CIOB 2007 International Innovation and Research AwardsEco hoardingRichard Bayfield Consultant to 3DMMatthew Locke, Innovation Manager, Bovis Lend Lease

Some facts and figuresUK uses around 5 million sheets of plywood per year for temporary worksBovis Lend Lease require plywood to be certified under the Forest Stewardship Council (FSC)Most FSC plywood is transported long distances UK generates over 5 million tonnes of plastic per year, landfill running out80% of plastic waste is incinerated or dumped as landfill Recycling usually involves sorting and segregation

1400 wasted per builders skipThe average skip costs 200. The average cost of what is being thrown away in that skip is over 1,200 (Source: WWW.CIRIA.ORG).

Powder Impression Moulding (PIM) process3DM developed and own the rights to PIMDirty co-mingled waste plastic can be used to produce products with up to 95% recyclingPilot plant built at Caerphilly to enable protoyping of new products

Bulk arrivesMaterial sterilisedPowder/granules

Opportunities in constructionIdentified temporary works uses in construction First stage a straight replacement for plyOpportunity to run trials at St Davids 2, Cardiff, a 300m retail development for St Davids Partnership (Land Securities and Capital Shopping Centres)3 way investment in moulds St Davids Partnership, Bovis Lend Lease and 3DM Initial requirement to be self coloured, graffitti resistant, non flammable

So what does it look like?

What is it like to handle?

Finishing touches

Use in concrete formwork

How green is the board Plywood hoarding panel = 23 Kg CO2 Mixed recycled PIM panel = 21Kg CO2 Potentially more uses of PIM panels

Note above figures are extremely positive given that generally recycling is seen as energy intensive.

Source of embodied energy coefficients Centre for Building Performance Research, Wellington (NZ)Assumes shipping of ply from South AmericaAssumes transport within UK by container truck

The Way forwardResearch project with Brunel University establish the effect of the range of plastics and the properties of the board Obtain BBA certificate to enable uses in permanent works to be explored Establish larger volume production facilityExplore other additives such as Titanium dioxideDevelop hoarding panels with integrally moulded rails and postsTrial further applications BPB Gypsum

FutureEco-board - further testing, trials and development 2007Commercial production with Express plastic and recycling 2008

3DMs UK Partners to develop PIM technology:ArupBovis Lend LeaseBrunel UniversitySevernside RecyclingTescoOthers tbcMore at www.3dmct.com

Guidelines

This sketch represents the Hyatt Centre at 71 S Wacker, Chicago, USA. This sketch can only be used with this image.

Construction Waste OverviewOn a large project its not uncommon to have several skips per week do the maths @ 1400 per skipCompelling financial argument as landfill tax risesChallenge - Large growing problem unlikely to be solved by legislationOpportunity - Need for new technologiesC.f. Value Engineering 2nd World War shortages alternative materials / technologiesIncreasing social / political pressure

Dimensions 2400 x 1000 x 19mm and 2400 x 150 x 19mmWeight of board 18 21 KgStrength similar to ply smoother surface than plyNo special tools requiredDoes not sustain burning Does not absorb moistureSelf coloured sheets - 55% recycled plastic; Painting grade - 80% with high proportion of WEEE materialLimited Production for Bovis supply chain Likely cost about 20 per sheet (3 rebate when returned for recycling after use)

Ease of workingImproved Incident and Injury Free on site and for publicIf graphics are to be used or painting required, do not specify graffitti resistant board Screw fixings are better than nail guns for reuse of panelsGood bite for screwsMake provision for thermal expansion when fixing boardsImprove control on mould closure to limit thickness variation

FormworkPIM sheets give similar finish to steel shuttering Less release oil required