July 27, 2005 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2005 through June 30, 2005 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period January 1, 2005 

through June 30, 2005. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental and 

Safety Leader, John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning – Fairburn Plant 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: January 1, 2005 through June 30, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of procedures outlined in the 

facility OMM/SSM Plans: 

None 

All instances of startup, shutdown and malfunction were dealt with in accordance with 

the facility Startup, Shutdown, and Malfunction Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 through June 30, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

<TABLE 3> 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2005 through June 30, 2005 the operating hours are: 

FG1 Furnace – 4344 hours 

FG1 Line – 4206 hours 

FG2 Furnace – 4344 hours 

FG2 Line – 4201 hours 

FG3 Furnace – 4344 hours 

FG3 Line – 4130 hours 
Deviations: 

 

FG-1 LOI 4 hrs 0.04 % deviation 

FG-2 LOI 6 hrs 0.14 % deviation 

FG-1 Furnace Crust 0.75 hrs 0.02 % deviation 

FG-2 Furnace Crust 1.25 hrs 0.03 % deviation 

FG-3 Furnace Crust 12.42 hrs 0.29 % deviation 

Based on the plant operating hours, none of the monitoring parameters exceedance times 

were greater than 1%. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2005 through June 30, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be beyond 

the 1% trigger level for this report. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
January 27, 2006 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting for 

Period July 1, 2005 through December 31, 2005 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period July 1, 2005 

through December 31, 2005. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental and 

Safety Leader, John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning – Fairburn Plant 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of procedures outlined in the 

facility Startup, Shutdown, and Malfunction (SSM) Plan. 

The FG2 incinerator was down for 0.33 hours on October 5, 2005 and 11.12 hours 

on December 24, 2005. The line continued to run with product during these 

periods. The SSM Plan states that once it is determined that an incinerator is not 

operating and cannot be restarted by an electrician, the line production must be 

suspended until the problem is resolved. This procedure was not followed during 

the periods of incinerator malfunction. 

All other instances of startup, shutdown and malfunction were dealt with in accordance 

with the facility SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility 

OMM Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

<TABLE 1> 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
<TABLE 2> 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

<TABLE 3> 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2005 through December 31, 2005 the operating hours are: 

FG1 Furnace – 4416 hours 

FG1 Line – 4199 hours 

FG2 Furnace – 4416 hours 

FG2 Line – 4270 hours 

FG3 Furnace – 4416 hours 

FG3 Line – 4296 hours 
Deviations: 

FG1 Incinerator 1.35 hrs 0.03 % deviation 

FG2 Incinerator 11.98 hrs 0.28 % deviation 

FG3 Incinerator 2.57 hrs 0.06 % deviation 

FG1 Furnace Crust 107.00 hrs 2.42 % deviation 

FG1 Batch Wetting 20.00 hrs 0.45 % deviation 

FG2 Batch Wetting 4.00 hrs 0.09 % deviation 

FG3 Batch Wetting 4.00 hrs 0.09 % deviation 

FG1 LOI 1.50 hrs 0.04 % deviation 

FG2 LOI 10.75 hrs 0.25 % deviation 

FG3 LOI 2.25 hrs 0.05 % deviation 

Based on these operating hours, the following monitoring parameter was over the 1% 

exceedance time: 

FG1 Furnace Crust 107.00 hrs 2.42 % deviation 

This instance will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 through December 31, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

FG1 Furnace Crust Deviation – Appendix A 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
APPENDIX A 

FG1 Furnace Crust Deviation
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2005 – December 31, 2005 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

FG1 Furnace Crust Deviations: 

During the reporting period, there were 107 hours of reported FG1 Furnace Lost Crust 

deviation. This time was required to perform specialized maintenance to the furnace 

structure. During this time batch feeding and glass pull from the furnace was temporarily 

suspended. 

The table below summarizes the FG1 Furnace Crust Deviations: 

FG-1 Furnace Crust Summary 

Owens Corning 

Fairburn, Georgia 

FG-1 Furnace Crust 

Beginning Date & Time Ending Date & Time Total Time

9/18/05 22:00 9/23/05 09:00 107 hours 
July 26, 2006 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2006 through June 30, 2006 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period January 1, 2006 

through June 30, 2006. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental and 

Safety Leader, John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning – Fairburn Plant 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

All instances of startup, shutdown and malfunction were dealt with in accordance with 

the facility Startup, Shutdown, and Malfunction Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring (OMM) 

Plan 

40 CFR 63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility 

OMM Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2006 through June 30, 2006 the operating hours are: 

FG1 Furnace – 4344 hours 

FG1 Line – 4245 hours 

FG2 Furnace – 3024 hours 

FG2 Line – 2660 hours 

FG3 Furnace – 4344 hours 

FG3 Line – 4101 hours 
Deviations: 

FG2 Batch Wetting 48 hrs 1.59 % deviation 

FG3 Batch Wetting 56 hrs 1.29 % deviation 

FG3 Furnace Crust 40.25 hrs 0.93 % deviation 

Based on these operating hours, the following monitoring parameter was over the 1% 

exceedance time: 

FG2 Batch Wetting 48 hrs 1.59 % deviation 

FG3 Batch Wetting 48 hrs 1.29 % deviation 

These instances will be described in more detail in the Parameter Exceedance Report that 

follows. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 through June 30, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

FG2 Batch Wetting – See Appendix A 

FG3 Batch Wetting – See Appendix B 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
APPENDIX A 

FG2 Batch Wetting Deviations
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 – June 30, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

FG2 Batch Wetting Deviations: 

During the reporting period, there were 48 hours of reported Batch Wetting deviation. 

The hours of deviation were due to operating the overhead feeding system. 

The table below summarizes the FG2 Batch Wetting Deviations: 

FG2 Batch Wetting Deviation 

Owens Corning 

Fairburn, GA 

January 1, 2006 to June 30, 2006 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

4/28/06 @ 9:00 4/30/06 @ 9:00 48 
APPENDIX B 

FG3 Batch Wetting Deviations
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2006 – June 30, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

FG3 Batch Wetting Deviations: 

During the reporting period, there were 56 hours of reported Batch Wetting deviation. 

The total hours of deviation consisted of 8 hours of low water flow and 48 hours of 

operating the overhead feeding system. 

The table below summarizes the FG3 Batch Wetting Deviations: 

FG3 Batch Wetting Deviation 

Owens Corning 

Fairburn, GA 

January 1, 2006 to June 30, 2006 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

4/5/06 @ 8:00 4/7/06 @ 8:00 48 

4/12/06 @ 11:00 4/12/06 @ 19:00 8 
 

January 29, 2007 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting for 

Period July 1, 2006 through December 31, 2006 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period July 1, 2006 

through December 31, 2006. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental and 

Safety Leader, John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning – Fairburn Plant 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility 

OMM plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1, 2006 through December 31, 2006 the operating hours are: 

FG1 Furnace – 8760 hours 

FG1 Line – 8441 hours 

FG2 Furnace – 7224 hours 

FG2 Line – 6776 hours 

FG3 Furnace – 8760 hours 

FG3 Line – 8216 hours 
Deviations: 

FG1 Batch Wetting 1.5 hrs 0.02 % deviation 

Based on the plant operating hours, none of the monitoring parameters exceedance times 

were greater than 1%. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, 2006 through December 31, 2006 

Owens Corning – Fairburn Plant 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be beyond 

the 1% trigger level for this report. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC - FAIRBURN 

700 MCLARIN ROAD 

FAIRBURN, GEORGIA 30213

 

July 27, 2007 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting for 

Period January 1, 2007 through June 30, 2007 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period January 1, 2007 

through June 30, 2007. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental and 

Safety Leader, John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning Insulating Systems, LLC – Fairburn 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility 

OMM Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period January 1, 2007 through June 30, 2007 the operating hours are: 

FG1 Furnace – 4344 hours 

FG1 Line – 4184 hours 

FG2 Furnace – 4344 hours 

FG2 Line – 4056 hours 

FG3 Furnace – 4344 hours 

FG3 Line – 4034 hours 
Deviations: 

FG1 Batch Wetting 2.5 hrs 0.06 % deviation 

FG2 Batch Wetting 24.0 hrs 0.55 % deviation 

FG3 Batch Wetting 8.0 hrs 0.18 % deviation 

High LOI 20.7 hrs 0.51 % deviation 

Based on the plant operating hours, none of the monitoring parameters exceedance times 

were greater than 1%. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1, 2007 through June 30, 2007 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be beyond 

the 1% trigger level for this report. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC - FAIRBURN 

700 MCLARIN ROAD 

FAIRBURN, GEORGIA 30213

 

January 30, 2008 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting - July 1 through December 31, 2007 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period July 1 through 

December 31, 2007. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental and 

Safety Leader, John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader 

Owens Corning Insulating Systems, LLC – Fairburn 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2007 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility 

OMM Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2007 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1 through December 31, 2007the operating hours are: 

FG1 Furnace – 3312 hours 

FG1 Line – 3167 hours 

FG2 Furnace – 4416 hours 

FG2 Line – 4167 hours 

FG3 Furnace – 4416 hours 

FG3 Line – 4162 hours 
Deviations: 

FG1 Batch Wetting 1.25 hrs 0.04 % deviation 

FG2 Batch Wetting 0.33 hrs 0.01 % deviation 

FG2 High LOI 15.83 hrs 0.38 % deviation 

FG1 Lost Furnace Crust 11.50 hrs 0.35 % deviation 

FG2 Incinerator 0.52 hrs 0.01% deviation 

Based on the plant operating hours, none of the monitoring parameters exceedance times 

were greater than 1%. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2007 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be 

beyond the 1% trigger level for this report. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
July 30, 2008 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting - January 1 through June 30, 2008 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period January 1 

through June 30, 2008. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental Leader, 

John Merrels at (770) 969-2916. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning Insulating Systems, LLC – Fairburn 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: January 1 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

There are no instances being reported as a deviation of procedures outlined in the facility 

OMM Plan. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period January 1 through June 30, 2008 the operating hours are: 

FG1 Furnace – 4368 hours 

FG1 Line – 4115 hours 

FG2 Furnace – 4368 hours 

FG2 Line – 3922 hours 

FG3 Furnace – 4368 hours 

FG3 Line – 3798 hours 
Deviations: 

FG1 Batch Wetting 9.5 hrs 0.22 % deviation 

FG2 Batch Wetting 24.5 hrs 0.56 % deviation 

FG3 Batch Wetting 9.5 hrs 0.22 % deviation 

FG1 High LOI 5.38 hrs 0.13 % deviation 

FG2 High LOI 31.3 hrs 0.80 % deviation 

FG3 Lost Furnace Crust 7.25 hrs 0.17 % deviation 

Based on the plant operating hours, none of the monitoring parameters exceedance times 

were greater than 1%. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1 through June 30, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

No instances of monitored parameter deviations were determined to be beyond 

the 1% trigger level for this report. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
OWENS CORNING INSULATING SYSTEMS, LLC 

7000 McLarin Rd 

Fairburn, GA 30213 

Ph: 770-964-9811

January 12, 2009 

Mr. Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting 

 Owens Corning Insulating Systems, LLC 

July 1 through December 31, 2008 

Dear Mr. Sanon: 

Please find enclosed two copies of the MACT Semi-Annual Report for our Fairburn, Georgia 

facility. One copy is marked “Public Version” and is intended for our public file. The other is 

marked “Confidential Version” and should be treated as confidential. Each copy includes three 

separate reports as required by 40 CFR 63 Subparts A and NNN. The first report summarizes 

periods of startup, shutdown, and malfunction where actions taken were inconsistent with the 

plan in accordance with MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The 

second report is the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e). 

The third report is the “Gaseous and Opacity Excess Emission and Continuous Monitoring 

System Performance Report” as required in 40 CFR 63.10(e)(3) and 40 CFR 63.1386(e) if 

monitored parameters deviate more than 1% of the total operating time. Each report is labeled 

appropriately and is for the period July 1 through December 31, 2008. 

As the responsible official, I certify to the accuracy of this report. If you have any questions 

regarding this information, please contact our Environmental Leader, Ryan Ponting, at (770) 969-

2916. 

Sincerely, 

Dennis Rogers 

Plant Leader 

Owens Corning Insulating Systems, LLC – Fairburn, GA 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

Based on the requirements within the OMM Plan, a LOI check is required every eight 

hours on each manufacturing line that manufactures MACT products. There were a total 

of nine instances where the duration between LOI testing exceeded eight hours. 

Based on the requirements within the OMM Plan for LOI testing, if a sample is taken 

where the LOI sample exceeds the maximum set by testing, facility personnel are 

required to retest “as soon as is practicable.” There were two occurrences when the 

retests were not conducted in a timely fashion. 

Based on the requirements within the OMM Plan for density testing, a density check is 

required every eight hours on each manufacturing line that manufactures MACT 

products. There were a total of 17 instances where the duration between density testing 

exceeded eight hours. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers

Signature: 

Title: Plant Leader
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1 through December 31, 2008 the operating hours are: 

FG1 Furnace – 4416 hours 

FG1 Line – 3969 hours 

FG2 Furnace – 4416 hours 

FG2 Line – 3951 hours 

FG3 Furnace – 4416 hours 

FG3 Line – 3763 hours 
Deviations: 

FG2 Incinerator Low Temp 0.35 hrs 0.01 % deviation

FG3 Incinerator Low Temp 0.59 hrs 0.02 % deviation

FG1 Batch Wetting 4.25 hrs 0.10 % deviation 

FG3 Batch Wetting 3.0 hrs 0.07 % deviation 

FG1 High LOI 6.08 hrs 0.15 % deviation 

FG2 High LOI 26.63 hrs 0.67 % deviation 

FG1 Lost Furnace Crust 62.0 hrs 1.40 % deviation 

The FG1 lost furnace crust instances will be described in additional detail in the 

Parameter Exceedance Report that follows (Appendix A). 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers

Signature: 

Title: Plant Leader
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1, through December 31, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

FG1 Lost Furnace Crust – See Appendix A. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers

Signature: 

Title: Plant Leader
APPENDIX A 

FG1 Lost Furnace Crust Deviations
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1 – December 31, 2008 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

FG1 Lost Furnace Crust Deviations: 

During the reporting period, there were 62.0 hours of reported lost furnace crust 

deviations. Furnace was on a hot idle during a MACT downtime to conduct annual 

inspection and perform routine maintenance. At this time additional maintenance was 

performed on the forehearth channel to address glass delivery issues. These maintenance 

activities required the hot idle to be extended. 

The table below summarizes the FG1 Lost Furnace Crust Deviation: 

FG1 Lost Furnace Crust Deviation 

Owens Corning Insulating Systems, LLC 

Fairburn, GA 

July 1, 2008 to December 31, 2008 

Deviation Start Time Deviation End Time Total Deviation (hrs) 

10/13/08 @ 03:00 10/15/08 @ 17:00 62 
July 30, 2009 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting - January 1 through June 30, 2009 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period January 1 

through June 30, 2009. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental Leader, 

Rick Darr at (770) 969-2931. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning Insulating Systems, LLC – Fairburn 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: January 1 through June 30, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

The following instances are being reported as a deviation of procedures outlined in the 

facility OMM Plan. 

1. Based on requirements within the Operations, Maintenance, and Monitoring Plan, 

an LOI is required at least once every 8 hours on each manufacturing line that 

manufactures MACT products. For the operating manufacturing lines there were 

a total of 3 incidents where the duration between LOI testing exceeded eight 

hours 

2. Based on requirements within the Operations, Maintenance, and Monitoring Plan, 

a density check is required at least once every 8 hours on each manufacturing line 

that manufactures MACT products. There were a total of 83 incidents where the 

duration between density testing exceeded eight hours. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: January 1 through June 30, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period January 1 through June 30, 2009 the operating hours are: 

FG1 Furnace – 456 hours 

FG1 Line – 173 hours 

FG2 Furnace – 4368 hours 

FG2 Line – 3738 hours 

FG3 Furnace – 1944 hours 

FG3 Line – 1834 hours 
Deviations: 

FG2 Batch Wetting 72.0 hrs 1.56 % deviation 

FG2 High LOI 4.0 hrs 0.11 % deviation

FG2 Lost Furnace Crust 3.17 hrs 0.08 % deviation 

Based on the plant operating hours, only the FG2 Batch Wetting was over the 1% 

deviation time. 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1 through June 30, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

FG2 Furnace – Batch Wetting: See Appendix A for details 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
APPENDIX A 

FG2 Batch Wetting 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: January 1 through June 30, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

FG2 Batch Wetting Deviations: 

For the first half of 2009 there were a total of 72.0 hours during the referenced time 

period when FG2 Batch Wetting deviated from the limit established by the original FG2 

MACT compliance testing. 

The table below lists dates and times for the FG2 Batch Wetting deviations during the 

referenced time period. 

FG2 Batch Wetting Deviations Summary 

Owens Corning Insulating Systems 

Fairburn, Georgia 

Beginning Date & Time Ending Date & Time Total Time

2/20/09 06:00 2/23/09 06:00 72 hrs 

 

 
OWENS CORNING INSULATING SYSTEMS, LLC - FAIRBURN 

700 MCLARIN ROAD 

FAIRBURN, GEORGIA 30213

January 29, 2010 

Pierre Sanon 

Environmental Engineer 

Stationary Source Compliance Program 

Georgia Department of Natural Resources 

Environmental Protection Division, Air Protection Branch 

4244 International Parkway, Suite 120 

Atlanta, Georgia 30354 

RE: MACT Semi-Annual Reporting - July 1 through December 31, 2009 

Dear Mr. Sanon, 

Please find enclosed two complete copies of the MACT Semi-Annual Report for our 

Fairburn, Georgia facility. One copy is marked “Public Version” and is intended for our 

public file. The other is marked “Confidential Version” and should be treated as 

confidential. Each copy includes three separate reports as required by 40 CFR 63 

Subparts A and NNN. The first report summarizes periods of startup, shutdown, and 

malfunction where actions taken were inconsistent with the plan in accordance with 

MACT requirements, 40 CFR 63.10(d)(5) and 40 CFR 63.1386(c). The second report is 

the “Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance” as required in 40 CFR 63.10(e)(3) and 40 CFR 

63.1386(e). The third report is the “Gaseous and Opacity Excess Emission and 

Continuous Monitoring System Performance Report” as required in 40 CFR 63.10(e)(3) 

and 40 CFR 63.1386(e) if monitored parameters deviate more than 1% of the total 

operating time. Each report is labeled appropriately and is for the period July 1 through 

December 31, 2009. 

As the responsible official, I certify to the accuracy of this report. If you have any 

questions regarding this information, please contact our Facility Environmental Leader, 

Nadia Holloway at (770) 969-2914. 

Sincerely, 

Dennis Rogers 

Plant Leader, Owens Corning Insulating Systems, LLC – Fairburn 
Report: Periods of Startup, Shutdown, and Malfunction Where Actions Taken were 

Inconsistent with SSM Plan

40 CFR 63 Subpart NNN

Reporting Period: July 1 through December 31, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

Although there were startups, shutdowns and malfunctions during this reporting period, 

all actions taken were consistent with the SSM Plan. 

Report: Periods of Deviation from the Operations, Maintenance and Monitoring 

(OMM) Plan

40 CFR 63 Subpart NNN

The following instances are being reported as a deviation of procedures outlined in the 

facility OMM Plan. 

1. Based on requirements within the OMM Plan, an LOI is required at least once 

every 8 hours on each manufacturing line that manufactures MACT products. 

The following deviations from the OMM Plan occurred: 

• FG1 LOI Check Exceeded 8-hrs 1 time 

• FG2 LOI Check Exceeded 8-hrs 6 times 

2. Based on requirements within the OMM Plan, a density check is required at least 

once every 8 hours on each manufacturing line that manufactures MACT 

products. The following deviations from the OMM Plan occurred: 

• FG1 Density Check Exceeded 8-hrs 1 time 

• FG2 Density Check Exceeded 8-hrs 3 times 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Summary Report – Gaseous and Opacity Excess Emission and Continuous 

Monitoring System Performance

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

HAP’s Monitored: The Wool Fiberglass MACT focuses on two surrogate pollutants for 

control of HAP’s from the Fiberglass manufacturing process. Particulate matter is 

limited to 0.5 lb PM per ton of molten glass produced from the glass melting process and 

formaldehyde is limited to 1.2 lb per ton of molten glass produced during fiber forming 

and curing. 

Process Units: In general the fiberglass manufacturing process is composed of a glassmelting furnace that melts batch materials into glass. The molten glass is passed through 

a rotary spin (RS) forming process where a fine, glass fiber is produced. Binder is 

applied to the fiber as it forms a “pack” on the surface of a foraminous conveyor. Once 

collected, the pack passes through a curing and cooling process followed by final 

fabrication and packaging. Tables 1 through 3 define the manufacturing sources at this 

facility, including individual processes, control devices, and monitored parameters. 

TABLE 1 

 Process Control 

Device 

Monitored Parameter 

FG1 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 
TABLE 2 

 Process Control 

Device 

Monitored Parameter 

FG2 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

TABLE 3 

 Process Control 

Device 

Monitored Parameter 

FG3 

Furnace Glass Melting Batch Wetting Water Flow 

Glass Melting Molten Glass Throughput 

 

Line Forming Premix Formulation 

LOI 

Resin Free Formaldehyde 

Molten Glass Throughput 

Curing Incinerator Temperature 

 

Emission Data Summary / Operating Hours for Facility

For the period July 1 through December 31, 2009 the operating hours are: 

FG1 Furnace – 4253 hours 

FG1 Line – 3188 hours 

FG2 Furnace – 4380 hours 

FG2 Line – 3793 hours 

FG3 Furnace – 0 hours 

FG3 Line – 0 hours 
Deviations: 

FG1 Batch Wetting 144.00 hrs 3.39 % deviation 

FG2 Batch Wetting 241.92 hrs 5.52 % deviation 

FG1 High LOI 3.92 hrs 0.12 % deviation 

FG2 High LOI 27.28 hrs 0.72 % deviation 

FG2 Lost Furnace Crust 0.50 hrs 0.00 % deviation 

FG1 Incinerator Offline 0.66 hrs 0.02% deviation 

FG2 Incinerator Offline 0.35 hrs 0.01% deviation 

Based on the plant operating hours, none of the monitoring parameters exceedance times 

were greater than 1% with the exception of the following: 

FG1 Batch Wetting 144.00 hrs 3.39 % deviation 

FG2 Batch Wetting 241.92 hrs 5.52 % deviation 

These instances will be described in more detail in the Parameter Exceedence Report that 

follows. 

Based on these percentages of deviations, the following monitoring parameters were over 

5% exceedence time, thus warranting a Quality Improvement Plan (QIP) per 

63.138(b)(2)(ii) and 63.10(e)(3)(viii): 

FG2 Batch Wetting 5.52 % deviation 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance 

40CFR63 Subpart NNN

Reporting Period: July 1 through December 31, 2009 

Owens Corning Insulating Systems, LLC - Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

The following instances are being reported as a deviation of a monitored parameter due to 

malfunction or startup/shutdown: 

FG1 Batch Wetting 144.00 hrs 3.39 % deviation 

FG2 Batch Wetting 241.92 hrs 5.52 % deviation 

As the responsible official, I certify that the content of this report is accurate. 

Print Name: Dennis Rogers 

Signature: 

Title: Plant Leader 
Appendix A 

FG1 BATCH WETTING 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC– Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

FG1 Batch Wetting:

During the reporting period, the FG1 Batch Wetting experienced 144.00 hours of 

monitoring parameter excursions. The attached tables list the date and time for the 

deviations. 

FG1 BATCH WETTING 

Owens Corning 

Fairburn, GA 

Date 

Beginning 

Time Ending Time Total Hours 

11/24/09 10:00 11/30/09 10:00 144.00 

Total Hours 144.0 
Appendix B 

FG2 BATCH WETTING 
Gaseous and Opacity Excess Emission and Continuous Monitoring System 

Performance

40CFR63 Subpart NNN

Reporting Period: July 1, 2009 through December 31, 2009 

Owens Corning Insulating Systems, LLC– Fairburn 

7000 McLarin Road 

Fairburn, GA 30213 

FG2 BATCH WETTING:

During the reporting period, the FG2 Batch Wetting experienced 241.92 hours of 

monitoring parameter excursions. The attached tables list the date and time for the 

deviations. 

FG2 BATCH WETTING 

Owens Corning 

Fairburn, GA 

Date Beginning Time Ending Time Total Hours 

8/30/09 9:00 9/1/09 9:00 72.00 

9/6/09 13:00 9/8/09 13:00 48.00 

9/11/09 1:30 9/15/09 9:20 103.83 

9/23/09 5:30 10:10 4.67 

9/29/09 8:30 10:00 1.50 

9/30/09 6:20 18:15 11.92 

Total Hours 241.92