area) installed in

Midstate Contractors, Inc.
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Emission Emission Source Control _ Control System
' Y
Source ID Description System ID Description
input rate,350 tons per '� Iseries
'hour maximum capacity) _
Observed. At the time of the inspection,the plant was not operating, no emissions were observed
Emission Emission Source Control Control System
Source ID Description System ID Description
'F14 1RAP screen(200.tons per N/A [N/A .
hour maximum capacity)
Observed.At the time of the inspection,the plant was not operating,no emissions were observed
Emission Emission Source Control Control System
Source ID Description I System ID Description
=F18 RAP_crusher(50 tons per:N/A N/A
`hour maximum capacity)
Observed.At the time of the inspection,the plant was not operating, no emissions were observed
Emission Emission Source Control Control System
Source ID Description System_ID Description
F15 Three(3)RAP i
conveyors(200 tons per N/A 'N/A
hour maximum capacity .
each)
Observed.At the time of the inspection,the plant was not operating,no emissions were observed
5. Observations of insignificant air emission. sources and control devices listed on the current
permit:
Source Exemption Souk rce of ; Source of Title V
Regulation TAPs? _ Pollutants?
I-F11 - liquid asphalt tank(30,000 gallons 2Q .0102 h Yes ' yes
•
capacity) . . (c)(1)(L)(xii) ;
;I-F12- liquid asphalt tank(30,000 gallons 2Q .0102 yes Yes
capacity) (c)(1)(L)(xii) `I
+ES3 -natural gas-fired burner(0.5 million 2Q .0102 yes Yes
Btu per hour maximum heat input rate) (c)(2)(B)(i)(I) ^----
I-ES2 -natural gas-fired burner(0.8 million 2Q .0102 yes Yes
Btu per hour maximum heat input rate) (c)(2)(B)(i)(I)

Midstate Contractors,Inc.
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Observed. Each burner is attached to an asphalt tank to keep the material warm prior to injection
into the mixing drum. At the time of inspection, the burners were not operating. There were no
emissions observed from the process.
Source Exemption [-Source_
of Source of Title V
Regulation i TAPs? Pollutants?
I-F 13 - one(1)No. 2 fuel oil storage tank ]2Q .0102 yes Yes
i(20,000 gallons capacity) (c)(1)(D)(i)
Observed. The storage tank had been disconnected from the'asphalt drum. The fuel was used
for vehicles only and there were no emissions observed.
Source Exemption Source of Source of Title V
Regulation TAPS? -Pollutants.?.,,-
J-F 17 -RAP feeder bin(200 tons per 2Q .0102
No Yes
hour maximum capacity) (c)(2)(E)(i)
Observed. The feeder bin was not in operation with no visible emissions.
Source Exemption Source of Source of Title V
Regulation TAPS? Pollutants?
4-179 -hot-mix asphalt storage silos(200 2Q .0102 No No
:tons) .__.. . _._ ._ . (c)(1)(L)(xii) -
4-177 drum main conveyor(525 tons per �2Qhour maximum capacity) ) No Yes
Observed.At the time of the inspection,the plant was not operating,no emissions were observed
6. Observations of air emission sources and control devices not listed on the current permit:
a. None noted. r
7. Compliance with specific permit conditions and limitations:
a. Condition A. 2. "Permit Renewal and Emission Inventory Requirement" states that at
least 90 days prior to the expiration date of this permit,the Permittee shall request permit
renewal by letter with AA application form and submit air pollution emission inventory
report with certification sheet for 2021 calendar year to MRO DAQ.
Observed. The facility has a permit that expires on July 31, 2022. Compliance with this
stipulation is indicated.
b. Condition A. 3. 15A NCAC 2D .0506 "Particulates from Hot Mix Asphalt Plants" states:
i. Particulate matter emissions resulting from the operation of a hot mix asphalt
plant shall not exceed allowable emission rates.

Midstate Contractors,Inc.
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ii. Visible emissions from stacks_or vents at a hot mix asphalt plant shall be less
than 20 percent opacity when averaged over a six-minute period.
iii. Fugitive dust emissions shall be controlled as required by 15A NCAC 2D .0540
"Particulates from Fugitive Dust Emission Sources."
iv. Fugitive emissions for sources at a hot mix asphalt plant not covered elsewhere
under this Rule shall not exceed 20 percent opacity averaged over six minutes.
Observed. At the time of this inspection,the plant was not in operation. No visible
emissions were observed: Compliance with this stipulation is indicated.
C. Condition AA 15A NCAC..0516. "Sulfur Dioxide Emissions from Combustion Sources"
states that the faci rn lity cannot bum fuel with sulfur dioxide emissions from the combustion
sources shall not exceed 2.3 pounds per million Btu heat input.
Observed. The facility operates solely on natural gas, compliance with this stipulation is
indicated.
d. Condition A.5. 15A NCAC .0521, "Control of Visible Emissions." The facility is limited
twenty percent opacity.
Observed. At the time.of this inspection,the plant was not in operation with no visible
emissions. Compliance with this condition is indicated.
e. Condition A. 6. 15A NCAC 2D .0524, "New Source Performance Standards." NSPS
Subpart I. The facility must comply with all applicable provisions, including the
notification,testing, reporting, record-keeping and monitoring.
Observed. The facility has complied with applicable NSPS requirements. Testing was
conducted on June IJ-12, 2019 for total particulate matter(PM) and on June 17, 2019 for
C opacity. Test results:were received by the Mooresville Regional Office on July 11, 2019
indicating 0.4% visible emissions and PM emissions of 6.7 g/dscm (limit 90 gr/dscm).
The test results were reviewed and approved by the SSCB on October 29, 2019.
Compliance with this condition is indicated.
f. Condition A.7. 15A NCAC 2D .0535. "Notification Requirement." The permittee of a
source of excess emissions that last for more than four hours and that results from a
malfunction, a breakdown of process or control equipment or any other abnormal
conditions, shall notify the Director or his designee of any such occurrence by 9:00 a.m.
Eastern time of the Division's next business day of becoming aware of the occurrence.
Observed. Based on a records review and a conversation with Mr. Lovins, no excess
emissions have occurred at the facility. Compliance with this stipulation is indicated.
g. Condition A.8. 15A 'NCAC 2D .0540, "Particulates from Fugitive Dust Emission
Sources." The Permittee,shall not cause or allow fugitive dust emissions to cause or
contribute to substantive complaints or excess visible emissions beyond the property
boundary.

Midstate Contractors,Inc.
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Observed. The MRO has not received any complaints regarding the facility and no
fugitive dust emissions were observed at the time oft his inspection. Compliance with
this condition is indicated.
h. Condition A.9. 15A NCAC 2D .0605, "Testing Requirement." The facility is required to
conduct PM emission testing on the drum-mix "asphalt/RAP plant (ID No. ESl) and
submit two (2) copies of the results to DAQ by September 30, 2020. The facility is also
required to submit a testing protocol to DAQ at least 45 days prior to testing for approval.
Observed. Testing was conducted on June 11-12, 2019 for total particulate matter(PM)
and on June 17, 2019 for opacity. Test results were received by the Mooresville
Regional Office on July 11, 2019 indicating 0.4%visible emissions and PM emissions of
6.7 g/dscm(limit 90 gr/dscm). The test results were reviewed and approved by the SSCB
on October 29, 2019. Compliance with this condition is indicated.
i. Condition A.10. 15A NCAC 2D .0611, "Fabric Filter Requirements." The facility is
required to conduct an annual internal inspection of the fabric filter system and record the
results of this inspection and any maintenance performed in a fabric filter log book.
Observed. The facility conducts periodic inspections of the fabric filter system and
records the results in a fabric filter log book. The last two internal inspections were
conducted on January 20, 2018 and January 17, 2019. The facility has another internal
inspection scheduled for'January 13, 2020 during their annual shutdown. Compliance
with this condition is indicated.
j. Condition A.11. 15A NCAC 2D .0611, "Cyclone Requirements." The facility is required
to conduct an annual inspection of the cyclone system and record the results and any
maintenance performed in a cyclone log book.
Observed. The facility conducts periodic inspections of the cyclone system and records
the results in a log book. The last two internal inspections were conducted on January 20,
2018 and January 17, 2019. The facility has another internal inspection scheduled for
January 13, 2020 during their annual shutdown. Compliance with this condition is
indicated.
k. Condition A.12. 15A NCAC 2D .1806, "Control and Prohibition of Odorous Emissions."
Control odors properly.
Observed —The MRO has not received any odor complaints concerning the facility, and
no odors were noted outside the facility at the time of this inspection. Compliance with
this condition is indicated.
1. Condition A.D. 15A NCAC 2Q .0501, "Synthetic Minor Facilities." Facility-wide
emissions of CO shall be.less than 100 tons per consecutive 12-month period. To comply
with the permit limit, the production of hot-mix asphalt shall be less than 1,490,941 tons
per consecutive 12-month period. The facility shall record monthly and total annually the
total asphalt produced. Within 30 days after each calendar year, the Facility is required
to submit an annual report to DAQ containing the total amount of hot-mix asphalt
produced during the previous 12 months and the Facility-wide CO emissions for the
previous 12 months.

Midstate Contractors,Inc.
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Observed - The facility is maintaining daily and monthly records of asphalt production.
The required .annual report for calendar year 2018 was received by the Mooresville
Regional Office on January 30; 2019, indicating compliance with the permit limits. The
report showed total asphalt production of 92,076.91 tons in calendar year 2018 with
resulting CO emissions of 6.53 tons. Records were provided for calendar year 2019 up to
Dec I`which showed production of 129,597.21 tons with resulting CO emissions of 9.02
tons. Compliance with this condition is indicated.
8. NSPS/NESHAP Review
40 CFR Part 60 Subpart DOO applies to the portable crusher that is contracted 1-2 times per year
for the RAP stockpile. The facility is also subject to 40 CFR Part 60 Subpart I. No other NSPS
or NESHAP apply.
9. Summary of changes needed to the current permit:
None.
10. Compliance assistance offered during the inspection:
None.
11. Section 112(r)gpplicability:
This facility does not appear to be subject to the requirements of the Chemical Accident Release
Prevention Program, Section 112(r)of the Clean Air Act.
12. Compliance determination:
Based on my observations, this facility appeared to be in compliance with the applicable air
quality regulations at the time of the inspection.
JRV:Ihe
c: MRO File
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