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Home My WebLink AboutNCG140418_COMPLETE FILE - HISTORICAL_20150731111A) I A,1 L,_ . V�u STORMWATER DIVISION CODING SHEET NCG PERMITS PERMIT NO. �V C� �-� Vj DOC TYPE, HISTORICAL FILE ❑ MONITORING REPORTS DOC DATE 6-7 31 YYYYM M DD — A July 31, 2015 DUNCKLEE & DUNHAM Mr. Cory Larsen, P.E. Environmental Engineer Division of Water Resources EINVIRONMENI'AL GEOLOGIST'S & ENGINEERS 511 KEISLER DRIVE - SUITE 102 CARY. NORTH CAROLINA 27518 OFFICE: (919) 858-9898 WWW.D N KIEFD NHAM COM North Carolina Department of Environment and Natural Resources 3800 Barrett Drive Raleigh, North Carolina 27609 Reference: Response to NPDES Stormwater Compliance Inspection Thomas Concrete of North Carolina — Knightdale Batch Plant Knightdale, Wake County, North Carolina COC Number NCG 140418 Dear Mr. Larsen: Duncklee & Dunham, P.C. (Duncklee & Dunham), on behalf of Thomas Concrete of North Carolina, submits this response to inspection comments generated by the Department of Environment and Natural Resources (DENR) Division of Water Resources (DWR) during an inspection of their facility at 507 Old Montague Lane, Knightdale, Wake County, North Carolina. The facility is currently operating under NDPES Permit General Permit Number Certificate of Coverage NCG 140418. This letter is in response to the June 5, 2015 facility inspection conducted by the DWR and the subsequent letter issued June 8, 2015. This response letter addresses the inspection comments noted in the letter with a description of corrective measures taken by the facility following the inspection. Improperly Graded Northwest Area During the DENR inspection, the inspector identified an area on the northwest section of the property with improper grading relative to the site -wide stormwater management strategy. As currently graded, this area could be considered as a potential outfall location associated with industrial activity and requiring monitoring. Therefore, Thomas Concrete is re -grading this area to ensure that stormwater runoff from industrial areas is properly diverted to the wastewater recycling pits and not allowed to discharge from the property. Additionally, seven concrete blocks will be added to the back side of this area to provide structural stability to the area and reduce the risk of erosion. MAILING ADDRESS -POST OFFICE. BOX 639 - CARY, NORTI'I CAROLINA 27512 NOR TII CAROLINA BOARD OF EXAMINERS FOR ENGINEERS AND SURVEYORS LICENSE C-J559 NORTH CAROLINA BOARD FOR LICENSING OF GFOLOG13'r5 LICENSE C-261 NC DENR REGISTERED ENVIRONMENTAI.CONSULTANT NUMBER 00061 �' . 4 Response to DWR Inspection Letter Thomas Concrete of North Carolina. Inc. Knightdale, Wake County. North Carolina Julv 31. 2015 Pagc 2 of 2 2. Freeboard Maintenance of Wash Pit During the DENR inspection, the inspector noted the available freeboard in the wastewater collection pit to be approximately six inches and adversely impacted by the accumulation of solids in the pit (measured at four feet during the inspection). The inspector reminded facility personnel that a freeboard level of at least 12 inches is required at all times to provide for the design storage capacity of the pit during a rain event. Thomas Concrete will remove the accumulated solids from the wastewater pits and maintain the freeboard at measured level of at least 12 inches. They will measure the depth of accumulated solids on a weekly basis and remove solids as needed to maintain the design storage capacity and freeboard level of the wash pits. 3. Unpaid Permit Fee A review of the database indicated that the facility had not paid the annual stormwater permit fee for 2014. Thomas Concrete has since paid this fee in advance of this response letter. We trust that the corrective measures implemented by Thomas Concrete based on the inspection observations sufficiently address the deficiencies noted. Please contact us at (919) 858-9898 or via e-mail at Susan _.dunckleedunham.com if you have any questions regarding this response. Sincerely, Duncklee & Dunham, P.C. zac.l 6"'(- Susan Bostian, P.E. Senior Engineer Senior Peer Review: David Dunckl_e_e_,,PP.G. President Cc: Sam Crawford, Thomas Concrete 6Z4 Andrew Rodak, P.E. Senior Engineer \\boss\files\Projects\Thomas Concrele\t:CAP (Triangle Area plants)- 201409\Stormwater Monitoring\KD DENR DWR resp to insp 2015- 15211doc tF ' DUNCKLEE & DUNHAM, P.C. NC®EN� North Carolina Department of Environment and Natural Resources Pat McCrory Donald R. van der Vaart Governor Secretary 16 June 2015 SAMUEL CRAWFORD, GENERAL MANAGER/EXECUTIVE VICE PRESIDENT THOMAS CONCRETE OF CAROLINA— KNIGHTDALE BATCH PLANT 3733 NATIONAL DRIVE SUITE 124 RALEIGH, NC 27612 . Subject: Multimedia Compliance Inspection Thomas Concrete of Carolina — Knightdale Batch Plant Wake County Dear Permittee: Department of Environment and Natural Resources staff from the Raleigh Regional Office conducted a multimedia compliance inspection of Thomas Concrete of Carolina — Knightdale Batch Plant on 5 June 2015 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 a Division report is not attached, you may assume compliance with that particular Division's rules and regulations at the time of inspection. If you have any questions regarding this multimedia inspection or the results of each program inspection, please contact the Raleigh Regional Office at (919) 791-4200 and ask to speak with the appropriate Division staff. Thank you for your cooperation. encl: Air Quality Inspection Report Stormwater Inspection Report cc: 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: 919-791-42001 Fax: (919) 788-7159 An Equal Opportunity 1 Affirmative Action Employer— Made in part with recycled paper NODE R North Carolina Department of Environment and Natural Resources Pat McCrory Donald R. van der Vaart Governor Secretary June 8, 2015 MR. SAMUEL CRAWFORD— EXECUTIVE VP/GM THOMAS CONCRETE OF CAROLINA, INC. 3733 NATIONAL DRIVE, SUITE 124 RALEIGH, NORTH CAROLINA 27612 Subject: NPDES Stormwater Compliance Evaluation Inspection COC Number NCG 140418 Knightdale Batch Plant NCG 14000 General Permit for Ready -Mixed Concrete Wake County Dear Mr. Crawford: Staff from the Department of Environment and Natural Resources conducted a stormwater compliance inspection on June 5, 2015 for permit no. NCG 140418 as part of a multimedia inspection of your facility. We appreciate the assistance provided by Daniel Rusnak during the inspection. Please reference the attached inspection report checklist and.summary in addition to the comments provided below. The facility appeared clean and well -kept and was in compliance with most all permit requirements at the time of inspection. However, a number of items do require your attention as follows: A potential stormwater discharge outfall (SDO) location was observed at the northwest property corner near the aggregate loading conveyor and should be brought up in grade such that all runoff flows back to the recycle pit. Alternatively, this location may be monitored as another SDO in accordance with the permit. 2. This facility is exempted from qualitative and analytical monitoring of process water (wash pit) discharge so long that the pit maintains its function as a closed loop recycle system capable of holding all process water flows and runoff from the 25-yr, 24-hr storm event. Facility personnel noted that the pit does overflow into the yard occasionally but does not discharge during normal rainfall. Freeboard level during the inspection was approximately six inches and should be managed at all times to provide at least 12 inches to prevent overflows resulting from storms smaller than the 25-yr, 24-hr event. Personnel also measured solids depth in the pit .of approximately 4 feet as stated. The Division strongly recommends removal and proper disposal of that material as soon as possible and more rigorous management of recycle basin freeboard levels. 3. A review of our database indicates this facility has unpaid permit fees from 2012-2014. Please see the enclosed invoice and provide payment for $300.00 along with your response. Division of Water Resources, Raleigh Regional Office, Water Quality Operations Section http://portal.ncdenr.org/web/wq/aps 1628 Mail Service Center, Raleigh, NC 27699-1628 Phone: (919) 791-4200 Location: 3800 Barrett Drive, Raleigh, NC 27609 Fax: (919) 788-7159 An Equal Opportunity 1 Affirmative Action Employer- Made in part by recycled paper June 8, 2015 Page 2 of 2 Please provide your written confirmation and response to the above items within 30 days of receipt of this letter. If you have any questions regarding these matters, please contact me at cory.larsenna,ncdenr.gov or 919-791-4200. Sincerely, Cory r , Environmental Engineer Raleigh Regional Office Encl: Compliance Inspection Report Permit Fee Ihvoice cc: RRO/SWPFiles NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES II I I III II III I I II II I I IIII it II INVOICE * 2 0 1 2 P R 0 0 9 0 3 6 Annual Permit Fee Overdue This annual fee is required by the North Carolina Administrative Code. It covers the administrative costs associated with your permit. It is required of any person holding a permit for any time during the annual fee period, regardless of the facility's operating status. Failure to pay the fee by the due date will subject the permit to revocation. Operating without a valid permit is a violation and is subject to a$10,000 per day fine. If the permit is revoked and you later decide a permit is needed, you must reapply, with the understanding the permit request may be denied due to changes in environmental, regulatory, or modeling conditions. Invoice Number: 2012PR009036 Permit Number: NCG140418 Wake County Knightdale Batch Plant Daniel Rusnak Thomas Concrete of Carolina Inc 507 Old Monague Ln Knightdale, NC 27545 Annual Fee Period: 2012-10-01 to 2013-09-30 Invoice Date: 09/06/2012 Due Date: 10/06/2012 Annual Fee: $100.00 Notes: 1. You may pay either by checklmoney order OR by electronic payment. 2. If payment is by check/money.order, please remit payment to: NCDENR- Division of Energy, Mineral and Land Resources Attn: Stormwater Billing 1612 Mail Service Center Raleigh, NC 27699-1612 3. If payment is electronic, see htti)://portal ncdenr orp/weblwg/hot-tonics/eoavment for additional details. See http�llportal ncdenr orp/web/wp/eoavment to pay electronically. Only eCheck transactions are allowed at this time. Credit card transactions are not accepted. 4. Please Include your Permit Number and Invoice Number on all correspondence. 5. A $25.00 processing fee will be charged for returned checks in accordance with North Carolina General Statute 25-3-512. 6. Non -Payment of this fee by the payment due date will initiate the permit revocation process. 7. - Should you have any questions regarding this invoice, please contact the Annual Administering and Compliance Fee Coordinator at 919-707-9220. (Return This Portion With Check) 111211111112111 I I II II I91 II II I I II ANNUAL PERMIT INVOICE Overdue Invoice Number: 2012PR009036 Permit Number: NCG140418 Wake County Knightdale Batch Plant Daniel Rusnak Thomas Concrete of Carolina Inc 507 Old Monague Ln Knightdale, NC 27545 Annual Fee Period: 2012-10-01 to 2013-09-30 Invoice Date: 9/6/2012 Due Date: 10/6/2012 Annual Fee: $100.00 Check Number: NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES II I I it I III II I I II II II I I II II II INVOICE * 2 0 1 3 P R 0 0 7 9 3 7 Annual Permit Fee Overdue This annual fee is required by the North Carolina Administrative Code. It covers the administrative costs associated with your permit. It is required of any person holding a permit for any time during the annual fee period, regardless of the facility's operating status. Failure to pay the fee by the due dale will subject the permit to revocation. Operating without a valid permit is a violation and is subject to a $10,000 per day fine. If the permit is revoked and you later decide a permit is needed, you must reapply, with the understanding the permit request may be denied due to changes in environmental, regulatory, or modeling conditions.. Invoice Number: 2013PR007937 Permit Number: NCG140418 Wake County Knightdale Batch Plant Daniel Rusnak Thomas Concrete of Carolina Inc 507 Old Monague Ln Knightdale, NC 27545 Annual Fee Period: 2013-10-01 to 2014-09-30 Invoice Date: 09/11/2013 Due Date: 10/11/2013 Annual Fee: $100.00 Notes: 1. You may pay either by checkimoney order OR by electronic payment. 2. If payment is by check/money order, please remit payment to: NCDENR- Division of Energy, Mineral and Land Resources Attn: Stormwater Billing 1612 Mail Service Center Raleigh, NC 27699-1612 3. If payment is electronic, see http://Portal.ncdenr.orotweb/wp/hot-topics/eoavment for additional details. See http://portal.ncdenr.orgtweblwo/eoavment to pay electronically. Only eCheck transactions are allowed at this time. Credit card transactions are not accepted. 4. Please Include your Permit Number and Invoice Number on all correspondence. 5. A $25.00 processing fee will be charged for returned checks in accordance with North Carolina General Statute 25-3-512. 6. Nan -Payment of this fee by the payment due date will initiate the permit revocation process. 7. Should you have any questions regarding this invoice, please contact the Annual Administering and Compliance Fee Coordinator at 919-707-9220. (Return This Portion With Check) ANNUAL PERMIT INVOICE Invoice Number: 2013PR007937 Permit Number: NCG140418 Wake County Knightdale Batch Plant Daniel Rusnak Thomas Concrete of Carolina Inc 507 Old Monague Ln Knightdale, NC 27545 II 121 II I1 II I I II II 1119111 II II Overdue Annual Fee Period: 2013-10-01 to 2014-09-30 Invoice Date: 9/11/2013 Due Date: 10/11/2013 Annual Fee: $100.00 Check Number: NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES II I I III I II II I I II II I I II I I I I II INVOICE * 2 0 1 4 P R 0 0 8 0 9 9 Annual Permit Fee - Overdue This annual fee is required by the North Carolina Administrative Code. It covers the administrative costs associated with your permit. It is required of any person holding a permit for any time during the annual fee period, regardless of the facility's operating status. Failure to pay the fee by the due date will subject the permit to revocation. Operating without a valid permit is a violation and is subject to a $10,000 per day fine. If the permit is revoked and you later decide a permit is needed, you must reapply, with the understanding the permit request may be denied due to changes in environmental, regulatory, or modeling conditions. Invoice Number: 2014PR008099 Permit Number: NCG140418 Wake County Knightdale Batch Plant Daniel Rusnak Thomas Concrete of Carolina Inc 507 Old Managua Ln Knightdale, NC 27545 Annual Fee Period: 2014-10-01 to 2015-09-30 Invoice Date: 09/05/2014 Due Date: 10/05/2014 Annual Fee: $100.00 Notes: 1. You may pay either by check/money order OR by electronic payment. 2. If payment is by checklmoney order, please remit payment to: NCDENR - Division of Energy, Mineral and Land Resources Attn: Stormwater Billing 1612 Mail Service Center Raleigh, NC 27699-1612 3. If payment is electronic, see http://oortal.ncdenr.ora/web/wc/hot-topics/eoavment for additional details. See http://portal.ncdenr.orgtweblwg/eoavment to pay electronically. Only eCheck transactions are allowed at this time. Credit card transactions are not accepted. - 4. Please include your Permit Number and Invoice Number on all correspondence. 5. A $25.00 processing fee will be charged for returned checks in accordance with North Carolina General Statute 25-3-512. 6. Non -Payment of this fee by the payment due date will initiate the permit revocation process. 7. Should you have any questions regarding this invoice, please contact the Annual Administering and Compliance Fee Coordinator at 919-707-9220. (Return This Portion With Check) ANNUAL PERMIT INVOICE Invoice Number: 2014PR008099 Permit Number: NCG140418 Wake County Knightdale Batch Plant Daniel Rusnak Thomas Concrete of Carolina Inc 507 Old Monague Ln Knightdale, NC 27545 1112111111 IIII I I II III810 I91191 II Overdue Annual Fee Period: 2014-10-01 to 2015-09-30 Invoice Date: 9/5/2014 Due Date: 10/5/2014 Annual Fee: $100.00 Check Number: Compliance Inspection Report Permit: NCG140418 Effective: 10/31/11 Expiration: 06/30/16 Owner: Thomas Concrete of Carolina Inc SOC: Effective: Expiration: Facility: Knightdale Batch Plant County: Wake 507 Old Montague Ln Region: Raleigh Knightdale NC 27545 Contact Person: Daniel Rusnak Title: Phone: 919-217-2946 Directions to Facility: System Classifications: Primary ORC: Secondary ORC(s): On -Site Representative(s): Related Permits: Inspection Date: 06/05/2015 Primary Inspector: Cory Larsen Secondary Inspector(s): Entry Time: 09:OOAM Certification: Exit Time: 10:30AM Phone: Phone: 919-807-6300 Reason for Inspection: Routine Inspection Type: Compliance Evaluation .Permit Inspection Type: Ready Mix Concrete Stormwater/Wastewater Discharge CDC Facility Status: Compliant ❑ Not Compliant Question Areas: ® Storm Water (See attachment summary) Page: 1 Permit: NCG1404/6 Owner - Facility: Thomas Concrete of Carolina Inc Inspection Date: 06/05/2015 Inspection Type: Compliance Evaluation Reason for Visit: Routine Inspection Summary: A multi -media pilot program inspection was conducted by Division staff from Water Resources, Energy, Mineral and Land Resources, Air Quality, and Solid Waste on June 5, 2015 to evaluate compliance with NPDES stormwater and air quality permits issued to the facility. The stormwater inspection results for NCG140418 are presented below. The stormwater pollution prevention plan (SPPP) was reviewed and contained all essential components. A site map was available and appeared suitable. The SPPP will need to be reviewed and certified annually going forward. Adequate secondary containment is provided for the bulk storage of liquid products onsite. Vehicle maintenance is not conducted onsite other than minor greasing or topping off oil levels. Qualitative and analytical monitoring of process water (wash pit) discharge is not required due its function as a closed loop recycle system. Facility personnel noted that the pit does overflow into the yard occasionally but does not discharge during normal rainfall. Freeboard during the inspection was approximately six inches and should be managed at all times to provide at least 12 inches freeboard to prevent overflows resulting from storms smaller than the 25-yr, 24-yr event. Personnel indicated solids depth in the pit of 4 feet, and Division staff recommend removal and proper disposal of that material as soon as possible. A potential stormwater discharge outfall (SDO) location was observed at the northwest property corner near the aggregate loading conveyor and should be brought up in grade such that all runoff flows back to the recycle pit. Alternatively, this location may be monitored as another SDO in accordance with the permit. Overall the site is clean and well -kept and no other compliance issues were identified. Air quality inspection results are covered under separate report. No solid waste or land resource program violations were observed. Page: 2 Permit: NCG140418 Owner -Facility: Thomas Concrete of Carolina Inc Inspection Date: 06/05/2015 Inspection Type : Compliance Evaluation Reason for Visit: Routine Stormwater Pollution Prevention Plan Does the site have a Stormwater Pollution Prevention Plan? # Does the Plan include a General Location (USGS) map? # Does the Plan include a "Narrative Description of Practices"? # Does the Plan include, a detailed site map including outfall locations and drainage areas? # Does the Plan include a list of significant spills occurring during the past 3 years? # Has the facility evaluated feasible alternatives to current practices? # Does the facility provide all necessary secondary containment? # Does the Plan include a BMP summary? # Does the Plan include a Spill Prevention and Response Plan (SPRP)? # Does the Plan include a Preventative Maintenance and Good Housekeeping Plan? # Does the facility provide and document Employee Training? # Does the Plan include a list of Responsible Party(s)? # Is the Plan reviewed and updated annually? # Does the Plan include a Stormwater Facility Inspection Program? Has the Stormwater Pollution Prevention Plan been implemented? Comment: Qualitative Monitoring Has the facility conducted its Qualitative Monitoring semi-annually? Comment: No discharges, pit overflows into yard Analytical Monitoring Has the facility conducted its Analytical monitoring? # Has the facility conducted its Analytical monitoring from Vehicle Maintenance areas? Yes No NA NE ®❑❑❑ ®❑❑❑ ®❑❑❑ ®❑❑❑ ❑❑®❑ ❑ ❑ ❑ ® ❑ ❑ ❑ ®'❑ ❑ ❑ ® ❑ ❑ ❑ ®❑❑❑ ® ❑ ❑ ❑ ®❑❑❑ ®❑❑❑ U ❑ ❑ ❑ ®❑❑❑ Yes No NA NE ❑ ❑ O ❑ Yes No NA NE ❑ ❑ ® ❑ ❑❑®❑ Comment: No discharge, pit overflows into yard Only minor onsite vehicle maintenance (grease Points) Permit and Outfalls Yes No NA NE # Is a copy of the Permit and the Certificate of Coverage available at the site? ® ❑ ❑ ❑ # Were all outfalls observed during the inspection? ® ❑ ❑ ❑ # If the facility has representative outfall status, is it properly documented by the Division? ❑ ❑ ® ❑ # Has the facility evaluated all illicit (non stormwater) discharges? ® ❑ ❑ ❑ Comment: Action items: - solids cleanout (pit): - manage freeboard to maintain 1ft - bring up grade in ago loading area to prevent offsite discharge Page: 3 NCDENR North Carolina Department of Environment and Natural Resources Pat McCrory Donald R. van der Vaart Governor Secretary June 12, 2015 CERTIFIED MAIL RETURN RECEIPT REQUESTED Mr. Samuel Crawford General Manager/Executive Vice President Thomas Concrete of Carolina — Knightdale Batch Plant 3733 National Drive, Suite 124 Raleigh, NC 27612 SUBJECT: Notice of Deficiency— Unpermitted Emission Source Thomas Concrete of Carolina — Knightdale Batch Plant Knightdale, Wake County, North Carolina Air Permit No. 09858ROI Facility ID No. 9200799 Dear Mr. Crawford: On June 5, 2015, the North Carolina Division of Air Quality conducted a compliance inspection at Thomas Concrete of Carolina — Knightdale Batch Plant located in Knightdale, Wake County. At the time of the inspection, it was found that Thomas Concrete of Carolina — Knightdale Batch Plant is operating its permitted air emission sources differently than this equipment is listed in Air Permit No. 09858ROL After speaking with company representatives during the inspection and reviewing the DAQ facility files, it appears the following changes need to be made to the current permitted equipment list: • ES-1 is listed as a cement storage silo and should be listed as a flyash storage silo; • ES-3 is listed as a flyash storage silo and should be listed as a cement storage silo; • Silo-CF-03 Cartridge filter (72 sq. ft. of filter area) is not installed; instead, • BF-01 Bagfilter (1,900 sq. ft. of filter area) controls emissions from the ES-3 storage silo This office recommends that you or a designated representative conduct a complete inventory of all air emission sources and/or air cleaning devices at your facility and assure that all sources are permitted as they are required to be. If you have questions concerning specific processes, contact this office. To resolve this issue, the DAQ Raleigh Regional Office requests that the following information be submitted on or before June 30, 2015: (1) a complete and signed air permit application for modification including forms A1, A2, B forms (one for each source), C forms and D1 forms; (2) a check or money order for fifty ($50) dollars made payable to the NC Department of Environment and Natural Resources (NCDENR), to cover the necessary permit processing fee. Air permitting applications forms and instructions can be downloaded from the DAQ website at the following address: www.ncair.orc . Raleigh Regional Office 3800 Barrett Drive, Raleigh, North Carolina 27609 Phone: 919-791-42001 FAX: 919-881-2261 1 Internet: www.ncdenr.gov An Equal Opportunity 1 AKonalive Action Employer- Made in part by recycled paper Thomas Concrete of Carolina — Knightdale Batch Plant June 12, 2015 Page 2 Under the provisions of North Carolina General Statute 143-215.108 - Control of sources of air pollution; permits required, paragraph (a) states, "Except as provided in subsections (al). and (a2) of this section, no person shall do any of the following things or carry out any of the following activities that contravene or will be likely to contravene standards established pursuant to G.S. 143-215.107 or set out in G.S. 143-215.107D unless that person has obtained a permit for the activity from the Commission and has complied with any conditions of the permit: (1) Establish or operate any air contaminant source, except as provided in G.S. 143-215.108A. (2) Build, erect, use, or operate any equipment that may result in the emission of an air contaminant or that is likely to cause air pollution, except as provided in G.S. 143-215.108A. (3) Alter or change the construction or method of operation of any equipment or process from which air contaminants are or may be emitted..." Failure to submit timely permit modification applications in the future may constitute a violation of your air permit. Any violation of air quality regulations is subject to the assessment. of civil penalties as per North Carolina General Statute 143-215.114A. Your cooperation is this matter is appreciated. If you have any questions, please contact Maureen Conner, Environmental Engineer, or Steve Hall, Compliance Supervisor, at (919) 791-4200. Sincerely, PW-JW-A Patrick Butler, P.E., Regional Supervisor Division of Air Quality, NCDENR cc: RRO Files NORTH CAROLINA DIVISION OF Raleigh Regional Office AIR QUALITY Thomas Concrete of Carolina - Knightdale Batch Plant Inspection Report NC Facility ID 9200799 Date: 06/08/2015 County/FIPS: Wake/183 Facility Data Permit Data Thomas Concrete of Carolina - Knightdale Batch Plant Permit 09858 / R01 507 Old Montague Road Issued. 12/14/2012 Knightdale, NC 27545 Expires 11/30/2017 Lat:35d47.9501m Long:78d30.0996m Classification Small SIC: 3273 / Ready -Mixed Concrete Permit Status Active NAICS: 32732 / Ready -Mix Concrete Manufacturing Current Permit Application(s) None Program Applicability Contact Data Facility Contact Authorized Contact Technical Contact SIP Daniel Rusnak Sam Crawford Sam Crawford General General (919) 217-2496 Manager/Executive Vice Manager/Executive Vice President President 919 832-0451 919 832-0451 Compliance Data Comments: Inspection Date 06/05/2015 Inspector's Name Maureen Conner Inspector's Signature: Operating Status Operating Compliance Code Compliance - inspection Action Code FCE Date of Signature: J✓� 1 U 15 On -Site Inspection Result Deficiency Total Actual emissions in TONS/YEAR: TSP S02 NOX VOC CO PM10 *HAP 2011 0.0880 --- --- --- --- 0.0320 0.0138 * 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: From the RRO, take I-440 Inner Beltline to exit 13B, US-64 East. Stay on US-64 East, make U-Turn at (Quarry entrance), which will be US-64 West, next right is Old Montague Lane, plant is on left. II) FACILITY DESCRIPTION: This facility is a concrete batch plant. The facility operates under Air Permit No. 09858RO1. 0 7. 8. FUGITIVE DUST CONTROL REQUIREMENT , As required by 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. APPEARED IN COMPLIANCE- I did not observe any excess visible emissions at the property boundary. The facility staff stated that they have not had any dust complaints. BAGFILTER REQUIREMENTS -.As required by 15A NCAC 2D .0611, particulate matter emissions shall be - controlled as described in the pemrittetiequipment list. Perform, at a minimum, an annual internal inspection of each fdt bager system. In addition, the Permittee shall perform periodic inspections and maintenance as recommended by the equipment manufacturer. The results of all inspections and any variance from manufacturer's recommendations shall be investigated with corrections made and dates of actions recorded in a logbook APPEARED IN COMPLIANCE- The facility contracts out their inspections and maintenance to Filter Kleen Environmental Services. They conduct regular maintenance. The last regular inspection was conducted on 12-18-14 and the last internal Inspection was conducted on 3-26-2015. TOXIC AIR POLLUTANT EMISSIONS LIMITATION AND REPORTING REOUIREMENT - Pursuant to 15A NCAC 21) .1100 "Control of Toxic Air Pollutants," and in accordance with the approved application for an air toxic compliance demonstration, the following facility wide permit limit of 0.034 cubic yards/yr. of arsenic shall not be exceeded. The amount of concrete produced shall not exceed 100,000 cubic yards per calendar year. No permitted equipment shall be less than 24 meters from the closest point of the facility's property line. Annual report due January 30 each year of the total amount of concrete produced. The Permittee shall record monthly the cubic yards of concrete produced. APPEARED IN COMPLIANCE- The facility keeps monthly records of concrete produced and so far for 2015 the facility has produced 6,602 cubic yards of concrete. The facility submitted their annual report on time and it stated that in CY 2014 the facility produces 9,438 cubic yards of concrete. The physical plant has not been moved since it was installed. 9. TOXIC AIR POLLUTANT EMISSIONS LMTATION REQUIREMENT - Pursuant to 15A NCAC 2Q .0711 "Emission Rates Requiring a Permit," for each of the below listed toxic air pollutants (TAPS), the Permittee has made a demonstration that facility -wide actual emissions do not exceed the Toxic Permit Emission Rates (TPERs) listed in 15A NCAC 2Q .0711. The facility shall be operated and maintained in such a manner that emissions of any listed.TAPs.from the facility, including fugitive emissions, will not exceed TPERs listed in 15A NCAC 2Q .0711. �IPollutant ( Carcinogens Chronic Toxicants -.. _.... _.. ........ . _... ..±.........(lb/yr) _.! .......(lb/day) . ... . Beryllium metal (unreacted) (Component of B.EC) (7440-01-7) Cadmium Metal (elemental unreacted, Component of CDC) (7440-43 9) :' 0.37 !� Chrommm (VI) Soluble Chromate Compounds (Component of CRC) (So1CR6) �� 0 013 j Manganese & compounds (MNC) _ . _ i�- _.....0.63 (Nickel metal (Component of 373024/NIC) (7440-02-0) �l 0.13 APPEARED IN COMPLIANCE- The original permit review indicated that the emissions would be below the facility's toxic emissions limits. The facility has not made any changes to the plant that would increase toxic emissions. VI) GENERAL CONDITIONS AND LIMITATIONS 4. A new air permit shall be obtained by the Permittee prior to establishing, building, erecting, using, or operating the emission sources or air cleaning equipment at a site or location not specified in this permit. DEFICIENCY NOTED- The facility has not installed control device Silo-CF-03 and instead ES-3 Silo emissions are being controlled by BF-01 an existing permitted bagfilter. ES-1 is also being used as a Byash silo and not a cement silo. ES-3 is being used as a cement silo and not a llyash silo. VH) COMPLIANCE HISTORY: No negative compliance history. Permit: N�/At il 0Yi Owner - Facility: Wk-Ai Inspection Date: 6 ($ 115- Inspection Type: Compliance Evaluation Reason for Visit: Routine Stormwater Pollution Prevention Plan Yes No NA_ NE Does the site have a Stormwater Pollution Prevention Plan? o/0 ❑ ❑ # Does the Plan include a General Location (USGS) map? C! Ar❑ ❑ # Does the Plan include a "Narrative Description of Practices"? elo ❑ ❑ # Does the Plan include a detailed site map including outfall locations and drainage areas? n!' ❑ ❑ ❑ # Does the Plan include a list of significant spills occurring during the past 3 years? ❑ ❑ (?/ ❑ # Has the facility evaluated feasible alternatives to current practices? # Does the facility provide all necessary secondary containment? # Does the Plan include a BMP summary? # Does the Plan include a Spill Prevention and Response Plan (SPRP)? # Does the Plan include a Preventative Maintenance and Good Housekeeping Plan? # Does the facility provide and document Employee Training? # Does the Plan include a list of Responsible Party(s)? # Is the Plan reviewed and updated annually? # Does the Plan include a Stormwater Facility Inspection Program? Has the Stormwater Pollution Prevention Plan been implemented? Comment: Qualitative Monitoring Has the facility conducted its Qualitative Monitoring semi-annually? Comment: Analytical Monitoring Has the facility conducted its Analytical monitoring? # Has the facility conducted its Analytical monitoring from Vehicle Maintenance areas? Comment: Permit and Outfalls # Is a copy of the Permit and the Certificate of Coverage available at the site? # Were all outfalls observed during the inspection? # If the facility has representative outfall status, is it properly documented by the Division? # Has the facility evaluated all illicit (non stormwater) discharges? Comment: _ N" ai� o9 �S 4,'T g,1.4—Pe` J [, Q ? 1�. G 0 own Yes No NA NE Yes No NA NE Ly" ❑ �❑ Aa n^ f GY❑0❑ d❑❑❑ ❑❑VD 9,D ❑ ❑ c,, J _ "�/( �e Worth Carolina De lartment of Env'ronclent and W itural Resources Beverly Eaves Perdue Governor Mr. John Holding Thomas Concrete of Carolina, Inc. P.O. Box 12544 Raleigh, NC 27605 Dear Mr. Holding: Division of Water Q,ality Coleen H. Sullins Director October 31, 2011 Subject: General Permit No. NCG 140000 Knightdale Batch Plant COC No. NCG140418 Wake County Dee Freeman In accordance with your application for a discharge permit received on October 14, 2011, we are forwarding herewith the subject certificate of coverage (COC) to discharge under the subject state — NPDES general permit. This permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the US Environmental Protection Agency dated October 15, 2007 (or as subsequently amended). Please note that NCG 140000 contains effluent limitations for process wastewater discharges (see Part IV, Section D). At present, those limits are 6-9 S.U. for pH (when discharging to freshwaters), 6.8-8.5 S.U. for pH (when discharging to saltwaters), 30 mg/I for TSS, 20 mg/I for TSS (when discharging to HQW waters), 10 mg/I for TSS (when discharging to Trout and PNA waters), 5 mL/L for Settleable Solids, and 50% of the Summer 7Q 10 Flow for discharges to HQW waters. Wastewater discharges must meet the requirements of these effluent limitations. An exceedence of any of these limitations will result in a violation of the permit conditions. Please note that groundwater standards in 15A NCAC 02L and 02T regulations must also be met for any recycle systems or discharges to groundwater. Please take notice that this certificate of coverage is not transferable except after notice to the Division of Water Quality. The Division of Water Quality may require modification or revocation and reissuance of the certificate of coverage. This permit does not affect the legal requirements to obtain other permits which may be required by the Division of Water Quality or permits required by the Division of Land Resources, Coastal Area Management Actor any other federal or local governmental permit that may be required. Wetlands acJ Storn.water Branch 1617 Mail Service t.-nter, Ralegh, North Caroli,a 2r699 1617 t All 512 N. Salisbury S' Ralegh, North Carolina 2 -04 Pliane: 919-807.63 91'AX: !9-807-64941 C ^doraer � wim 1-877-62' ,7,�3 In :m t: wm nwrner,aality., rq Ai - ryal Oppo6mly ,, fi::nalivr - Aion Employ+i NorthCaroli na Altural�j Mr. 'ahn Holding; Thomas Concrcl, of Carolina, Inc. NCG , 40418 October 31, 2011 Per the requirements of the Neuse Riparian Buffer Rile, all stormwater drainage to stream buffers, from portions of this site that have been constructed after July 22, 1997, must be discharged through a correctly designed level spreader or another device that meets diffuse flow requirements per 15A NCAC 2B .0233. Diffuse flow requirements are described in Chapter 8 of the North Carolina Stormwater BMP Manual, available at: http://portal. ncdenr.org/web/wq/ws/su/bmp-manual. If you have any questions.' concerning this permit, please contact Robert Patterson at (919) 807-6375, or robert.patterson@ncdenr.gov. cc: Raleigh Regional Office Central Files Stormwater Permitting Unit Files enclosure Sincerely, ORIGINAL SIGNED B) KEN PICKLE for Coleen H. Sullins Page 2 of 2 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER QUALITY GENERAL PERMIT NO. NCG140000 CERTIFICATE OF COVERAGE No. NCG140418 STORMWATER AND PROCESS WASTEWATER DISCHARGES NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Federal Water Pollution Control Act, as amended, Thomas Concrete of Carolina, Inc. is hereby authorized to discharge stormwater and process wastewater from a facility located at Knightdale Batch Plant 507 Old Montague Lane Knightdale Wake County to receiving waters designated as Milburnie Creek & UT to Beaverdam Creek, both class C; NSW water in the Neuse River Basin, in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts 1, II, III, IV, V, and VI of General Permit No. NCG140000 as attached. This certificate of coverage shall become effective October 31, 2011. This Certificate of Coverage shall remain in effect for the duration of the General Permit. Signed this the 3151 day of October, 2011. ORIGINAL SIGNED Bl KEN PICKLE for Coleen H. Sullins., Director Division of Water Quality By the Authority of the Environmental Management Commission NCG140418 Map R ale 1:24, 000 Thomas Concrete of Caeolina, Inc. Knightdale Batch Plant Latitude: 351 47' 57" N Longitude: 780 30' 06" W Count`: Wake Receiv,ng ;ream: Milbu.nie rk. & UT to Bea.erdam Stream Class: C; ^:SW ;ub-basin: 0,-0�.-02 (Neusr River Basin) -i;Cliity Loci t�oli