Concrete Batch Plant Dust Calculator - AP-42 Ch 11.12 PM Emissions for Batch Plants
Yards batched per year in. PM from handling, mixing, and truck loading per AP-42 Chapter 11.12.
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.
Check visible opacity readings beside batch-plant PM source reviews
Stack Opacity Assessment Tool →Add batch plant PM and combustion emissions to your Title V fee calculation worksheet
Title V Fee Calculator →Use AP-42 emission factors for batch plant sources to cross-check your dust estimates
AP-42 Emission Factor Lookup →Evaluate baghouse collection efficiency to model controlled emissions for your permit application
Control Device Efficiency →How It Works
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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.
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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.
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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.
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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.
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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
Assumptions
- Emission factors are from EPA AP-42 Chapter 11.12 for concrete batching operations.
- Aggregate and cement throughput is proportional to the entered concrete production rate.
- Control equipment operates continuously and at the rated efficiency during plant operation.
- Unpaved road emissions use AP-42 Chapter 13.2.2 factors based on average vehicle weight and road surface silt.
- Mix design ratios (aggregate, cement, water) follow standard ready-mix concrete proportions.
Limitations
- Does not account for wind speed and direction effects on fugitive dust dispersion.
- Aggregate moisture content significantly affects actual emissions but is assumed at a default value.
- Control efficiencies for water spray depend heavily on application rate and frequency.
- Stockpile wind erosion emissions are not modeled - only active material handling is calculated.
- Does not include emissions from on-site mobile equipment (loaders, forklifts) exhaust.
References
- EPA AP-42, Chapter 11.12 - Concrete Batching.
- EPA AP-42, Chapter 13.2.1 - Paved Roads and Chapter 13.2.2 - Unpaved Roads.
- EPA AP-42, Chapter 13.2.4 - Aggregate Handling and Storage Piles.
- Portland Cement Association - standard concrete mix design proportions.