Startup, Shutdown and Malfunction Plan In Accordance with Brick and Structural Clay

National Emission Standard for Hazardous Air Pollutants

For

BORAL BRICKS,INC

AUGUSTA FACILITY

PLANT 4 AUGUSTA, GEORGIA

LAST REVISED

January 2011

Responsible Official Signature

________________________________________________________________________ Bill Tudor Regional Production Manager DateTABLE OF CONTENTS

SECTION 1.0- INTRODUCTION ................................................................................................. 1

SECTION 2.0- PURPOSE .......................................................................................................... .... 2

SECTION 3.0 - REGULATORY ANALYSIS .............................................................................. 3

SECTION 3.1 DEFINITION OF “MALFUNCTION” ......................................................... 3

SECTION 4.0- AFFECTED SOUR CES AND CONTROL DEVICES ......................................... 5

SECTION 5.0- PROCEDURES FOR STARTUP, SHUTDOWNS, & .......................................... 6

MALFUNCTIONS .................................................................................................................. ....... 6

SECTION 5.1- STARTUP PROCEDURES............................................................................... 7

SECTION 5.2- SHUTDOWN PROCEDURES ......................................................................... 8

5.2.1 Normal Shutdown Procedures .............................................................. 8

5.2.2 Emergency Shutdown Procedures ...................................................... 10

SECTION 5.3- MALFUNCTION PROCEDURES ................................................................. 11

SECTION 6.0- RESPONSIBILITIES AND POINTS OF CONTACT........................................ 42

SECTION 6.1- ORGANIZATIONAL CHART ....................................................................... 42

SECTION 6.2- RECORDKEEPING PLAN ............................................................................. 42

SECTION 6.3- TRAINING REQUIREMENTS ...................................................................... 42

SECTION 6.4- SSMP VERSION CONTROL PROCEDURES .............................................. 42

SECTION 7.0- RECORDKEEPING AND REPORTING REQUIREMENTS ........................... 43 SECTION 7.1- OVERVIEW OF REQUIREMENTS .............................................................. 43

SECTION 7.2- EXAMPLE REPORT FORMS........................................................................ 45

7.2.1 Malfunction reports (internal) ............................................................. 45

7.2.2 Malfunction Log ................................................................................. 45

7.2.3 Example Notifications ........................................................................ 45

7.2.4 Addresses ............................................................................................ 45

Appendix A – Blank SSMP Reports Incident Report Form Incident/Malfunction Tracking Log Startup Shutdown Log Notification Report for Malfunctions not Covered by SSMP Appendix B – Completed SSMP Reports Appendix C – Semi Annual Reports Appendix D – Previous Versions of SSMPRevision to SSMP:

Date of Revision Reason for Revision July 7, 2006 Original SMMP July 2, 2007 Plan revised/ updated based on NOV from GA DEP (March 2007)Startup, Shutdown and Malfunction Plan Boral Bricks, Inc. Augusta Plant 4

Page 1 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 1.0 INTRODUCTION

This Startup, Shutdown, and Malfunction Plan (SSMP) has been deve loped to meet the requirements found in the National Emission St andard for Hazardous Air Pollutants (NESHAP) codified in 40 CFR Part 63, Subpart A {§63.6( e)} and Subpart JJJJJ {§63.8420(c)}. This SSMP covers the Augusta facility tunnel kiln Kiln 4 (EU 41) and the Procedair dry injection fabric filter (DIFF) system (CE41), which are the a ffected sources in the Subpart JJJJJ.

At all times, including periods of startup, shutdown, and malfuncti on, Boral Bricks, Inc. (BoralAugusta) will operate and maintain any air pollution control equipment and monitoring equipment that are used to comply with the standa rd in a manner consiste nt with safety and good air pollution control practices fo r minimizing emissions to the le vels required by the relevant standards (i.e., meet the emission standard or co mply with the SSMP). Determination of whether such operation and maintenance procedures are bei ng used will be based on information that may include, but is not limited t o, monitoring results, review of operation and maintenance procedures (e.g. the SSMP), review of operation a nd maintenance records, and inspection of the

source.

Malfunctions will be corrected as soon as practicab le after their occurrence in accordance with this SSMP. To the extent that an unexpected event arises during a startup, shutdown, or malfunction, Boral-Augusta will comply by mi nimizing emissions dur ing such a startup, shutdown, and malfunction event consistent with safety and good air pollu tion control practices.

The remainder of this document summarizes the procedures that will be followed during periods when Kiln 4 and the control device are being st arted, shutdown, and during malfunctions. BoralAugusta must record each start-up, shut down, or malfunction period and document any additional information required by th e regulation. Examples of forms that can be used for these

instances have been in cluded in this SSMP.Startup, Shutdown and Malfunction Plan Boral Bricks, Inc. Augusta Plant 4

Page 2 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 2.0 PURPOSE

Under 40 CFR 63.6(e), Boral-Augusta is required to develop and implement for Kiln 4, and control device a written SSMP that describes, in detail: (1) procedures for operating and maintaining the source during periods of startu p, shutdown, and malfunction; (2) a program of

corrective action for a malfuncti oning process; and (3) the air pollution control and monitoring equipment used to comply with the relevant standard. The purpose of the SSMP is to:

(A) Ensure that, at all times, Boral-Augusta operates and maintains air pollution control and monitoring equipment in a manner consistent with safety and good air pollution control practices for minimizing emissions to the levels required by the relevant standards;

(B) Ensure that Boral-Augusta is prepared to correct malfunctions as soon as practicable after

their occurrence in order to minimize excess em issions of hazardous air pollutants; and

(C) Reduce the reporting burden associated with periods of startup, shutdown, and malfunction (including corrective action take n to restore malfunctioning process and air pollution control equipment to its normal or usual manner of operation).Startup, Shutdown and Malfunction Plan Boral Bricks, Inc. Augusta Plant 4

Page 3 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 3.0 REGULATORY ANALYSIS

The general regulatory requirements cite d below are addressed in this plan:

 §§63.6(e)(3) of Subpart A, General Provisi ons and 63.8420(c) of Subpart JJJJJ requires that Boral-Augusta develop and implement a SSMP for operations used to comply with the Brick and Structural Clay NESHAP. This SSMP is intended to meet the requirements for Boral-Augusta kiln operation.

 §63.6(e)(3) of Subpart A, Gene ral Provisions, requires Boral- Augusta to describe the

corrective action that will be taken if a malf unction occurs at an affected process, air pollution control device or monitoring equipment.

 In addition to the requirements to develop and implement a written SSMP, Boral-Augusta is also required under §63.6(e )(3)(vii) to perform the followi ng activities or functions:

o Keep records of any malfunction event that occurs and keep records of the actions taken to minimize emissions during the event.

o Submit reports if procedures taken during the event are not consistent with the procedures that are included in the SSMP and excess emissions occurred.

o Revised the SSMP if a malfunction occurs th at has not been described within this SSMP or procedures for corrective action have not been adequately described.

o Update the plan if requested by EPA or the appropriate State or Local Air Pollution Control Authority.

SECTION 3.1 DEFINITION OF “MALFUNCTION”

During the course of normal operations, Boral-Augusta may e xperience malfunction events. Please be aware that facilities may use a different definition of the term “malfunction” than the regulatory definition. The General Pr ovisions define a “malfunction” as:

Any sudden, infrequent, and not re asonably preventable failure of air pollution control and mon itoring equipment, process equipment, or a process to opera te in a normal or usual manner which causes, or has the potential to cause, the emission limitations in an applicable standard to be exceeded. (§63.2).

As stated above, a malfunction, as defined under Pa rt 63, must have the potential to cause an

exceedance in the emission limitations of the st andard. This plan, however, is designed to document all upsets and to determine whether or not they meet the definition of a “malfunction”

under the rule.Startup, Shutdown and Malfunction Plan Boral Bricks, Inc. Augusta Plant 4

Page 4 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Boral-Augusta also has a separate plan for rou tine maintenance of Kiln 4 and control device covered under the Brick and Structural Clay NES HAP that is called our Operating, Monitoring, and Maintenance Plan (OMMP). According to our OMMP, routine maintenance operations must be performed in accordance with the equi pment manufacturer’s specifications and recommendations, as well as the procedures speci fic to Boral-Augusta th at are detailed in our

OMMP.Startup, Shutdown and Malfunction Plan Boral Bricks, Inc. Augusta Plant 4

Page 5 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 4.0 AFFECTED SOUR CES AND CONTROL DEVICES

This plan covers the following devices:

General Description: Plant 4 Kiln 4 controlled by a Procedair dry injection fabric filter (DIFF)

Affected Source: Tunnel Kilns -Kiln 4 (EU41)

Capture/Control/Monitoring De vice ID: Procedair dry inje ction fabric filter (CE41)

Brief Description of System:

The tunnel kiln is currently operating at approximately 10 t ons of fired brick per hour, respectively. Due to the site-wide potential emissions of HF, HCL and total HAP, the BoralAugusta facility is a major source of HAP.

The tunnel kiln was operating prior to the promul gation date of July 22, 2002, and thus the kilns must comply with the “existing source MACT requi rements” that are contained in 40 CFR Part 63, Subpart JJJJJ. The existing source MACT re quirements require the kilns to meet the following limits:

HF – 90% control or 0.057 lb/ton (0.029 kg/Mg)

HCl – 30% control or 0.26 lb/ton (0.13 kg/Mg) PM – 0.42 lb/ton (0.21 kg/Mg) (Method 5 filterable PM) VE - No Visible Emissions per Method 22

Boral-Augusta elected to add a Procedair dry inj ection fabric filter system in order to comply

with the above limits.Startup, Shutdown and Malfunction Plan Boral Bricks, Inc. Augusta Plant 4

Page 6 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 5.0 PROCEDURES FOR STARTUP, SHUTDOWNS, &

MALFUNCTIONS

This section includes a description of Boral-A ugusta standard procedur es for starting Kiln 4 (EU41) and a Procedair dry injection fabric f ilter system, shutting down the kiln and Procedair dry injection fabric filter system, and for dealing with malfunctions that occur. For the purposes of this plan, the malfunctions include only those incidents that have the potential to cause an exceedance of the emission or operating lim its. These situations would include:

o A situation that causes the emissions from kiln 4 tunnel kiln to bypass the control device (DIFF-01) and be vented di rectly to the atmosphere; and

o A situation that causes the reagent in jection baghouse system to fail, thus increasing emissions above the NESHAP limits.

o An occurrence that causes the operating limits to be exceeded.

o Failure of the electronic monitoring system.

In general, the focus of our procedures is to pr otect both the integrity of the control system and reduce the emissions to the atmosphere. Boral be lieves that both are critical to ensuring the long-term emission reduction ability of the system. In addition, the safety of plant personnel and visitors is always the first priority.

To balance these, Boral follows the following general principles:

 The exhaust from the kiln is vented through the control device when the stack temperature is within the acceptable range. Ve nting at too low a temperature could cause moisture to enter the system and cause th e lime to solidify. Venting at too high a temperature could damage the bags which woul d lead to visible and gaseous emissions. [It should be noted that Boral uses bags appr opriate for the expected temperature ranges to be encountered].

 There must be a clear path though the system for the exhaust to be vented through the control. Exhausting when there is no clea r path (e.g., dampers closed to all cleaning modules) would damage the control, creating potential safety issues and potentially damaging the integrity of the cleaning process.

 The lime feed into the control is continuous, unless feeding additional lime could damage the system. For example, the lime flow woul d be halted if there is not sufficient flow

since the lime needs sufficient air flow to keep the particles suspended and to avoid blockages.

All of these principles were considered when the procedures were developed.

This plan includes one procedure for start-up, a regular shutdown pro cedure, an emergency shutdown procedure (i.e., “hard shutdown”) and numerous malfunction scenarios.Boral Bricks, Inc. Augusta Plant 4

Page 7 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 SECTION 5.1- STARTUP PROCEDURES

The startup procedures for the kiln and Procedair dry injection fabric filter system are outlined below. Boral-Augusta will document each time the systems undergoes startup.

Steps for Cold Kiln/Cold Control Startup Notes 1. Prior to starting the baghouse system, the kiln should be brought up to temperature through the bypass to avoid damage to the bags. Suitable range (400-450 degrees)

2. Turn control I.D. fan on in manual Th e control device has a startup sequence. Once all the steps have been completed the control device startups.

Steps for Hold Kiln/Cold Control Startup Notes

1. Press scrubber reset butt on to activate start up

sequence 2. Inspect all components for operation

Steps Taken to Minimize Emissions:

1. When there is any type of malfunction of the k iln that results in the kiln stoppage such as interruption of natural gas s upply or electrical power, no new product is placed into or

comes out of the kiln.

2. No new product is processed in the kiln unt il a proper operational temperature is reached for pushing new product into the kiln. The mi nimum temperature requi red for the fabric filter operation will be re ached before the kiln is at a pr oper temperature for introduction of new product. With no new product being introduced to the kiln, the leve l of emissions will be continually decreasing until the pushing of new production resumes. STARTUP - NORMALBoral Bricks, Inc. Augusta Plant 4

Page 8 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 SECTION 5.2- SHUTDOWN PROCEDURES

There is generally minimal need for shutting down the control and/or the kiln. The kiln tends to remain in operation. If the control and/or th e kiln need to be stopped, the following general principles impact the procedures

 Unless a safety issue or control device integr ity issue occurs, the ki ln will continue to vent through the control device until the exha ust reaches the low temperature set point (150 o F).

 Unless safety to Boral personnel and visitors or ongoing integrity of the control is threatened, all procedures will be aimed at minimizing avoidable emissions of HAP to the atmosphere.

If the control must be taken offline for rout ine maintenance, the time will be documented as being part of the time allowed under the Rou tine Maintenance Bypass Allowance in Boral’s permit

.

5.2.1 Normal Shutdown Procedures

The normal shutdown procedures for the kiln and Procedair dry injection fabric filter system are listed below. Boral-Augusta will document each time the system is shutdown.

Steps for Kiln Shutdown Notes 1. Initiate shutdown through the kiln controls. 2. The burners are stopped at the kiln and the pushing of new product into the kiln is immediately stopped.

Steps for Minor DIFF Shutdown Notes

1. Turn scrubber main control switch to the off position

2. Turn ID fan to Manual 3. Wait for scrubber to complete shutdown

sequence 4. Inspect all components to make sure it is completely shutdown SHUTDOWN

- NORMALBoral Bricks, Inc. Augusta Plant 4

Page 9 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Steps for Long Term DIFF Shut Down

ID Fan Offline Notes

1. Turn scrubber main control switch to the off position 2. Wait for scrubber to complete shutdown sequence 3. Manually turn on main baghouse conveyor (unless that is the equipment for repair) 4. Inspect all components to make sure it is completely

shutdown 5. Turn the ID fan control switch to the off position. Steps for Long Term DIFF Shut Down Baghouse Entry Notes

1. Turn scrubber main control switch to the off position 2. Wait for scrubber to complete shutdown sequence 3. Inspect all components to make sure it is completely

shutdown 4. Manually close ID fan damper to 0% 5. Allow system to cool to an expectable entry level

temperature 6. Manually turn off main baghouse conveyor 7. Manually turn off baghouse dump

Steps Taken to Minimize Emissions:

1. The introduction of new product into the ki ln is stopped at the same time that the burners are stopped. This results in a continual decrease of emissions until the exhaust fan is stopped.Boral Bricks, Inc. Augusta Plant 4

Page 10 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 5.2.2 Emergency Shutdown Procedures

The emergency shutdown procedures for the kiln and Procedair dry injection fabric filter system are listed below. Boral-Augusta will documen t each time there is an emergency shutdown. Emergency shutdown is triggered automatically by the system when it senses conditions that can lead to imminent danger or damage to equipment.

 Press the “E” stop button on the front of main scrubber control panel

Steps Taken to Minimize Emissions:

 In an emergency shutdown, safety is the pr imary issue. Boral-Augusta will work to minimize emissions to the extent practicable.

 Maintenance will determine whether the shutdown was due to true malfunction of the system or due to a malfunction of a sensor. The kiln will be stopped if the shutdown is due to a baghouse malfunction that stops the exhaus t fan or if the malfunction is a part of the kiln control system. If the emergency pertains to only the baghouse, only the baghouse will cease operation and the system w ill operate in bypass until the situation is

controlled. SHUTDOWN

- EMERGENCYBoral Bricks, Inc. Augusta Plant 4

Page 11 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 SECTION 5.3- MALFUNCTION PROCEDURES

This section describes the overall approach to identifying the cause of a malfunction and correcting it. It should be noted that Boral-Augusta has a responsibility to assure worker safety and to comply with all NFPA safety requirements. This will often affect the approach that must be taken to rectify a malfunction situation. Boral-Augusta will work to minimize emissions at all times, while ensuring all other health a nd safety requirements are also met.

Any malfunction of the ba ghouse initiates an alarm:

1. WARNING ALARM: This is an audible alarm and a light will fl ash. The alarm devices are located both at the baghouse and in side the main plant facility to ensure that prompt attention can be given. There are a number of malfunctions that can trigger a fa ult within the system and trigger an alarm. Depending on the nature of the malfunction, the baghouse may or may not go to bypass immediately. Mo st of the faults begin as wa rnings of a minor malfunction that if not given attention w ill lead to a bypass of the syst em after a predetermined time period. The only malfunctions that lead to an immediate switch to bypass are loss of I.D. fan, loss of compressed air or loss of power. T oo high or too low temperature to the baghouse will also lead to a bypass if they are not corre cted. These conditions both have an alarm set point to give a warning before reaching the critical bypass set point. The graphic display will

show the nature of the malfunction and indicate the part of the device th at needs attention.

Boral-Augusta ’s approach for minimizing emi ssions during any malfunc tions are based on the following concepts:

1. Minimize the amount of time the system is shut down . To minimize the amount of time the kiln and the DIFF systems are shutdown, Boral-Augusta will:

a. Respond as quickly as possible to each WARNING ALARM.

b. Maintain spare parts on hand for all components that have or are known to have the potential for failure, as well as any parts recommended by the Kiln manufacturer and Reagent Injection Fabric Filter System manufacturer.

c. Boral-Augusta will maintain a trained employ ee on each shift that will be able to respond to the alarms, correct the malf unctions or have the ability to contact key staff to handle any malfunctions of the systems.

2. Minimize the amount of emissions that are vented when the control device is not fully operational. To ensure that the amount of emissions that are vented to the atmosphere are minimized, Boral-Augusta will: MALFUNCTIONS- OVERVIEWBoral Bricks, Inc. Augusta Plant 4

Page 12 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 a. In any instance where the kiln is operating under normal conditions but the reagent injection system is malfunctioning, Boral-Augus ta will work as expeditious as possible to get the reagent injection fabric filter system either back on-line or operating under normal operating conditions.

b. During any malfunction of the kiln, Boral-Augusta will work as expeditious as possible to get the kiln operating under normal conditions. As long as all Procedair dry injection fabric filter parameters are within normal operating ranges, the Pr ocedair dry injection fabric filter system will continue to be operated during any malfunction of the kiln.

c. Boral-Augusta will either minimize the leng th of the control device downtime and bypass, or both, to the extent pr acticable during any malfunction.

It is highly possible that there may be episodes that fit the malfunction listed in this SMMP, where the described malfunction may be occurr ing, but in reality all emission and operating limits are being met by the emission source. For instance, we may lose a motor on one of the baghouse discharge valves for a few hours, but due to constant addition of reagent, we are continually meeting all limits while the motor is being replaced. In any circumstance where it can be determined that the specific malfunction even t as listed in this document is occurring, but has no potential for exceeding the NESHAP limits, Boral-Augusta will document each occurrence as a malfunction event, document the speci fics of the event, but will not report it as a malfunction (see malfunction definition in §63.2 or in Section 3.0 of this document) when compliance can be documented for the occurrence.Boral Bricks, Inc. Augusta Plant 4

Page 13 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 For purposes of this plan, a list of the types of potential malfunctions that can occur, the primary alarm type, and the Malfunction Number assigned are presented below. Boral-Augusta has generated standard procedures that will be follow ed when these malfunctions occur as well as any malfunctions due to Acts of God or power failures.

KILN MALFUNCTIONS

MALFUNCTION

NUMBER MALFUNCTION NAME Type of Alarm

1 Flashing System (including solenoid valves, timers, pressure regulators) None – visual observationPossible temperature alarm 2 Kiln out of Balance (improper balance of air flow ) (out of dryer stack) None – Visual observation

3 Kiln Malfunction that causes a bypass of Procedair dry injection fabric filter

system Visible and audible alarm if burners are out or high temperature alarm condition.

REAGENT INJECTION FABRIC FILTER SYSTEM MALFUNCTIONS

MALFUNCTION

NUMBER MALFUNCTION NAME Type of Alarm

1 No Reagent Feed - Failure of the silo reagent indicator level; Run out of reagent unknowingly (Indicator levels high. Reorder; low) Audible and visible alarm.

2 No Reagent Feed – Bridging of reagent

within the silo. Audible and visible alarm - “Pod”

has a low level alarm 3 Failure of fresh reagent silo feed mechanism that feeds dosing screw Audible and visible alarm.

4 Failure of reagent dosing screw metering and feed system Audible and visible alarm.

5 Failure of the reagent fill pipe feed

system. None –Visual observation

6 Failure of compressed air syst em Audible and visible alarm.

Low alarm – 80 PSI 7 Bag cleaning system failure Audible and visible alarm. 8 Mechanical and Electrical Components – Failure of Motors, Fans, Valves, Bearings, Belts, etc. Audible and visible alarm. (Depending on extent of failure.)

9 Ductwork Failure Visible alarm.Boral Bricks, Inc. Augusta Plant 4

Page 14 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 MALFUNCTION

NUMBER MALFUNCTION NAME Type of Alarm

10 Damper/ damper Drives failure Audible and visible alarm.

11 Electrical Controls Failure (thermocouple, pressure transmitter in duct) Audible and visible alarm. (Depends on component failing.)

12 Failure of the discharge rotary valve to

the waste lime silo . Audible and visible alarm.

13 Bag Failure- Manufacturers Defect, High Pressure Drop, Temperature, hole Observation

14 Pressure drop across baghouse too high Indicator 15 Pressure drop across baghouse too lo w Low Pressure alarm; low (70 PSI) goes to disable cleaning; low-low (50 PSI) to bypass

16 Visible emissions from stack None – visible inspection 17 High temperature in baghouse System alarm at 425 o F

Critical alarm if >450 o F 18 Low temperature in baghouse System alarm at 200 o F

Critical alarm if < 180 o F

19 Failure of Automatic Resets after a

power outage
Acts of God

Loss of Power or Gas Audible and visible alarm.

The general approach taken for each of these is presented in the remainder of this section.Boral Bricks, Inc. Augusta Plant 4

Page 15 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The flashing system, a key component of the kiln, uses natural gas in excess of normal usage, to “flash” the brick in a zone of the kiln. This flashing provides a coloring

finish and/or texture finish. A malfunction of this system can provide an excessive amount of smoke from either the kiln exhaust stack, the dryer exhaust stack, or the holding

room exhaust stack. Type of Malfunction: Flashing System

Possible Causes: Part failure such as timers, pressure regulators and solenoid valves, PLC components, wiri ng, or networking problems. Type of Alarm: WARNING ALARM (In most cases there will be no

alarm. It will have to be discovered by observation. This is mostly unattended at night and could possibly go on until dayshift arrives. The plant ope rates 7 days and thus would not have a possibility of not being discovered on the weekends.)

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual observation (or aler ted by an indicator light or alarm) and responds immediately. This could be observed as smoke out of one of the exhaust stacks or smoke within the plant. The malfunction could be a failure of the flashing to activate and would not cause visible emissions, but could cause the kiln car pusher to be stopped until proper repair is made.

2. Staff will identify the source of the smoke and take immediate action to stop the operation of the device ca using this condition.

3. If there is an improper sensor indicator, the sensor will be corrected to ensure proper

electronic feedback to the computer system.

4. If possible, the flashing system will be corrected while operating the kiln.

5. If the excessive smoke problem cannot be corrected while operating the kiln, BoralAugusta will follow one of the shutdown procedures identified in this SSMP.

6. If the flashing system is working properl y, any systems stopped for repair will be

restarted.

Steps Taken to Minimize Emissions:

1. Boral-Augusta will continue to operate the control device as long as there is no inlet temperature variance that requires the ba ghouse to go to bypass to prevent damage. (Inlet temperature exceedances are addr essed later in Kiln Malfunction 3, DIFF Malfunction 17, and DIFF Malfunction 18).

2. The continued operation of the control device will minimize all pollutant emissions. Only visible emissions should be aff ected by a flashing system malfunction. KILN

MALFUNCTION 1Boral Bricks, Inc. Augusta Plant 4

Page 16 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 3. Boral-Augusta will consider th e flashing system to be a malfunction if there are visible emissions as identified by Method 22 during such episode. As long as all control device operating parameters are within desira ble ranges, the control device will be operated to minimize emissions.

4. If there are no visible emissions in accord ance with Method 22, the above occurrence will be documented, but will not be consider ed a malfunction as identified in §63.2 and will not be reported as such.Boral Bricks, Inc. Augusta Plant 4

Page 17 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: It is possible that the kiln can experience an out of balance malfunction. During such a malfunction, there would be an improper balance of air flows within the kiln. The kiln will

continue to exhaust to the c ontrol device. However with improper balance of air flows, there could be an improper

exhaust of kiln combustion z one pollutants that is backdrafted through the dryer and dryer stack. A malfunction of this system can provide an excessive amount of smoke Type of Malfunction: Kiln out of Balance

Possible Causes: Improper balance of airflow Type of Alarm: WARNING ALARM (In most cases there will be no

alarm. It will have to be discovered by observation. This is mostly unattended at night and could possibly go on until dayshift arrives. The plant ope rates 7 days and thus would not have a possibility of not being discovered on the weekends.)

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual observation and responds immediately.

2. If there is an improper sensor indicator, the sensor will be corrected to ensure proper

electronic feedback to the computer system.

3. If the kiln is out of balance, the superv isor on call will be contacted immediately.

4. Key Boral-Augusta staff will identify the cause of the out of balance problem.

5. If possible, the balance problem will be corrected while operating the kiln.

6. If the balance problem cannot be corrected wh ile operating the kiln, Boral-Augusta will follow one of the shutdown proce dures identified in this SSMP.

Steps Taken to Minimize Emissions:

1. Boral-Augusta will continue to operate the control device as long as there is no inlet temperature variance that requires the baghous e to go to bypass to prevent damage. (Inlet temperature exceedances are addressed late r in Kiln Malfunctio n 3, DIFF Malfunction 17, and DIFF Malfunction 18).

2. For the exhaust sent to the cont rol device, only visible emissi ons should be affected by an out of balance malfunction. The continued ope ration of the control device will minimize all pollutant emissions.

3. If there is back-drafting through the dryer, Bo ral-Augusta will consider such occurrence a malfunction as described herein. If operati ng parameters are acceptable, Boral-Augusta will continue to operate the control device to minimize emissions from the kiln exhaust.

4. If there is no back-drafting through the dryer, Boral-Augusta will consider the balance problem to be malfunction if there are vi sible emissions as identified by Method 22KILNMALFUNCTION 2Boral Bricks, Inc. Augusta Plant 4

Page 18 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 during such episode. As long as all control device opera ting parameters are within desirable ranges, the control device will be operated to minimize emissions. (New plant only)

5. If there is no back-drafting through the dr yer and if there are no visible emissions in accordance with Method 22, the above occurr ence will be documented, but will not be considered a malfunction as identified in §63. 2 and will not be repo rted as such. (New plant only)Boral Bricks, Inc. Augusta Plant 4

Page 19 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: There may be occurrences that dictate for safety and good air pollution control practice reas ons that the control device may be bypassed, as a result of a kiln malfunction, in order to protect equipment. Type of Malfunction: Kiln Malfunction that Causes a Bypass of the Reagent Injection Fabric Filter System Possible Causes (not complete): Excessive Inlet Temperature Type of Alarm: WARNING ALARM Visible and audible alarms at the baghouse and inside the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. If there is an improper sensor indicator, the sensor will be corrected to ensure proper

electronic feedback to the computer system.

3. The plant manager or regional production ma nager will be contacted immediately.

4. Key Boral-Augusta staff will identify the cause of the operating problem.

5. If possible, the operating problem will be corrected while operating the kiln.

6. If the operating problem cannot be corrected while operating the kiln, Boral-Augusta will follow one of the shutdown proce dures identified in this SSMP.

Steps Taken to Minimize Emissions:

1. During a bypass of the control de vice, Boral-Augusta will work to get the kiln back to normal operating conditions as soon as feasib ly possible. The Procedair dry injection fabric filter system will be diverted from bypass back to the control device as soon as the problem is corrected. KILN

MALFUNCTION 3Boral Bricks, Inc. Augusta Plant 4

Page 20 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The dry injection fabric filter system requires free flowing reagent. The system is equipped with a reagent silo to provide this reagent. There ar e sensors and level indicators

within and below the silo to monitor free flowing reagent. Type of Malfunction: No Reagent Feed Possible Causes (not complete): Failure of sensor monitoring free flowing reagent; Failure of Level Indicator; Reagent availability issue. Type of Alarm: WARNING ALARM Audible and visible alarm at both the baghouse and in the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not free flowing reagent, that the sensor has failed, or that there is no fresh reagent available.

3. If there is free flowing reagent, the reagent fl ow sensor system and level indicator sensors will be analyzed and corrected to ensure proper feed to the computer system.

4. If there is no free flowing reagent, maintena nce will document either the mechanical problem (most likely one of the malfunctions listed as DIFF Malfunction 1 or 2) or the lack of reagent in the silo.

5. If there is insufficient reagent in the si lo, the plant manager and regional production manager will be contacted immediately.

6. Key Boral-Augusta personnel will contact reagent suppliers and will have reagent expedited to the site.

7. Reagent will be fed into the system as soon as received in the reagent storage silo.

Steps Taken to Minimize Emissions:

1. If there are only alarm, light, or sensor pr oblems, these will be corrected to properly monitor the system. If the sy stem is properly operating from a mechanical standpoint at or above the feeder setting w ith sufficient reagen t in the silo, the system is properly operating and is reducing emissi ons at or above the levels indicated in th e performance

test. There is no malfunction as defined in §63.2, and there are no additional steps to

minimize emissions.

2. If there is no reagent in the silo, Boral- Augusta will stop bag cleaning to preserve the reagent in the filter cake on the bags. When new reagent is available, the bags will be

cleaned and the feed rate will be increased until the normal operating pressure drop is

restored. DIFF

MALFUNCTION 1Boral Bricks, Inc. Augusta Plant 4

Page 21 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The Procedair dry injection fabric filter system requires free flowing reagent. The system is equipped with a reagent silo to provide this r eagent. There are sensors and

level indicators within and below the silo to monitor free flowing reagent. Type of Malfunction: No Reagent Feed Possible Causes (not complete): Bridging of reagent within the hopper over the feed

mechanism. Type of Alarm: Audible and visible alarm - “Pod” has a low level alarm

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not free flowing reagent.

3. Through mechanical means or controls, the te mporary bridging of th e material will be eliminated. If the problem occurs with freque ncy, additional devices will be installed to eliminate the problem. These new devices wo uld most likely have to be ordered and installed. More frequent at tention to this potential pr oblem by observation would be required during this time and a schedule would be assigned to the proper personnel to insure that reagent flow was as c ontinuous as possible in the interim.

4. If there is insufficient reagent in the si lo, the plant manager and regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will contact reagent suppliers and will have reagent expedited to the site.

6. Reagent will be fed into the system as soon as received in the reagent storage silo.

Steps Taken to Minimize Emissions:

1. If there are only alarm, light, or sensor pr oblems, these will be corrected to properly monitor the system. If the sy stem is properly operating from a mechanical standpoint at or above the feeder setting w ith sufficient reagen t in the silo, the system is properly operating and is reducing emissi ons at or above the levels indicated in th e performance

test. There is no malfunction as defined in §63.2, and there are no additional steps to

minimize emissions.

2. More frequent attention to this potentia l problem by observation would be required during this time and a schedule would be assign ed to the proper personnel to insure that reagent flow was as continuous as possible in the interim. DIFF

MALFUNCTION 2Boral Bricks, Inc. Augusta Plant 4

Page 22 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: On the bottom of the reagent storage silo, there is a feed mechanism similar to an auger, which turns and discharges the reagent to the bottom of the silo into the dosing screw. Type of Malfunction: Failure of fresh reagent silo feed mechanism that feeds dosing screw Possible Causes (not complete): Feed mechanism failure. Alarm Type: Audible and visible alarms at the baghouse and within the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not free flowing reagent.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If the feed mechanism is not operating, the plant manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs.

8. Reagent will be fed into the system as soon as repairs are completed.

Steps Taken to Minimize Emissions:

1. If there are only alarm, light, or sensor pr oblems, these will be corrected to properly monitor the system. If the sy stem is properly operating from a mechanical standpoint at or above the feeder setting w ith sufficient reagen t in the silo, the system is properly operating and is reducing emissi ons at or above the levels indicated in th e performance

test. There is no malfunction as defined in §63.2, and there are no additional steps to

minimize emissions.

2. If the feed mechanism is broken and not opera ble, Boral-Augusta will stop bag cleaning to preserve the reagent in the filter cake on the bags. When the repair is completed, the bags will be cleaned and the reagent feed will be increased until the normal operating pressure drop is restored. DIFF

MALFUNCTION 3Boral Bricks, Inc. Augusta Plant 4

Page 23 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: Reagent is fed by gravity th rough the feed mechanism to the dosing screw. Type of Malfunction: Failure of dosing screw reagent metering and feed
system Possible Causes (not complete): Malfunction of the indicator, electronics failure. Alarm Type: Audible and visible alarms at the baghouse and within the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not free flowing reagent and that there either is or is not a problem with the dosing screw.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If the dosing screw is not ope rating, the plant manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs.

8. Reagent will be fed into the system as soon as repairs are completed.

Steps Taken to Minimize Emissions:

1. If there are only alarm, light, or sensor pr oblems, these will be corrected to properly monitor the system. If the sy stem is properly operating from a mechanical standpoint at or above the feeder setting w ith sufficient reagen t in the silo, the system is properly operating and is reducing emissi ons at or above the levels indicated in th e performance

test. There is no malfunction as defined in §63.2, and there are no additional steps to

minimize emissions. 2. If the dosing screw is broken and not operabl e, Boral-Augusta will stop bag cleaning to preserve the reagent in the filter cake on the bags. When the repair is completed, the bags will be cleaned and the reagent feed will be increased until the normal operating pressure drop is restored. DIFF

MALFUNCTION 4Boral Bricks, Inc. Augusta Plant 4

Page 24 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: A tanker truck brings reagent to the site. The silo is filled pneumatically from the tanker truck. Type of Malfunction: Failure of the silo fill pipe system. Possible Causes (not complete): Malfunction of the indicator, electronics failure. Alarm Type: Audible and visible alarms at the baghouse and within the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that the tanker truck cannot fill the silo.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If the feed mechanism is not operating, the plant manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs.

8. Reagent will be fed into the silo as soon as repairs are completed.

Steps Taken to Minimize Emissions:

1. If there are only alarm, light, or sensor pr oblems, these will be corrected to properly monitor the system. If the system is properly operating such that the silo can be filled, the system is properly operating and is re ducing emissions at or above the levels indicated in the performance test. There is no malfunction as de fined in §63.2, and there are no additional steps to minimize emissions.

2. If the silo fill pipe system is broken and not operable, Boral-Augusta w ill operate as normal if there is an adequate supply of r eagent in the silo. If not, Boral-Augusta will stop bag cleaning to preserve the reagent in the filter cake on the bags. When the repair is completed, the bags will be cleaned and the reagent feed will be increased until the normal operating pressure drop is restored DIFF

MALFUNCTION 5Boral Bricks, Inc. Augusta Plant 4

Page 25 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The compressed air system, an integral part of the reagent injection baghouse system, supplies compressed air for bag cleaning and for the bypass damper. Type of Malfunction: Failure of compressed air system Possible Causes (not complete): Mechanical or El ectrical Failure Alarm Type: Audible and visible alarms at the baghouse and within the main production facility.. Low Level alarms at 80 PSI.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a problem with the compressed air

system.
3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there is a mechanical failure such as a leak in the system or other mechanical failure, the plant manager or regional production ma nager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. The air piping system allows Boral-Augusta to use more than one air compressor to furnish compressed air to the baghouse. In the event of a compressor failure, the baghouse will be switched to a backup compressed air source.

3. The compressed air pressure has two set po ints. The LOW set point disables bag cleaning to preserve air for valve operations . When the LOW set point is reached, bag cleaning will be disabled and Boral-Augusta will continue to ope rate the baghouse until an undesirable pressure drop is achieved in th e baghouse. Even though the pressure drop might increase, the control efficiency s hould not vary much if any at all.

4. If the LOW-LOW set point is reached, the baghouse will be bypassed as air pressure is required to keep the baghous e outlet poppet valves open.

5. If an undesirable pressure drop is met or ex ceeded, the baghouse system will go to bypass after a preset time until the compressed air system is corrected. During this phase of operation, the baghouse will be bypassed. DIFF

MALFUNCTION 6Boral Bricks, Inc. Augusta Plant 4

Page 26 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 6. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction.Boral Bricks, Inc. Augusta Plant 4

Page 27 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: In order to operate at optimal control efficiency, the bags within the baghouse system must be systematically cleaned. Type of Malfunction: Bag Cleaning System Failure Possible Causes (not complete): Seal failures; timing circuit failure Alarm Type: Audible and visible alarms at the baghouse and within the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a problem with the bag cleaning system.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there is a bag cleaning system failure , the plant manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. If there is a failure of the bag cleaning system, Boral-Augusta will attempt to fix the failure while continuing to operate the reag ent injection baghouse system as long as all other operating parameters are within desirable operating ranges.

3. If the failure of the bag cleaning system ca nnot be corrected while operating the reagent injection baghouse system, the reagent inje ction baghouse system will go to bypass after a preset time until the bag cleaning system failure is corrected.

4. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 7Boral Bricks, Inc. Augusta Plant 4

Page 28 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The reagent injection baghouse system has a fan on the outlet side of the baghous e and has numerous valves, bearings, and other mechanical and electrical components. Type of Malfunction: Mechanical & Electrical Components - Failure of motors, fans, valves, bearings, belts, etc. Possible Causes (not complete): Motor, fan, valves, bearings , etc. component failures Alarm Type: Audible and visible alarms at the baghouse and within the main production facility.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a problem with the mechanical and electrical component s associated with the reag ent injection baghouse system.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there are mechanical and electrical compone nt failures, the plant manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. If there is a failure of the mechanical and electrical component s, Boral-Augusta will attempt to fix the failure while continuing to operate the reag ent injection baghouse system as long as all other operating paramete rs are within desirabl e operating ranges.

3. Some of the failures listed in this malfunction cannot be corrected while operating the reagent injection baghouse syst em. If a mechanical and el ectrical component failure cannot be corrected while operating the reag ent injection baghouse system, the reagent injection baghouse system will be shutdow n until the failure is corrected.

4. During this phase of operation, the baghouse will be bypassed. During any bypass or control device shutdown, the kiln will be operat ed as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 8Boral Bricks, Inc. Augusta Plant 4

Page 29 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The dry injection fabric filter system has inlet ductwork from the kiln, outlet ductwork to the stack exit, and associated ductwork for bypass and control device gas recirculating during bypass or down time. Type of Malfunction: Ductwork Failure Possible Causes (not complete): Excessive temperature from kiln; unexpected abrasion; hidden damage under the insulation; etc. Alarm Type: Visible alarms at the baghouse and within the main production facility (possible in some cases.)

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a proble m with the ductwork.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there are ductwork failures, the plant ma nager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site a nd make adequate repairs.

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. If there is ductwork failure, Boral-Augusta will attempt to fix the failure while continuing to operate the Procedair dry injection fabric filter system as long as all other operating parameters are within desi rable operating ranges.

3. If the failure of the ductwork cannot be corr ected while operating the reagent injection baghouse system, the reagent injection baghouse system will be shutdown until the ductwork failure is corrected. During this phase of operation, the baghouse will be bypassed.

4. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 9Boral Bricks, Inc. Augusta Plant 4

Page 30 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: Each baghouse module has inle t and outlet isol ation valves and the system has a bypass va lve to allow bypass of the

DIFF. Type of Malfunction: Damper/Damper Drives Failure Possible Causes (not complete): Compressed air; damper fa ilure; electronics failure Alarm Type: Audible and visible alarms at the baghouse and within the main production facility

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a proble m with the damper.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there is a damper compone nt failure, the plant manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site a nd make adequate repairs.

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. If there is damper failure, Boral-Augusta will attempt to fix the failure while continuing to operate the reagent injecti on baghouse system as long as all other operating parameters are within desirable operating ranges.

3. If the damper failure cannot be corrected while operating the reag ent injection baghouse system, the reagent injection baghouse system will be shutdown until the damper is corrected. During this phase of ope ration, the baghouse will be bypassed.

4. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 10Boral Bricks, Inc. Augusta Plant 4

Page 31 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The dry injection fabric fi lter system has numerous electrical controls that are required to operate and monitor all operations associated with the system. Many of these systems may have been covere d in previous sections, but this has been added as a “catch-all” malfunction for any

outliers. Type of Malfunction: Electrical Controls Failure Possible Causes (not complete): Motors; fans; sensors; indicators; etc. Alarm Type: Audible and visible alarms at the baghouse and within the main production facility

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a problem with any electrical control.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there is an electrical c ontrol failure, the plan t manager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. If repairable by Boral-Augusta staff, mainte nance will work non-stop until the system is repaired.

7. If non-repairable by Boral-Augusta staff, the vendor or its representatives will be

contacted to visit the site and make adequate repairs.

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. All sens or or indicator malfunctions that affect compliance status will be recorded under this Malf unction No. 11.

2. If there is an electrical component failure, Boral-Augusta will attempt to fix the failure while continuing to operate th e reagent injection baghouse system as long as there is power to key operating components of the reagent injection ba ghouse and all other operating parameters are within desirable operating ranges.

3. If the electrical component failure cannot be corrected while operating the reagent injection baghouse system, the reagent injection baghouse system will be shutdown until the damper is corrected. During this phase of operation, the baghouse will be bypassed.

4. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 11Boral Bricks, Inc. Augusta Plant 4

Page 32 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: A rotary valve discharges used reagent from the bagfilter hopper and pneumatically conveys it to a storage silo using

a blower. Type of Malfunction: Disc harge rotary valve failure Possible Causes (not complete): Motor failure; bearing/air lock failure; electronics failure,

blower failure. Alarm Type: Audible and visible alarms at the baghouse and within the main production facility

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obser vation (or alerted by an indicator light or alarm) and responds immediately.

2. Maintenance verifies that there either is or is not a valve or va lve component failure.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there is a valve failure, the plant ma nager or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. Maintenance will immediately re pair the valve or order parts or replacement as quickly as possible.

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. If the discharge valve is not operable, re agent will be continuously injected and the baghouse will alarm as usual. If the hopper fills and the valve is not re paired, reagent dry injection fabric filter system and bag cleaning will stop until the valve is fixed. As a last resort, the baghouse will be shut down a nd bypassed to repair the valve.

3. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 12Boral Bricks, Inc. Augusta Plant 4

Page 33 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: The bags within the reagen t injection baghouse system will periodically fail due to unforeseen reasons. Type of Malfunction: Bag Failure Possible Causes (not complete): Manufacturers defect; high pressure drop, temperature Alarm Type: None. Detected by visual observation.

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual obs ervation (or alerted by a change in operating parameters) and responds immediately.

2. Maintenance verifies that there e ither is or is not a bag failure.

3. If there is a sensor failure, the sensor syst em will be analyzed and corrected to ensure proper electronic feedback to the computer system.

4. If there is a bag failure, the plant mana ger or regional production manager will be contacted immediately.

5. Key Boral-Augusta personnel will identify the cause of the problem.

6. Maintenance will immediately replace the damage bags.

Steps Taken to Minimize Emissions:

1. If the malfunction is just an indicator light or sensor malfunction the light or sensor will be corrected as specified above. Since the system is properly operating from a mechanical standpoint, there is no malfunc tion as defined in §63.2 and there are no additional steps to minimize emissions.

2. If there is bag failure, Boral-Augusta will attempt to fix the failure by isolating the modules and doing a bag inspection from the top plenums one at a time. When the bad bag is found by inspection, it will be replaced with a spare bag (on hand) and the plenum will be closed and the unit restarted immediately. If this does not take care of the problem or if many bags appear to need repla cement, the baghouse will be bypassed and a

contractor will be called in to assist in the replacement of the whole set of bags as quickly as possible.

3. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 13Boral Bricks, Inc. Augusta Plant 4

Page 34 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: There is a pressure indicator to measure PD at the inlet and outlet of the baghouse. Type of Malfunction : Pressure Drop Higher Than Acceptable Range

Possible Causes: Inefficient cleaning cycle in baghouse (e.g., timing orinsufficient compressed air); faulty pressure indicator, reentrainment of reagent low fan motor amperage Type of Alarm: If pressure rises above 10” wc. Audible and visible alarms at the baghouse and within the main production facility

Steps Taken to Correct Problem:

1. Check all indicators to see if root cause can be determined.

2. Determine if exhaust can still safely vent through one or more baghouse modules. If so, continue to vent through baghous e. If not, switch to bypass mode.

3. If malfunction cannot be repaired in 2 hours, notify management to evaluate whether change in kiln operation is warranted.

4. Once the malfunctioning equipment has been repaired, follow start-up procedures.

Steps Taken to Minimize Emissions:

1. Since high pressure drop most likely indicate s excessive reagent on the bags, exhaust will continue to flow through the system unle ss it will cause a danger to personnel or the equipment. This will ensure that the maximum possible emissi on reduction is still achieved during the incident.

2. Boral-Augusta will maintain spare parts recommended by the baghouse vendor to ensure parts most likely to require replacement are available.

3. If there is an excessive pressure drop th at can damage the baghouse, Boral-Augusta will bypass the system until the pressure drop issue is resolved and the baghouse can operate under normal operating conditions.

4. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during malfunction. DIFF

MALFUNCTION 14Boral Bricks, Inc. Augusta Plant 4

Page 35 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: There is a pressure indicator measure PD at the inlet and outlet of the baghouse. Type of Malfunction: Pressure Drop Across Baghouse Lower Than Acceptable Range

Possible Causes: Cleaning cycle too frequent; cleaning cycle based on time rather than pressure drop; power failure; exhaust Fan

Failure Type of Alarm : Audible and visible alarms at the baghouse and within the main production facility. Baghouse will alarm is has not

cleaned in 15 minutes.

Steps Taken to Correct Problem:

1. Check all indicators to see if root cause can be determined.

2. Determine if exhaust can still safely vent through one or more baghouse modules. If so, continue to vent through baghous e. If not, switch to bypass mode.

3. If malfunction cannot be repaired in 2 hours, notify management to evaluate whether change in kiln operation is warranted.

4. Once the incident has been repaired, follow st art-up procedures, if the system was shut

down.

Steps Taken to Minimize Emissions:

1. Increasing the reagent feed helps build the reag ent cake up on the bags faster. The increase in reagent builds it up as soon as pos sible without causing other problems.

2. If the exhaust has been minimized or is nil, there are little or no emissions.

3. If there is an insufficient pressure drop that can damage the baghouse, Boral-Augusta will bypass the system until the pressure drop issue is resolved and the baghouse can operate under normal operating conditions.

4. During any bypass or control device shutdown, the kiln will be operated as smoothly as possible to minimize emissions during malfunction. DIFF

MALFUNCTION 15Boral Bricks, Inc. Augusta Plant 4

Page 36 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: Visible emissions are observed from the DIFF

Exhaust Stacks. Type of Malfunction: Visi ble Emissions from Stack

Possible Causes: Bag breakage; improper duct ba lancing; improper seal at tube sheet; insufficient filter cake Type of Alarm: None- determined from visible observation

Steps Taken to Correct Problem:

1. Check all monitors/indicators to see if root cause can be determined.

2. To check for bag breakage, systematically clos e off one module at a time until location of

leak can be determined.

3. If bag breakage in one modul e is the cause, continue to vent through remaining, nonleaking modules.

4. If the issue is other than bag breakage, determ ine if exhaust can still safely vent through one or more baghouse modules while work continues to fix the malfunctioning equipment. If so, continue to vent thr ough baghouse. If not, switch to bypass mode.

5. If malfunction cannot be repaired in 2 hours, notify management to evaluate whether change in kiln operation is warranted.

6. Once the incident has been repa ired, follow start-up procedures.

Steps Taken to Minimize Emissions:

1. Boral-Augusta will seek to identify whether a single baghouse module is causing the visible emissions (this would most often be the case) as soon as practicable. Then, the

exhaust will be vented th rough the remaining modules.

2. If the malfunction can only be fixed by s hutting the baghouse down, Boral-Augusta will bypass the baghouse and will correct the problem

3. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during the malfunction. DIFF

MALFUNCTION 16Boral Bricks, Inc. Augusta Plant 4

Page 37 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: There are thermocouples that measure the temperature of the incoming gas flow. Type of Malfunction: High Temperature in Baghouse

Possible Causes: High kiln exhaust temperature High kiln exhaust flow Type of Alarm: Indicator alarm at 425 o F (“High temperature”)

Critical alarm if > 450 o F (“High-high temperature”)

Steps Taken to Correct Problem:

1. If critical alarm, DIFF will automatically sw itch to bypass to avoid damage to the DIFF.

Check all indicators to see if root cause can be determined.

2. If temperature remains below 450 o F, continue to vent through one or more baghouse modules, unless there is a personnel safety or an additional contro l device integrity issue.

3. Depending on root cause, follow remedy step s listed in the vendor operation and

maintenance manual.

4. If malfunction cannot be repaired in 2 hours, notify management to evaluate whether change in kiln operation is warranted.

5. Once the incident has been repa ired, follow start-up procedures.

Steps Taken to Minimize Emissions:

1. Boral-Augusta will respond to the indicator alar m as soon as practicable to help ensure

that the Critical Al arm is not triggered.

2. If there is an excessive temperature that can damage the baghouse, Boral-Augusta will bypass the system until the temperature issue is resolved and the baghouse can operate under normal operating conditions.

3. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during malfunction. DIFF

MALFUNCTION 17Boral Bricks, Inc. Augusta Plant 4

Page 38 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: There are thermocouples that measure the temperature of the incoming gas flow. Type of Malfunction: Low Temperature in Baghouse

Possible Causes: Type of Alarm: System alarm at 200° F

Critical alarm if < 180° F

Steps Taken to Correct Problem:

1. Check all indicators to see if root cause can be determined.

2. Verify that reagent is fl owing to control device

3. Determine if exhaust can still safely vent through one or more baghouse modules. If so, continue to vent through baghous e. If not, switch to bypass mode.

4. Depending on root cause, follow remedy step s listed in the vendor operation and

maintenance manual.

5. If malfunction cannot be repaired in 2 hours, notify management to evaluate whether change in kiln operation is warranted.

6. Once the incident has been repa ired, follow start-up procedures.

Steps Taken to Minimize Emissions:

1. If the temperature is sufficient in any modul e, flow will continue through the control.

2. If there is an insufficient temperature a nd can damage the baghouse, Boral-Augusta will bypass the system until the temperature issue is resolved and the baghouse can operate under normal operating conditions.

3. During any bypass or control device shutdown, th e kiln will be operated as smoothly as possible to minimize emissions during malfunction. DIFF

MALFUNCTION 18Boral Bricks, Inc. Augusta Plant 4

Page 39 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Description of Equipment: Failure of equipment to reset itself to correct operation after

a power outage. Type of Malfunction: Failure of Automa tic Resets following a power outage
Possible Causes (not complete): Power failure Alarm Type: Observation by Boral-Augusta Staff

Steps Taken to Correct Problem:

1. Maintenance is contacted due to visual observation and responds immediately.

2. Key Boral-Augusta personnel will identify the cause of the problem.

3. Boral-Augusta staff and maintenance will work and trouble shoot the system until repaired.

4. Upon resetting the equipment, the DIFF silo will be re -filled (if required) to normal levels with reagent.

Steps Taken to Minimize Emissions:

1. After a power failure, Boral-Augusta personnel will confirm that all default settings have been reset to the correct operating order as quickly as possible.

2. In most cases, the DIFF will continue to operate and since there is reagent in the system during much of the malfunction HF will continue to be removed. DIFF

MALFUNCTION 19Boral Bricks, Inc. Augusta Plant 4

Page 40 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Type of Malfunction: Acts of God

General Steps Taken to Correct Malfunction and Reduce Emissions

 Ensure that the situation has become stable and the hazards have been cleared before proceeding further.

 Confirm the system status and note which e quipment is off-line or otherwise impaired.

 Notify appropriate maintenance or other responsible personnel (see Section 6.1).

 Respond to correct or repair the malfunction in a safe, efficient and timely manner as soon as it is practicable, for example:

o Right overturned equipment and a ttempt to reinstall/restart; and

o Ensure all power and gas lines are functio ning correctly and are free from defect

 Suspend operations as soon as practicable un til compliance can be assured if failure cannot be repaired in a timely manner. ACTS OF GODBoral Bricks, Inc. Augusta Plant 4

Page 41 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Type of Malfunction: Loss of Power or Gas

General Steps Taken to Correct Malfunction and Reduce Emissions

 Ensure that the situation has become stable and the hazards have been cleared before proceeding further.

 Confirm the system status and note which e quipment is off-line or otherwise impaired.

 Notify appropriate maintenance or other responsible personnel.

 Respond to correct or repair the malfunction in a safe, efficient and timely manner as soon as it is practicable, for example:

 Call power company if power failure seems plant-wide; if not, trace power failure from equipment to power source;

o Check source of gas;

o Trace gas line from equipment to the s ource and determine whether any leaks or breaks in line exist; and

o Repair any breaks or leaks that are found in the utility system at the facility.

 A loss of gas pressure or a general loss of power will result in an automatic stoppage of the kiln operation and thus emissions will be minimized until power and or gas is restored to allow normal operations. If th e power loss is only at the baghouse unit,

there will be no exhaust from the kiln and th e kiln will automatically stop and will not operate until the situation is corrected. LOSS OF POWER/GASBoral Bricks, Inc. Augusta Plant 4

Page 42 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 6.0- RESPONSIBILITI ES AND POINTS OF CONTACT

SECTION 6.1- ORGANIZATIONAL CHART

Table of key individuals (by name or position), their contact information (phone, pager, cell, email), their responsibili ties, back up personnel.

Plant Manager Carl Williamson

Direct Phone: 706-849-5192

Regional Production Manager Neal Ruth

Direct Phone: 706-823-8047

Corporate Environmental; Frank Porter

Cell Phone: 706-575-1359

SECTION 6.2- RECORDKEEPING PLAN

All data and reports demonstrating compliance with a MACT standard, as well as previous versions of the SSMP, must be maintained for five years.

Location of Electronic File: All records will be kept at the plant premises for inspection on

demand.

SECTION 6.3- TRAINING REQUIREMENTS

To be completed

SECTION 6.4- SSMP VERSIO N CONTROL PROCEDURES

Protocol for identifying when to update the pla n, managing previous vers ions of the plan and document control procedures is included in Section 7.0.Boral Bricks, Inc. Augusta Plant 4

Page 43 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

### SECTION 7.0- RECORDKEEPING AND REPORTING REQUIREMENTS

SECTION 7.1- OVERVIEW OF REQUIREMENTS

The types f records that will be retained by Bora l-Augusta meet the requirements of Part 63.

These records include:

 Log of all startups and s hutdowns of the machines

 Record of each malfunction, and whether the ac tions taken to correct the malfunction were the same as the SSMP. (It may be possible that some events are not malfunctions. If it can be

determined that an event was not a malf unction, such an event will be documented).

The types of reports that are required to be submitted by Boral-Augusta vary considerably, depending on whether the actions take n were consistent with the SSMP.

 If the actions taken during the malfunction were consistent with this SSMP, Boral-Augusta will state this fact in our semiannual excess emissions report (due within 30 days following the end of each 6-month period) with the following information in cluded (§63.10(d)(5)(i)):

o Certifying signature of th e owner/operator or other responsible official;

o Statement that the actions taken during th e malfunction were consistent with the Malfunction Plan;

o The number, duration, and a brief descripti on of malfunction that occurred during the reporting period (§63.10(d)(5)(i)) or a c opy of a malfunction report form that includes this information (see Section 7.2.1 for an example form);

o Whether any excess emissions and/or para meter monitoring exceedances are believed to have occurred during the ma lfunction (§63.10(d)(5)(ii)); and

o Any additional information required by our State or permitting authority.

 If the actions taken during a malfunction were not consistent with th is SSMP, because the plan did not address the type of malfunction th at occurred and/or the actions taken were not included in the current SSMP, and excess emissions occurred, the Environmental Supervisor should report the actions take n by telephone or facsimile (FAX) transmission within two (2) working days after the malfunction. A letter must then be sent within seven (7) working days

after the malfunction. The letter should incl ude the following information (§63.10(d)(5)(ii)):

o Name, title, and certifying signature of responsible official;

o Explanation of the circumst ances of the malfunction;

o The reasons for not following the current SSMP; and

o Any additional information required by our State or permitting authority.

 If actions taken during the malfunction were not consistent with the SSMP or did not address the particular type of malf unction that occurred, and the Boral-Augusta ’s SSMP shouldBoral Bricks, Inc. Augusta Plant 4

Page 44 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 include these events or actions for future ev ents. Then General Provisions also require ((§63.6(e)(3)(viii)):

o Revise the SSMP within 45 days after th e malfunction to include procedures for operating and maintaining the source during similar malfunction events, with a program of corrective action to address the malfunctions; and

o Report the revisions of your SSMP in the semi annual excess emissions report (within 30 days following the end of each 6-month period).Boral Bricks, Inc. Augusta Plant 4

Page 45 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 SECTION 7.2- EXAMPLE REPORT FORMS

Malfunction reports (internal)

Forms to be completed for each malfunction that o ccurs - must include determination of whether

SSMP was followed.

Malfunction Log

Table listing each malfunction and whether it was included in plan or, if not, whether required notifications were provided

Example Notifications

Provide examples of: verbal/wri tten notification required within 2 days of malfunction not included in SSMP; written notific ation required within 7 days of the end of a malfunction not included in SSMP; language to include in semiannual reports.

Addresses

GEORGIA DEPARTMENT OF NATURAL RESOURCES

Georgia Department of Natural Resources

Environmental Protection Division

Air Protection Branch 4244 International Parkway, Suite 120 Atlanta, Georgia 30354

US Environmental Protection Agency

EPA Region 4 Regional Office 61 Forsyth Street Atlanta, GA 30303Page 46 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 

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### SSM E VENTSBoral Bricks, Inc. Augusta Plant 4 Plant

INCIDENT REPORT FORM

Page 47 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 MALFUNCTIONING DEVICE:

DATE OF INCIDENT: ___________________________________

Explanation of Incident (include suspected cause- can reference Incident Code, if applicable)

Duration : (Estimated)Start Time:

End Time:

Duration:

Provide an estimate of excess emissions or a description parameter monitoring exceedances:

1. Were all operating parameters (reagent feed setting, free flowing reagent and visible emissions (if applicable )) monitored during the incident? Y / N

2. Were all parameters monitored to be within the permitted ranges during

the incident? Y / N

If answers to 1 and 2 above are YES, this is not a malfunction, please sign below and stop. If either (or both) of the answ ers to 1 and 2 are NO, proceed with answering 3 and 4 below.

3. Was this event included in the SSM plan? Y / N If YES, please list malfunction No. (i.e., DIFF-01) ____________________________

4. Were the procedures in SSM plan followed? Y / N

 If the answer to both questions 3 and 4 above is YES, sign below and stop. List malfunction in semi-annual report. See Section 7.1 of SSMP for information.

 If either answer is NO, sign below and comp lete the remainder of the form. Immediate reporting required. See Section 7.1 of SSMP for information; see Sections 7.2.3 for example notifications.

Signature: ___________________ Date: _________________________

If the answer to questions 3 and/or 4 above is NO, complete the following on Page 2: TRACKING NUMBER: ________Boral Bricks, Inc. Augusta Plant 4 Plant

INCIDENT REPORT FORM

Page 48 of 45 BORA-3_Augusta 4 SSMP.doc Revision 2- July 2, 2007 Action Taken to Correct the Problem:

Actions Taken to Minimize Emissions During Problem:

Measures Taken to Prevent a Reoccurrence of the Problem:

Is this incident a malfunction under 40 CFR, Part 63? If not, why?:

NOTE: SSM Plan must be revised to inco rporate this malfunction (see Section 7.1)Boral Bricks, Inc.Augusta Plant 4 PlantPage 49 of 45BORA-3_Augusta 4 SSMP.docRevision 2- July 2, 2007Incident/Malfunction Tracking LogDateTrackingNumberWas theIncident aMalfunction?If YES, wasthe SMMPfollowed?If SSMP not followed....Who completedthis log?SeeNote1Was 2nddayreport calledin or faxed?Was 7thdayreport mailedWas SSMPmodified?1Add a reference letter to this column, ifyou need to add additional information below:abcd-Boral Bricks, Inc. Augusta Plant 4 Plant

Start up – Shutdown Log

DATE Begin “Start-up” End “Start-up” Begin
“Shutdown” End
“Shutdown” NotesBoral Bricks, Inc. Augusta Plant 4 Plant

NOTIFICATION REPORT FOR MALFUNCTIONS NOT COVERED BY SSMP

Type of Malfunction:

Date of Malfunction:

Explanation of the circumst ances of the malfunction:

Reasons for not following the current SSMP:

Responsible Official: Name:

Title:

Signature

Fax the above information within two (2) working days after the malfunction to:

Georgia Department of Natural Resources

Environmental Protection Division

Air Protection Branch

FAX: 404.363.7100

Mail a letter with the above information within se ven (7) working days after the malfunction to:

Georgia Department of Natural Resources

Environmental Protection Division

Air Protection Branch 4244 International Parkway, Suite 120 Atlanta, Georgia 30354

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### V ERSIONS OF 

### SSM P LAN