# OAR Box 1500 Prepped byOllie Stewart



### Document

Number: 

# 5 ) ll-C-3 1 Docket Number: 

# A-94-5 2

Printed 8/5/20081:45:55PM Sheet 5of 343 p. 1P. 2 

## A-94-5Z

^e o sr,, , 

# S R o \ PRO^ ° UNITE D STATE S ENVIRONMENTA L PROTECTIO N AGENCY RESEARC H TRIANGL E PARK, N C 2771 1



### MAY9 199 6
Mr . Stephe n McNall y Composit e Fabricator s Associatio n 173 5 Nort hLynn Street , Suit e 95 0 Arlington , Virgini a 22209-202 2 OFFIC E O F AI R QUALIT

YPLANNIN G AN D STANDARD S

tyS* EPAAIHDOCiXgr* *


### Dea r Steve : Than k yo u fo r you r lette r o f Apri l 11 , 199 6 regarding you r concern s wit hthe maximu machievabl e contro l technolog y(MACT ) floo r determination s fo r th e reinforce d plasti c composite s sourc e category . W e loo k forwar d t o meetin g wit hyo u an d gettin g you r idea s afte r w e hav e complete d furthe r analyse s an d potentia l subcategorizatio n o f th e ope n moldin g subcategory . W e ar e als o waitin g fo r th e Offic e o f Researc han d Developmen t t o analyz e th e dat a from

th e "fille d resin " study , a s w e hav e recentl ylearne d tha t thes e mayaffec t th e floo r analysis . Befor e w e ge t together , I wante d t o addres s the issu e o f th e LASC O facilitie s raise d i n you r letter . W e wan t t o mak e sur e tha t w e hav e accurat e data , s o w e ar e enclosing th e dat a w e hav e tha t le d t o the conclusion s yo u hav e questioned . Enclose d ar e dat a tha t sho wtha t th e LASC O facilitie s tha t hav e contro l device s us e themt o contro l no t onl ythe gelcoatin g operations , bu t als o some resi n operations . Th e 50/9 5 i n th e chart s indicate s tha t sinc e LASC O doe s no t kno wthe captur e efficienc yfo r thi s particula r process , i t i s assume d t o b e 5 0 percent ; the 9 5 indicate s th e destructio n efficienc yo f th e therma l oxidizer . Th e "contro l factor " value s presente d i n th e Marc h20 , 199 6 presumptiv e MAC T meetin g accoun t fo r th e exten t tha t resi n operation s ar e controlle d base d o n thi s data . Als o enclose d i s informatio n provide d b yLASC O regarding th e Sout h Bosto n facility . W e classifie d a barrie r coa t a s a resi n base d o n thi s information . W e woul d b e intereste d i n a definitio n o fP. 3



### gelcoa t versu s resi n tha t woul d tak e int o accoun t th e formulatio n o r chemica l difference s a s wel l a s th e functiona l differences . Pleas e le t m e kno wi f ther e ar e error s i n thi s informatio n s o w e ca n incorporat e th e change s int o th e dat a base . Thank you , and w e loo k forward t o speakin g wit hyo u soon . Sincerely ,
Madelein e Stru

m Coating s an

d Consume r Product s Grou p 2 Enclosure sSEN T BV-TOMKIN S IND. . INC . 11 - 1-3 0 iii-DiA M ;LA5C 0 D/n-DNLiitLKtUll" ' J1 J -J4 1 *Uj6t1,rr T/ 4

LASC O BATHWAR E 325 5 east Miralom a Ave . Anaheim , CA . 9280 6 

## F A X

DATE : TO : FROM : RE : CC : 

## COVE R

Novembe r1,199 5 Madelein e Stru m USEP A M . Wm . Seymou r LASC O Bathwar

e 

# S H

TIME : PHONE : FAX : PHONE : PAX : Averagin g (Contro l Status) Forma t G.Lowe 

# E E T
10:4 9 A M (919 ) 541-232 8 (919 ) 541-568 9 (714 ) 993-122 0 (714 ) 524-878 4

Numbero

fpages indudin g cove rshee t 5 

### Message Madeleine Here i s th e bes

t infonnatio n I have a t thi s time . W e di d no t pursue th e variances i n styrene content a s a percent o fth e resins content whe n differen t o n a plan t b

yplant fcwsis. Instead w e hav e talcen data o n th e relevan t averages o fth e eac h proces

s .are a a a predicat e withi n you rchar t Agai n ther

e i s some degree ofvariance i n th e cur e facto r(gr/m2) result

s betwee n on e proces

s .area , o rtype , du e to th e difference s i n materia l processin g viscosities , cur e times an d pea k

exothermi c temperatures . However , we d o hav

e a-considerabl e amount o fcur e facto rdat

a based o

fth e 1162 ca n H

d test , an d we fee l these results are fairlyrepresentative . Tota l (tpy

) hav e t»e n take n straigh t fro m o rlatest 199 4 TR I reportin g data sheets . I fyo u hav

e questions o rnee d furthe rinformation , please d o no t hesitat e i n contactin g me . Thante ,

J >StN i tit- lOMKllX s UNU . . »INC

. 'il - L~d O > i i • vJ-irtl U -L-nO^ V ii /

i* UMJUIVJU-JJ

II P. 5

Plan t Moapa , NV
.

(199 4 - TR I Reportin g Data - Unavailable ) Materia l

Resi n 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 BamerCoat Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S

G S G S Quantit

y Cpy )

N/ A

N/ A N/ A CUr

e Facto r wit h filler (g/m2 ) 38. 7

32. 7 55. 0 Cur e Facto r w/ o fille r (g/m2) 54. 4

44. 8 N/ A HA P content wit h fille r % 18 2

20 2 36. 4 HA P content w/ o fille r % 47. 0

45. 0 N/ A Add-O n capture / contro l %/ % 0/ 0

0/ 0 07 0 Applicatio n Metho d * •
A S

A S A S

Plan t YelnuWA .

(199 4 - TR I Reportin g Data) Materia l

Resi n 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 BamerCoat Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S A S

G S G S Quantit

y 

### fay)

224 5 267. 8

241. 1 603. 7 Cur

e Facto r with ' filler (g/m2 ) 42. 1 39. 4

32. 7 55. 0 Cur e Facto r w/ o fille r (g/m2) 57. 5 56. 1

44. 8 N/ A HA P content wit h finer' % 18. 5 21. 6

20 2 36. 4 HA P content w/ o fille r % 48. 0 49. 0

45. 0 N/ A Add-O n capture / contro l %/ % 07 0 0/ 0

0/ 0 OA )

. Applicatio n lUetho d

A S AAS

A S A S



# 4iDN l D l • lUMMIV i UU» . uno . T T I\73 * 1 1 • 'J—rui*

— 7\W~~~~ —uJ II—uiuauiaTM^ - P. 6

Plant : Materia l

Resi n 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 BarrierCoa

t Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S A S

G S G S Sout h Boston , VA . (199 4 - TR I Reportin g Data) Quantit y Opy )

1.78 2 795

213. 5 479 Cur e Facto r wit h filler (o/m2) 42. 1 39. 4

32. 7 55. 0 Cur e Facto r w/ o fille r (g/m2 ) 57. 5 58. 1

44. 8 N/ A j

HA P content wit h filler % * 18. 5 21. 6

20 2 36. 4 /
HA P content w/ o filler % 48. 0 49. 0

45. 0 N/ A Add-O n capture / contro l %/ % 50/9 5 0/ 0

0/ 0 50/9 5 Applicatio n

Metho d * • A S AAS

A S A S

Plan t Anaheim , CA .

(199 4 - TR IReportingData ) Materia l

Resin-1 Resi n 2 Resi n 3 Resi n 4 F?esin 5 BamerCoat Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S

G S G S Quantit

y Opy )

2838. 3

297. 2 760. 5 Cur

e Facto r with ' filter fe/m2) 42. 1

32. 7 55. 0 Cur e Facto r w/ o fille r <g/m2 ) 57. 5

44. 8 N/ A HA P content wit h filler % 18. 5

20 2 36. 4 HA P content w/ o filler % 48. 0

45. 0 N/ A Add-O n capture / contro l %/ % 0/ 0

0/ 0 0/ 0 t Applicatio n Method • •
A S

A S A S



# 601-4* 1 U l ' .Vl'lHlils J Ull^ . , 4t»v* . P. 7

Plan t Lancaster , TX . (1994 - TR

IReportin gData ) Materia l

Resi n 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 Barrie rCoa

t Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S

G S G S Quantit

y Cpy )
2,06 9

190. 3 55 6 Cur e Facto r wit h filler (g/m2) 42. 1

32. 7 55. 0 Cur e Facto r w/ o filler <g/m2 ) 57. 5

44. 8 N/ A HA P content wit h fille r % 18. 5

20 2 36. 4 HA P content w/ o filler % 48. 0

45. 0 N/ A Add-O n capture / contro l %/ % 50/9 5

07 0 50/9 5 Applicatio n

Metho d

A S

AS A S

Plan t Elizabethtown , PA .

(1994 - TR

IReportin gData ) Materia l

Resin- 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 Barrie rCoa

t Gdcoat 1 Gelcoa t 2 Gelcoa t 3 I D

G S

G S G S Quantit

y Gpy )
1,897

227. 8 54 1 Cur e Facto r with ' fille r (g/m2 ) 42. 1

32. 7 55. 0 Cur e Facto r w/ o fille r (g/m2) 57. 5

# 44. 8 N/ A HA P content with filler % 18. 5

20 2 38. 4 HA P content w/ o filler % 48. 0

45. 0 N/ A Add-O n capture / contro l 50/9 5

50/9 5 50/9 5 t Applicatio n Method • •
A S

A S A S



## GOI_n l U l • IVIFUM44 J iiuy . P. 8

Plan t Thre e Rivers , Ml
.

(199 4 - TR I Reportin g Data) Materia l

Resi n 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 BamerCoat Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S

G S G S Quantit

y (tpy )
2,53 5

280. 4 685. 1 Cur

e Facto r wit h fille r (g/m2 ) 4Z 1

32. 7 55. 0 Cur e Facto r w/ o filler (g/m2 ) 57. 5

44. 8 N/ A HA P content wit h fille r % 18. 5

20 2 36. 4 ^ HA P content w/ o filler % 48. 0

45. 0 N/ A Add-O n capture / contro l %/ % 0/ 0

0/ 0 07 0 Applicatio n Metho d

AS

A S A S



### Plant Cordele , GA .

(199 4 - TR I Reportin g Data) Materia l

Resin- 1 Resi n 2 Resi n 3 Resi n 4 Resi n 5 Barrie rCoa

t Gelcoa t 1 Gelcoa t 2 Gelcoa t 3 I D

G S

G S G S Quantit

y Cpy )
1,81 4

162. 6 47 0 Cur e Facto r wit h filler (g/m2 ) 42. 1

32. 7 55. 0 Cur e Facto r w/ o fille r (g/m2 ) 57. 5

44. 8 N/ A HA P content wit h filler % 18. 5

20 2 36. 4 HA P content w/ o fille r % 48. 0

45. 0 N/ A Add-O n capture / contro l %/ % 07 0

07 0 0/ 0 1 Applicatio n Method

A S

A S A S



# nP. 9 

## ^HadhrYvLfv

f c 

## ^~

U.S . EPA/

LASC O Bathwar e Sout h Bosto n Plan t Visi t Thursda yJun e 22,199 5

1 . Wha t i s th e numbe ro femployee s a t th e Sout h Bosto n fadlity ? LASCO Bathware's

South Boston facility emphys

a total of 280 people, which

Includes

all management

and office staff personnel, as well as, plant

personnel

and truck drivers. Our

South Boston facility is also one of the top 10 employers

within the South Boston, Halifax County area, with

respect to total number employed.
Wha t i s you rlates t calculatio n o fstyren e emission s an d th e methodolog yused ? The methodology

used in our determination

of styrene emissions

is EPAMethod

24AFID

and EPAMethod

25. Based

upon the results of these tests and subsequent

analysis, our

latest calculations

for styrene emissions

at the South Boston facility are as follows:
GELCOAT

SURFACED

PRODUCTION

UNE - 7.312.713

soft Per Year Application/Process

Boom All Incinerated

Booths All Non-Incinerated

Booths Total Styrene Emissions/Year Stvrene Pounds Per Year 14,427.70

T 111.145.20 125,572.90

#/Yr
ACRYLIC

SURFACED

PRODUCTION

UNE - 7.385.197

soft Per Year Application/Process

Boom All Non-Incinerated

Booths Total Styrene Emissions/Year Stvrene Pounds Per Year 254.305.30 254,305.30 

# L eP.1 0

3 . Wha t proces s typ e i s involve d i n th e manufactur e o feac h product ? South Boston's

primary manufacturing

ska operates

two (2) independent

production

lines, one

(1) production

Bne dedicated

to the manufacture

of gelcoat surfaced

fiberglass

rein forced products

(tubs, showers & unitized

tub/showers)

and, one

(1) production

line dedicated

to the manufacture

of merrnofbrmed

acrylic surfaced fiberglass

reinforced

products

(unitized

tub/showers). At our secondary

manufacturing

site, we

operate a single production line dedicated

to the manufacture

of thennoformed

acrylic surfaced

fiberglass reinforced

products

(jetted tubs). The Open Mold spray-up

process

is utilized in the manufacture

of all three (3) of our product Ones. Additionally, the hand lay-up process

is utilized in the construction

of production

molds/tooling

and, in repair of any sub-standard

manufactured

product
4 . Wha t proces s type s ar e bein g controlled ? 77i e Open

Mold spray-up

and hand lay-up processes

are controlled and, no other composites

pmcesses

are utilized in our manufacture

of FRP products.
5 . Wha t quantit yo fresin (pe ryear ) i s used ? Three (3) different

resin products

are utilized in the production

of our three product lines. All

three resin products

are vapor suppressed. Resins: Pounds Used Laminating

Resin 3,523,593 lbs Barrier-Coat

Resin rvsWooo r427,00510s CSScrvlic

Laminating

Resin} < «^ L J 1.589.775 lbs Total Resin

5 uppfeS ^ 5,540.373 lbs l$tf -bripfepocV J 6 . Wha t quantit yo fgelcoa t (pe ryear ) i s used ? Total gelcoat pounds ust Gelcoat: Gelcoats Total Gelcoat }d equal:


# 4 Pounds Used 958.279 Ihs 958.279 lbsP.1 1

7 . Wha t percen t filleri s used ? All LASCO facilities

utilize in their manufacture

of gelcoat surfaced reinforced

products

five (5) separate

spray-up

applications, with

five (5) separate

spray-up

material

formulations. The

following

is a breakdown

of the five (5) spray-up

applications

and their respective formulation

filler percentages. GELCOAT

SURFACED

PRODUCTS As Used/Processed

(spray-up): Application/Process

Booth Gelcoat Spray-up Barrier-Coat

Spray-up First Laminate

Spray-up Second Laminate

Spray-up Third Laminate

Spray-up Formulation Filler Percentage 25.00% (by mfg) 55.00% 61.00% 63.00% 60.00% The acrylic surfaced

products

manufactured, utilize two (2) spray-up applications

whh a single (1) spray-up

material

formulation

in both. ACRYUC

SURFACED

PRODUCTS As Used/Processed

(spray-up): Apolication/Process

Booth First & Second Laminate

Spray-up Formulation Filler Percent 52.33%
8 . Wha t I s th e styren e percen t o fth e resi n (afte rfille rand/o radditiona l styren e i s added) ? All LASCO facilities

utilize in their manufacture

of gelcoat surfaced reinforced

products

five (5) separate

spray-up

applications, whip

five (5) separate

spray-up

material formulations. The

following

is a breakdown

of the five (5) spray-up

applications

and their respective formulation

styrene percentages. Note: The formulation

styrene percentages

were calculated using the most recent baseline

data supplied

in the accompanying

resin supplier

Quality Control Reports

and Material Safety Data Sheets (see Appendix

A).



## idP.1 2

GELCOAT

SURFACED

PRODUCTS As Used/Processed

(spray-up): AooBcathn/Process

Booth Formulation Stvrene Percent Gelcoat Spray-up

36.41 % Barrier-Coat

Spray-up

20.25% First Laminate

Spray-up

18.72% Second Laminate

Spray-up

17.76% Third Laminate

Spray-up

19.20%
The acrylic surfaced

products

manufactured, utilize two (2) spray-up applications

with a single (1) spray-up

material

formulation

in both.
ACRYUC

SURFACED

PRODUCTS As Used/Processed

(spray-up): Application/Process

Booth Formulation Stvrene Percent First & Second Laminate

Spray-up

21.60%
9 . Wha t i s th e styren e percen t o fgelcoat ? 777 6 styrene

percentage

of the gelcoats

supplied

to the South Boston facility are 36.41 %, as

stated in our suppliers

most recent Quality Control Reports and Material

Safety Data Sheets (see Appendix

B).
10 . Wha t percen t resi n supplie d t o th e plan t i s use d fo reac h proces s (exclud e compressio n molding) ? As previously

identified, LASCO

utilizes numerous

indivkiual

spray-up applications

and formulations. Here

is a percentage

breakdown

of the total pounds of resin thru-put

by application/process

booth. » GELCOAT

SURFACED

PRODUCTS Application/Process

Booth Pounds

Resin Thm-Put

bv Percent All Gelcoats:

Pounds Percent Gelcoat Film Spray-up

Booth 958,279 100%P.1 3

Barrier-Coat

Resin: Barrier-Coat

Film Spray-up

Booth 427,005

100% Laminating

Resin: 1st, 2nd & 3rd Lam. Spray-up

Booths 3,502,451 99.4% Repair/Rework

Spray/Hand

Lay-up 21,142

.6%
ACRYUC

SURFACED

PRODUCTS Application/Process

Booth Pounds

Resin Thru-Put

bv Percent Acrvlic Laminating

Resin: Pounds P_u__mt First Laminate

Spray-up

794.887.5 50%-

• Second Laminate

Spray-up

794,887.5 50%
1 1 . Wha t percentag e o fresi n withi n eac h proces s typ e i s associate d wh h th e us e o fa n add-on ?
GELCOAT

SURFACED

PRODUCTS Application/Process

Booth Percentage of Resin Thru Add-on Pounds Percent Gelcoat Film Spray-up

100% Barrier-Coat

Film Spray-up

0% Laminatino

Resin: First Laminate

Spray-up

100% Second Laminate

Spray-up

100% Third Laminate

Spray-up

100% Repair/Rework

Spray/Hand

Lay-up 0%
ACRYUC

SURFACED

PRODUCTS Application/Process

Booth Percentage

of Resin Thm Add-on Pounds Percent First Laminate

Spray-up

0% Second Laminate

Spray-up

0%

I 2-P.1 *

12
. Wha t i s th e inle t concentratio n o fstyrene ? Outlet ? Based on our most recent data, the

inlet concentration

of styrene emissions

to the incinerator

is 77.34 pounds per hour. Outlet concentrations

based on a 95%destruction

efficiency

is 3.87 pounds per hour. Note: The thermal incinerator

is identified

as a Reeco Re-Therm Model E Thermal Oxidation

System. The

Reeco incinerator

is rated for an input of 17,345 SCFM < ® 90 F. and lists a minimum

destruction efficiency

of 95%. The

maximum

destruction

efficiency

rating is 99%. These

destruction

efficiency

ratings were supported

by Reeco Company

data and actual field monitoring

of a similar unit.
13
. Wha t specifi cemissio n point s i n th e proces s ar e bein g controlle d b y th e oxidize r(e.g.
. storag e tan k (s U mixin g vessels , etc.) ?
GELCOAT

SURFACED

PRODUCTION

UNE Production/Process

Booth Gelcoat Film Spray Boom Barrier-Coat

Film Spray Booth First Laminate

Spray Booth Second Laminate

Spray Booth Third Laminate

Spray Booth Gelcoat Storage Room i. Mixing

&Holding

Tanks (GC &ACR) res

ivuvb 

# -fr MIX/A/6> 

# +W/5 nor

\j<tf\kAhmo/xircchr

Lstp jrffi KPa ACRYUC

SURFACED

PRODUCTION

UNE *--~^- T ^ T Production/Process

Booth Controlled Source &Percentage To Incinerator

Percent First Laminate

Spray-up

No 0% Second Laminate

Spray-up

No 0%
14
. Wha t i s th e captur e efficienc yfo reac h emissio n poin t vente d t o a n add-on ? All LASCO plants operate with ventilation

systems

engineered

to create a negative

pressure, with

respect to the outside atmosphere, within all spray-up

and grinding booths and, again

within the entire | 3 

### TQ

Incinerator Yes No Yes Yes Yes Yes Yes Percent

100% 0% 100% 100% 100% 100% 100%P.1 5



### plant production

area. Moreover, the

buildings

are kept closed up for the most part. Therefore, it

is our contention

that the capture efficiency

from each production

emissions

source point (spray-up application

booms) is 100%. 15 . I s th e contro l devic e used fo ran yprocess not i n th e reinforced composit e plasti c source category ? I fso,.wha t percentag e ofth e flo wrat e t o th e add-o n i s fro m th e reinforced composites ? 777 e thermal

oxidizer

in operation

here, is solely used

fbr the capture and destruction

of styrene emissions

originating

fiom the spray-up and curing processes

associated

with reinforced

composites. 16 . Wha t i s th e volumetri c flowrate diroug h th e contro l device ? 77; © Reeco incinerator

is rated for an input how rate

of 17,345 SCFM @90F.
17 . Wha t wa s th e capita i Investmen t fo rth e contro l device ? Wha t i s th e operatin g cost pe ryea rfo rthi s device ? 777 0 initial capital investment

for the Reeco Incinerator

was $ 738,092.00

in 1986 and began operation

in December

of that year. Operating

costs do vary. However, fiom information

pulled from our 1995 plant performance

data, the

operating

costs for

gas and electricity

were $ 105,582.50

and, maintenance

costs were 

### $14,983.20. Note: Currently, LASCO

(Lancaster, Tx.)

is undertaking

a cost analysis to detemiine

best long-term

approach

to either rebuilding

or replacing

Reeco Incinerator. Life

expectancy

without major rebuild or overhauling

of the Reeco systems

is approximately

8-10 years, i

(A-