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Beneficial Use of Foundry SandBeneficial Use of Foundry Sand

AFS Environmental, Health & Safety ConferenceAFS Environmental, Health & Safety Conference

Nashville, TennesseeNashville, Tennessee

August 23August 23--25, 201025, 2010

John T. Kurtz, PresidentJohn T. Kurtz, President

Kurtz Bros., Inc.Kurtz Bros., Inc.

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Cleveland

•• AvonAvon

•• GarfieldGarfield

•• Valley ViewValley View

•• WillowickWillowick

Columbus

•• DublinDublin

•• GroveportGroveport

•• WestervilleWesterville

LocationsLocations

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““Waste to Resource Experts!Waste to Resource Experts!””

•• Foundry SandFoundry Sand

•• Construction DebrisConstruction Debris

•• Biosolid CompostBiosolid Compost

•• Anaerobic Digestion SystemsAnaerobic Digestion Systems

•• Pallet/Wood ReclamationPallet/Wood Reclamation

•• Yard Waste RecyclingYard Waste Recycling

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We are industry leaders in environmental work. We are industry leaders in environmental work. Our successes in pioneering new technology and product Our successes in pioneering new technology and product

development all focus on quality and integrity.development all focus on quality and integrity.

Honorary Mention Honorary Mention

ARTBA Globe Award for Environmental Excellence ARTBA Globe Award for Environmental Excellence

for the ABRAMS CREEKfor the ABRAMS CREEK--HOPKINS AIRPORTHOPKINS AIRPORT

Members of the United States Green Building Council (USGBC) which sets

(Leadership in Energy and Environmental Design) LEED Criteria

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U.S. EPA Is Focused On RecyclingU.S. EPA Is Focused On Recycling

Resource Conservation ChallengeResource Conservation Challenge

(1) Foundry Sand

(2) Construction & Demolition Materials (C&D)

(3) Coal Combustion Products

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The U.S. EPA is focused on recycling.

Two of the focus materials for KB:

1) Construction & Demolition Debris

2) The Beneficial Reuse of Foundry Sands

Recycling to Beneficial ReuseRecycling to Beneficial Reuse

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Recycling Materials

Materials that can be used Materials that can be used safely and effectively:safely and effectively:

•• Foundry SandFoundry Sand

•• Biosolid CompostBiosolid Compost

•• Crushed Concrete & Other Crushed Concrete & Other Building MaterialsBuilding Materials

•• Yard Waste MulchYard Waste Mulch

•• Clean Wood MulchClean Wood Mulch

Biosolid Compost

Foundry Sand

Wood Mulch

Crushed Concrete

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Foundry SandFoundry Sand

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Waste…What a waste!

Waste is not waste if it is reused!

How is Foundry Sand Used?

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Foundry SandFoundry Sand

•• Metal foundries use large amounts of sand as part Metal foundries use large amounts of sand as part of the metal casting processof the metal casting process

•• Foundries successfully recycle and reuse the sand Foundries successfully recycle and reuse the sand many times in a foundrymany times in a foundry

•• Foundry sand can be used up to 100 times. When Foundry sand can be used up to 100 times. When the sand can no longer be reused in the foundry, it the sand can no longer be reused in the foundry, it is removed from the foundry and is termed is removed from the foundry and is termed ““spent spent foundry sandfoundry sand””

•• Production is nearly 6 to 10 million tons annuallyProduction is nearly 6 to 10 million tons annually

•• Like many waste products, foundry sand has Like many waste products, foundry sand has beneficial applications to other industriesbeneficial applications to other industries

(Federal Highway Admin, 2004)

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Recycling Foundry SandRecycling Foundry Sand

• Prior to beneficial reuse, this material was simply being dumped in landfills

• Kurtz Bros., Inc. has beneficially reused over 6,000,000 tons

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• 1993 - Worked with the Ohio Cast Metals Association (OCMA) and the Ohio EPA resulting in development of OEPA Policy 400.007 in November 1994

• New policy allowed for greater flexibility in use, led to Kurtz Bros., Inc. being granted the first Permit to Install (PTI) for unrestricted topsoil blends utilizing Ford Cleveland Casting Plant’s Spent Foundry Sand (SFS)

Kurtz/Ford/Recycling Foundry Sand

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Recycling Materials – Facts About Foundry Sand

• High quality silica sand

• Meets or exceeds drinking water standards for the State of Ohio – Cleaner than typical Ohio Farmland soil

• Meets 203.03 N ODOT Specification

• Accepted as the fine aggregate component of many ODOT specifications

• Can be used as or in:

– Flowable Fill

– Structural Fill and Embankment

– Soil Blending including Bio-Retention media, Rooftop media and Landscape media

– Asphalt and Concrete

– Road Base

Foundry Sand, 45X Mag

Natural Ohio Fine Grained Sand , 45X Mag

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Kurtz Bros., Inc. has beenan active advocate of the beneficial use of foundry sand and has contributed to efforts to inform public and private entities regarding the possibilities of its safe, effective use.

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Foundry Sand Fact SheetFoundry Sand Fact Sheet

Interim Research Results Show Foundry Interim Research Results Show Foundry

Sand Safe for Reuse Sand Safe for Reuse –– July 2010July 2010

www.foundryrecycling.orgwww.foundryrecycling.org

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Foundry Sand Soil ClassificationFoundry Sand Soil Classification

•• Foundry sand would normally be classified under the Foundry sand would normally be classified under the

Unified Soil Classification System (USCS) as SP, SM or Unified Soil Classification System (USCS) as SP, SM or

SPSMSPSM

•• And under AASHTO as AAnd under AASHTO as A--3, A3, A--2, or A2, or A--22--44

•• It is a nonIt is a non--plastic or low plasticity sand with little or no plastic or low plasticity sand with little or no

finesfines

•• The silt or clay content can range from 0 to 12% The silt or clay content can range from 0 to 12%

(Federal Highway Admin, 2004)(Federal Highway Admin, 2004)

–– Typical for KB sands is 2 Typical for KB sands is 2 –– 3%3%

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Structural Engineered FillsStructural Engineered Fills

•• Keeps Options OpenKeeps Options Open•• Safe Safe

•• Saves Natural Resources Saves Natural Resources –– Sustainability Sustainability

•• Excellent Engineering PropertiesExcellent Engineering Properties

•• Readily available from a qualified processor or Readily available from a qualified processor or a foundry with good housekeepinga foundry with good housekeeping

•• Nothing New Nothing New –– ItIt’’s Just Sands Just Sand

•• It Works!It Works!

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Foundry Sand in Soil Blending Foundry Sand in Soil Blending

ApplicationsApplications

What took thousands of years to produce by mother nature is destroyed by bulldozing and stockpiling of natural topsoil.

To begin rebuilding that soil structure, amendments must be added to create a sandy loam texture. Recycled Foundry Sand is particularly well-suited as the sand component.

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Horticultural ApplicationsHorticultural Applications

Blended with foundry sand, biosolids compost, rice hulls, pine bark and natural soil, Kurtz Bros. Container Mix has become the preferred soil blend for Ohio nurseries.

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Landscape ApplicationsLandscape Applications

Barrington Country Club

Medina Country Club

Foundry sand is an essential ingredient in Kurtz Bros. Bed Mix to create a well-drained sandy loam growing medium for more successful landscape projects.

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Commercial ApplicationsCommercial Applications

Euclid Corridor, Cleveland, OH2008 – 7,000 yards planting mix

Cleveland Clinic, Cleveland , OH2008 – 20,000 yards topsoil

Cleveland Art Museum, Cleveland, OH2007/8 – 12,000 yards topsoil

Foundry sand in the mix creates the economic advantage needed to provide quality soil to large projects.

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Green Building ApplicationsGreen Building Applications

Rooftop gardens are proven to save heating and cooling energy and costs, remediate storm water, and create better environments for building occupants.

Sandy loam soil with foundry sand in the mix helps create an ideal, light weight blend when combined with Haydite expanded shale aggregate.

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Clean Water ActClean Water Act

•• Developed as a guide for states to improve Developed as a guide for states to improve

water quality from storm water runwater quality from storm water run--offoff

•• Mandatory regulations for developers to handle Mandatory regulations for developers to handle

ALL storm water on siteALL storm water on site

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RaingardensRaingardens

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Raingardens/BioRaingardens/Bio--Retention Retention

Seven Hills Bioswale BEFORESeven Hills Bioswale BEFORE

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PLANTING Seven Hills RaingardenPLANTING Seven Hills Raingarden

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Raingardens/BioRaingardens/Bio--Retention Retention

Seven Hills Raingarden AFTER 1 YearSeven Hills Raingarden AFTER 1 Year

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BioBio--RetentionRetention

•• Provides water remediation at the source pointProvides water remediation at the source point

•• Typically specified for draining areas of 2 acres Typically specified for draining areas of 2 acres or lessor less

•• Used where land uses include highly Used where land uses include highly impervious areas like parking lots, roadways, impervious areas like parking lots, roadways, culcul--dede--sacs and parking islandssacs and parking islands

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BioBio--Retention in TheoryRetention in Theory

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BioBio--Retention in PracticeRetention in Practice

Grass Buffer

Bio-Retention Soil Mulch Layer

Overflow

Plant Material

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Dynamic Compaction at Dynamic Compaction at

Embassy SuitesEmbassy Suites

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Abrams Creek Improvement ProjectAbrams Creek Improvement Project

Cleveland Hopkins AirportCleveland Hopkins Airport

•• Diversion and Enclosure of Abrams CreekDiversion and Enclosure of Abrams Creek

•• 20,000 cu. yds. of Flowable Fill Required as Pipe 20,000 cu. yds. of Flowable Fill Required as Pipe

Bedding Around (4) 10Bedding Around (4) 10’’ Diameter PipesDiameter Pipes

•• Conventional Fill would not have worked due to Pipe Conventional Fill would not have worked due to Pipe

Placement and Project DesignPlacement and Project Design

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Liberty Way Project

Cover of Modern Casting Magazine

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What Kind Of Foundry Sand?What Kind Of Foundry Sand?

•• Green SandGreen Sand

•• AFS 50AFS 50--53 Lake Sand53 Lake Sand

•• Sand From Iron FoundrySand From Iron Foundry

•• Had Moisture Content of 4%Had Moisture Content of 4%--6% as Stockpiled6% as Stockpiled

•• Free from Debris after ProcessingFree from Debris after Processing

•• No Sharps, No ContaminationNo Sharps, No Contamination

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Why Use Spent Sand?Why Use Spent Sand?

•• Good Fit For ApplicationGood Fit For Application

•• Approved For Use Under OEPA DSW Policy Approved For Use Under OEPA DSW Policy

400.007 400.007

•• Smaller Similar Projects Have Worked WellSmaller Similar Projects Have Worked Well

•• Competitive Pricing AdvantageCompetitive Pricing Advantage

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Required EmbankmentRequired Embankment

•• Reinforced Pavement Supporting EmbankmentReinforced Pavement Supporting Embankment

•• Reinforced Using a PreReinforced Using a Pre--Cast Concrete Modular Wall Cast Concrete Modular Wall System Provided by the Reinforced Earth CompanySystem Provided by the Reinforced Earth Company

•• This System Develops a Coherent Gravity Mass Which is This System Develops a Coherent Gravity Mass Which is Engineered to Resist Applied LoadsEngineered to Resist Applied Loads

•• The system uses a series of PreThe system uses a series of Pre--Cast Modular Wall Cast Modular Wall Pieces in Conjunction with Galvanized Steel Reinforcing Pieces in Conjunction with Galvanized Steel Reinforcing Strips Which are Layered into the Select Granular SubStrips Which are Layered into the Select Granular Sub--base Backfillbase Backfill

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Why Use Spent Sand for Sub Base Why Use Spent Sand for Sub Base

or Embankment?or Embankment?

•• Not Susceptible to Freeze/ThawNot Susceptible to Freeze/Thaw

•• Excellent Compaction PropertiesExcellent Compaction Properties

•• Easy to Use, Handling Not an IssueEasy to Use, Handling Not an Issue

•• Extremely Uniform MaterialExtremely Uniform Material

•• Relatively Abundant and Low CostRelatively Abundant and Low Cost

•• Not Moisture Sensitive, Less than ClayNot Moisture Sensitive, Less than Clay

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Great Lakes ConstructionGreat Lakes Construction

II--271 Slide Repair 271 Slide Repair –– ODOT #801102ODOT #801102

•• 10,000 Tons of Spent Foundry Sand10,000 Tons of Spent Foundry Sand

•• Excellent DrainageExcellent Drainage

•• Excellent CompactionExcellent Compaction

•• Layered CompositeLayered Composite

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Embankment that Blends with NatureEmbankment that Blends with Nature

Stepped EmbankmentStepped Embankment

(Ohio Turnpike, sand supplied by Kurtz Bros., Inc., (Ohio Turnpike, sand supplied by Kurtz Bros., Inc.,

construction by Trumbull Corp.)construction by Trumbull Corp.)

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Tests Required for Your Marketing ArsenalTests Required for Your Marketing Arsenal

•• CBR ValueCBR Value

•• CorrosivityCorrosivity

•• pHpH

•• Analytical Analytical –– Must meet OEPA DSW Policy 400.007 Must meet OEPA DSW Policy 400.007 parameters, which are based upon drinking water parameters, which are based upon drinking water standardsstandards

•• Friction AngleFriction Angle

•• Sieve AnalysisSieve Analysis

•• Standard ProctorStandard Proctor

•• ConductivityConductivity

•• Sodium Sulfate SoundnessSodium Sulfate Soundness

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•• Sieve Requirements:Sieve Requirements:

SieveSieve OTCOTC RR--EarthEarth FordFord 703.11703.11

SizesSizes % Pass% Pass % Pass% Pass % Pass% Pass % Pass% Pass

44”” -- 100100 100100 --

33”” -- 7575--100100 100100 --

3/43/4”” 100100 -- 100100 100100

3/83/8”” 8080--100100 -- 9999 100100

No. 4No. 4 6060--100100 -- 9797 9999

No. 8No. 8 4545--9595 -- 9595 9595

No. 50No. 50 77--45****45**** ********** 53******53****** 4949

No. 200No. 200 00--77 00--1515 3.63.6 1.61.6

Select Granular Backfill RequirementsSelect Granular Backfill Requirements

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Select Granular Backfill RequirementsSelect Granular Backfill Requirements

PropertyProperty Specification Specification ResultsResultsSoundnessSoundness 15% Max Loss15% Max Loss 3%3%

Liquid LimitLiquid Limit 25% Max25% Max N/AN/A

PlasticPlastic 6% Max6% Max Non PlasticNon Plastic

ProctorProctor >=120 pcf>=120 pcf 122 pcf122 pcf

Friction AngleFriction Angle >=34 degrees>=34 degrees 35 degrees35 degrees

ResistivityResistivity >=3000 ohm>=3000 ohm--cmcm 5,600 ohm5,600 ohm--cmcm

pHpH 55--1010 9.29.2

SulfatesSulfates <200 ppm<200 ppm 87.6 ppm87.6 ppm

Chloride LevelsChloride Levels <100 ppm<100 ppm 35 ppm35 ppm

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The HurdlesThe Hurdles

•• Although Used, Not Used CommonlyAlthough Used, Not Used Commonly

•• FearsFears

–– NewNew

–– Dirty?Dirty?

–– LiabilityLiability

•• Many MisconceptionsMany Misconceptions

•• CompetitionCompetition

•• Beneficial Use Policy IssuesBeneficial Use Policy Issues

•• Conflicting RequirementsConflicting Requirements

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Significant Marketing PlanSignificant Marketing Plan

•• Enlist the Experts Where NeededEnlist the Experts Where Needed

•• Network with Project Owner, Architect, Engineer, and Network with Project Owner, Architect, Engineer, and

Material Manufacturer Material Manufacturer

•• Big PR Positive for the Governor (RBig PR Positive for the Governor (R’’s s –– not always not always

viewed as green)viewed as green)

–– Also Positive For Industry Also Positive For Industry

–– Promote Innovation Promote Innovation

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Geotech Consultant InvaluableGeotech Consultant Invaluable

•• CredibleCredible

•• IndependentIndependent

•• Experienced with Spent SandExperienced with Spent Sand

•• Talks their LanguageTalks their Language

•• Nothing to Gain, Nothing to LoseNothing to Gain, Nothing to Lose

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Notable Foundry Sand ProjectsNotable Foundry Sand Projects

Project/Location Quantity Project Number Owner Contractor

MSE Wall Projects

Ohio Turnpike Third Lane Project 779901 54,000 tons 779901 Ohio Turnpike Commission Great Lakes Construction

Schaaf Road Bridge Replacement 27,000 tons Cuyahoga County Great Lakes Construction

I-271 & Route 303 IR Bridge Replacement 21,272 tons 050316 ODOT Kokosing

Fulton Road Bridge Replacement 12,600 tons 060372 ODOT Kokosing

I- 71 & Route 83 7,600 tons 050048 ODOT Kokosing

ODOT Projects

I-271 Slide 10,000 tons 8011(02) ODOT Great Lakes Construction

I-271 Express Lanes 5,000 tons ODOT Independence Excavating

Route 82 & Route 8 ODOT Subbase – Macedonia 500 tons ODOT Independence Excavating

SR 237 Front St. Railroad Grade Separation – Berea 86,000 tons 080598 ODOT Great Lakes Construction

Public Projects - Embankments

Ohio Turnpike Third Lane Project 439901 58,000 tons 439901 Ohio Turnpike Commission Trumbull Corp/National Engineering

Ohio Turnpike Great Lakes Service Plazas 50,000 tons Ohio Turnpike Commission Independence Excavating

Patriot’s Way 25,000 tons Independence City Independence Excavating

Public Projects – Flowable Fill

Abrams Creek Diversion Cleveland Hopkins Airport

20,000 tons FAA Independence Excavating

Private Projects – Embankments Location

Cloverleaf 600,000 tons Valley View/Independence Kurtz Bros., Inc.

West Creek 500,000 tons Independence Independence Excavating

Rockside Road 500,000 tons Valley View Kurtz Bros., Inc.

Footes/Cinemark Theatre 250,000 tons Valley View Kurtz Bros., Inc.

Vale 160,000 tons Valley View Kurtz Bros., Inc.

Majewski 96,000 tons Valley View Kurtz Bros., Inc.

PLPI Heinton Road 48,000 tons Valley View Kurtz Bros., Inc.

CDF Area I – Final Grade 25,000 tons Cuyahoga Heights Kurtz Bros., Inc.

Embassy Suites 20,000 tons Independence Independence Excavating

City of Aurora Sewer 20,000 tons Aurora Kurtz Bros., Inc.

Towpath I/Towpath II 15,000 tons Valley View Kurtz Bros., Inc.

Richfield Retail Development 10,000 tons Richfield Kurtz Bros., Inc.

Delta – York Drive 10,000 tons North Royalton Kurtz Bros., Inc.

Leachate Collection Systems

Rosby Hill 12,000 tons Brooklyn Heights Kurtz Bros., Inc.

Waste Management Leachate Collection 10,000 tons Glenwillow Waste Management

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ConclusionConclusion

•• Economical Economical ““Save the Tax Payers MoneySave the Tax Payers Money””

•• Safe Safe –– Wave the Green FlagWave the Green Flag

•• Excellent Engineering PropertiesExcellent Engineering Properties

•• Readily AvailableReadily Available

•• It Works!!!It Works!!!

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Affiliated CompaniesAffiliated Companies

Harmony Real Estate Co. Brookside Sand & Gravel

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Thank You!Thank You!