INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM A - GENERAL INFORMATION

Parent Company Information

Parent Company Hanson Brick East, LLC

Street Address- Line 1 15720 John J Delaney Drive

Street Address- Line 2

City Charlotte

State North Carolina

Zip code 28277

Mailing Address (if different)- Line 1

Mailing Address (if different)- Line 2

City

State

Zip code

Number of Employees in Parent Company >500

Dun and Bradstreet number 06-186-0110

Facility Information

Facility 1 Facility 2 Facility 3 Facility 4 Facility 5 Facility 6 Facility 7 Facility 8 Facility 9 Facility 10 Facility 11 Facility 12 Facility 13 Facility 14 Facility 15

Facility ID HANS1 HANS2 HANS3 HANS4 HANS5 HANS6 HANS7 HANS8 HANS9 HANS10 HANS11 HANS12 HANS13 HANS14 HANS15

Facility Name Hanson - Ashland Hanson - Athens Hanson - Blacksburg Hanson - Caddo Hanson - Elgin Hanson - Michigan Hanson - Mineral Wells East Hanson - Monroe Hanson - Ninety Six Hanson - Pleasant Garden Hanson - Roseboro Hanson - Stanton Hanson Columbia - Plant 2 Hanson Columbia - Plant 4 Hanson Mineral Wells

Address 1 510 US Route 60 200 Athens Brick Road 550 York Road 8469 Barnette Road Route 6 Box 338 3820 E. Serr Road 7510 Hwy 180 East 2304 Brickyard Road 624 Brickyard Road 1410 Forest Acres Circle 2981 Autry Hwy 2014 Morris Creek Road 5100 Brickyard Road 5100 Brickyard Road 500 N.E. 14th Avenue

Address 2

City Ashland Athens Blacksburg Mooringsport Elgin Corunna Mineral Wells Monroe Ninety-Six Pleasant Garden Roseboro Stanton Columbia Columbia Mineral Wells

County Boyd Henderson Cherokee Caddo Parish Bastrop Shiawassee Palo Pinto Union Greenwood Guildford Sampson Powell Richland Richland Palo Pinto

State KY TX SC LA TX MI TX NC SC NC NC KY SC SC TX

Zip code 41105 75751 29702 71060 78621 48817 76080 28111 29666 27313 28382 40380 29203 29203 76067

Mailing Address (if different)- Line 1 PO Box 156 PO Box 5012 PO Box 518

Mailing Address (if different)- Line 2

City

State

Zip code

Number of employees at facility 28 38 40 29 186 46 23 99 90 54 37 36 100 100 115

What is your size classification for HAP emissions? Area Source (true) Major source Major source Area Source (true) Major source Area Source (synthetic) Major source Major source Major source Area Source (synthetic) Major source Major source Major source Major source Area Source (synthetic)

Hours of operation for this facility (hr/yr) 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760 8760

Facility's primary NAICS or SIC code 327121 327121 327121 327121 327121 327121 327121 327121 327121 327121 327121 327121 327121 327121 327121

Total Number of Periodic Kilns at this Facility 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Total Number of Tunnel Kilns at this Facility 1 2 1 1 2 2 1 6 3 1 2 2 2 2 2

Contact Person for this ICR David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown David McKeown

Contact Phone Number 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121 803-691-3121

Contact Email Address david.mckeown@hanson.co

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090000648192f137

FORM A - General Information
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM B - KILN INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and PK1,2, etc for periodic]Reporting year 

(if not 2007) Type of Kiln

If periodic, number 

of identical kilns 

included on this 

line Year Built

Stack 

Diameter 

(ft)

Major Products Types 

Fired in this Kiln (see 

list at bottom of 

spreadsheet)

Annual 

Operating 

Hours for Kiln

Does this kiln 

have an Air 

Pollution 

Control Device 

(APCD)?

 Full Design 

Capacity (tph)

Permitted 

Capacity (tph) 

if applicable

Actual 

Capacity 

Utilization (%) Primary Fuel Secondary Fuel

Percent Use of 

Secondary Fuel (% 

of operating time)

HANS-1 tk-1 2007 Tunnel NA 1973 2.00 2,6,7,9,10,13,15 7272.00 No 5.70 46.17 Natural gas None NA

HANS-2 tk-1 2007 Tunnel NA 1955 2.50 2,6,7,9,10,13,15 8760.00 No 9.53 93.31 Natural gas None NA

HANS-3 1LK 2007 Tunnel NA 1966 3.50 2,6,7,9,10,13,15 8760.00 No 8.23 87.07 Natural gas None NA

HANS-4 tk-1 2007 Tunnel NA 1953 2.17 2,6,7,9,10,13,15 8760.00 No 5.00 83.26 Natural gas None NA

HANS-5 tk-1 2007 Tunnel NA 1955 2.00 2,6,7,9,10,15 8760.00 No 11.50 9.95 82.15 Natural gas None NA

HANS-5 TK-2 2007 Tunnel NA 1998 3.00 2,6,7,9,10,15 8760.00 Yes 12.20 76.11 Natural gas None NA

HANS-6 tk-1 2007 Tunnel NA 1977 3.33 2,6,7,9,10,13,15 0.00 Yes 11.13 0 Natural gas None NA

HANS-6 tk-2 2007 Tunnel NA 1979 3.33 2,6,7,9,10,13,15 4512.00 Yes 11.13 38.99 Natural gas None NA

HANS-7 tk-1 2007 Tunnel NA 1956 2.50 2,6,7,9,10,13,15 8760.00 No 7.99 80.08 Natural gas None NA

HANS-8 1AK 2007 Tunnel NA 1949 3.50 2,6,7,9,10,13,15 8760.00 No 4.68 83.27 Natural gas None NA

HANS-8 1LK 2007 Tunnel NA 1963 3.00 2,6,7,9,10,13,15 0.00 No 7.16 0 Natural gas None NA

HANS-8 2AK 2007 Tunnel NA 1950 3.33 2,6,7,9,10,13,15 2136.00 No 4.68 20.58 Natural gas None NA

HANS-8 2LK 2007 Tunnel NA 1965 4.00 2,6,7,9,10,13,25 0.00 No 7.16 0 Natural gas None NA

HANS-8 3AK 2007 Tunnel NA 1957 4.00 2,6,7,9,10,13,15 8760.00 No 6.69 58.25 Natural gas None NA

HANS-8 3LK 2007 Tunnel NA 2002 4.00 2,6,7,9,10,13,15 5832.00 Yes 22.80 25.1 Natural gas None NA

HANS-9 tk-1 2007 Tunnel NA 1956 3.25 2,6,7,9,10,13,15 7200.00 No 8.90 64.45 Natural gas None NA

HANS-9 tk-2 2007 Tunnel NA 1958 4.75 2,6,7,9,10,13,15 4944.00 No 8.90 44.25 Natural gas None NA

HANS-9 tk-3 2007 Tunnel NA 1962 4.75 2,6,7,9,10,13,15 2136.00 No 8.90 19.18 Natural gas None NA

HANS-10 8-LK2 2007 Tunnel NA 1981 4.00 2,6,7,9,10,13,15 6552.00 Yes 13.45 52.66 Natural gas None NA

HANS-11 1LK 2007 Tunnel NA 1966 3.67 2,6,7,9,10,13,15 6528.00 No 10.50 <10 tph 57.74 Natural gas None NA

HANS-11 2LK 2007 Tunnel NA 1974 3.67 2,6,7,9,10,13,15 0.00 No 10.50 <10 tph 0 Natural gas None NA

HANS-12 2 2007 Tunnel NA 1972 2.50 2,6,7,9,10,13,15 8604.00 No 8.00 83.12 Natural gas None NA

HANS-12 3 2007 Tunnel NA 1978 4.00 2,6,7,9,10,13,15 0.00 No 8.84 0 Natural gas None NA

HANS-13 tk-1 2007 Tunnel NA 1955 2.95 2,7,9,10,13,15 8352.00 No 11.30 < 10 tph 86 Coal Natural gas

<20%NG used 100% 

of time

HANS-13 tk-2 2007 Tunnel NA 1956 2.95 2,7,9,10,13,15 8352.00 No 11.30 < 10 tph 86 Coal Natural gas

<20%NG used 100% 

of time

HANS-14 tk-3 2007 Tunnel NA 1964 4.92 2,3,6,7,9,10,13,15 8280.00 Yes 11.30 76.92 Natural gas None NA

HANS-14 tk-4 2007 Tunnel NA 1965 4.92 2,3,6,7,9,10,13,15 8376.00 Yes 11.30 77.82 Natural gas None NA

HANS-15 tk-1 2007 Tunnel NA 1980 2.00 2,6,7,9,10,15 8760.00 Yes 11.42 90.69 Natural gas None NA

HANS-15 tk-2 2007 Tunnel ----- 1980 2.00 2,6,7,9,10,15 8760.00 Yes 11.42 90.7 Natural gas None NA

FACILITY and KILN IDs GENERAL INFORMATION KILN SIZE (a) FUEL USAGE

090000648192f137

FORM B - Kiln Information 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM B - KILN INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and PK1,2, etc for periodic]

HANS-1 tk-1

HANS-2 tk-1

HANS-3 1LK

HANS-4 tk-1

HANS-5 tk-1

HANS-5 TK-2

HANS-6 tk-1

HANS-6 tk-2

HANS-7 tk-1

HANS-8 1AK

HANS-8 1LK

HANS-8 2AK

HANS-8 2LK

HANS-8 3AK

HANS-8 3LK

HANS-9 tk-1

HANS-9 tk-2

HANS-9 tk-3

HANS-10 8-LK2

HANS-11 1LK

HANS-11 2LK

HANS-12 2

HANS-12 3

HANS-13 tk-1

HANS-13 tk-2

HANS-14 tk-3

HANS-14 tk-4

HANS-15 tk-1

HANS-15 tk-2

FACILITY and KILN IDs ADDITIONAL INFORMATION ON PERIODIC KILNS

Back-up Fuel

Reason(s) back-up 

would be used (e.g., 

NG curtailment)

Total time backup fuel was 

used during 

year (hr)

Do you vent 

this kiln to a 

sawdust 

dryer?

Sawdust 

Dryer ID 

(Assign)

Total Number 

of kilns vented 

to this Dryer

Average percent of 

operating time this 

kiln vents to dryer

Average 

percent of flow 

sent to dryer

Kiln batch 

capacity 

(tons)

Average batch 

cycle time (hr)

Average 

number of 

batch cycles 

per year

Average time 

required to load 

unfired shapes 

into kiln (hr)

Average time 

required to 

unload fired 

shapes from kiln 

(hr)

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Propane NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Propane NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Propane NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Propane NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

Fuel Oil NG curtailment N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

None NA N/A No NA NA NA NA NA NA NA NA NA

Natural gas

inadequate coal 

supply or high coal 

cost N/A No NA NA NA NA

Natural gas

inadequate coal 

supply or high coal 

cost N/A No NA NA NA NA

Propane NG curtailment N/A No NA NA NA NA

Propane NG curtailment N/A No NA NA NA NA

None N/A No NA NA NA NA

None N/A No NA NA NA NA

FUEL USAGE FOR SAWDUST FIRED KILNS ONLY

090000648192f137

FORM B - Kiln Information 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM C - APCD INFORMATION

FACILITY AND KILN IDs

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and 

PK-1,2, etc for 

periodic]

Control ID # (assign 

based on ID used in 

Title V or using CD-1, 2, 

etc) Type

Reason Control 

was Installed

Number of kilns 

vented to this 

control device

Year control device 

was installed Reagent Type

Reagent feedrate 

(value) Units/ time Total fan hp

Total hp for 

other motors

Water usage 

(gpd)

Added cooling 

air, acfm

Other utility 

requirements Units/time

HANS-10 8-LK2 CD-ES8LK2

Dry Limestone Scrubber 

(DLA)

Become Synthetic 

Minor 1 2005 limestone 90 lbs/hr 40 17.8 0 0 Unavail Unavail

HANS-14 tk-3, tk-4 da-1

Dry Limestone Scrubber 

(DLA) Other 2 1998 limestone 93 lbs/hr 60 22.5 0 0 Unavail Unavail

HANS-5 TK-2 DLS-1 Dry Lime Scrubber (DLS) Other 1 2007 lime 167 lbs/hr 212.3 30.6 0 0 Air Unavail

HANS-6 tk-1 diff-1

Dry Injection/Fabric Filter 

(DIFF)

Particulate/ opac. 

control 1 1993 hydrated lime 180 lbs/hr 150 26.5 0 0 Unavail Unavail

HANS-6 tk-2 diff-2

Dry Injection/Fabric Filter 

(DIFF)

Particulate/ opac. 

control 1 1994 hydrated lime 181 lbs/hr 150 26.5 0 0 Unavail Unavail

HANS-8 3LK CD-8

Dry Limestone Scrubber 

(DLA) Other 1 2002 limestone 154 lbs/hr 70 22.5 0 0 Unavail Unavail

HANS-15 tk-1 diff-1

Dry Injection/Fabric Filter 

(DIFF) Other 1 1993 lime 240 lbs/hr 150 Unavail 0 0 Unavail Unavail

HANS-15 tk-2 diff-2

Dry Injection/Fabric Filter 

(DIFF) Other 1 1993 lime 240 lbs/hr 150 Unavail 0 0 Unavail Unavail

DESIGN AND OPERATING PARAMETERS

090000648192f137

FORM C - APCD Info 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM C - APCD INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and 

PK-1,2, etc for 

periodic]

HANS-10 8-LK2

HANS-14 tk-3, tk-4

HANS-5 TK-2

HANS-6 tk-1

HANS-6 tk-2

HANS-8 3LK

HANS-15 tk-1

HANS-15 tk-2

Number of bags Bags- Length (ft) Bags- Width (ft) Bags- Diam (ft)

Bag- material of 

construction

Avg Life of bags 

(yrs) Cleaning method Air-to-cloth ratio

Cost of full set of 

bags

Avg. compressed 

air requirements, 

acfm

Is reagent 

recirculated or 

one-pass?

If recirculated, 

average ratio of 

recirculated to 

fresh reagent

Number of 

cascades

Do you use 

reconditioning 

drum/peeler?

What is the rate 

at which 

limestone is 

removed from 

the system as 

waste?

Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic NA 4 No 90 lbs per hr

Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic NA 6.5 No 93 lbs per hr

464 16 Not Applic 0.5416

Polytetrafluoroet

hylene 5 pulse ~5:1 167040 90 Recirculated ~6.5 : 1

204 16.17 Not Applic 0.5625 GoreTex 7 Reverse Pulse Jet ~5:1 85000 175 One pass NA

204 16.17 Not Applic 0.5625 GoreTex 8 Reverse Pulse Jet ~5:1 85000 175 One pass NA

Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic Not Applic NA 7 No 154 lbs per hr

240 10 Not Applic 0.46875 GoreTex 7 Reverse Pulse Jet ~5:1 85000 110 One pass NA

240 10 Not Applic 0.46875 GoreTex 7 Reverse Pulse Jet ~5:1 85000 110 One pass NA

BAGHOUSE/FABRIC FILTER (Stand-alone or as Part of DLS/DIFF system) DIFF or DLS DLA

090000648192f137

FORM C - APCD Info 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM C - APCD INFORMATION

Facility ID

Kiln ID(s) [Use the ID 

from your permit or 

assign using TK-1, 2, 

etc for tunnel and 

PK-1,2, etc for 

periodic]

HANS-10 8-LK2

HANS-14 tk-3, tk-4

HANS-5 TK-2

HANS-6 tk-1

HANS-6 tk-2

HANS-8 3LK

HANS-15 tk-1

HANS-15 tk-2

WET SCRUBBER OTHER CONTROL (please identify parameters and units monitored to verify control is functioning properly)

If complying with 

the MACT, do 

you monitor 

pressure drop or 

use an 

alternative?

If complying with 

the MACT, how 

do you verify 

sufficient 

limestone in 

hopper?

Explain Other or 

Alternative

Type of scrubber 

(e.g., venturi)

Liquid flow rate 

(gal/min)

Pressure drop 

across scrubber 

(inches of water)

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

Design or 

Monitoring 

Parameter Units / Time

Not Subject to 

MACT NA NA NA NA NA NA NA NA NA

Pressure Drop

Remote visual 

insp. NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

Alternative

Fill/discharge 

records

Continuous 

Monitor of 

Bypass Damper NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

NA NA NA NA NA NA NA NA NA

DLA

090000648192f137

FORM C - APCD Info 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM D - TEST DATA NOTE TO EPA: THIS TABLE DOES NOT INCLUDE TEST REPORTS SUBMITTED UNDER A PREVIOUS SECTION 114 REQUEST

GENERAL INFORMATION TEST INFORMATION ADDITIONAL INFORMATION

FAC ID Control ID

Kiln/ 

Stack ID Test Date Report Date

Type of TestUncontrolled (or inlet to 

control), Controlled, 

Both HF HCl PM HAP Metals Other Reasons for Test

APCD Parameters Monitored 

During Test

Production rate of fired 

product during test (tph) Notes

HANS-10 CD-ES8LK2 8-LK2 5/10/2006 Jun-05 Both X X X Demonstrate compliance To remain a Synthetic Minor

HANS-12 N/A 2,3 12/1-2/2004 Dec-04 Uncontrolled X X Demonstrate compliance State Requirement

HANS-5 Plt 2 Scrubber Kiln 2 10/21/2007 Oct-07 Both X X X SO2 Demonstrate Compliance State Requirement

HANS-8 CD-8 3LK 11/30/2006 Dec-06 Both X X X MACT Compliance Test

HANS-14 Kilns K3&K4 10/5/2006 Nov-06 Both X X X MACT Compliance Test

HANS-14 Kilns K3&K4 10/11/2006 Nov-06 Controlled X SCDHEC PM Emission Factor Potential Emissions Calculations

POLLUTANTS TESTED (Please put X in box to indicate pollutant 

was tested)

090000648192f137

FORM D - Test Data 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID HANS 5 - Hanson - Elgin

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh ~0.08/kwh

Reagent: lime

Reagent Cost, $/ton ~$260/ton est.

Waste Reagent disposal cost, $/ton Not Avail

Water treatment costs, $/gal $0

Activity Required by Activity

Estimated 

Hours Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 40 once EHS Manager - Controls Technician

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 4 1/year Controls Technician - Plant Manager

Bag replacement Replace single bag 3 2 Maintenance Technicians

Bag replacement Replace all bags 24 4 Maintenance Technicians

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level) Ensure all lime injection lines are clean 2 hours Daily 1 kiln operator

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If 

different approaches are taken at different 

plants, please add rows and provide 

information on each approach Monitor lime levels via computer screen 1 Daily

kiln operator Controls Technician 

Supervisor Plant Manager

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level) Monitor (lbs/hour) lime feed via the system 1 Continuously

kiln operator Controls Technician 

Supervisor Plant Manager

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level) Verify (lbs/hour) weight 1 1/day kiln operator

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Daily Maintenance (list activity(ies) in next 

column)

Waste lime removal. Grease rotary air 

locks. Verify lime feed. Check gates. 

Differential pressure 2 1/day Kiln operator

Weekly Maintenance (list activity(ies) in next 

column) Compressed air, hose connections. 1 1/wk Kiln operator

Monthly Maintenance (list activity(ies) in 

next column)

Flue gas fan bearing and motor 

lubrication. Ventillation - function. 1 1/month Kiln operator

Semi-Annual Maintenance (list activity(ies) 

in next column)

Paddle screw bearing lubrication. Flush 

cylinoid valves 1 1/6 months Kiln operator

Yearly Maintenance (list activity(ies) in next 

column) Transmission oil level. 2 1/year Kiln operator

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any site/preparation 

costs not included in estimate)

2007

Inlet and outlet test for Sulfides, 

Flourides, Chlorides $50,000 2 Tests

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing 

permanent access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls

Standard Activities- Wet Scrubber or Other Control

090000648192f137

FORM E - HANS 5 - Elgin 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID HANS 6 - Hanson - Michigan

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh 0.08/kwh

Reagent: hydrated lime

Reagent Cost, $/ton $258

Waste Reagent disposal cost, $/ton $22

Water treatment costs, $/gal N/A

Activity Required by Activity

Estimated 

Hours Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 40 once EHS Manager - Controls Technician

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 4 1/year Controls Technician - Plant Manager

Bag replacement Replace single bag 2 annual maintenance person

Bag replacement Replace all bags 48 every 5 years outside contractor

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level) Visual checks. At charge times. 10 to 15 minutes Up to 10 times daily kiln operator

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If 

different approaches are taken at different 

plants, please add rows and provide 

informati

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Daily Maintenance (list activity(ies) in next 

column) Storage silo- compartment cleanliness & condition, housing & hopper leak, eductor feed, blower filter, lime injection point in duct. Bin activator- air vibrators. Baghouse- exhaust air, inlet  1 hour Daily kiln operator

Weekly Maintenance (list activity(ies) in next 

column) Pneumatic conveying system- blower filter, lime feed at injection point. Baghouse- blower filter, exhaust bearings. Cooling tower- buildup on floor. 1-hour Weekly kiln supervisor

Monthly Maintenance (list activity(ies) in 

next column) Bin activator- vibrating bin activator. Volumetric feeder- cleanliness & operation, feeder drive. Baghouse- housing & hopper leaks, pulse jet cleaning mechanism. Cooling tower- water pum 1-hour Quarterly kiln supervisor

Semi-Annual Maintenance (list activity(ies) 

in next column) Bin activator- vibartor. Volumetric feeder- feeder motor, feeder controller. Baghouse- controls. Controls- control panel, control transformer, baghouse hi-lo temp. alarm, baghouse therm 1-hour Semi-annual Electrician

Yearly Maintenance (list activity(ies) in next 

column) Baghouse- compartment cleanliness & condition, bag condition, check couplings on purge tubes for tightness. Cooling tower- water nozzle spray pattern. 1-hour Bi- annual maintenance person

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column) Visiual emissions readings 15 minutes per kiln Weekly Health & safety director and Kiln supervison. Both certified in emission reading. 

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any site/preparation 

costs not included in estimate)

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing permanent 

access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls

Standard Activities- Wet Scrubber or Other Control

090000648192f137

FORM E - HANS 6 - Michigan 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID HANS 8 - Hanson - Monroe

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh 0.063

Reagent: Limestone

Reagent Cost, $/ton 18.25

Waste Reagent disposal cost, $/ton none - material re-used on-site Dispose on site

Water treatment costs, $/gal N/A

Activity Required by Activity

Estimated 

Hours Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 40 once EHS Manager - Controls Technician

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 4 1/year Controls Technician - Plant Manager

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level)

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If 

different approaches are taken at different 

plants, please add rows and provide 

informati

Capture used limestone in hopper, weigh 

and dump.

15 Minutes 4 times/day Operator

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Daily Maintenance (list activity(ies) in next 

column)

N/A

Weekly Maintenance (list activity(ies) in next 

column)

N/A

Monthly Maintenance (list activity(ies) in 

next column)

Grease dosing device and rod end 

bearings

15 Minutes Bi-Monthly Maintenace

Semi-Annual Maintenance (list activity(ies) 

in next column)

Grease discharge device demag brake 

gear motors

2 hours Semi-Annual Maintenace

Yearly Maintenance (list activity(ies) in next 

column)

N/A

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

N/A

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any site/preparation 

costs not included in estimate)

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing 

permanent access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls

Standard Activities- Wet Scrubber or Other Control

090000648192f137

FORM E - HANS 8 - Monroe 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID HANS 10 - Hanson - Pleasant Garden

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh 0.07

Reagent: Limestone

Reagent Cost, $/ton 18.25

Waste Reagent disposal cost, $/ton none - material re-used on-site

Water treatment costs, $/gal N/A

Activity Required by Activity

Estimated 

Hours Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 40 once EHS Manager - Controls Technician

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 4 1/year Controls Technician - Plant Manager

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level)

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If 

different approaches are taken at different 

plants, please add rows and provide 

informati

Capture used limestone in hopper, weigh 

and dump.

15 Minutes 4 times/day Operator

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Daily Maintenance (list activity(ies) in next 

column)

N/A

Weekly Maintenance (list activity(ies) in next 

column)

N/A

Monthly Maintenance (list activity(ies) in 

next column)

Grease dosing device and rod end 

bearings

15 Minutes Bi-Monthly Maintenace

Semi-Annual Maintenance (list activity(ies) 

in next column)

Grease discharge device demag brake 

gear motors

2 hours Semi-Annual Maintenace

Yearly Maintenance (list activity(ies) in next 

column)

N/A

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

N/A

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any site/preparation 

costs not included in estimate)

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing 

permanent access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls

Standard Activities- Wet Scrubber or Other Control

090000648192f137

FORM E - HANS 10 - Pleas Gard 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID HANS 14 - Hanson - Columbia

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh 0.089

Reagent: 769 Limestone - Martin Marietta

Reagent Cost, $/ton $32/ton

Waste Reagent disposal cost, $/ton none - material re-used on-site

Water treatment costs, $/gal N/A

Activity Required by Activity

Estimated 

Hours Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 40 once EHS Manager - Controls Technician

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 4 1/year Controls Technician - Plant Manager

Bag replacement Replace single bag

Bag replacement Replace all bags

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level)

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If 

different approaches are taken at different 

plants, please add rows and provide 

informati

Regulate feed rate to blow limestone to 

top of scrubber 2 hours once a week 1

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Daily Maintenance (list activity(ies) in next 

column) Dump waste hopper 30 min / time twice / day 1

Daily Maintenance (list activity(ies) in next 

column) Daily log of scrubber data & VE check 10 min each day 1

Weekly Maintenance (list activity(ies) in 

next column) 15 min VE check 15 min per week 1

Monthly Maintenance (list activity(ies) in 

next column)

Greasing of shaker arms / PM visual 

inspection of belts, motors, mechanical 

devices 45 min per month 1

Semi-Annual Maintenance (list activity(ies) 

in next column) n/a

Yearly Maintenance (list activity(ies) in next 

column) Check stack and damper integrity 2 hours year 4

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column) see daily and weekly

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any site/preparation 

costs not included in estimate)

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing 

permanent access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls

Standard Activities- Wet Scrubber or Other Control

090000648192f137

FORM E - HANS 14 - Columbia 4 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM E - MONITORING AND OTHER COSTS

Facility ID HANS 15 - Hanson - Mineral Wells

Unit Costs for January 2008

Parameter Cost

Electricity cost, $/kwh ~.09/kwh est.

Reagent: lime

Reagent Cost, $/ton ~250/ton est.

Waste Reagent disposal cost, $/ton none - material is recycled

Water treatment costs, $/gal N/A

Activity Required by Activity

Estimated 

Hours Frequency Staff Level

Develop a start-up, shutdown, and 

malfunction plan Develop plan and educate staff 40 once EHS Manager - Controls Technician

Develop and implement an operating, 

maintenance, and monitoring plan Develop plan and educate staff 4 1/year Controls Technician - Plant Manager

Bag replacement Replace single bag 2-4 Hours As Required 2 Workers

Bag replacement Replace all bags 24 Hours As Required 6 Workers

Maintain free-flowing lime (Describe action 

in next box and then add estimated hours, 

frequency, and staff level) Ensure all lime injection lines are clean. 2 Hours Daily 2 Workers

Meet requirement to "maintain adequate 

amount of limestone in hopper." (Describe 

action taken in next box, then add estimated 

hours, frequency, and staff level). If 

different approaches are taken at different 

plants, please add rows and provide 

informati

Control Device: 

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Compliance demonstration activity (describe 

and estimate hours, frequency, and staff 

level)

Daily Maintenance (list activity(ies) in next 

column) *Read Comment* 1.5 Hours Daily 1 Worker

Weekly Maintenance (list activity(ies) in next 

column) *Read Comment* .50 Hours Weekly 1 Worker

Monthly Maintenance (list activity(ies) in 

next column) *Read Comment* 2 Hours Monthly 1 Worker

Semi-Annual Maintenance (list activity(ies) 

in next column) *Read Comment* 2 Hours Semi-Annual 1 Worker

Yearly Maintenance (list activity(ies) in next 

column) *Read Comment* 6 Hours Yearly 1 Worker

Other Frequency Maintenance (specify 

frequency and list activity(ies) in next 

column)

Stack Test Costs for the Previous 3 Years

Stack Test Year

Test Methods (please list all test methods 

conducted during stack test)

Uncontrolled 

(include 

uncontrolled 

stack or APCD 

inlet)? 

Controlled? 

Both? Cost ($)

Notes (Include Any site/preparation 

costs not included in estimate)

none

Please also provide separately an itemized list of site/preparation costs not included in the estimate (e.g., costs for drilling ports in stack, costs for installing 

permanent access to sampling ports, etc.)

Standard Activities- DLA (limestone)

Standard Activities- Baghouse/DIFF/DLS

Standard Activities- All Controls

Standard Activities- Wet Scrubber or Other Control

090000648192f137

FORM E - HANS 15 - Min Wells 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM F - ECONOMICS IMPACTS INFORMATION

Product Selling Price Labor Rates as of January 2008

Facility ID Product type

Average Selling Price 

per Ton ($)

Reporting Year for 

Selling Price (if not 

2007)

Operator wage 

rate, $/hr

Maintenance wage 

rate, $/hr

Engineer wage 

rate, $/hr

Managerial/Supervisory 

wage rate, $/hr

HANS 5

FORM F BEING SUBMITTTED UNDER 

SEPARATE COVER

HANS 6

FORM F BEING SUBMITTTED UNDER 

SEPARATE COVER

HANS 8

FORM F BEING SUBMITTTED UNDER 

SEPARATE COVER

HANS 10

FORM F BEING SUBMITTTED UNDER 

SEPARATE COVER

HANS 14

FORM F BEING SUBMITTTED UNDER 

SEPARATE COVER

HANS 15

FORM F BEING SUBMITTTED UNDER 

SEPARATE COVER

090000648192f137

FORM F - Economics Info - CBI 11/17/2014
INFORMATION COLLECTION REQUEST FOR THE BRICK AND STRUCTURAL CLAY PRODUCTS MANUFACTURING INDUSTRY

FORM G - ADDITIONAL QUESTIONS

Question Response

1. Please provide a copy of the cost estimate for 

your selected control device and explain any 

differences between the estimated and final 

installed costs. Costs should include costs for 

ancillary equipment, such as reconditioning 

drums, water treatment systems, etc NA

2. Do you currently do any work or operating 

practices (i.e., other than the use of an air 

pollution control device) that would have an 

impact on HF, HCl, or PM emissions from your 

kilns? If yes, please explain. NA

3. Do you have any data available on the 

fluorine or chlorine contents of your raw 

materials? If yes, please explain the types of 

information you have, the test method used to 

determine these contents, the frequency in 

which you test your raw materials, and any 

other information you feel is relevant to this 

discussion. Yes

4. If you answered YES to #3, please include 

copies of your raw material testing for either: 

the past two months OR the past 10 tests, 

whichever is more. Please indicate which you 

are submitted in the response section to this 

question.

5. If you operate periodic kilns, please provide a 

time-temperature profile for each typical batch 

cycle. The profiles should show the duration of 

each temperature phase of the cycle from the 

time the kiln is fired to the time when the fired 

shapes can be removed from the kiln. (See 

instructions for example profile.) Also provide 

the additional information requested on Form B. NA

6. If you operate periodic kilns, do you have any 

information regarding technological and/or 

economic limitations to testing those kilns? NA

7. Please provide a copy of a process flow 

diagram for your facility, if available. N/A

090000648192f137

FORM G - Additional Questions 11/17/2014
These are the picklists for the other tables - this sheet will be hidden when the survey is sent to facilities.

CORPSIZE HAPSIZE KILNTYPE FUEL SECFUEL CONTROL REASON YESNO TESTS STAFF RECIR DLA1 DLA2 Yes

 0-99 Major source Tunnel Natural gas None

Dry Limestone 

Adsorber (DLA)

Comply with 

MACT Yes Uncontrolled Operator Recirculated

Pressure 

Drop

Daily climb to 

hopper

100-249 Area Source (true)

Tunnel- low profile or 

roller Sawdust

Natural 

gas

Dry Injection/Fabric 

Filter (DIFF)

Become 

Synthetic 

Minor No Controlled Maintenance One pass Alternative

Remote visual 

insp.

249-499 Area Source (synthetic) Tunnel-inactive Coal Sawdust

Dry Lime Scrubber 

(DLS) SO2 control Both Engineer

Fill/discharge 

records

>500 Not sure Periodic Fuel Oil Coal Wet Scrubber

Particulate/ 

opac. control Manager Other

Periodic-shuttle Landfill/Biogas Fuel Oil

Fabric Filter/ 

Baghouse only Other

Periodic-beehive Other Propane

Lime system 

(unsure if DIFF or 

DLS)

Landfilll/ 

Biogas

Spray Dryer/ 

Electrostatic 

Precipitator

Other Other