Document qdRkwKQo8zK9DODqq5OQBxbk

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 5 77 WEST JACKSON BOULEVARD CHICAGO, ILLINOIS 60604 DATE: SUBJECT: FROM: THRU: TO: September 29, 2021 CLEAN AIR ACT INSPECTION REPORT BlueScope Buildings North America, 273 Water St, Evansville, WI 53536 Karina Kuc AECAB (IL/IN) Nathan Frank, Section Chief AECAB (IL/IN) File BASIC INFORMATION Facility Name: BlueScope Buildings North America (BlueScope) Facility Location: 273 Water St, Evansville, WI 53536 Date of Inspection: August 26, 2021 EPA Inspector(s): 1. Karina Kuc, Environmental Engineer 2. Daniel Heins, Environmental Scientist Other Attendees: 1. Rebecca Hackl, Health, Safety, Environmental Manager, BlueScope 2. John Forslund, Plant Manager, BlueScope 3. Robert Thomaschek, Plant Supervisor, BlueScope 4. Randy Fletcher, Maintenance Supervisor, BlueScope Contact Email Address: Rebecca.hackl@bsbna.com Purpose of Inspection: to determine compliance with the Clean Air Act (CAA) Facility Type: Prefabricated building manufacturing Page 1 of 5 Arrival Time: 11:30 AM Departure Time: 1:40 PM Inspection Type: Unannounced Inspection Announced Inspection OPENING CONFERENCE Presented Credentials Stated authority and purpose of inspection Provided Small Business Resource Information Sheet Small Business Resource Information Sheet not provided. Reason: not a small business Provided CBI warning to facility The following information was obtained verbally from BlueScope representatives. Process Description: The company processes metal components by welding, plasma cutting, shearing, painting, etc to produce prefabricated metal buildings, made to order. Steel arrives to the facility in coil, flange, and plate form. The facility has three plasma cutting stations (detail, north and south), each controlled by a separate baghouse. Plasma cutting occurs on a grate. Negative pressure beneath the grate pulls fumes to the baghouse, which vents back into the facility. The welding units are equipped with Torit air filters, which vent into the facility. The metal components are sprayed with a water-based primer for rust prevention in a paint booth. The large paint booth is equipped with particulate matter (PM) filters which vent to the atmosphere. It is mostly enclosed but has an opening on two sides to allow an overhead conveyor to run through it. The small paint booth is not enclosed and has no filter. According to staff it is used occasionally. The final product is a set of parts, ready to assemble into a building, shipped off site by truck. Staff Interview: Approximately 900 tons of metal are processed per month. An industrial hygiene study conducted at the facility indicated that manganese standards were exceeded, as a result, welders are equipped with supplied air and some stations have fume extractors. The paint booth filters are changed out every couple of days. The Torit filters are cleaned approximately quarterly by blowing them off with an air compressor outside. According to maintenance, the gages for the baghouses are checked daily and should be between 0 and 7" water. TOUR INFORMATION EPA Tour of the Facility: Yes Data Collected and Observations: EPA observed the control panels on the baghouses. Page 2 of 5  The "Detail Plasma" baghouse showed a pressure of 2.1" water while the "high alarm" was flashing and the "manual override" light was on. Staff stated that the unit was not running and plasma cutting was not being conducted at the time. The North baghouse showed a pressure of 3.8" water while the "low alarm" and "high alarm" flashed. Staff stated the unit was running and plasma cutting was being conducted. The South baghouse showed a pressure of 0.0" water while the "low alarm" flashed. Staff stated the unit was running and plasma cutting was being conducted. The Maintenance Supervisor stated that he didn't know how to resolve the North and South baghouse alarms and that he would have to check the manual. Photos and/or Videos: were taken during the inspection. Field Measurements: were not taken during this inspection. RECORDS REVIEW Reviewed documents (copies taken): Safety Data Sheets for primer Steel composition, selected components below: o Chromium 0.18% o Nickel 0.1% o Manganese 0.75% CLOSING CONFERENCE Provided U.S. EPA point of contact to the facility Requested documents: Safety Data Sheets for: coolant, lubricant, welding rod Owner's manual for baghouses Emissions tracking spreadsheet for Jan 2019 to present Annual emissions report to Wisconsin Department of Natural Resources for 2019 and 2020 Permit application and most recent issued operating permit Performance tests Follow up on the baghouse alarm and pressure drop readings Concerns: EPA indicated that the North and South baghouse alarms should be checked and any issues should be resolved. Page 3 of 5 SIGNATURES Digitally signed by Kuc, XKuc, Karina Karina Date: 2021.09.29 14:16:00 -05'00' Karina Kuc Report Author NATHAN X FRANK Nathan Frank Section Chief Digitally signed by NATHAN FRANK Date: 2021.10.01 14:20:15 -05'00' Page 4 of 5 APPENDICES AND ATTACHMENTS 1. Appendix A: Digital Image Log Page 5 of 5 Facility Name: BlueScope Buildings North America Facility Location: 273 Water St, Evansville, WI 53536 Date of Inspection: August 26, 2021 APPENDIX A: DIGITAL IMAGE LOG 1. Inspector Name: Karina Kuc 2. Archival Record Location: C:\Users\kkuc\OneDrive - Environmental Protection Agency (EPA)\Documents\Bluescope\insp photos Image Number 1 File Name IMG_0011 Date and Time (CST) 08/26/2021 14:18 Description of Image South baghouse control panel 2 IMG_0012 08/26/2021 14:18 North baghouse control panel 3 IMG_0013 08/26/2021 14:19 North baghouse control panel NOTE: THE TIMESTAMP ON THE PHOTOS IS INCORRECT AND SHOULD BE AN HOUR EARLIER Appendices Page 1 of 1