NCG140350_COMPLETE FILE - HISTORICAL_20160920

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STORMWATER DIVISION CODING SHEET
NCG PERMITS
PERMIT NO.
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DOC TYPE,
1�- HISTORICAL FILE
❑ MONITORING REPORTS
DOC DATE
❑ aDI(p ��a
YYYYM M DD

NC®ENR
North Carolina Department of Environment and Natural Resources
Pat McCrory Donald R. van der Vaart
Governor
Secretary
September 20, 2016
JUSTIN HARTLEY
THOMAS CONCRETE OF CAROLINA INC.
PO Box 12544
RALEIGH, NC 27605
Subject: Multimedia Compliance Inspection
Thomas Concrete -Wake Forest
Wake County
Mr. Hartley:
Department of Environment and Natural Resources staff from the Raleigh Regional Office conducted a
multimedia compliance inspection of Thomas Concrete on September 13,2016 for permits and programs
administered by the following Divisions:
Division of Air Quality
Division of Energy,
Division of Water.
Division of Waste
Mineral, and Land
Resources
Management
Resources
We appreciate your cooperation during the inspection and hope that you have enjoyed the benefit of our
initiative to provide a single inspector capable of handling multiple areas of environmental compliance at
your facility. The results of each applicable inspection and any associated response actions or necessary
corrective measures are detailed in the inspection letters/reports attached to this transmittal sheet.
If you have any questions regarding this multimedia inspection or the results of each program inspection,
please contact the Raleigh Regional Office at [phone] and ask to speak with the appropriate Division .
staff. Thank you for your cooperation.
Copies: DAQ RRO Files
DEMLR RRO Files
DWR RRO Files
DWM RRO Files
NCDENR Raleigh Regional Office
- 1628 Mail Service Center, Raleigh, North Carolina 27699.1617
Location: 3800 Barrett Drive, Raleigh North Carolina 27609
Phone: 919.791 A200 \ Fax: [phone]
An Equal Opportunity \ Affirmative Action Employer- Made in part with recycled paper

PAT MCCRORY
Covemor
DONALD R. VAN DER VAART
secretary
September 20, 2016
Mr. Justin Hartley
Thomas Concrete of Carolina., Inc.
PO Box IZ544
Raleigh, NC 27605
Subject: NPDES Stormwater Compliance Evaluation Inspection
Certificate of Coverage No. NCG140350
Thomas Concrete -Wake Forest
Wake County
Dear Mr. Hartley:
Staff from the Department of Environmental Quality (DEQ) conducted a storm water inspection on
September 13, 2016, as part of a multimedia inspection of your facility. The assistance provided by Mr.
Andrew Rodak with Duncklee & Dunham and Casey Wiggins with Thomas Concrete during the
inspection was greatly appreciated. The inspection report is attached. Findings during the inspection
were as follows:
Certificate of Coverage (COC) No. NCG140130 under NPDES General Permit NCG140000
was issued to Thomas Concrete of Carolina., Inc. to discharge storm water runoff to the
Neuse River Basin.
2. The facility has developed and implemented a storriiwater pollution prevention plan (SPPP).
A review of the plan indicated that it included all components required by the general permit.
3. Semi-annual qualitative and analytical monitoring has been conducted at one storm water
discharge outfall (SDO), as required by the General Permit. However, TSS and ph readings
have consistently shown levels above the approved benchmark when a sample could be
taken: The facility is actively sampling according to the tier two protocol, but according to
the guidelines of the permit, should have initiated tier three protocol. This requires that the
facility notify the DEMLR Regional Office Supervisor (John Holley) in writing within 30
days of the receipt of the fourth analytical results above the benchmark. Additional measures
or practices which need to be implemented and a report outlining actions taken and follow up
analytical results is also required.
Raleigh Regional Office1628 Mail Service Center, Raleigh, North Carolina 27699-1628
Phone:.[phone] / FAX: [phone] / Internet: http://portal.ncdenr.org/web/lr/
An Equal Opportunity \ Affirmative Action Employer — 50% Recycled \ 10% Post Consumer Paper

Page 2 of 2
4. The SDO was observed and found accessible. An additional outlet point was identified that
was not shown on,the plan and was not actively being sampled. This additional SDO will
need to be added to the site map and sampling should begin immediately. The facility has the
option to eliminate the runoff to that outlet point, if practical, and divert the runoff to the
existing, sampling point (SDO) shown on the site map.
If you have any questions regarding the attached report or any of the findings, please contact Thad
-- .. .. Valentine at 919-791-4200 (or email: thad.valentine(c�ncdenr.g_ov)..

,
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- I
Compliance Inspection Report
Permit: NCG140350 Effective: 07/01/16 Expiration: 06/30/17 Owner: Thomas Concrete of Carolina Inc
SOC: Effective: Expiration: Facility: Thomas Concrete -Wake Forest Plant
County: Wake 2621 Teletec Piz .
Region: Raleigh -
Wake Forest NC 27587
Contact Pelson: Accounts Payable Title: Phone: [phone]
Directions to Facility:
System Classifications:
Primary ORC:
Secondary ORC(s):
On -Site Representative(a):
Related Permits:
Certification: Phone:
Inspection Date: 09/13/2016 Entry Time: 10:30AM Exit Time: 12:OOPM
Primary Inspector: Thaddeus W Valentine Phone:
Secondary Inspectore):
Reason for Inspection: Routine Inspection Type: Compliance Evaluation
Permit Inspection Type: Ready Mix Concrete Stormwater/Wastewater Discharge COG
Facility Statue: E] Compliant Not Compliant _
Question Areas:
E Storm water
(See attachment summary)
Page: 1

permit. NCG140350 Owner • Facility: Thomas Concrete of Carolina Inc
Inspection Date: 09/13/2018 Inspection Type : Compliance Evaluation Reason for Visit: Routine
Inspection Summary:
1. Please address the issue with the outfall in the NE corner of the parking lot that is not shown on the site map or being
sampled. Reply by September 30th outlining the method for resolving that issue.
- - 2. Clean up the concrete deposited at the top of the hill and down into the stream at the NE corner of the parking lot— ...
3. Place the oil drums and the used batteries inside the shop or under a shelter. Cover the greasy used parts drum and
cap off any drums that are missing plugs or otherwise open.
4. Add the required extra samples to the protocol for the maintenance shop (oil and grease)
5. Repair broken drain valves and secure all drain outlets for the secondary containment areas. -
6. Due to repeated high concentrations of TSS and ph, Tier 3 should be implemented and the Raleigh Regional Engineer.
John Holley should receive in writing notification of such with a copy of the last analytical results. The permittee is required
to implement additional methods to address the high TSS and ph results and submit a plan of action for that resolution by
October 15th. -
Page: 2

permit: NCG140350
Inspection Date: 09/13/2016
Analytical Monitoring
Has the facility conducted its Analytical monitoring?
Owner -Facility: Thomas Concrete of Carolina Inc
Inspection Type : Compliance Evaluation Reason for Visit Routine
# Has the facility conducted Its Analytical monitoring from Vehicle Maintenance areas?
Comment:
of oil per month so the sampling requirements for that condition should be implemented.,
Permit and Outfalls - Yes No NA NE
# Is a copy of the Permit and the Certificate of Coverage available at the site? ®0 ❑ ❑
# Were all ouflails observed during the Inspection? El ■ ❑ ❑
# If the facility has representative outfall status, Is it property documented by the Division? ' ❑ ❑
# Has the facility evaluated all Illicit (non stormwater) discharges? i El ❑ ❑
Comment: The one additional cutfall noted during our walk through should be addressed
Qualitative Monitoring Yes No NA NE
Has the facility conducted its Qualitative Monitoring semi-annually? M❑ ❑ ❑
Comment: Samoles recorded
Stormwater Pollution Prevention Plan
Does the site have a Stormwater Pollution Prevention Plan?
■ El El El
# Does the Plan Include a General Location (USGS) map? -
® ❑ Q ❑
# Does the Plan Include a `Narrative Description of Practices"?
e ❑ ❑ ❑
# Does the Plan include a detailed site map including outfall locations and drainage areas?El
®Q El
# Does the Plan Include a list of significant spills occurring during the past 3 years?
M,El El El
# Has the facility evaluated feasible alternatives to current practices?
M El ❑ ❑
# Does the facility provide all necessary secondary containment?
®El ❑ ❑
# Does the Plan include a BMP summary?
®El ❑ ❑
# Does the Plan include a Spill Prevention and Response Plan (SPRP)?
® ❑ 0 ❑
# Does the Plan include a Preventative Maintenance and Good Housekeeping Plan?
. ❑ ❑ ❑
# Does the facility provide and document Employee Training?
- 0 ❑ ❑ ❑
# Does the Plan include a list of Responsible Party(s)?
a 0 ❑ ❑
# Is the Plan reviewed and updated annually?
. ❑ ❑ ❑
# Does the Plan include a Stormwater Facility Inspection Program?
®1:1 ❑
Page: 3

Peank: NCG140350 - Owner -Facility: Thomas Concrete of Carolina Inc.
Inspection Date: 09/13/2016 Inspection Type: Compliance Evalua ton Reason for Visit Routine
Stormwater Pollution Prevention Plan - Yes No NA IN
Has the stormwater Pollution Prevention Plan been implemented? - _ ® ❑ 1111
Comment: While walking the site an additional outfall was discovered on the NE side of the Parking lot that
was not shown on the site map or being sampled It aPoe ared concrete was scraped -and
Page: 4

r
NORTH CAROLINA DIVISION OF
AIR QUALITY
Inspection Report
Date: 09/16/2016
Facility Data
Kaieigh Regional Office
Thomas Concrete of Carolina - Wake Forest
NC Facility ID 9200650
County/FIPS: Wake/183
Permit Data
u
Thomas Concrete of Carolina - Wake Forest
2621 Teletec Plaza
Wake Forest, NC . 27587
Lat 35d 55.2590m . Long: 78d 32.9710m
SIC: 3273 / Ready -Mixed Concrete .
NAICS: 32732 / Ready -Mix Concrete Manufacturing
Facility Contact Authorized Contact Technical Contact
Casey Wiggins Tim Coughlin Justin Hartley
Plant Manager Senior Vice President Area Manager
[phone] [phone] 1 [phone]
Comments: Compliance Assurance Visit —/In Compliance
Inspector's Signature:
l U�1^-
Date of Signature:
I Total Actual emissinnu in TnNSlVFAR-
Permit n/a
Issued n/a
Expires n/a
Classification n/a
Permit Status Permit Exempt
Current Permit Application(s) None
Program Applicability
SIP
Data
Inspection Date 09/13/2016
Inspector's Name Thaddeus Valentine
Operating Status Operating
Compliance Code Compliance - inspection
Action Code FCE
On -Site Inspection Result Compliance
TSP
S02
NOX
VOC
CO
PM10
*HAP
2013
0.2543
---
---
---
0.1211
0.0109
2008
4.95
---
---
---
---
2.33
0.0692
None
None
(1) DIRECTIONS TO SITE: From the RRO, take I440 Inner Beltline to Capital Boulevard North. Go through the intersection
at Burlington Mill Road. Immediately after this intersection, get in the left lane and turn around at the two-way connector.
Teletec Plaza will be the next road on the right. The facility is located at the end of Teletec Road.
(In FACILITY DESCRIPTION: The facility is a concrete batch plant. Standard safety gear is to be worn on facility visits.

(III) INSPECTION SUMMARY: On September 13, 2016, I (Thad Valentine) met with Mr. Casey Wiggins, Plant Manager &
Andrew Rodak, their Environmental Consultant, to conduct a compliance assurance visit at the Thomas Concrete Wake Forest
Plant. Thomas Concrete submitted a request to DAQ on July 14, 2016, to have their air permit for the Wake Forest plant
rescinded since the facility's overall emissions are below the new permit exemption thresholds in 15A NCAC 2Q .0102. The
request for permit rescission was approved, and the facility's air permit was inactivated on September 8, 2016. According to
the rescission request review document, this concrete batch plant remains eligible for permit exemption as long as total plant
_ production does not exceed 500,000 cubic yards of concrete per year.
During my September 13, 2016 site visit, I checked the plant's monthly and annual production rates, and they were well below
the permit exemption limit. For calendar year 2015, the Wake Forest plant produced a total of 24,648 cubic yards of concrete
and the YTD production total for 2016 is 19,540 tons. I also visually inspected the condition of the plant's bagfilter systems
and the associated ductwork, and all plant equipment appeared to be well maintained and in good working order. No visible
emissions were observed from any of the plant's emission sources. No fugitive dust or odorous emissions were observed
beyond the facility's property boundary. I reviewed the plant's inspection and maintenance records, and they appeared to be
complete and up to date. The last bagfilter inspections at the plant were performed July 19, 2016 with'no problems found.
Filter Kleen regularly inspects the facility's baghouses. Overall, the facility appeared to be operating well from an air quality
standpoint
A copy of the DAQ Compliance Assurance Checklist is attached to this report.
(IV) COMPLIANCE HISTORY: This facility has not been issued any NODs or NOVs within the last five years.
(V) CONCLUSIONS/RECOMMENDATIONS: At the time of the compliance assurance visit, the facility appeared to be in
compliance with all applicable au quality regulations. The facility's overall emissions were verified to be below the permit
exemption thresholds. It is recommended that the facility be revisited in two years.
Attachment

Coin Iiance Assurance'Visit Checklist
rev.8/05/16
Facilik; ame:
' Physical Site Address:
City: C,' Zip Code ::x7 County: :W 64 G
Facility Contact: Title:
Phone.No.i';cj 5-& —
Mailing'Address Q /3dr nJ_S CP ffu — LIZ ` �7 .. tj
Facility Contact Email Address:
Is the facility contact the person that you met?. if not, fill out the. following:
Contact Name: ;u' L Title:
Phone No.:,.:...
Mailing Address: `Sr'
Email Address: C'O?w_
Safety requirements safety shoes ye no) -safety glassesno) hearing protection (yes, ,hardhat es no)
other.(please descri e):
Normal operating schedule (hr/d, d/wk, wk/yr):
Opacity (%) - indicate any nonzero opacities observed:
Odors indicate if any objectionable odors were detected beyond the property boundary: Mph_
Fugitive dust - indicate whether fugitive dust was observed leaving property boundary: AJQ tiff
Since'last inspection, have there been any changes in equipment or operation?
Throughput and/or fuel usage with units:
Control device(s) (list):
Properly operated and maintained? 14 k5-
For permit exempt facility
) found to be iro
P P m erlY p g
o eratin rmamtaining plant equipment 1) provide compliance
assistance as a first o tion 2 initiate enforcement action m e regious repeat cases; 3) re evaluate'fa' ility's emissions using a
more representative control efficiency/emission factor; 4) If re-evaluated actual emissions result in a classification/ registration
change, follow, enforcement guidelines for operation without a permit/registration;and 5) increase compliance visit frequency'.
Notes or calculation space
Permit Exemption:
• Actual emissions from the previous year(s) (and projected actual) of PM10, S02, NOx, VOCs, CO, HAPs, and TAPs
are each < 5 tpy and whose actual total aggregate of these emissions are '< 10 tpy
• Can be subject to 40 CFR Part 63 (MACT or GACT) and 40 CFR Part 60 (NSPS)
• Cannot be subject to Rule 2Q.0315 (Synthetic Minor Facilities) or 2Q.0500.(Title V Procedures)
Registration:
• Actual aggregate emissions >= 5 tpy and < 25 tpy: PM10, CO, NOx, S02, VOCs, HAPs, and TAPS.
• Cannot meet permit exemption under 2Q.0102(d)
• Cannot be subject to Rule 2Q .0315 (Synthetic Minor Facilities) or 2Q.0500 (Title V Procedures)
• Cannot be subject to 40 CFR Part 63 (MACT) {Can be subject to 40 CFR Part 63 (GACT))
• Cannot emit volatile organic compounds or nitrogen oxides if the facility is located in a nonattainment area
• Cannot be subject to 40 CFR Part 60 (NSPS) except for sources which are exempt under 2Q .0102 (g) or (h)

6
Boilers: AUAL
ID No.
#1
#2
43
#4
Installed or last modified date
Size (mmBTU heat input):
Primary/backup fuel:..
Fuel used (annual)'
NSPS Subpart Dc subject?.
'NSPS Subpart Dc boiler if >10 mmBtu/hr and <1UU mmbtu/nr instanea or moamea arcer June 7, 1707.
Gas only Dc subject boilers: have they submitted initial' notification (only requirement)?,::': Yes / No / NA
Gas/fuel oil Dc subject boilers: records kept of each fuel type and startup notification for each fuel? : Yes / No / NA.
Fuel oil certification required for Dc boilers (0.5% max content). Are copies kept? >_ . `__Yes / No / NA "
If fuel oil Dc subject boiler > 30 mmBtu/hr, was opacity'testing performed on schedule based'on results?` Yes / No / NA
`If VE=O%then done annually, <=5% done semiannually, <=10%done quarterly, >10%done every 45 days.
GACT 6J Gas Curtailment option claimed? Yes / No .
If no, has a one time energy assessment been performed. Yes / No / NA
If no, are tune-ups being done biennially (25 months since last tune-up.)?. Yes / No / NA
If yes, are records kept for natural gas curtailment and testing less than 48 hours per year. Yes / No / NA
Generators:
ID No #1.,.. #2.. .._..... #3..::.. ,__ #4
Engine type: emergency, peak shaving, or
non -emergency /process related.'
Size (hp and_kW)
Fuel type
Manufacture date
Constructed (ordered).date
NSPS 41, 4J, or NESHAP 4Z subject?
NSPS 41, 4J, or NESHAP'4ZYeq met?,
If spark engine gas -only units),indicate '
4SRB; 45LB, 2SRB, or 25L8
Control Device if non -emergency.;;=
Fuel oil cert (<15 ppm S) copies kept?
Hour meterreadm '
g;
41"subject if Cl engine constructed (ordered) after 7/11/05 and manufactured after 4/1/06 .
4J subject if SI engine constructed (ordered) after 6/12/06 and manufactured after 4/1/06
4Z: existing constructed before 6/12/06 or new constructed on orafter 6/12/66 (compliance shown with 41 or 4J compliance).
Emerge ncy:'<100 hr/yrvon-emergency use. allowed: No notifications required Maintenance req: change oil/filter
inspect hoses/belts every 500 hrs/annually & air cleaner every 1000 hrs/ann; gas units inspect spark plugs every 1006 hrs/ann.
Non=emergency': performance test, operating limitations; notifications; semiannual compliance report's, and maintenance:
Is unit used for demand response? if so, cannot be considered emergency use after 5/1/16.
Notes or calculation space.

tonne ete Batch Plant77
Actual annual production (cy/yr): f CI S
Truck mix or, Central mix; plant?: Trucl' Central MR) (circle one) Controls Baghous / Cyclone / None
Quarries:
Annual production (tpy):
Crushers How many? Wet suppression?
Primary Y / N
Secondary 777TN
Tertiary Y / N
Screens: Y / N
Conveyer transfer pts Y / N
Is facility NSPS Subpart 000 subject (manufactured after 8/31/83). Yes / No / NA
If subject, must have site map; updated equipment list with throughputs, and initial PM/opacity testing. Yes / No / NA
sa a an
Type (Drum or Batch): Annual production (tpy):
Fuel type.
Fabric filter (y or n) Date constructed or modified:
Dryer rating (mm8tu/hr):.. If afterjune ll; 1973 then subject to NSPS Subpart I and
RAP Crushing onsite? Methods San d 9 testing required.
If yes, lump buster or crusher . If applicable, test date:
AC heater rating (m . u/hr)
FeedMills:
Indicate throughput (in tpy) for each:,
Process:. Process: t
Unloading: Bin Loading:
General (dump end) Load out (Shipping):
Railcar hopper bottom dump pit Truck
Truck hopper bottom dump pit Rail
Cleaning: Hammermill:
Drying: Cyclone
Column,. Baghouse
Rack Pellet Coolers:
Internal operations: Cyclone - std eff.
(belts, grain cleaner, head house, Cyclone - high eff.
closed -loop system -w/o grain clean)
NESHAP Subpart 7D subject if operate a prepared feeds manufacturing facility that uses a material containing Cr or Mn.
If subject, how is compliance demonstrated?
Woodworking; %eachmusttotal 100
Wood waste (tpy): Planing
or Sawing /chipping
Throughput (board ft/yr): Rough sawing
Wet / dry wood? Fine sawing
Bagfilter or cyclone? Milling (&hog)
Molding
Sanding
Wood Kiln:
Throughput (board ft/yr):
Hardwood:
Softwood:
For softwood, circle one kiln type: steam heated, direct -fired suspension, or direct -fired kiln gasifier.