AQ_F_1800462_20181116_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: 11/16/2018
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: 35d 37.8594m Long: 81d 12.7206m Classification 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 11/16/2018
Inspector's Name Karyn Barksdale
Inspector's Signature: Operating Status Operating
Compliance Code Compliance-inspection
Action Code FCE
Date of Signature: /ZG1B J 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:None
Date Test Results Test Method(s) Source(s)Tested

Midstate Contractors,Inc.
November 16, 2018
Page 2
Type X Full Compliance —Partial Compliance _Complaint Other:
Action: Evaluation Evaluation/Reinspection Investigation
Data Date submitted for initial review 11/16/2018 _IBEAM WARNING/OB,NOD,NOV,NRE
Tracking: X IBEAM Document
X IBEAM Inspection, list date inspected _IBEAM LAULONG,Facility Locked
X IBEAM Inspection, list date draft is submitted X IBEAM LAT/LONG,Coordinates checked
X IBEAM Inspection,pollutants/programs _IBEAM Complaint
checked X IBEAM Planning,Next Inspection Date
11/1/2019
Directions: From MRO,travel Hwy. 150 west toward Lincolnton. Turn right onto Hwy. 16 north.
Travel approximately 9 miles and turn left onto Smyre Farm Road. Travel approximately 3 miles turn left
onto Indian Trail,the facility will be immediately to your left.
Safety Equipment: Safety glasses,hardhat and safety shoes are recommended.
Safety Issues: None noted.
Lat/Long Coordinates: A review of the facility's coordinates on "Maps of DAQ Regulated Facilities"
indicates the facility's latitude and longitude coordinates are accurate and NOT locked in IBEAM.
Email Contacts: IBEAM contacts were verified and the Invoice Contact needed updating. An email requesting
the update was sent to Sandy Sherer.
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 has a variable operating schedule that is approximately 20-30 per
week. I arrived at the facility Friday, November 16, 2018 and Mr. Raymond Lovins, Plant
Manager, accompanied me during this inspection.
2. Facility Contact Information.
IBEAM contacts were verified and the Invoice Contact needed updating. An email requesting the update
was sent to Sandy Sherer.
3. Compliance history.
A Notice of Deficiency was issue to the facility on July 25, 2012 for not performing the bagfilter
and cyclone inspections as required.

Midstate Contractors,Inc.
November 16, 2018
Page 3
4. Observations of permitted air emission sources and control devices
Emission Emission Source Control Control System
Source ID Description System ID Description
ES 1 natural gas-fired hot drum-mix CD 1, CD2 cyclone(112 inches in
(NSPS) . asphalt/RAP plant(110 million diameter) and bagfilter
Btu per hour maximum heat input Al 1,581 square feet of
rate, 350 tons per hour maximum filter area) installed in
capacity) series
The rotating drum at,the plant is a counterflow arrangement. Virgin materials are added to
five bins by front end loader, screened and conveyed to the drum where they were heated to
remove moisture. RAP is crushed, screened and conveyed to the opposite side of the drum
where it is added along with liquid asphalt beyond the heating point. The finished asphalt
mix is conveyed into 2 large storage silos.
Observed. At the time of this inspection, the plant was in operation producing a binder
asphalt comprised of 25% RAP (recycled asphalt) and 75% virgin material. The NG hot
drum mixing unit(ID No. ES 1)was operating at 175 tons per hour at a mix temperature of
300 degrees (varying by +/- 10%). The pressure drop in the baghouse was 2.9 inches of
water. There were no emissions observed from this process other than steam.
Emission' Emission Source Control Control System
Source ED Description System ID Description
F 14 RAP screen(200 tons per hour maximum N/A N/A
capacity)
.................
Observed. RAP is conveyed from the crusher(F18)to the screen. RAP that is too large
is rejected and conveyed back to the crusher. The RAP screen (ID No. F14) was in
operation.No emissions were observed from this process at the time of inspection.
Emission Emission Source F__ Control Conrol
Source Description System ID Sstem
ID [1l)esyritption
F18 RAP crusher(50 tons per hour N/A F N/A
maximum capacity)
Observed. RAP stockpiles from the yard are brought to the crusher,which drops material
into a conveyor and brings it to the RAP screen(1714). Larger particles are rejected by the
screen and returned via conveyor belt to be re-crushed. The RAP crusher (ID No. F18)
was in operation at the time of inspection. No emissions were observed from this process
at the time of inspection.

Midstate Contractors,Inc.
November 16,2018
Page 4
Contro
Emission Emission Source Control l
System
Source ID Description System ID ' Description
F15 JThree(3)RAP conveyors(200 tons N/A N/A
per hour maximum capacity each)
Observed. There are actually 4 conveyor belts. A short conveyor belt (1) that brought
material from the RAP crusher to a long RAP conveyor belt(2)that brought the RAP to
the RAP screen. A return belt(3) brought rejected material from the screen back to the
crusher and a weigh conveyor belt (4) brought material from the screen into-the asphalt
drum. The conveyors were in operation at the time of inspection. No emissions were
observed from this process at the time of inspection.
5. Observations of insignificant air emission sources and control devices listed on the current
Source Exemption Source of Source of Title V
Regulation TAPS? Pollutants?
I-1711 - liquid asphalt tank 2Q .0102 yes Yes
'(30,000 gallons capacity) (c)(1)(L)(xii)
I-F12 - liquid asphalt tank 2Q .0102 yes Yes
(30,000 gallons capacity) i (c)(1)(L)(xii)
I-ES3 -natural gas-fired burner 2Q .0102
(0.5 million Btu per hour (c)(2)(B)(i)(I) Yes Yes
maximum heat input rate) i _
I F
I-ES2 -natural gas-fired burner 2Q .0102
0.8 million Btu per hour Yes Yes
maximum heat input rate)
( p (c)(2)(B)(i)(1)
�
Observed. Each burner is attached to an asphalt tank to keep the material warm prior to
injection into the mixing drum. The above units were observed at the time of inspection.
No emissions were observed from the process.
Source Exemption Source of Source of Title V
Regulation TAPs? Pollutants?
I-F13 - one(1)No. 2 fuel oil 2Q .0102 `
storage tank(20,000 gallons (c)(1)(D)(i) Yes Yes
.--F
:capacity)
Observed. The storage tank(ID No. 1-F13) is disconnected from the asphalt drum. This
was observed at the time of inspection.

Midstate Contractors,Inc.
November 16, 2018
Page 5
Source Exemption Source of Source of Title V
Regulation TAPS? Pollutants?
I-1`17 -RAP feeder bin (200 1 i
tons per hour maximum 1 2Q .0102
? (c)(2)(E)(i)
capacity) No Yes
Observed. The feeder bin was being loaded at the time of inspection with no visible
emissions.
Source Exemption Source of Source of Title V
Regulation Source
Pollutants?
I-F9 -hot-mix asphalt 2Q .0102
storage silos(200 tons) (c)(11)(L)(xii) No No
i
I-F7 - drum main conveyor
(525 tons per hour 2Q No Yes
maximum capacity) (c)(2)(E)((E)(i) f
Observed. The main drum conveyor is used to bring virgin material to the drum so that it
can be dried prior to adding the RAP and liquid asphalt. The conveyor was in operation
with no visible emissions. The two silos were not being loaded at the time of inspection.
6. Observations of air emission sources and control devices not listed on the current permit:
a. None noted.
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 21) .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.
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."

Midstate Contractors,Inc.
November 16,2018
Page 6
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. The plant was in operation at the time of inspection. No visible emissions
were observed other than steam. Compliance with this stipulation is indicated.
C. Condition A.4. 15A NCAC .0516 "Sulfur Dioxide Emissions from Combustion Sources"
states that the facility cannot burn 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. The plant was in operation at the time of inspection with no visible emissions
observed other than steam. 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 September 23, 2010 and was observed by Ms. Donna Cook of this Office.
Test results were received by the Mooresville Regional Office on October 27, 2010
indicating 0% visible emissions and PM emissions of 0.020 gr/dscf(limit 0.04 gr/dscf).
The test results were reviewed and approved on May 25, 2012. Mr.Lovins stated that the
facility has plans to conduct testing in 2019, it is not required until 2020. 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.
Observed. This office has not received any complaints regarding the facility,and no
fugitive dust emissions were observed at the time of this inspection. Compliance with this
condition is indicated.

Midstate Contractors,Inc.
November 16,2018
Page 7
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.ES 1)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. The required initial testing was conducted on September 23, 2010 and was
observed by Ms. Donna Cook of this Office. The test was approved. The next test must
be performed by the facility in a timely manner. Mr. Lovins stated that the facility has
plans to conduct testing in 2019, it is not required until 2020. 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. Previous inspections were conducted on
October 3, 2016 and February 1, 2017; all bagfilter bags were replaced in 2017 as well as
the cages. The most recent inspection was conducted January 20, 2018. 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. Previous inspections were conducted on October 3, 2016 and
February 1, 2017. The most recent inspection was conducted January 20, 2018.
Compliance with this condition is indicated.
k. Condition A.12. 15A NCAC 2D .1806. "Control and Prohibition of Odorous Emissions."
Control odors properly.
Observed. This office has not received any odor complaints concerning the facility, and
no odors were noted outside the facility at the time of inspection. Compliance with this
condition is indicated.
1. Condition A.13. 15A NCAC 20 .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.
Observed.The facility is maintaining daily and monthly records of asphalt production.For
the month of October 2018, total production was 10,025.74 tons. The required annual
report for 2017 was received on January 25, 2018 indicating compliance with the permit

Midstate Contractors, Inc.
November 16, 2018
Page 8
limits. Total asphalt production for 2017 was 83,862.38 tons with resulting CO emissions
of 6.02 tons. Compliance with this stipulation is indicated.
8: NSPS/NESHAP Review
40 CFR Part 60 Subpart 000 applies to the portable crusher that is contracted 1-2 times per year
for the RAP stockpile. An e-mail request was made to the facility for the required emission testing
documentation. 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 duringthe the inspection:
Mr. Lovins was reminded that testing required under 2D .0605 will be due in 2020. Mr. Lovins
stated the facility plans to conduct the test in 2019 and we discussed the protocol submitting
requirements as well and the notification requirement for DAQ to be present during testing.
11. Section 112(r)applicability:
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.
KRB:Ihe
c: MRO File
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