Everything Concrete Plants Need to Know About Permitting (and More!) in the U.S.
Are you planning to open or expand a concrete plant - ready-mixed, precast, or otherwise - anywhere in the United States? Not sure what permits or approvals you’ll need? Or maybe you have a general idea, but want to be absolutely sure before you invest time and money?
If that sounds like you, you’re in the right place. Here at RMA, we've helped hundreds of concrete producers across the U.S. get up and running with the right approvals - quickly, efficiently, and compliantly. With 5 stars across each of our offices and over 30 years working with all kinds of concrete plants across the country - we know concrete!
In this comprehensive guide, we’ll break down the entire permitting process, step by step from start to finish, so you know exactly what to expect, what’s required, how much it costs, how long it takes, and what to do to stay on track.
And if you still have questions when you're done, or you just want someone to take all this off your plate, reach out to our concrete plant permitting experts here! Okay, let's jump in.
Table of Contents
What Is Meant by "Concrete Plant Permitting"?
If you're totally new to this, then here's your newsflash: yes, you do need to get various "permits" to run a concrete plant. These are laws, rules, and regulations (just like wearing your seatbelt), typically originating at the federal, state, and local levels. Concrete plants, whether new or expanding, almost always need to follow these regulations in some form, which, to the layman, usually equals "I need a permit to run this business".
Now, when we refer to "permitting" in the title of this article, it's actually a bit of a misnomer on the big-picture scale. While we are going to talk about permits, some of the requirements we’ll cover aren’t technically "permits". To give you the full picture, we also need to talk about things like approvals, plans, notifications, reporting, and documentation. Not "permits" per se, but still required to run a plant.
Just know that for the sake of clarity, we’re using "concrete plant permitting" here and in the title as a catch-all term for all of the laws and requirements you’ll need to follow in order to legally open and run a concrete plant.
Step 1: Local Approvals Come First
Okay, so you're opening a concrete plant. But before you set up shop, your project most likely needs to be "greenlit" at the local level. This might include zoning and land use approvals, site plan reviews, and construction approvals from your local town, township, city, or county government. Here's what we see most often.
Common Local Permits & Approvals:
- Zoning or Use Variance: To ensure your land is approved for industrial use
- Site Plan Approval: Including traffic patterns, parking, buffers, and lighting
- Planning Board Presentations: In some cases, you’ll need to appear publicly
- Construction Permits: Electrical, plumbing, fire code compliance
See that? Only one real category of "permits", but still plenty of hoops to jump through. At this stage, your team will likely include engineers, surveyors, maybe a consultant, and possibly an architect or even a lawyer. Don’t skip this step, your entire project timeline hinges on it. We've seen operators purchase land and start building their plants when the city caught wind and completely pulled the rug from underneath them!
Step 2: Construction Phase Permits
Once you have your local approval all pinned down, it’s time to break ground. But that doesn’t mean you’re done with permits. This phase introduces several construction-related and environmental approvals you’ll need to secure to keep the ball rolling on the road to your first pour.
Key Construction Permits & Rules:
- Erosion and Sediment Control Plan: Usually coordinated through your County Soil Conservation District
- NPDES Construction General Permit: Required if your site disturbs more than one acre of land
- Stormwater Pollution Prevention Plan (SWPPP): Often tied to your NPDES permit
- Fuel Tank Permits and Inspections
Most of these permits must be obtained before construction begins. Failing to get them before you begin construction (or waiting to get them until the last minute) can mean stop-work orders and fines! Get ahead by coordinating with local officials and your state’s environmental agency early in your design process.
Step 3: Operational Environmental Permits
Once your plant is built and ready to go live, the most significant environmental regulations kick in. These are not optional, and they stay with your operation for the life of the facility. Keep in mind that we're just touching on the biggest ones here, but there may be additional regulations for operating a concrete plant at your state or local level!
Common Operating Permits & Regulations Include:
Pro tip: design your facility to avoid discharges other than stormwater (such as truck washwater or chute rinseout water). If you plan to discharge process water or washout, NPDES permitting becomes significantly more complex (and may not even be feasible in some states). If you're planning to discharge process water, you should definitely speak with one of our concrete plant environmental experts first!
Step 4: Ongoing Compliance & Annual Reporting
Once your permits are in place, they come with strings attached: reporting, inspections, sampling, renewals, and fees. Compliance doesn’t stop at approval, it’s an ongoing responsibility.
Typical Ongoing Requirements:
- Stormwater Sampling, Inspections, and Training (quarterly, semi-annually, or annually)
- Air Monitoring, Emissions Reports, or Stack Testing, if required
- Annual Permit Fees renewal fees, or ongoing fees, based on permit length, emissions, and discharges
- SPCC Plan Reviews, Inspections, Employee Training, and Updates as needed or annually
- Tier II and TRI Reporting (annually, if required)
Letting these slip can lead to violations, fines, or shutdowns. If you're not working with a professional like us, we recommend building permit renewal timelines into your calendar and assigning someone internally to own compliance monitoring. This is where most facilities get inspected (and in trouble) down the line once all the startup headaches have died down.
For more on steps 3 and 4, check out this article on Everything Concrete Plants Need to Know About Environmental Regulations!
What If I'm Operating in a Remote or Temporary Location?
If you’re building a temporary concrete batch plant on a construction site or in a rural area, you might get some relief from local zoning or planning requirements. But don’t let your guard down. Lots of these regulations originate at the Federal level. And that means states or counties usually can't just say "no thanks, we're not going to do that here". If you're in the United States, some of these are almost certainly going to apply to you.
Even mobile or temporary concrete operations are typically subject to stormwater and air permitting at a minimum. We always say: there's no such thing as "too remote to regulate" when it comes to these environmental laws. Always check with local and state agencies before assuming... or partner with a professional like us to do it for you!
How Much Does All of This Cost?
Let’s get this out of the way: it depends. It depends on what you need, where you’re located, how complex your site is going to be, who you hire, and about a thousand other variables. But here’s the thing: the cost of not doing these things right is almost always higher than the cost of getting it right the first time.
We’ve seen companies get hit with six-figure fines because they skipped key permits or made critical mistakes during setup. Noncompliance is expensive, stressful, and avoidable.
So how much does it cost, ballpark? Here’s a rough estimate based on the types of clients we work with:
- Basic compliance help: If you’re already well into your setup and just need help with a couple of key areas to operate, like NPDES and air permitting, you might spend anywhere from $5,000 to $20,000.
- Full project guidance: If you’re starting from scratch (no site picked, no team in place) you’ll likely need engineers, architects, surveyors, and consultants... maybe even lawyers. That puts you closer to six figures.
- Moderate project needs: Somewhere in between? Then plan for $20,000 to $80,000 depending on your timeline and requirements.
Yes, these are big numbers, and big ranges. But compared to the cost of trucks, equipment, payroll, and everything else it takes to open a concrete plant, they’re a fraction of the total investment. And they protect that investment long-term.
If you want a real number for your actual situation, get in touch here. We’ll take time to understand where you are and what you need and give you a straightforward estimate, no strings attached (even if that means you don't work with us, or abandon your plant entirely!).
At RMA, we work hard to be transparent about our pricing, so you can also check out our pricing page here, or try our free online pricing estimators here!
How Long Does All of This Take?
Just like cost, the timeline depends. It depends on your team, the professionals you hire, your location, the complexity of your site, and - often the biggest wildcard - how fast or slow your local and state regulators are at reviewing and approving applications.
If you’re starting completely from scratch, give yourself a realistic window of 12 months or more from the time you select your site to the moment you’re pouring your first batch of concrete. It can be done faster, but if you want to plan conservatively, that’s a smart benchmark.
Some of the more straightforward items (like a construction stormwater permit or developing an SPCC plan) might only take a few weeks to a few months in some areas. But again, it all depends. We’ve seen NPDES permit reviews take a year or more in certain states!
If your situation falls somewhere in between, say you already have a site and a rough layout but need environmental support, you’re likely looking at a 3–9 month runway. That’s assuming things move fairly smoothly and you’ve got a good team keeping things moving forward.
The best way to speed things up? Plan early, work with people who’ve done this before, and stay ahead of what’s required. That’s where we come in.
What Does RMA Do?
Let’s be clear - we’re not going to tell you we do it all. Anyone who says that is either uninformed or not being honest. We’re environmental consultants, and our specialty typically lies in Steps 3 and 4 of the permitting process: environmental operating permits and ongoing compliance.
That said, we’ve been involved in more concrete plant projects than we can count, and we’ve helped plenty of companies go from day one to fully operational, compliant, and profitable businesses by facilitating Steps 1 and 2. So even though we don’t do engineering or construction directly, we can help guide you through the first two phases and connect you with trusted partners who do.
If you’re starting from square one, we’ll help you build a game plan and bring in experienced professionals to cover every angle. We can even help oversee the project so you’re not stuck juggling a dozen vendors and wondering who’s doing what. And when it comes to environmental regulations, NPDES, stormwater, air permits, SPCC plans, reporting, hazardous waste, and everything else required to operate compliantly, that’s our bread and butter. This is what we do every day, and you’ll be in good hands with us.
Our Process
When you reach out to us, here’s what happens: we have a real conversation. Nothing high-pressure, no cookie-cutter sales pitch. Just regular people talking about what you need and where you’re at. Depending on your situation, we might:
- Get on a quick call to walk you through your next steps if you’re just getting started
- Schedule a site visit if you’re already under construction and need to get the ball rolling on permits
- Trade emails to help you file this year’s report or permit renewal if you’ve been operational and just realized you missed something
- Or, point you in another direction entirely. If we’re not the right fit, we’ll tell you. No hard feelings.
We’re not here to sell you anything you don’t need. That’s a waste of your time and ours. But if you’re serious about running a compliant, successful concrete plant, we’re here to help you do it right.
Where to Get Help for Your Concrete Plant
If you're feeling overwhelmed - deep breath. This stuff might sound intimidating at first, but it absolutely doesn't need to get in the way of opening your concrete plant. And once you're up and running, most of the ongoing requirements are manageable with the right systems in place.
At RMA, we've helped more concrete plants get permitted and stay compliant than we can even count. Whether you’re building your first ready-mix site, expanding into a new state, or setting up a mobile batch plant, we’ve been there. We understand the unique environmental challenges of the concrete industry, and we know how to solve them.
We’re one of the leading environmental firms in the country for concrete plant compliance, and we’ve built our reputation by making complex permitting simple, fast, and reliable for our clients. Need a second opinion? Want someone to just handle it for you? That’s what we do.
Reach out here - we’ll help you build a solid and compliant concrete plant starting today.
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