Everything Concrete Plants Need to Know About Environmental Regulations

A Complete Guide to All That "Environmental Stuff" at Concrete Plants

Are you running a concrete plant and wondering whether you’ve got your environmental permits and approvals setup right? Maybe you’re thinking about buying an existing concrete plant, or just stepping into the role of plant manager or environmental manager and want to make sure you’ve got all your bases covered so you stay out of trouble and ahead of the curve.

Or maybe you're pretty sure you're up to speed, but you just want a refresher.

If that sounds like you, you're in luck. Kick back, grab a coffee (or beer if that's more your style and it's after hours), and dig in!

This is going to cover it all - written by a pro who has done this firsthand, for decades.

We’re going to walk through the core environmental considerations for concrete plant operations: what you need to know, what you can do yourself, what a consultant like us can do, how much it might cost, and how long it takes.

Table of Contents:

• Who Do We Think We Are? Our Concrete Resume
• Your Playbook to Environmental Regulations at a Concrete Plant
  • What To Do When Acquiring a Property or Existing Concrete Plant
  • Core Environmental Regulations for Concrete Plants
  • How & When We Help Concrete Plants (Short, Medium, and Long-Term)
• The Cost of Environmental Stuff at Concrete Plants
  • Costs When Acquiring a Property or Existing Plant
  • Cost of Core Regulations at Concrete Plants
  • An Example of Costs at a Typical Plant
  • I Have to Do WHAT? And it Costs HOW MUCH?
  • Is It Worth It? What Happens if You Get in Trouble?
• How Long Does All of This Take?
• Still Have Questions?

Author Note: So Who Are We to Talk About Concrete Compliance?

Before we dive in, here’s why we’re even qualified to talk about this.

Since the early '90s, we’ve worked with hundreds of ready mix, precast, brick, block, pipe, and specialty concrete plants across the U.S., Central and South America, Canada, and even the Middle East. We've worked across lots of other industries too, but concrete is what we do.

From big, new high-tech plants, to smaller, old-school mom & pop operations, we’ve seen it all. We’re not going to call you a “cement plant” (it makes us cringe every time we hear it) - but we do know how your silos work. We understand why you use water reducers, retarders, and other admixtures. We've seen more chute rinse-outs than we can count. And we also know how all of those things can impact your compliance obligations. This isn't abstract stuff to us, it's exactly what we've been doing since day one.

On a personal level, I’ve been teaching the environmental course at the National Ready Mixed Concrete Association (NRMCA) since the very first session back in 1998. I also helped write the NRMCA’s Green-Star Environmental Management System (EMS). Over the years I’ve partnered with concrete producers nationwide to tackle real-world problems, from helping to pick out a new site to break ground on, to the nitty-gritty of environmental planning and permitting, to building full-fledged EMS programs.

I don’t say this lightly, but I truly don’t think there’s another environmental consulting firm that’s been on-site at more concrete plants than we have here at RMA. That’s not bragging. It’s just... the truth. And it’s the reason we (and I) feel confident saying this is going to cover everything you need to know (without overwhelming you).

And if you get to the end and still have questions or think you need a hand, reach out to talk to an environmental expert about your concrete plant.

There's me a few years back at a precast plant, being the "environmental guy"!

A Concrete Plant's Playbook to Environmental Regulations

At RMA we specialize in environmental regulatory compliance, due diligence, and “greener” services like EMS support, including NRMCA’s Green-Star program. That pretty much covers all of the bases when it comes to environmental stuff at a concrete plant.

But what do you actually need to do, and when? Let’s break that down into a kind of timeline.

Acquiring a Property or Existing Concrete Plant

Before you purchase a property, your lender will likely require a Phase I Environmental Site Assessment (ESA) , which is basically an investigation to make sure you're not buying an environmentally contaminated property that will cost thousands (or more) to clean up. It's kind of like a background check to make sure you're not going to get stuck holding the bill for someone else's mess.

If you’re buying an existing operation, you should also consider an environmental audit . An audit helps identify which compliance requirements apply and what the current operation is already addressing. The goal is to find out where you’ll need to invest, and what potential liabilities may need attention going forward. Think of it like a check-up at the doctor just to see how things are going, but geared toward an environmental program.

We can handle both of these for you—just reach out to us . We’ve completed more Phase Is and environmental audits than we can count at all types of concrete plants—ready mix, precast, brick, block, you name it—as well as at virgin sites being developed into concrete plants. So when it comes to Phase Is, environmental audits, and the concrete industry, we’ve seen just about everything.

Core Environmental Regulations for Concrete Plants

Once you've gotten your property all squared away, there's usually a little downtime on the environmental stuff. You're researching and buying equipment, looking at hiring staff, and have your hands full with a million other things trying to get up and running. As your plant gets closer to starting operations, that’s usually when we come back into the picture to lend a hand.

Here are the top environmental regulations that will likely apply to any concrete facility (that we help with!):

• Water quality permitting , often called stormwater permitting, or technically, NPDES permitting, is typically required in every state for any type of concrete plant.
• SPCC plans , which are federally mandated, are generally necessary if you’ll have fuel storage or a maintenance garage on-site.
• Tier II and TRI Reporting are both annual requirements for hazardous material storage and use. Most concrete plants will need to file Tier II reports. TRI reporting, on the other hand, usually only applies to medium to larger facilities, but it depends on the specifics.
• Hazardous waste registration , which again depends on your operation and location.
• Air quality permitting , which, if you can believe it, depends on your operation and location. Full transparency: we don't always handle air permitting, but we can hook you up with someone if we can't help.

There are also other environmental concerns outside our scope, such as local issues like wetlands, wildlife, noise, zoning, and surveying that we don’t handle directly. But no worries, we've been around the block and can point you toward trusted nationwide providers.

Now, if you’re looking to take things a step further, many concrete producers pursue NRMCA’s Green-Star Environmental Management System. But that’s getting a bit ahead of ourselves.

How (and When) We Help Concrete Plants

In the short term, we can assist with a Phase I ESA or an environmental audit before you finalize buying a location or an operation to purchase. This sets you up for success right out of the gate.

In the medium term, we’d help with filing your stormwater permit and your air permit, as well as developing your SPCC Plan, if needed (depending on your operation). Once the plant is up and running, we’d circle back to handle Tier II and TRI reporting requirements, as well as any hazardous waste considerations. For anything we don't handle in-house, we'll get you set up with someone we trust.

In the long term, we can support ongoing compliance. That includes things like annual training (such as SPCC training online), keeping up with NPDES requirements (like stormwater analysis result submittals), and filing your yearly Tier II and TRI reports.

Think of it like hiring us like hiring an accountant for your taxes, but for your environmental stuff. If you don’t need any ongoing help, then we really won’t be around long-term, and that’s fine too. But if you just want a set of eyes to stick around and make sure you’re staying on course, we do that for a variety of concrete facilities across the country.

If you're already sick of thinking about all this, give us a shout and we'll take it off your plate.

How Much Does All This Cost?

Let’s talk about what this all costs – the million-dollar question! And no, it won’t cost a million dollars. If you’re handling everything yourself, the cost is really just your time.

But let’s assume you’re thinking about this because you’re considering hiring a consultant like me. We always try to be transparent about our pricing, so here are some ballpark figures if you go that route:

Environmental Costs When Acquiring a Property or Existing Concrete Plant

A Phase I ESA at a concrete plant typically runs between $4,000 and $8,000. And yes, you might find someone local who says they’ll do one for $2,000, but it won’t be good. Realistically, expect to pay around $5,000 for a solid Phase I. If you need a Phase II (and hopefully you don’t), that can run tens of thousands depending on the findings. But for now, let’s assume you don’t.

If you’re buying an existing concrete plant, it’s also worth knowing whether their environmental program is up to speed. If it is, you’ll likely spend less in the long run. If it's not, it’ll cost you more. That’s where an environmental audit comes in. An audit takes a deep dive into a plant’s current compliance status. It identifies what applies, what’s already in place, and what you’ll need to take care of once this concrete plant is your responsibility. Environmental audits at concrete plants typically range from $3,000 to $8,000, so let’s call this one about $5,000 as well.

Cost of Core Environmental Regulations at Concrete Plants

NPDES permits typically range from $3,500 to $9,000, including both the application fees paid to the state and consultant costs. For budgeting purposes, plan on about $5,000. This is a permit you’ll almost certainly need if you operate any type of concrete plant in the United States. In fact, several states have NPDES stormwater permits specifically just for concrete plants.

SPCC Plans fall into a similar range – again figure roughly $5,000. Whether you need one depends on your operation. For small to medium plants, it’s a solid “maybe.” For medium to large operations, it’s usually a “yes,” and if you have a maintenance garage or fuel stored on-site, it’s almost definitely required.

Tier II and TRI Reporting are a bit more affordable. Tier II typically costs between $1,500 and $3,000, while TRI can range from $2,000 to $5,000. Let’s say you need both and split the difference – you’re looking at about $5,000 total in the first year. The good news is that year 2 is usually cheaper, since your consultant will have already set up the process. At least it is with us!

Hazardous waste registrations are even less expensive, usually falling between $1,500 and $4,000. Depending on your generation and storage volumes, you might also need a hazardous waste management plan, which could run between $3,000 and $6,000. For planning purposes, let’s call this all $4,000.

Air quality permitting is going to largely depend on the type of permit (or permits) you need, but as a general ballpark, you can figure around that same $3,500 to $9,000 range as the NPDES permit for an application and consulting fees.

Example Scenario: Environmental Costs at a Typical Concrete Plant

Let's take a look at those numbers all together in an example scenario of a pretty standard concrete plant.

So, all in, before buying the property, plan to spend about $5,000 for a Phase I ESA. If you’re buying an existing concrete plant, budget another $5,000 for an environmental audit. That puts you at around $10,000 total just to understand what you’re getting into from a compliance standpoint and to cover your bases that you're not buying a liability.

To get operations started, expect about $10,000 for your stormwater permit and SPCC Plan combined. Add another $5,000 for Year 1 of Tier II and TRI Reporting. If hazardous waste registration and a management plan are needed, that’s about $4,000 more. Let's say that this particular plant doesn't require an air permit, so you squeak by with no costs there.

You may also have additional considerations like AST registrations or other local requirements. Those could add a few hundred to a few thousand dollars – let’s estimate around $3,000.

That’s $10,000 before purchase, and roughly $22,000 in year 1 to get your environmental compliance up and running.

Ongoing Environmental Costs at Concrete Plants

Okay, so what's this going to cost in the long run, after year 1?

After all of that, you’ll be looking at annual, ongoing compliance costs. These might include NPDES permit fees, sampling or lab work tied to your permit, and annual SPCC training. You’ll also have your Tier II and TRI Reporting due each year.

While that may sound like a lot, a good rule of thumb is that your annual costs will run about 10–30% of your initial compliance setup. So, if your NPDES permit cost $5,000 upfront, expect to spend $500 to $1,500 per year to stay compliant (though of course, the exact figure depends on the permit and the specifics of your site).

If you need someone to handle parts of this for you, like submitting your DMRs, expect an annual compliance contract to start at a few thousand dollars. Basically, we can usually take all of this ongoing stuff off your plate for a couple grand. Contact us if you'd like to explore that option.

The bottom line? Some facilities get by with minimal annual costs. Others, especially larger or more complex operations, spend tens of thousands per year to stay in full compliance.

And if you want to go above and beyond, pursuing an Environmental Management System (EMS) (like NRMCA’s Green-Star) will typically run a few thousand dollars.

At that stage, though, you’re likely treating environmental compliance as a measurable part of your operation. The cost becomes part of a broader strategy tied to things that matter: efficiency, risk management, reputation, and long-term performance.

Just remember, these are ballpark figures, not fixed quotes. Your actual costs will vary based on your site, your setup, and your needs. We can support you through every stage: upfront due diligence, the initial round of compliance, ongoing regulatory work, and long-term planning around environmental performance and impact. To find out exactly what it'll cost for your setup, get in touch with us for a quote.

Let's Hit Pause for a Second: We Know What You're Thinking

If you didn’t realize there was this much to environmental compliance at a concrete plant, you’re definitely not alone. When we lay all this out for a plant manager who’s hearing it for the first time, we usually get wide eyes, a head shake, and a “You’ve gotta be kidding me.”

We get it. It’s a lot. It’s confusing. And yeah, it’s probably more expensive than you were expecting. That’s why, around here, we’ve got names for those exact reactions: sticker shock and regulatory whiplash.

Check out the video below for a breakdown.

If you're feeling the heat, deep breath. Some of this can be done yourself, or may not even apply to your site. Items like SPCC Plans, Tier II Reporting, hazardous waste registration, and local AST requirements can often be handled internally, if you have the time, knowledge, and confidence to do it right. The key is knowing where to draw the line and when to call someone who’s been through it before.

Is It Worth It? The Cost of Getting it Wrong

There are no participation trophies when it comes to environmental compliance.

In fact, it’s the opposite – violations can cost tens of thousands of dollars per day if you get it wrong. Enforcement actions can be financially devastating, especially if it’s found that you knowingly or willfully violated the rules.

We’ve seen it happen. Not often, but enough. Some of the worst cases we’ve dealt with dragged on for years and cost clients a small fortune in legal fees.

It’s always cheaper and easier to follow the law, rather than try to fly under the radar and risk everything. So yes, let's just say it's worth it.

That's me performing an environmental audit at a plant way back in 2012 – time flies!

How Long Does All of This Take?

Let’s talk timelines to wrap things up.

Audits and Phase I ESAs, your due diligence items, typically take a few weeks to a month to complete. They can be expedited if needed, but doing a thorough, well-rounded job usually takes around four weeks.

NPDES permits, SPCC plans, and air permits also take a few weeks to a month or so to prepare. However, because NPDES permits and air permits must be submitted to and approved by state agencies, you're somewhat at the mercy of the government. Some states issue permits within hours. Others can take months, or even years. The same timeline generally applies to hazardous waste considerations as well, including plan development, if that's required.

Tier II reporting is generally quick to complete, but for your first year, allow a few weeks just to be safe. TRI reporting tends to be more complex—expect a month or two to get it done right, especially if it's your first time.

As for other local or third-party requirements, like AST registrations or zoning, those usually fall into the same ballpark: allow a few weeks to a month, depending on who’s doing the work and how responsive your local agencies are.

Wrapping Up... Now What?

So now that you’ve got a better sense of what environmental compliance at a concrete plant looks like, what it costs, and how long it takes, you might still have questions specific to your site or situation. That’s totally normal.

If you’re already working through these requirements or just starting to look at a new site, we’re happy to have a conversation and help point you in the right direction, whether you work with us or not.

At the end of the day, we want concrete producers to succeed in this space and avoid the costly pitfalls that come with getting it wrong. If you’ve made it this far, chances are you care about doing things right, and that’s exactly the kind of company we like working with.

To schedule a quick chat to talk about what all this means for your plant, reach out to us here.