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Concrete Batch Plant Dust Calculator - AP-42 Ch 11.12 PM Emissions for Batch Plants

Estimate particulate emissions from material handling, batching, mixing & truck loading at concrete plants

Estimate particulate matter (PM, PM10, PM2.5) emissions from concrete batch plant operations using EPA AP-42 Chapter 11.12 emission factors. Enter production rate, material handling volumes, and control equipment to get emission estimates from aggregate handling, cement transfer, batch weighing, mixer loading, truck loading, and vehicle travel on unpaved roads. Includes controlled and uncontrolled rates for baghouse, wet suppression, and enclosure controls.

Pro Tip: Cement silo filling is often the largest single PM source at a batch plant, and it is the easiest to control. A properly maintained baghouse on the silo vent reduces PM from this source by 99%. But if the bags are torn, the bypass damper is stuck open, or the pulse-jet timer is broken, you might as well not have the baghouse. Monthly visual checks of the silo vent during filling take 5 minutes and prevent your biggest compliance headache.

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Concrete Batch Plant Dust Emissions Calculator
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How It Works

  1. Enter Production Rate

    Input annual concrete production in cubic yards per year and typical operating days per year. The calculator converts to tons of material processed using standard mix design ratios.

  2. Configure Material Handling Sources

    Specify aggregate types and quantities (sand, gravel, crushed stone), cement delivery method (pneumatic truck, rail), and any supplementary materials (fly ash, slag, admixtures). Each source has its own AP-42 emission factor.

  3. Select Control Equipment

    Choose controls for each emission point: baghouse on silo vents (99% control), water spray on aggregate (50-80% control), enclosed conveyor and batch plant (70-90% control), paved vs unpaved haul roads with watering.

  4. Add Vehicle Traffic Emissions

    Enter number of truck trips per day and haul road length. Unpaved road dust is often the single largest PM source at a batch plant and uses AP-42 Chapter 13.2.2 factors.

  5. Review Emission Inventory

    See emissions by source point (silo, conveyors, batching, mixer, truck loading, roads) and pollutant (PM, PM10, PM2.5) in tons/year. Compare against permit limits and major source thresholds.

Built For

  • Batch plant operators preparing emission inventories for air permit applications or renewals
  • Ready-mix concrete companies evaluating major source status before expanding production
  • Environmental consultants developing AP-42 emission estimates for new plant construction permits
  • State air quality inspectors verifying emission estimates during batch plant inspections
  • Plant managers calculating emission reductions from control equipment upgrades
  • Corporate environmental staff benchmarking PM emissions across multiple batch plant locations

Frequently Asked Questions

The primary PM emission sources at a concrete batch plant are: cement silo filling and venting (pneumatic transfer), aggregate material handling and conveying, weigh hopper loading, central mixer or truck mixer loading, cement and fly ash truck unloading, vehicle travel on unpaved roads, and wind erosion from aggregate stockpiles. Cement silo filling and unpaved road traffic are typically the two largest sources.
AP-42 Chapter 11.12 covers concrete batching, with emission factors for both central-mix and transit-mix operations. Chapter 13.2.1 covers aggregate handling and storage piles. Chapter 13.2.2 covers unpaved road dust. These chapters provide emission factors in units of lb/ton of material processed, with particle size multipliers for PM10 and PM2.5 fractions.
A well-controlled 200 cubic yards/day batch plant with a silo baghouse, enclosed conveyors, and watered haul roads typically emits 5-15 tons/year of total PM. Without controls, the same plant could emit 50-100+ tons/year. Silo venting alone can produce 20-40 tons/year uncontrolled. This is why most batch plants require at least a minor source air permit and silo baghouse.
Most state permits require at minimum: a baghouse or vent filter on cement and fly ash silos (99%+ control), water spray or enclosure on aggregate handling (50-90% control), and dust control on unpaved roads (water, chemical suppressant, or paving). Many states also require enclosure of the weigh hopper and mixer loading point. NSR or PSD review may require additional controls if emissions exceed major source thresholds.
Most modern batch plants with proper controls are minor sources (under 100 tpy of any single pollutant in attainment areas). However, plants with high production rates, poor controls, or extensive unpaved road traffic can exceed major source thresholds for PM. In PM2.5 nonattainment areas, thresholds drop and more plants may trigger major source requirements. An accurate emission inventory is essential for making this determination.
Unpaved road dust from truck traffic is often the largest single PM source at a batch plant, sometimes exceeding all process emissions combined. AP-42 Chapter 13.2.2 calculates emissions based on vehicle weight, vehicle speed, road surface silt content, and road moisture. Watering unpaved roads reduces PM by 50-80%, but the effect only lasts a few hours. Paving or applying chemical dust suppressants provides longer-lasting control.
Disclaimer: This calculator uses EPA AP-42 emission factors for concrete batch plant sources. Actual emissions depend on production rates, material moisture content, control equipment condition, and meteorological conditions. AP-42 factors represent average conditions and may not reflect site-specific operations. Emission estimates should be verified by your state air quality agency during the permitting process.

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