P.1 

OAR Box 1500 

Prepped by Ollie Stewart 

Document Number: 

7DII-C-97 

Docket Number: 

A-94-52 

Printed 8/5/2008 1:51:29 PM Sheet 71 of 343 
tfl **%,. 

PACIFIC ENVIROtJMENTAL SERVICES, INC. 

Central Park West 

5001 South Miami Boulevard, Suite 300 

P.O. Box 12077 

Research Triangle Park, NC 27709-2077 

(919) 941-0333 

FAX (919) 941-0234 

FAX COMMUNICATION M" V 

Date: allUL 

FROM . s^//*">'* f~<ocJ

0" 

TO: Name: 

Address: 

Ai*. If* mo"* k;<sWfbcf_ 

^~g__<? * y> o- £<>*) 

Phone Number-- \tl '-—*-=^ 

FAX NUMBER: . ( *'^ /

 7 * "> <-

REFERENCE CODE: ^2£L_2£_ L 

THIS COMMUNICATION COMPRISES j£ . PASES INCLUDING THIS PAGE. 

COMMENTS: 

D PACIFIC ENVIRONMENTAL SERVICES. INC. 25 

MELANIE S. PROCTOR 

Central Park West 

5001 S. Miami Blvd. PO Box 12077 

Research Triangle Park. NC 27709-2077 

(919)941-0333 

mproctor® rtp.pes.com 

FAX: (919) 941-0234 

WASH,NQTO,O.C,RESEARCHTR.ANQLEPAR.NC • LOSANQELES.CA • CNCINNATt. OH 
P.3 

/§gi^/g|g|7 (§|gF7 

[SI PACIFIC ENVIRONMENTAL SERVICES, INC. 

July 9,1998 

Central Park West 

5001 South Miami Boulevard, Suite 300 

P.O. Box 12077 

Research Triangle Park, NC 27709-2077 

(919) 941-0333 

FAX (919) 941-0234 

Mr. Kamama Kigweba 

Ferro Corporation 

Via Facsimile @(219) 935-5278 

Dear Mr. Kigweba: 

Thank you for providing information on gel coat properties and chemistry during our 

telephone conversation yesterday. The EPA and its contractor, Pacific Environmental Services, Inc., 

are in the process of collecting gel coat property .and cost data that will be used in developing the 

maximum achievable control technology (MACT) standard for the pl^tic composites industry 

pursuant to Section 112 of the Clew Air Act, as amended in 1990. 

Per your request I am sending you a copy of the draft MACT database for gel coating 

(Enclosure 1). As I explained to you during our telephone conversation, the EPA has separated gel 

coating operations into pigmented production applications, clear production applications, and tooling 

applications. 

We would like to collect data on the properties and costs for gel coats sold by Ferro 

Corporation in order to .assess the costs that facilities would incur by switching from gel coats with 

a high hazardous air pollutant (HAP) content to a low HAP content. Based on our assessment, the 

following HAP contents are considered low: (1) 30 percent or less HAP for pigmented production 

gel coats, (2) 40 percent or less HAP for clear production gel coats, and (3) 40 percent or less HAP 

for tooling gel coats. We would appreciate if you would provide information on properties and costs 

for the gel coats shown in Enclosure 2. In addition, we would like you to identify low HAP 

replacements that Ferro Corporation sells for high HAP pigmented, clear, and tooling gel coats. 

When you select these high and low HAP gel coat pairs, we would like you to match the gel coat 

properties for each ofthe pairs as closely as possible and provide average list costs for each pair. 

Please provide as many of these gel coat pairs as possible for each ofthe three gel coat applications 

(pigmented production, clear production, and tooling). The costs for these resin pairs identified by 

Ferro Corporation can be added to the table in Enclosure 2. 

If any ofthe information you submit in response to the list of questions in Enclosure 2 is 

considered by your company to be confidential business information (CBI), please indicate those 

portions of your response considered to be CBI and mail the entire response to: 

WASHINGTON, D.C. • RESEARCH TRIANGLE PARK, NC • LOS ANGELES, CA • CINCINNATI, OH 

2^ 
P.4 

Ms. Melva Toomer 

Office of Air Quality Planning and Standards 

CBI Manager 

411 West Chapel Hill Street, Room 944 

Durham, North Carolina 27701 

If none ofthe information in your response to this request is considered by your company to 

be CBI, please submit the response directly to me either through the mail or through our fax number 

(919)941-0234. 

If you have any questions concerning this request, please do not hesitate to call me at (919) 

941-0333 or the EPA task order project officer, Ms. Madeleine Strum, at (919) 541-2383. Thank 

you for your cooperation. 

Sincerely, 

PACIFIC ENVIRONMENTAL SERVICES, INC. 

2 Enclosures 

cc: PES Project File 

Ms. Madeleine Strum, US EPA 

/Pbdzru^/O^ 

Melanie Proctor 

Project Lead 

3 
Pigmented Production DB/ain 

Pigmented Production Gel Coats 

Important Notes: 

The average emissions factors used in this spread sheet to calculate emissions should not be used to determine or estimate actual emissions at a specific facility. 

A facility's specific emissions shown in this spread sheet may not represent the facility's actual emissions and should therefore not be used. I 

- ^ 

This database only contains facilities for which the Administrator has information. Other facilities that should be part of this database are likely to exist 

< 

Pagel 

TJ 
Pigmente

d Production C ID \1 S? 

u 

31 20th Century Fiberglass, Inc. (Plant Four) 15.0 35.0 2.5 338 

32 A1 Fiberglass, Inc. 95.0 35.0 16.0 338 

33 Aero Transportation Products 93.0 35.0 15.7 338 

34 Altec Industries, Inc. (Midwest Oper.) 25.0 35.0 4.2 338 

35 Americ

h Corp. (Charlotte, NC) 3.5 35.0 0.6 338 

36 Americ

h Corp. (Hollywood, CA) 3.0 35.0 0.5 338 

37 Arrow Dynamics, Inc. 10.0 35.0 1.7 338 

38 Attbar Plastics, Inc. 79.0 35.0 13.3 338 

39 

C & K Fiberglass Plastics, Inc. 43.0 35.0 7.3 338 

40 Century Manufacturin

g Co. 25.5 35.0 4.3 338 

41 Charlom

a Fiberglass, Inc. 86.0 35.0 14.5 338 

Covermaster, Inc. 11.8 338 

Fiberdome, Inc. (Plant #1) 

0.8 338 

0.9 338 

35.0 5.1 338 

U 

46 Glasspec Associates, Ltd. 7.5 35.0 1.3 338 

47 Grea

t Lakes Plastics Corp. 80.0 35.0 13.5 338 

48 HEMC

O Corp. 9.0 35.0 1.5 338 

49 Heritag

e Marble of Ohio, Inc. 1.0 35.0 0.2 338 

50 Holida

y Rambler Corp., Plant 36 and 37 150.0 35.0 25.3 338 

51 Kivett's

, Inc. 4.5 35.0 0.8 338 

52 Krueger International, Inc. 

54 Lawrence Wittman & Co., Inc. 

55 56 57 58 Leer East, Inc. 

Leer Midwest 

McClarin Plastics, Inc. 

Melcher Manufacturing Co., Inc. 

61.7 

4.4 

3.3 

109.7 

200.0 

109.7 

14.0 

35.0 10.4 338 

0.7 338 

35.0 

35.0 

35.0 

35.0 

35.0 

0.5 338 

18.5 338 

33.8 338 

18.5 338 

2.4 338 

59 Molde

d Plastic Industries, Inc. 49.0 35.0 8.3 338 

60 Murph

y Body Co. 17.2 35.0 2.9 338 

61 Osborn

e Industries, Inc. 12.0 35.0 2.0 338 

62 Peterson Products 7.5 35.0 1.3 338 

63 Phi

l Carter System, Inc. 9.0 35.0 1.5 338 

64 Picken'

s Plastics, Inc. 45.0 35.0 7.6 338 

65 Piedmon

t Fiberglass, Inc. 22.2 35.0 3.7 338 

66 Plasti

c Development Co. 1.0 35.0 0.2 338 

67 Retterbus

h Injection Molded Fiberglass Corp. 3.2 35.0 0.5 338 

Page 2 

TJ 
Pigmented Production DIMI 

68 Robroy Industries, Inc. (Belding, Ml) 3.6 35.0 0.6 338 

69 Seal Reinforced Fiberglass 3.3 35.0 0.6 338 

70 Simon-Telelect, Inc. 24.0 35.0 4.1 338 

71 Standard Glas, Inc. 15.0 35.0 2.5 338 

72 Style Crest Products 35.0 35.0 5.9 338 

73 Tom Smith Fiberglass, Inc. 8.1 35.0 1.4 338 

74 Trail Wagons, Inc. 8.0 35.0 1.4 338 

75 Universal Plastics, Inc. 46.6 35.0 7.9 338 

76 Universal Rundle Corp. (Union Point) 300.0 35.0 50.6 338 

77 Universal-Rundle Corp. (New Castle) 607.5 35.0 102.6 338 

78 Xenon Co., Inc. 0.8 35.0 0.1 338 

6"\ 

Nordic Fiberglass, Inc. (Devils Lake) 

Raven Industries, Inc. (Sioux Falls) 

Nordic Fiberglass, Inc. (Warren) 

i_^rf-##g^/%_ft£i%^ 

Bathcraft, Inc. 

4.1 341 

0.6 341 

2.2 341 

0.2 345 

2.4 347 

78.1 349 

67.0 350 

21.6 

1.9 

350 

351 

Eljer Manufacturing (Valdosta) 

92 Fiberglass & Plastic Fab., Inc. 9.0 36.0 1.6 356 

93 Florida Line of Astatula, Inc. 50.1 36.0 8.9 356 

94 Hy-Tec Fiberglass, Inc. 6.0 36.0 1.1 356 

95 Kreider Manufacturing, Inc. 102.0 36.0 18.2 356 

96 Newport Laminates 30.0 36.0 5.3 356 

97 Northwest Bodies, Inc. 22.6 36.0 4.0 356 

98 Oasis Industries, Inc. 16.2 36.0 2.9 356 

99 Primero, Inc. 7.0 36.0 1.2 356 

100 Vertex Plastics, Inc. 15.0 36.0 2.7 356 

101 Pearl Baths, Inc. 4.5 36.2 0.8 360 

102 LASCO Bathware (Anaheim) 760.5 36.4 138.2 363 

103 LASCO Bathware (Cordele) 470.0 36.4 85.4 363 

104 LASCO Bathware (Moapa) 1596.0 36.4 289.9 363 

105 LASCO Bathware (Three Rivers) 685.1 36.4 124.5 363 

106 LASCO Bathware (Yelm) (aka Hytec Inc.) 603.7 36.4 109.7 363 

107 Arrowhead Plastic Engineering, Inc. 28.9 36.6 5.3 367 

Page 3 
Pigmented Production ID 12 MI T 

Sunset Plastics, Inc. 

112 

113 

114 

115 

116 

117 

118 

119 

120 

121 

122 

123 

Diamond Fiberglass Fabricators, Inc. 

E-T-M Enterprises, Inc. 

ED Industries Inc. (Sportsman Pickup Covers) 

Glasstite, Inc. 

Hood Manufacturing, Inc. 

Jason Industries, Inc. (Elkhart, IN) 

Miracle Recreation Co. 

Odom Fiberglass, Inc. 

Plastic Composites Corp. 

S.W.C. Industries, Inc. (Swirl-Way Div.) 

Xerxes Corp. (Seguin) 

Xerxes Corp. (Williamsport) 

126 Fibre Body Industries, Inc. 

9.2 

9.8 

109.7 

109.7 

109.7 

109.7 

109.7 

109.7 

20.0 

109.7 

109.7 

1.6 

109.7 

109.7 

109.7 

109.7 

37.0 

36.8 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

36.9 

37.0 

20.3 

20.4 

20.4 

20.4 

20.4 

20.4 

3.7 

20.4 

20.4 

0.3 

20.4 

20.4 

20.4 

20.4 

70.0 37.0 

6.9 

9.0 

13.1 

367 

368 

371 

373 

373 

373 

373 

373 

373 

373 

373 

373 

373 

373 

373 

373 

375 

375 

375 

127 Monarch Plastic, Inc. 13.8 37.0 2.6 375 

- 3 128 

130 

National Fiber Glass Products, Inc. 

Plasti-Fab, Inc. 

167.3 

20.5 

37.0 31.3 375 

1.9 375 

37.4 3.9 382 

131 ACME Reinforced Plastics, Inc. 21.0 37.5 4.0 384 

132 Aqua Glass Corp. (Adamsville) 

133 Blue Dolphin Fiberglass Pools 

134 Epoch Industries 

1170.0 

109.7 

12.0 

37.5 224.7 384 

37.5 21.1 384 

37.5 2.3 384 

135 Appalachian Plastics, Inc. 2.0 37.5 0.4 385 

136 Associated Plastics, Inc. 12.5 37.5 2.4 385 

137 Fleetwood (Fontana - Formerly Gold Shield) 158.0 37.5 30.4 385 

Page 4 

u 

co 
Pigmented Production ISMIT 

1.5 

1.4 

52.3 

1.1 

413 

416 

419 

433 

8.1 433 

23.8 433 

0.8 433 

0.9 433 

156 Bittner Industries, Inc. 3.0 40.0 0.7 433 

157 Bradley Specialties Corp. 1.7 40.0 0.4 433 

158 Ceramic Cooling Tower Company 17.6 40.0 3.8 433 

159 Chance Operations, Inc. 22.8 40.0 4.9 433 

160 Comtech Antenna Systems, Inc. 27.0 40.0 5.9 433 

161 Continental Camper Company, Inc. 72.5 40.0 15.7 433 

162 Delta Fiberglass Structures, Inc. 23.0 40.0 5.0 433 

163 Diamond Coach Corp. 24.0 40.0 5.2 433 

164 Elmore Truck Accessories, Inc. 7.0 40.0 1.5 433 

165 Fiberglass Forms, Inc. 8.0 40.0 1.7 433 

166 Fiberglass Plus Recreational Industries, Inc. 12.5 40.0 2.7 433 

167 Fiberglass Products, Inc. 30.0 40.0 6.5 433 

oCl 

168 Fiberglass Specialties, Inc. 20.0 40.0 4.3 433 

169 Fiberglass Systems, Inc. 158.6 40.0 34.4 433 

Page 5 

u 

CO 
Pigmented Production 

CTP 

188 Teco, Inc. 4.0 40.0 0.9 433 

189 Warminster Fiberglass Co. (Jacksonville) 30.0 40.0 6.5 433 

190 Warminster Fiberglass Co. (Southampton) 37.3 40.0 8.1 433 

191 Yankee Plastic Co. 1.5 40.0 0.3 433 

192 Custom Fibreglass Manufacturing Co. 124.0 40.4 27.4 442 

193 

195 

American Reinforced Plastics 

GPI Corp. 

56.0 

109.7 

15.0 

40.5 12.4 444 

24.3 444 

41.0 3.4 454 

196 Fleetwood (Decatur - Formerly Gold Shield) 673.7 41.4 155.7 462 

197 Bristol Fiberlite Industries 15.6 41.4 3.6 463 

198 Gorman-Rupp Co. 7.5 42.0 1.8 475 

199 Brunnel Products of Florida, Inc. 27.5 45.0 7.4 540 

200 Fiberglass Engineering Corp. 13.5 45.0 3.6 540 

201 United Panel, Inc. 22.0 45.0 5.9 540 

202 MFG - Molded Fiber Glass Co. (Union City) 102.0 49.0 32.3 634 

203 Amtech Corp. 

204 Marblecast Products, Inc. 

205 Rynone Manufacturing Corporation-Sayre Plant 

17.3 

109.7 

50.0 

50.0 5.7 658 

50.0 36.1 658 

50.0 16.5 658 

0.2 658 

Projected Total (includes assumed values): 22596.2 3502.8 

__-> Average: 109.7 36.9 17.0 369 

Legend 

Assumed values - no data provided 

Page 6 
i l l 

Clear Production II1H 

Clear Production Gel Coats 

Important Notes: 

The average emissions factors used in this spread sheet to calculate emissions should not be used to detemnine or estimate actual emissions at a specific facility. 

A facility's specific emissions shown in this spread sheet may not represent the facility's actual emissions and should therefore not be used. | 

This database only contains facilities for which the Administrator has infonnation. Other facilities that should be part of this database are likely to exist 

Weighted 

Average MACT Model 

% HAP in MACT Model Emissions 

Gel Coat Neat Gel Emissions per Ton Gel Coat 

Usage Coat plus (before MACT) (before MACT) Reduction 

Bank Plant Name mi m mi ^lbs/ton. Technique 

Builders Marble, Inc. 

Century Marble Co., Inc. 

Athena Marble, Inc. 

9.0 

17.5 

7.4 

35.0 1.5 

35.0 3.0 

40.0 1.6 

338 

338 

433 

Newartesian Limited Partnership (Marble Plant) 135.0 40.0 29.3 

Treasure Coast Marble, Inc. 

Tri-City Marble, Inc. 

24.0 5.2 

12.0 40.0 2.6 

433 

Venetian Marble (Helotes, TX) 14.1 40.0 3.1 433 

Wilson Marble Co. 7.8 40.0 1.7 433 

9 Marbelite Corp. 20.0 43.0 5.0 496 

10 Marble Designs, Inc. 

Accent Marble Co., Inc. (Houston, TX) 

15 Austin Countertops, Inc. 26.0 45.0 7.0 540 

16 Cameo Marble 47.2 45.0 12.8 540 

17 Capital Marble Creations, Inc. 15.0 45.0 4.1 540 

18 Carolina Counters 10.6 45.0 2.9 540 

19 Central Marble Products, Inc. 9.0 45.0 2.4 540 

20 Foremost Interiors, Inc. 5.9 45.0 1.6 540 

21 Gesmar Corp. 15.1 45.0 4.1 540 

22 Kerrico Corp. 26.0 45.0 7.0 540 

23 Lippert Corp. 60.0 45.0 16.2 540 

24 Schmitt Marble Products 50.0 45.0 13.5 540 

25 Southeast Marble, Inc. 12.2 45.0 3.3 540 

26 United States Marble, Inc. 

28 American Bluegrass Marble Co., Inc. 

29 

30 

31 

32 

33 

34 

35 

36 

Custom Marble, Inc. 

General Marble Co. (Guasti) 

General Marble Co. (Homed) 

General Marble Co. (Lincolnton) 

International Paper (Hampton, SC) 

United Technologies Motor Systems 

Vendura Industries, Inc. 

AGCO, Inc. 

3.5 

17.5 

13.5 

14.0 

17.5 

17.5 

17.5 

17.5 

17.5 

17.5 

10.0 

45.0 

46.2 

46.2 

46.2 

46.2 

46.2 

46.2 

46.2 

46.2 

47.0 

0.9 

4.9 

3.8 

4.0 

5.0 

5.0 

5.0 

5.0 

5.0 

5.0 

2.9 

540 

563 

568 

568 

568 

568 

568 

568 

568 

568 

586 

37 Lehigh Cultured Marble, Inc. 7.5 47.0 2.2 586 

38 Marble Works, Inc. 8.0 47.0 2.3 586 

Pagel 

IO 
P.12 

Clear Production 

in I Li a r-J

 *— rt 11 

Page 2 
P.13 

Tooling !? 

! I; 11 n 

Tooling Gel Coats 

Important Notes; 

The average emissions factors used in this spread sheet to calculate emissions should not be used to detennine or estimate actual emissions at a specific facility. 

A facility's specific emissions shown in this spread sheet may not represent the facility's actual emissions and should therefore not be used. 

This database only contains facilities for which the Administrator has information. Other facilities that should be part of this database are likely to exist 

Weighted 

Average MACT Model 

Gel % HAP in MACT Model Emissions 

Coat Neat Gel Emissions per Ton Gel Coat 

Usage Coat plus (before MACT) (before MACT) Reduction 

Rank Plant Name iiml (%_ mi flbs/toni Technique 

11 

12 

13 

14 

15 

16 

17 

A. R. E., Inc. (Massillon) Thermal Oxidizer (95% Control) 

Bathcraft Inc 

' VMC Fiberglass Products, (ftc fTn-Gtes 

' Prestigious Accassori4S. toe 

" Couture Coach Inc. 

' Global Glass. Ins. 

" AKER fHsstws Company, Jno iPivroouth Nr.th Csk} 

FO Pwdtete ?r» 

S R Smith Inc 

180 

28 

- 2 

05 

04 

- J 

- 0 

OS 

28 

46 0 

45 5 

4?5 

47 0 

4?.-

47 _ 

47.4 

48 0 

0.9 

0.1 

0.1 

0.6 

0.6 

0.2 

0.9 

574 

575 

585 

590 

592 

595 

610 

Projected Total (includes assumed values): 47.3 12.4 

Average: 2.8 44.3 0.7 493.8 

legend 

Assumed values - no data provided 

Page 1 
Ferro Corporation Gel Coats 

^_ 

<s* 

NOTE: 

CLEAR PRODU 

«arrtjfacttif4jr : 

Please provide the information requested in the table and add infonnation for high HAP/low HAP gel coat pairs. Make additional copies of this table as needed. 

CTJQNGIStCQAI 

Produst 

Number 

Stytene 

Content 

w 

• 

~s ' ' ' 

SrtMA ; 

Cont4»nt 

m 

Total tjAP 

Confeiit 

m 

Bds© 

GblO* 

Average 

UsiCo-t 

BuftQuaiitity 

Average 

MtfCost j 

J-WttiQtBftiW 

mm 

Usiof Key PifopiMfies that AffiM*P*od^Perlo4*iran^* 

Property* Property 2 : Pttjperty 3 Prepay 4 Prop«ty$ toap&ty* Ptapetty7 

N ^ 

* Please identify what the key gel coat properties are. If the space provided in the table is not sufficient, please footnote additional properties. 

Page 1 

In 
Ferro Corporation Gel Coats 

NOTE: Please provide the information requested in the table and add information for high HAP/low HAP gel coat pairs. Make additional copies of this table as needed. 

• 

TOOLING GEL COATS f < -

Mantdfcetofer 

Ferro Corp 

Pro**** 

Number 

GV03894 

Styfene 

Content 

m 

36 85% 

MMA : 

Content 

m 

3.00% 

contort 

m 

39.85% 

Ba$e 

CeJor 

Orange 

1 

• 

: AV4*fag4t , 

i_S*£tos:t 

BufikQyantity 

($iLB) 

Average ,; 

U$tCo& ] 

PmQ«ttntty 

list of Key Pr_4»j«»4t$$E that A„fe<& Pmdatf P^mawte** 

Pmmtyi Prop$t^2 

y r 

P|t)perty3 

1

' 

Property 4 !Pfop$»#$ Pgopaly* property 7 

Please identify what the key gel coat properties are. If the space provided in the table is not sufficient, please footnote additional properties. 

Pagel 

TJ 
_-

o\ 

* 

Ferro Corporation Gel Coats 

NOTE: 

PIGMENTED P 

1U&nuta<&i*ef 

Ferro Corp. 

Ferro Corp. 

Ferro Corp. 

Please provide the information requested in the table and add information for high HAP/low HAP gel coat pairs. Make additional copies of this table as needed. 

RODUCT 

product 

Number 

GV51093 

GV47056 

GV49084 

\OH GEL COATS 

Styrerte 

Content 

m 31.31% 

31.48% 

31.90% 

MMA 

Content 

m 

2.00% 

2.00% 

2.00% 

Total HAP 

Content 

m 

33.31% 

33.48% 

33.90% 

5 I > 

;Ba$e 

I: Color 

White 

White 

Beige 

1 

• 

1 

Average 

Bulk Quantity 

Average 

LfetCdSt 

mm 

Ust of Key Properties that Affect Product petornwiee * 

PmptVty * Propert/?: Property 3 Propel 4 Property- Pmp&ty* Pmpam^ 

* Please identify what the key gel coat properties are. If the space provided in the table is not sufficient, please footnote additional properties. 

* 

Page 1 

i