What common issues should be looked for on a Phase I for a concrete ready mix plant? I am especially looking for information on the acid washdown areas. According to the bank, the facility does all acid washing over base stone. Any feedback would be appreciated. Thanks.
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Some of the questions I would ask include:
What sort of acid is it? Sulfuric, hydrochloric, how concentrated, etc. How is it stored, and how much? Do they have a spill plan and countermeasures in place in case there's a spill? What's the depth to groundwater? Are there any water bodies, wells, water supply areas, or other possible enviro receptors? Do they have permits? How is waste handled?
Some states consider major aberrations in pH in soil and groundwater to be a contaminant, so that might be a possible problem. I did some stuff at an old coal ash landfill once where the groundwater downgradient of it had a pH of 13.
Also, if they have kilns, what do they fuel them with?
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Isn't it usually muriatic acid (which breaks down the concrete)? I've also seen some people put kerosene on their tools when working with concrete. Usually this is done with asphalt because it keeps the tools clean, but some people do the same with concrete. I don't think it is effective, but people are crazy.
There could also be USTs/ASTs that are/were used to fuel the trucks. If it's an old plant, don't be surprised if there are some which aren't registered, but should be.
In the same vein as Tom's issues, I'd check the outfall of any stormwater handling system to see if the stormwater is causing distressed vegetation, etc.
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I have assessed and remediated many ready mix plants. Ready-mix plants often use petroleum-based form-release compounds (they make blocks out of unused concrete). They also have boilers with fuel USTs. Many older plants have or had gas/diesel pumps. There are often repair shops with hoists, service pits, and waste oil ASTS. Generally, mix plants aren't too contaminated, but you never know
If its an old plant, look at old air photos. Check for waste ponds and large whitish areas. They often washed out trucks and dumped the slurry onto the ground. This can be a high-PH material that does not harden. I had a plant site that had a whole gully filled with slurry back in the 60s and 70s. Groundwater migrating off-site had high pH. -Rob Roberts
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Oh, one other thing. Mix plants often have (or had) asphalt plants. Again, check the air photos.
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Do they service their trucks and equipment on site? Fuels?
If they have on-site rock crushing, their crushing equipment is no doubt serviced/lubricated where it stands, and staining or other signs of contamination are likely to be obscured by dust. Same is probably also true of whatever conveyor system they use to move cement and aggregate into the batch plant for mixing. There's likely a fair quantity of grease and oil stored somewhere on site, and I'd just about bet that their housekeeping isn't great.
Some of the concrete admixtures may be regulated. They may have large containers of them piped into the batch plant from somewhere, most likely pretty nearby.
Somewhere they will have a washdown area where the returning concrete trucks rinse and discharge whatever residue is left in the drum. Could be wastewater discharge issues there, possibly issues with soil alkalinity, if that's regulated where you are.
Acid washing has the issues others mentioned above. I'd suspect it's muriatic (hydrochloric) acid, and could create soil acidity or wastewater discharge issues, depending on how they are using it, and also the obvious storage/safety concerns.
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In colder climates calcium chloride is often added to the concrete to control the cure rates in lower tempartures. It may be worth inquireing about its potential use, storage and handling at the facility. Chloride is a regulated "public welfare" groundwater contaminant in WI, and may also be in other states. Although I am not sure about the chemical properties of calcium chloride and its potential as a groundwater contaminant due to leaching.
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As someone noted above, the surface impoundments have all the usual concerns.
But one big one often overlooked....check the clinker dust that usually covers everything... Hex Chrome is a common contaminant.
And don't forget to look off site while you're at it. The stuff tends to blow all over the neighbor's houses, yards, pets and kids.
If you note the latter, look for lawyers lurking in the alleys.
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Clinker dust? is that the same as Cement Kiln Dust (CKD)? If so, thats from the manufacture of cement, not concrete mixing. Good point though for cement plants. Here in Seattle, we have many cement plants on the Duwamish R. and CKD was used as fill at alot of low-lying areas near the plants.
One more point about batch plants: from a regulatory standpoint, they usually have problems with NPDES discharge limits on total suspended solids (pH is handled pretty easily with neutralizers). -Rob
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There's also the RCRA allowance for certain hazardous wastes to be disposed of in cement kilns, though AFAIK they would have to be a RCRA facility to do that.
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Remember that cement kilns are found at portland-cement plants, not at concrete plants. Concrete plants make the hard stuff (or rather the gooey stuff that becomes hard); cement plants make the dusty stuff (portland cement) that is a component in concrete.
I agree with those who say that the biggest problems are likely to be fuel-related. Acids are going to be rapidly neutralized by cement dust, which is highly alkaline. Metals may be there, I agree, especially if fly ash is being used as an extender or otherwise to replace some of the portland cement.
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Something that I haven't seen mentioned here that I encountered at a concrete plant in Houston was fly ash. Fly ash is the ash produced during combustion of coal. It was used as a replacement of Portland cement and as a mineral filler at the plant I was inspecting. The theory was that it added to the chemical resistance and durability of the concrete. It is also thought to reduce the greenhouse gas "foot-print" of concrete as the production of one ton of Portland cement produces approximately one ton of CO2 as compared to zero CO2 being produced using existing fly ash. Huge amounts were stored in big piles on the soil at the plant I inspected. Since coal contains trace levels of arsenic, barium, beryllium, boron, cadmium, chromium, thallium, selenium, molybdenum and mercury, its ash will continue to contain these traces and therefore cannot be dumped or stored where rainwater can leach the metals and move them to the aquifer. A Phase II on this Project showed that not only were there high levels of contamination in the groundwater at the Project, but also the adjacent bayou. It was a serious problem.
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Yes, many forget that cement....and/or fly ash are used in concrete.
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Good Point Manno. FYI - Fly ash comes from coal fired power boilers and is the dust which comes off electrostatic precipitators. Fly ash used to be a waste product but at some point it was discovered that this material had cementitious properties. Meaning that in some way it acts like Portland cement. It can imporve strength and finishes smother.
So, over the last 2 decades flyash has been incorporated into concrete mix designs as a substitute for Portland cement (but not 100%).
Rob
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