J A M E S B. HUNT. JR GOVERNOR

STATE OF NORTH CAROLINA

DEPARTMENT OF TRANSPORTATION DIVISION OF HIGHWAYS

P.0. BOX 25201. RALEIGH. N.C. 27611-5201

S l u l HUNT SECRETARY

March 17,1993

Memorandum To:, Mr. W. G. Marley, Jr., P. E. State Highway Administrator

From: Melissa Whitmill <& Resource Conservatio Engineer Value Management Section - Design Services Unit

Subject: Status Report on Division of Highways Recycling and Solid Waste Management Efforts

The following represents a summary of the recycling and solid waste management efforts accomplished by various units within the Division since January 1991. Supporting documentation for this report and cost information is attached for your reference.

I. Pilot Projects:

A. Six roadway projects let in 1991 and 1992 will have utilized approximately 117.21 1 waste tires in the hot mix asphalt pavement.

An Orange County project let in February 1991 incorporated 10 unique recycled products or methods, including 20,100 chipped waste tires for embankment material and 2,500 waste truck tires for a retaining wall. Recycledlrecyclable plastic fence, fence posts, traffic barricades, and delineators were used and the project clearing and grubbing debris was chipped and used for mulch.

B.

C. A Mecklenburg County project let November 1992 will contain recycled plastic fence posts and delineators, and 231,482 chipped waste tires for embankment fill. Crushed glass will be utilized as a subdrain aggregate to construct a blind drain. Also, an advanced alkaline stabilized sludge material will be used in lieu of agricultural limestone for adjustment of soil pH, The first NCDOT use of plastic pipe made with recycled polyethylene resins will be included in this project.

MI. Marley March 17, 1993

D. The Highway Design Branch has identified 9 projects to be let before December 1993 as potential recycling projects. The Design Services Unit is currently investigating the feasibility of incorporating waste materials into these projects.

We will be using chipped tires and lightweight aggregate to raise the roadway grade over an existing culvert which will allow us to retain the culvert. The culvert would have had to been removed and rebuilt if earth was used to raise the grade.

Preconstruction and Operations jointly developed a special provision to reward contractors for suggesting innovative ideas for using solid waste materials in highway construction. The special provision is being used on a limited number of projects.

A recycling pilot program was initiated in 1991 in 6 rest areas for the collection of glass, newspapers, plastic soda containers, and aluminum cans. A summary report of the effectiveness of this program is attached.

E.

F.

G.

11. Municipal, Industrial, and Agricultural Solid Waste Usage

A. We are continuing to investigate the practicality of using waste glass material that is a product of the manufacture of Christmas ornaments in Gastonia. We are also continuing to investigate the feasibility of using approximately 70,000 cubic yards of material wasted from the manufacture of ceramic tiles and currently stockpiled in Lexington. Additionally, we are investigating the feasibility of using waste tile material which is generated at the rate of 75 tons per week, and used foundry sand. We areinvestigating the possibility of using settling pond fines which are generated from the production of crushed aggregate.

Approximately 3,300 tons (5,000 cubic yards) of composted turkey litter and horse litter were used in 1991 in wildflower beds. Approximately 6,700 cubic yards of composted turkey litter was used in 1992.

We are examining the feasibility of using yard waste, wood ash, sewage sludge, and municipal solid waste for landscaping applications. In 1992 we used 50 tons of wood ash and 60 tons of lime stabilized sewage sludge. In 1992 we used 800 cubic yards of leaf compost, 200 cubic yards of leaf mulch and 300 cubic yards of yard waste for mulch cover.

We are continuing the use of fly ash as a replacement for a portion of the cement used in most classes of concrete. Fly ash has been mixed with

B.

C.

D.

2

h

Mr. Marley March 17, 1993

existing roadway base material to create a new base for a few secondary roads in Robeson County. A research report was completed on the usage of fly ash mixed with a lime to create a pavement subgrade for an experimental project in Jackson County. The results were favorable and fkrther evaluation was recommended. Fly ash is proposed to be used as embankment fill material for the Elizabethtown By-Pass.

Used 2,500 cubic yards of wood chips from clearing and grubbing debris generated from Hurricane Hugo waste. In July 1992 used 1,000 cubic yards of Hugo debris as mulch for roadside plantings.

E.

111. Research and Field Testing of Recycled Products

A. Picnic tables, trash receptacles, and parking bumpers made of recycled plastic were placed at rest areas throughout the State in 1991 and 1992

Shredded newspapers were tested for use as mulchhacking agent in 1991 and 1992. Poor results were reported.

The New Products Evaluation Committee continues to evaluate innovative products made with solid waste materials for highway construction applications.

We will be testing the usage of fibers from recycled tires in cold mix asphalt for maintenance applications. We are also investigating the practicality of recycling the aggregate from old concrete into new concrete.

B.

C.

D.

IV. Conventional Recycling in Highway Projects

A. We are continuing to use reclaimed asphalt pavement which is allowed to comprise up to 60% of the total material used in a hot mix asphalt design. Historically, approximately 25% of asphalt produced in the state contains reclaimed asphalt pavement.

Approximately 126,000 tons of existing concrete pavement will be rubblized and reused as base material for new pavement in Northampton and Wake Counties in 1992 and 1993.

B.

C. Crack and Seat methods allowed the reuse of 50,000 cubic yards of existing concrete for new pavement base in 1992.

3

MI. Marley March 17, 1993

D. 8,633 cubic yards of bark products and 841,640 bales of straw and hay were used in 1991 for landscape applications. In 1992 we used 11,000 cubic yards of bark and 441,884 bales of straw and hay.

V. In-house Solid Waste Management Programs

A.

B.

C.

D.

E.

F.

G.

H.

Most worn tires are recapped or sold to commercial businesses for recapping, tire derived &el, or making crumb rubber which can be used in hot mix asphalt.

Volatile fluids to clean equipment are rehrbished by contractors and reused.

Much of our used motor oil is sold to oil recyclers. A small percentage of the waste is used to fuel state asphalt plants or shop heating systems.

Used antifreeze is being directly reused in radiators by mixing it with fresh antifreeze. It is also used in earth moving equipment tires as ballast.

Used batteries are sold by closed bid to battery recyclers.

Recycling of prime paper and aluminum beverage containers is on-going in many of our ofice buildings. A study is presently in progress investigating the possibility of recycling other types of waste paper including blue line, fax, CADD, etc., within the Century Center and Highway Building.

All Divisions recycled 100% of their pesticide containers (total of 7,005) during 1992.

Plans to implement a corrugated cardboard collection program before July 1993 are presently being developed for the Century Center Complex, Highway Building, Division of Motor Vehicles, and State agencies located on Blue Ridge Road.

VI. Personnel Commitments

A. The position of Resource Conservation Engineer in the Design Services Unit was established and filled in September 1992. The primary purpose of this position is to facilitate the incorporation of recycled and solid waste materials into highway construction projects. The position also facilitates the reviews needed to ensure that environmental and material performance

4

MI. Marley March 17,1993

criteria are satisfactorily addressed in accordance with present legislation, environmental laws, and Department design guidelines and policy.

The Resource Conservation Engineer is currently assisting on the Exhibitor Committee of the North Carolina Recycling Association (NCRA) which will be hosting its annual recycling conference and exhibition in the Research Triangle Park in March 1993.

The Recycled Products and Solid Waste Utilization Task Force was established in the fall of 1992 for the purpose of recommending goals for the use of recycled and solid waste materials with an emphasis on developing markets for such materials. Three other Task Forces presently exist:

B.

C.

1. Solid Waste Management Task Force 2. Waste Tires in Pavements Task Force 3. Interagency Task Force on Recycling

The Value Management Section of the Division of Highways is working with General Services to investigate and initiate the use of energy efficient systems for operating Department buildings and equipment.

D.

Please do not hesitate to contact me in the Value Management Section of the Design Services Unit at 250-4128 if you require additional information on this subject.

Attachments

cc: Secretary Sam Hunt Deputy Secretary Garland B. Garrett, Jr. Mr. J. T. Peacock, Jr., P.E. Mr. D. W. Bailey, P.E. Mr. D. R. Morton, P.E. Mr. B. G. Jenkins, Jr., P.E. Mr. W. D. Campbell, P.E. Mr. R. W. Reaves, P.E. Mr. W. K. Creech, P.E. Mr. W. R. Brown, P.E. Mr. S . M. Manilla, P.E. Mr. Mike Stanley, P.E. Mr. W. D. Johnson Mr. Drew Harbinson Mr. John Burns, Jr.

5

PILOT PROJECTS

COST SUMMARY for USING RECYCLED MATERIALS Jan. 1991 to Dee 1992

MATERIAL OUANTITY COSTS or SAVINGS

(monitoring water quality) $19,700 cost* Chipped Scrap Tires 25 1,528 tires $50,4 13 cost

Crumb Rubber Scrap Tires 117,211 tires (health & air quality testing)

$416,967 cost $250,000 cost

Whole Truck Tires 2,500 tires $200,230 savings

Chipped Clearing & Grubbing 14.1 acres $274,208 cost

Plastic Barricades 400 linear feet $1,176 cost

Plastic Delineators 168 delineators $1,676 savings

Plastic Fence Posts 904 posts $25,590 cost

Crushed Glass 95 cubic yards $480 savings

*The Division of Environmental Management of the D E W will not require the monitoring of chipped tires within an embankment forfurwe highway projects contingent upon long term results of present monitoring systems in Orange and Mecklenburg counties.

COST COMPARISON CONVENTIONAL ITEMS vs. RECYCLED ITEMS for ORANGE COUNTY PILOT PROJECT

CONVENTIONAL: RECYCLED:

ITEM DESCRIPTION UNIT BID I$)* ITEM DESCRIPTION Clearine & Grubbine 7.094.46LS-ACR C h i n e & Grubbine -

( ~ u m or Dump Debris j Mulching M e r Planting 47.8VCY

Bomw Excavation 3.29XY

Concrete or Brick Masonry 300.00/CY Retaining Wall

Bituminous Concrete Base Course 20.00flON (BCBC) TypeHB

Bituminous Concrete Binder 19.50rrON Course (BCBC) Type HDB

4" Timber Fence Posts, 7'6" long 13.34 EA 5" Timber Fence Posts, 8'4" long 26.99 EA

Roadway Delineators 21.00 EA

Type 111 Barricades 12.06 LF

Traffiic Signal Heads 155.00 EA

I~

(Wood chi;) Mulching M e r Planting**

Chipped Tire Material***

Tire Retaining Wall

Rubber Filled BCBC****

Rubber FiIIed BCBC****

W Mould)

Type HB

Type HDB

Plastic Fence Posts, 7'4" long Plastic Fence Posts, 8'4" long

Flexible Roadway Delineators

Tvce 111 Barricades (Plastic

UNIT BID 6) 80,OOOLS-ACR

50.00/CY

20.001cY

123.43/CY

30.00/TON

32.00flON

35.00 EA 100.00 EA

4.00 EA

15.00 LF

UNIT COST DIFF. % +IO28

+5

+508

-59

+SO

if54

+I62 +270

-8 1

+24 ,r

Support Members Only) Refurbished Traffic Signat Heads 75.00 EA -52

TOTAL ADDITIONAL COST AND % INCREASE TO PROTECT = +0.7%

*Based on 1990 average bid prices except the HB and HDB are Orange County bid prices. **The leaf mould was donated by the Town of carrboro. Thus, the unit bid was for application only. ***20,100 tires were used at a cost of $.43/tire. (NOTE: Borrow Excavation incurs a 2W? shrinkage factor in its calculations). ****7.600 tires were used at a cost of $3.45/tire.

TOTAL COST OTY. DIFF. 3 ACRS +218,716.62

5 CY +10.95

434.4 CY +6,972.99

1,134 CY -200,230.38

1,420 TONS +14,200.00

860 TONS +10,750.00

45 EA +974.70 9 EA 657.09

128 EA -2,176.00

400 LF +1,176.00

33 EA -2,640.00

+ $48,411.97

Orange County Pilot Project

Federal Aid Project F-100-l(8) State Construction Project 8.1500605 (U-2003AA)

Resident Engineer - Mr. Jim Parker, Durham 560-6857 (Mr. Wally Bowman was Resident Engineer during initial stages of project. He is presently working in the Raleigh office at 733-9499).

Project was awarded to English Construction Co., Inc., of Altavista, Virginia Total estimated cost difference to incorporate recycled materials was $48,411.97 which increased the cost ofthe project only 0.7%.

Let February 1991 to construct the widening of a two-lane segment of NC 54 in Orange County to a four-lane divided highway for a distance of 2.182 miles. This project incorporated the following ten recycled and /or recyclable products:

Recvcled Plastic Products: 128 roadway flexible delineator posts made from recyclable/recycled plastic at a cost of $4.00 each. 400 Linear Feet of Type 111 Barricades (traffic control devices) at a cost of $15.00 per linear foot. The uprights and skids, which are the support members of the barricade, were constructed from recyclable/recycled polyvinyl chloride (PVC). 600 foot section will utilize plastic line and pull posts with braces which required :

45 plastic fence posts 7'-6" long at a cost of $35.00 each and 9 plastic fence posts 4'-1/2" long at a cost of $100.00 each.

72 foot long plastic rail fence (lump sum cost of $6,000) which consisted of the following:

10 plastic posts 10 finish boards 27 plastic rails

Recvcled Waste Tires: 434.4 cubic yards of shredded waste fires, approximately 20,100 waste tires, were incorporated into a section of the embankment at a cost of $20 per cubic yard and approximately $0.43 per tire. 2,500 - 42" waste truck tires were used to construct a 2,915.9 square foot tire retaining wall (maximum height of 12') at a cost of $48 per square foot and $55.99 per tire andconcrete. 2,280 tons or 7,600 waste scrap tires will be mixed with the concrete base and binder courses as a crumb rubber modifier scheduled to be constructed in the spring 1993. This application added $26,200 to the cost of the project or 58%. The estimated average cost is $3 1 per ton of crumb rubber and $3.45 per tire.

Recvcled Usage's for Mulch: Clearing and grubbing debris was chipped for temporaly mulch for erosion control to be used on 3 acres. Another 80 cubic yards of chipped material was supplied to the Town of Carrboro. The high cost to shred the material, $80,000 per acre, was probably due to the contractor's inexperience with this method of clearing and grubbing. Leaf mould, donated by the Town of Carroboro, was used on 5 cubic yards for mulching after planting at an application cost of $50 per cubic yard.

Rehrbished Materials:

Flv Ash:

33 traffic signal heads at a cost of $75 each were refurbished

Up to 20% fly ash shall be substituted for a portion of the portland cement in most classes of the concrete.

r

COST COMPARISON: CONVENTIONAL ITEMS vs. RECYCLED ITEMS for MECKLENBURG COUNTY RECYCLING PROJECT

CONVENTIONAL: RECYCLED:

ITEM DESCRBTION UNIT BID ($I* ITEM DESCRIPTION UNITBID@ DIFFO/.. o n . JFJ UNIT COST TOTAL COST

Clearing & Grubbing 5,811.55LS-ACR Clearing & Grubbing 10,810.81LS-ACR +86 11.1 ACRS +55,491.79 (Burn of Dump Debris) (Wood Chips)

Borrow Excavation 2.76/CY

Subdrain Fine Aggregate 20.05/CY

4" Outlet Pipe 3.41LF 4" Shoulder Drain Pipe .85LF

4" Timber Fence Posts, 7'4" long 12.60 EA 5" Timber Fence Posts, 8'4" long 25.29 EA

7' Delineator Posts 15.00 EA

Agricultural Limestone***

Chipped Tire Material**

Crushed Glass Subdrain Aggregate

4" outlet Pipe - Recycled PE 4" Shoulder Drain Pipe -

Recycled PE

Plastic Fence Posts, 7'4" long Plastic Fence Posts, 8'4" long

Flexposts

Advanced Alkaline Stabilized Sludge (AASS)

12.00/CY +335 5000 CY +43,440.00

15.00/CY -25 95 CY -479.75

5.001LF +47 340 LF C540.60 1.00iLF +18 4020 LF W3.00

30.00 EA +138 690 EA +12,006.00 100.00 EA +295 160 EA +11,953.60

40.00 EA +167 20 EA +500.00

***

TOTAL ADDITIONAL COST AND % INCREASE TO PROJECT = +4.2% +$124,055.24

*Based on 1992 average bid prices. ** 231,428 tires were used at a cost of $.26/tire. (NOTE: Borrow excavation incurs a 20% shrinkage faclor in its calculations). ***The costs of these items arc usually included in the cost of Seeding & Mulching. AASS for this project was donated by McAlpine Wastewater Treatment Facility. It is expected that continued usage of AASS will result in $IO.OO/acre reduction in costs for this bid item.

Mecklenburg County Recycling Project

State Construction Project 8.U670119 (R-21 IDF) Federal Aid Project NHF-I 17-l(27) Resident Engineer - Mr. Bill Strickland (704) 289-1330 Project was awarded to Blythe Industries, Inc., of Charlotte, NC The total bid for the project was 2.9 million dollars which was 1.1% below the engineer's estimate. Total estimated cost difference to incorporate recycled materials was $124,055.24 which increased the cost ofthe project only 4.2%.

The project was let November 1992 to construct a portion of the Charlotte Outer Loop (1-485) from East of McAlpine Creek to West of Elm Lane for a distance of less than one mile. The following solid waste and recycled materials will be incorporated into this second highway construction-recycling project:

Recvcled Plastic Products: 20 roadway flexible delineator posts at a cost of $40 each. 690 plastic line fence posts 7'-6" long at a cost of $30 each and 160 plastic corner or pull posts 8'-0" long at a cost of $100 each will be used for a woven wire control access fencing rather than timber posts.

Recvcled Waste Tires: 5,000 cubic yards, approximately 231,428 waste tires will be chipped and placed into a section of the embankment at a cost of $12 per cubic yard or only $0.26 per tire.

Recvcled Usage's for Mulch: 1 1.1 acres of Clearing and Grubbing debris will be chipped and used for temporary and permanent mulch in lieu of grain straw on approximately 40 acres at a cost of $120,000 lump sum ,

Advanced Alkaline Stabilized Sludge: 0 34 acres, at a rate of 4000 pounds per acre, will utilize an advanced alkaline

stabilized sludge material in lieu of agricultural limestone to adjust the soil pH before planting. This material will be supplied by McAlpine Wastewater Treatment Facility - contact Mr. Bill Yetman, Engineer at Charlotte- Mecklenburg Utility Department.

Crushed Glass Subdrain Aggregate: 95 cubic yards of crushed waste glass wrapped in an engineering fabric shall be used to construct a blind drain along the centerline of the median (1 100 linear feet) at a cost of $15 per cubic yard.

Flv Ash: Up to 20% fly ash shall be substituted for a portion of the portland cement in most classes of the concrete.

Corrugated Plastic Pipe and Fittings: The pipe and fittings shall be made of recycled PE compounds:

4,020 linear feet of 4" shoulder drain pipe at a cost of $1.00 per linear foot 340 linear feet of4" outlet pipe at a cost of $5.00 per linear foot

NCDOT CRUMB RUBBER MODIFIER PROJECTS

COST $COST INCREASE NUMBER OF COST PER COUNTY LET DATE PER TON OVER C O W . MIX TIRES TIRE

Johnston Jan 1991 $33.08 (1) $15,280 (56%) 7,091 $2.15

Yancey Mar 1991 $36.04 (1) $3 1,224 (37%) 11,876 $2.63

Orange Feb 1991 $31.00 $26,200 (58%) 7,600 $3.45

Buncombe July 1992 $71.30 (2) $2,172,424 ( 1 1 OYo) 140,600 $15.45

Rockingham July 1992 $54.40 (2) $1,529,359 (1 37%) 170,000 $9.00

Rockingham Sept 1992 $55.69 (3) $268,499 (129%) 40,644 $6.61

Guilford Nov 1992 $27.12 $57,051 (23%) 37,500 $1.52

Polk Dec 1992 $26.54 $18,713 (23%) 12,500 $1.50

(1) Projects are showing early distress (2) Bids were rejected (3) Project will include Air Quality Testing

NOTE: Total Number of Tires Utilized in Projects Let to Contract = 117,211

Crumb Rubber Modifier Projects

Two asphalt rubber demonstration projects utilizing the dry method were constructed during the summer of 1991: Johnston County 7.31 11 109 -Division Resurfacing Pro-iect:

0 Let January 1991 Contract awarded to Barnhill Construction Co., Fayetteville, NC Resident Engineer - John Naylor, (919) 592-6316, Division 3 - Clinton 2% crumb rubber was utilized in the standard 1-2 mix 7,091 tires were used to produce 1,934 tons of crumb rubber - dryprocess $2.15/tire and $33.08/ton of crumb rubber Cost increase of $15,280 to the project or 56%

Yancev County 7.881 11 14 - Division Resurfacing Pro-iect: Let March 1991

During the summer of 1992, approximately one year after construction, the

Contract awarded to Brown Brothers Construction Co., Zionville, NC Resident Engineer - Max Phillips, (704) 298-0080, Division 13 - Asheville 2% crumb rubber was utilized in the standard 1-1 mix 11,876 tires were used to produce 3,329 tons of crumb rubber - dryprocess $2.63/tire and $36.04/ton of crumb rubber Cost increase of $3 1,224 to the project or 37%

performance of these pavements were studied. The results indicated a "great deal of raveling" distresses.

As a result of Senate Bill 11 1, the Department selected a highway widening project in Orange County to incorporate ten unique solid waste and recycled materials One of those recycled items included utilizing waste tires as a crumb rubber modifier Orange Countv U-2003AA:

Let February 1991 Contract awarded to English Construction Co., Inc., of Altavista, VA Resident Engineer - Jim Parker, (919) 560-6857, Division 5 - Durham 2% crumb mbber will be used in each the base and binder courses. Due to the distresses noted in the previous two crumb rubber projects, the crumb rubber will not be mixed with the surface course as was originally specified during the letting of the project. 7,600 tires will be used to produce 2,280 tons crumb rubber - dryprocess $3.45/tire and $31.00/ton of crumb rubber Cost increase of $26,200 to the project or 58%

As a result of the Intermodal Surface Transportation Efficiency Act (ISTEA) of 1991, the Pavement Management Unit selected two additional projects to utilize crumb rubber in the asphalt mix: Buncombe Countv U-2000:

Bid for $8.4 million was rejected during the July 1992 Letting Cost increase of $2.1 million or 110% to the project 140,600 tires to produce 56,500 tons crumb rubber - wetprocess $15.45/tire and $71.30/ton crumb rubber (NOTE: High cost) Re-let September 1992 for $5.6 million removing the usage of crumb rubber

Rockingham . Countv R-2401BA:

. Bid for $3.7 million was rejected during the July 1992 Letting Cost increase of $1.5 million or 137% to the project 170,000 tires to produce 62,650 tons crumb rubber - wetprocess $9.OO/tire and $54.40/ton crumb rubber (NOTE: High cost) Re-let September 1992 for $2.5 million (still over Engineer's Estimate at

Contract awarded to Thompson-Arthur Construction Co., Greensboro, NC Resident Engineer - Alan Hill, (919) 634-5635, Division 7 - Reidsville 40,644 tires will be used to produce 13,000 tons crumb rubber - wetprocess $6.61/tire and $55.69/ton ofcrumb rubber Cost increase of $268,499 to the project or 129% First project to include Air Qualily Testirig to be conducted by TRIGON, a Greensboro consultant. This testing is scheduled to begin after March 1993.

The following are a list of projects selected to date (January 1993) to incorporate crumb rubber into the asphalt or related modifier: Guilford Countv R-609D:

7.3%)

Let November 1992 Contract awarded to Thompson-Arthur Construction Co., Greensboro, NC Resident Engineer - Tracy Conrad, (919) 761-2220, Div 9 - Winston-Salem 37,500 tires will be used to produce 11,250 tons crumb rubber - dryprocess $1.52/tire and $27.12/ton ofcrumb rubber Cost increase of $57.05 1 to the project or 23%

Polk Countv R-099BD: Let December 1992 Contract awarded to BoggsNaughn Construction Co., Monroe, NC Resident Engineer - Jamie Wilson, (704) 891-5367, Div. 14 - Horseshoe, NC 12,500 tires will be used to produce 3,750 tons crumb rubber - dryprocess $1.50/tire and $26.54/ton of crumb rubber Cost increase of $18,713 to the project or 23%

Pitt Countv R-1022E: Letting Date of April 1993 Research project on US 264 which will consist of seven test sections: 1. Control section 2. Stone Mastic Asphalt (SMA) with fiber 3. SMA with polymer 4. Dense-graded mix with polymer 5. Large stone mix 6. Crumb rubber asphalt mix 7. Dense-graded mix with carbon black

Recycled Products or Waste Materials Provision

"This provision provides an incentive to the Contractor to initiate, develop, and present to the Department of Transportation for consideration any proposal conceived by him involving changes in drawings, designs, specifications, or other requirements of the contract for the purpose of incorporating targeted recycled or waste products into the construction of the project."

"The targeted materials include but are not limited to the following: Plastic Recycled Plastic Glass Paper Cardboard Tires Fly Ash Bottom Ash Debris from:

Clearing and Grubbing Structure Demolition Pavement Removal Activities"

Contractors who successfully submit an idea to use these materials are rewarded in the following manner:

100% ofthe net savings (but not less than $1,000) shall be awarded to the Contractor if 100% of the Department's originally proposed material is replaced by any of the targeted materials which would otherwise be placed in the North Carolina waste stream.

From 50% to 100% of the net savings (but not less than $500) shall be awarded to the Contractor if less than 100% of the Department's originally proposed material is replaced by any of the targeted materials which would otherwise be placed in the North Carolina waste stream.

A minimum of $500 (but not less than $2,500) shall be awarded to the Contractor if the proposal results in a net increase in the project cost but is judged to have a significant effect on the development of long term markets for the targeted materials; or results in significant beneficial usage of project generated debris which would have otherwise been disposed of in accordance with Section 802 of the Standard Specifications. The Department will bear the increased costs, if any.

The following three highway projects have included this provision:

R-21 IDF Construction of Charlotte Outer Loop from East ofMcAlpine Creek to West of Elm Lane. Let November 1992. Project awarded to Blythe Industries, Inc., of Charlotte, NC.

U-2108C, U-2108D, and B-2173 Widening of 1-440 from East of Wake Forest Road to East of US 64 in Raleigh. Let December 1992. Project was awarded to W. C. English Construction Co., of Altavista, VA.

R-2000BE Construction of Northern Wake Expressway from .I5 mile NE of Lumley Road to .24 mile NE of US 70. Let January 1993. Project was awarded to Blythe Industries, Inc., of Charlotte, NC.

JAMES G. MARTIN GOVERNOR

THOMAS J. HARRELSON SECRETARY

MEMORANDUM TO:

FROM :

SUBJECT :

STATE OF NORTH C A R O L I ' q - DEPARTMENT OF TRANSPORTAT& -

se t -_ RALEIGH 27611-5201 +,? -

__ P 0 BOX 25201

November 3 . 1992 .I- , , . .,,. .. .... -

1,:: ., '.'. DIVISION - >.:,:1:-.-.-..1 OF HIGHWAYS iiviri

C'!..? ._._._--": WILL:AM G. MARLEY, JR.. P E.

STATE HlGHWAY ADMINISTRATOR

E. D. WALKER ASSISTANT TO STATE HIGHWAY ADMINISTRATOR

ASSISTANT STATE MATE La S ENGINEER C . L. JONES, P. E.

Recycled Products Currently Under Study

b-L3

In our Recycled Products and Solid Waste Utilization Task Force Meeting I stated that we were currently working with several industries concerning the potential use of industrial by-products within the highway system. These items which are currently being explored are described below.

1. Mannington Ceramic Tile: We have been meeting since June, 1991, to consider the potential use of approximately 70,000 cubic yards of waste material from their manufacturing process which has been stockpiled f o r many years. This material contains some lead which was used in some of their glazes in the past and has therefore been classified as a hazardous waste. Mannington has performed extensive studies of this problem and is proposing to treat this material to render it nun-hazardous, crush it to a desirable size and deliver it to a project site f o r incorporation into a highway embankment, above the water table. We have coordinated with various environmental agencies, the Geotechnical Unit and the Design Services Unit and the material is acceptable from an engineering point of view if it can be successfully made non-hazardous. A treatability study has been presented by Mannington and is currently under review by the Department of Environment, Health and Natural Resources. If this study is accepted, then the Department of Transportation must determine if it is going to accept treated hazardous waste from industrial sources and obtain legal assistance in addressing the future potential liability if it is accepted.

An Equal Opporlunllyl~!llrmali . ie Action Employer

- 2 -

E. D. Walker- November 3 , 1992

2. Mannington Ceramic Tile: We are currently evaluating potential uses for their current waste products which are non-hazardous and is currently being disposed of in a landfill. This material consists of broken, fired and unfired tile which could be crushed to a size deemed desirable by the Department. A continuous supply of this material would be available with approximately 7 5 tons being generated each week.

3 . Rauch Industries: Approximately 10 tons of glass per week is being generated from the production of Christmas ornaments at this plant in Gastonia. A potential use for this material has been identified provided it is hammer-milled to a specified size. The environmental aspects of the use of this material are currently being evaluated by the Solid Waste Section of DEHNR.

4. Foundry Service Company: We have met with this company to discuss the use of foundry sand by the Department. We are currently waiting for them to provide laboratory data about the environmental properties of this material.

5. Plastic Pipe Industry: We have approached manufacturers of plastic pipe about the use of recycled PE resins in the production of pipe. Current AASHTO specifications do not allow the use of recycled plastics but we have initiated the revision of this specification and have begun testing of recycled plastics to determine its long term durability. The use of recycled plastic is required on one project in the November letting. I currently serve on an AASHTO Task Force to investigate this issue.

6. Holly Farms Poultry Industries, Inc.: We just received a sample of Feed Grade Poultry Fat for use as a truck release agent for bituminous asphalt. We are currently testing its effectiveness and potential environmental hazards.

7 . N. C. Aggregates Association: We are currently working with the aggregates industry in seeking potential uses for the settling pond fines which are a waste from the production of crushed aggregates. A potential usage has been identified based upon testing from one source. No environmental data has been submitted to date. A substantial volume of this material exists at quarries throughout the state.

The items listed above are currently being evaluated by this Unit and are in addition to the varied uses of tires (in pavements, embankments and walls), plastic lumber and pozzolins (flyash, ground granulated blast furnace slag, silica fume, etc.).

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E. D. Walker- November 3 , 1992

A s I stated in our meeting, I believe we are at the point where the Department must decide if we are going to accept treated materials which have previously been considered hazardous wastes for u s e in the highway system. If the answer is yes, then the legal staff should be involved to address how best to protect the Department from future potential liability problems. I also strongly recommend the rapid development of a tracking system to physically identify where all such materials have been used. This system should be readily accessible throughout the Department to assist in monitoring the effectiveness of recycled products and assist the field forces in the future when maintenance is required.

I look forward to serving on this task force and believe that it will serve as the focal point for the Department's recycling and solid waste utilization efforts. Please let me know if you have questions concerning any of the above items.

CLJ/mk

CC: B. G. Jenkins, Jr., P. E

c . \r NORTH CAROLINA

1 DEPARTMENT OF TRANSPORTATION

Ro ads i de Environmental

Unit

Recycling Summary 1992

North Carolina Department of Transportation

Environmental Services Section Recycled Materials Data

OPERATIONS

1.

2.

3.

4.

5 .

Pesticide Containers: Recycled 540 containers during 1991 (one REU Division). During 1992 all Divisions recycled 100% of their containers,

June 1992 - 1855 conisiners recycled (1260 pounds)

(4350 containers) November 1992 - Second collection planned

In addition approximately 800 containers have been recycled via county programs in 1992.

Total containers for 1992 = 7005 - All containers were HDPE #2 containers. They were recycled into slotted drain pipe.

Shredded Newspaper: Tested during 1991 and 1992 as mulchhacking agent. Poor results with seed germination and as tacking agent - difficult to apply and direct to specific site using present equipment.

Wood Chips: Used 2500 cyd of Hugo waste during 1991. Testing use of shredded hardwoods (stumps, limbs, etc.) in maintenance operations. 1000 cyd Hugo waste used in July 1992, as mulch in roadside ornamental plantings.

Yard Waste: Have physical test analysis from several municipalities. Results good as plant bed mulch. Very poor results when incorporated due to C-N ratio. In 1992 several Divisions used this material with expanded use anticipated. Leaf compost for black creek clay 800 cyd. Leaf mulch for planting project 200 cyd. Yard waste (limbs, etc.) for planting project 300 cyd as a mulch cover.

Composed Turkev Litter: Used approximately 5000 cyd (2000 tons) in wildflower beds during 1991. Great results, especially in poorer sandy coastal soils. Used 1200 cyd in Division 4, April 1992 on Black Creek Clay Vegetation establishment. Used approximately 300 cyd in Division 6, September 1992 on Black Creek Clay Vegetation establishment. Used approximately 5200 cyd in wildflower bed establishment in 1992 as soil amendment.

6. Composed Horse Litter: Used approximately 1300 tons during 1991 in wildflower beds.

\

1992 Planting projects: 1000 cyd used as mulch in ornamental planting projects.

7. Bark Products: in 1992 we used Hardwood 3,287 cyd Pine 5,346 cyd

1992 usage has increased and final figures will be available in December.

8 . Straw and Hay: 1Y91 usage 1992 usaee Pine straw 35,849 bales 1,498 bales Grain straw 794,721 bales 419,386 bales Coastal bermuda hay 11,066 bales 21,000 bales

9. Other Materials: Wood ash, lime stabilized sewage sludge, and Municipal Solid Waste (MSW) (End product of major household garbage recycling) show promise for potential use. Utilization in research plots is continuing and is based on DEM permits.

1992 usage: Wood Ash 50 tons Lime Stabilized Sewage Sludge 60 tons

Wood Ash and Lime Stabilized Sewage Sludge show potential as substitutes for limestone where pH adjustment are required for proper plant growth.

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CONSTRUCTION

1. PROCESSED - RECYCLED PAPER AND WOOD (HYDROMULCH)

Used on projects with High Quality Waters, Critical Habitat, and environmentally sensirive areas.

Applied on approximately 100 acres at a rate of 750 Ibs. per acre in 1992.

2. PROJECT 8.1500605 U-2003AA ORANGECOUNTY

@ Special Recycled Plastic Post and Rail Fence:

The fence was 72 ft. long and consisted of 10 post, 10 finish boards and 27 rails.

@ Clearing and Grubbing Debris for Temporary Mulch:

Chipped material was used as temporary mulch on 4.5 acres.

Approximately 80 cubic yards of chipped material was provided to the Town of Carborro.

.

Composted Leaf Mulch for Plants:

Composted leaf mulch, supplied by the Town of Carborro, was utilized as mulch on plant beds (no specific quantity).

3. PROJECT 8.U670119 R-211DF MECKL.ENBURG COUNTY

Advanced Alkaline Stabilized Sludge Used in Lieu of Agricultural Limestone:

Application on 34 acres at a rate of 4000 lbs. per acre.

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0 Shredded Clearing and Grubbing Debris for Temporary and Permanent Mulch in Lieu of Grain Straw:

Application on approximately 40 acres.

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1.

2.

3.

4.

North Cerolina Department of Transportation

Rest Area Section Recycled Materials Data

Picnic Tables: Made of recycled materials. During 1991 and 1992 a total of 9) recycled material picnic tables were purchased for use in rest areas and as roadside picnic tables. They were purchased from 3 different companies, with two different manufacturing methods used. At the present, they are all holding up well, but we are continuing to monitor their weathering characteristics.

Trash Receptacles: Made of recycled materials. 6 trash receptacles have been purchased in 1992 for use in rest areas and roadside table sites.

Parking Bumpers: Made of recycled materials. 6 parking bumpers were purchased in 1991 for use in rest areas. We have had no problems with them up to this point. 3

Lumber: Made of recycled materials. On our initial order of picnic tables in 1991, we purchased 8 - 2" x 6" x 8' timbers for use as replacements for the picnic table benches, should that be necessary. f

All the recycled materials above mentioned are continually being monitored in order to judge their cost effectiveness verses their durability. We have high expectations as to the future for these materials and look forward to more diversity in available products.

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7

North Carolina Department of Transportation

Rest Area Recycling Pilot Program

In accordance with House Bill 746, Section I, the North Carolina Department of Transportation has enacted a Rest Area Recycling Pilot Program at six rest area sites across the state. Essential'y 3 different collection methods are used, in order ta determine which method is best suited for Rest Area Recycling. The methods consist of (a.) 6 small individual containers for collection, (b.) 1 medium sized (2.8 cubic yard) container with 6 bins, and (c.) 1 large (20 cubic yard) dumpster type container with 6 bins.

Division personnel check the containers regularly and send a monthly collection report to the Central Roadside Environmental Unit. All materials collected are either taken to the counties recycling collection center or picked up by a private collection company. See the Total Project-To-Date Collection Report for the totals on materials collected.

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North Carolina Oepaltmenl of Transportation

CLEAR 325

150

150 GLASS

Rest Area Recvcling Program

Nash A1aman.E

50 7 176

20 1 64

125 48

Total Project-To-Date Collection Report

NEWS- 742 456 PAPER

0 ' PLASTIC 209 127 14 BEVERAGE

November 1991 - December 1992

573 573

182 31 9

ALUM1 N U M

Emptying Containers

Hours

154 175 ' 551 487

X X X 41.25

Containers Emptying Mileaae i x

I I

X X x "

General

Hours Clean-up

Contract Cost/Pickup

126 2 148 77.5

X $800 $1 ao $0

!

Box Rental per Year

X X $2590 $840

S u rry McDowell TOTAL

41 0 1906 2,650

202 56'1 1,282

207 449 1,099

3,576 1232*

335 502 .1,674

2,606 331 * 908

85.75 44.5 X

X 12 12

451.5 60 38

x $ 1133.i4 $195.00 -41.86 $153.14 It. 1 I

X $1 350 $4780

* Actual poundage recorded when container was emptied in August 1992. All other figures are estimatsd dae to the sizes and types of containers. * Refund check for recycled materials collected.

X = not applicable

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