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Industrial Materials

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Industrial Materials Recycling Projects and Examples of Previous Industrial Materials Recycling Projects and Grants:

General:

Grant: AFS-FIRST, Field Demonstration of Blended Base Recycled Material ($49,545 FY2010) ONGOING

AFS-FIRST will evaluate the performance of a combination of recycled concrete aggregate (RCA) and foundry sand in roadway base. A test section would be added to a local road construction project in Ohio. Field data is needed to confirm the anecdotal information regarding improved performance from two sites in Texas that currently blend the materials. Data will be incorporated into a larger DOT pool-funded RCA research study that will lead to standards and specifications for base courses. A comprehensive case study would be developed and disseminated.

GRANT: Chicago Manufacturing Center (CMC) Develop a Sustainable Growth Network for Regional Implementation of Byproduct Synergy ($40,500 FY 2008) COMPLETED

Working with the State of IL and other interested stakeholders, CMC developed a guide for implementing Waste to Profit-type networks in other areas in Region 5. CMC also worked with stakeholders to develop an approach for regional and collaborative implementation. The Guide and the approach were shared and discussed at a Summer 2009 meeting in Chicago. CMC stopped operations in 2010 and no longer operates the Waste to Profit Network. The Delta Institute has acquired the Waste to Profit Network (see http://www.delta-institute.org/news/delta-acquires-chicagos-waste-profit-network) Exit EPA Disclaimer.

Green Building & Green Highways Efforts ONGOING

Region 5's Solid Waste Program promotes sustainable materials management in construction projects. Regional efforts encompass many aspects of green building, green highways, green infrastructure and sustainable development. Our program's focus is on increasing reuse and recycling within the construction industry by working with stakeholders such as material generators and end-users. For example, the highway/ road construction and building construction sectors have the potential to use significant amounts of industrial byproducts and compost as well as to reuse and recycle considerable debris during construction, renovation, deconstruction and demolition. EPA's WasteWise program offers access to data tracking software, climate benefits calculations, and EPA recognition (http://www.epa.gov/epawaste/partnerships/wastewise/index.htm or contact gevrenov.julie@epa.gov for more information). The Region is also interested in developing case studies on reuse projects. Case studies from WisDOT and IN DOT have been developed and are available upon request.

Green Highways Webinar Series (December 2008 to April 2009)

Region 5 hosted a series of three collaborative and informational webinars focused on bringing innovative, sustainable development concepts to key Region 5 road building stakeholders and seeking their input and agreement on implementing these concepts. The topics for the meetings were an overview of the “Green Highway” Concept, Using Class C and Off-Spec Fly Ashes in Recycled Pavement Stabilization Projects, and Using Foundry Sand in Road Construction. A second webinar series, on Compost Use for Stormwater and Erosion Control, is described in the MSW/Organics section.

GRANT: Chicago Manufacturing Center (CMC) – Establishment of the Chicago Waste-to-Profit Network and Development of an Online Database/Web Site Development ($84,900 FY 2006 (funding provided by Region 5's Great Cities Program); $44,875, FY 2007) COMPLETED

Region 5, along with the City of Chicago and the State of Illinois, supported the establishment of Chicago's Waste to Profit Network . The Network was a byproduct synergy effort, which facilitates the transformation of one company's waste, or byproduct, into an industrial input for another company. The first and second year report is available from EPA. . More than 180,000 tons of waste were diverted from land disposal through the network from 2007 to 2009. This translates to a reduction of more than 127,000 tons of greenhouse gas emissions. The Network had more than 300 members. CMC stopped operation in 2010 and no longer operates the Waste to Profit Network. The Delta Institute has acquired the Waste to Profit Network (see http://www.delta-institute.org/news/delta-acquires-chicagos-waste-profit-network).Exit EPA Disclaimer.

National Beneficial Use of Industrial Materials Summits COMPLETED

Formerly known as the Byproducts Beneficial Use Summits. Region 5 worked with the National Council on Air and Stream Improvements to organize the first Byproduct Beneficial Use Summit in Chicago in August 2002. The purpose of this summit was to bring state regulators, generators, and end users together to discuss the challenges and opportunities for beneficial use of industrial byproducts. Three challenge areas were identified at the first summit: regulatory, market development, and education/communication. Several working groups were established to target ongoing projects. Since then, the Region has helped to plan the annual National Byproducts Beneficial Use Summits in Atlanta (2003), Kansas City (2004), Philadelphia (2005), and San Francisco (2006), and Denver (2008). See http://www.byproductsummit.com/ Exit EPA Disclaimer for agendas and presentations from all previous Summits. Since the Denver conference, industrial materials recycling topics have been incorporated into the national Resource Conservation Challenge Training Workshops in Washington, D.C. See http://www.epa.gov/osw/rcc/resources/meetings/index.htm.

GRANT: National Recycling Coalition ($22,400, FY06) COMPLETED

The Industrial Resources Council, a part of the National Recycling Coalition developed an integrated web site that provides technical and market development information on 6 industrial byproducts: coal combustion products, foundry sand, construction and demolition debris, pulp and paper mill residuals, steel slag, and tires. Information on characteristics of the material, potential end uses, case studies, and environmental safety can be found at http://www.industrialresourcescouncil.org/ Exit EPA Disclaimer.

Education and Outreach to Stakeholders via Workshops and Meetings ONGOING

EPA Region 5 participates in workshops and meetings that address reuse and recycling of non-hazardous industrial materials, including construction and demolition debris, in the region. The purpose of these meetings and workshops is to educate end-users about beneficial uses of industrial byproducts and identify byproduct synergies between material generators, brokers and end-users. Examples include end-user workshops, local-level stakeholder meetings, joint meetings with industry and state environmental agencies, and industry association meetings.

GRANT: Great Lakes Byproduct Management Association (GLBMA) (FY05, $19,500) COMPLETED

GLBMA worked with stakeholders in WI interested in blending of byproducts for soil-based uses to identify obstacles to this end market in Wisconsin. Regulatory, technical and market issues were addressed. This effort built on a previous GLBMA effort in WI (see below). The presentations from a June 2006 meeting are available on the GLBMA website and the final report for this project is available upon request. GLBMA also supported the validation of a previously developed model on blending of byproducts for manufacturing soil. The validation included testing the model on byproducts from Region 5 generators. This work is also summarized in the final report. In addition, a PowerPoint presentation, made at the 2006 Byproducts Summit in San Francisco, can be accessed at: http://www.byproductsummit.com/2006/presentations/Terry_Logan/frame.htm Exit EPA Disclaimer.

GRANT: University of Toledo ($58,356 FY05) COMPLETED

This EPA Innovations Pilot supported the development of a tool for state and local regulators, end users, and the public to evaluate the benefits and impacts of using certain industrial byproducts in transportation applications. The web-based BenReMod tool is available at http://benremod.eng.utoledo.edu/BenReMod/ Exit EPA Disclaimer. The final report for this grant is also available upon request.

GRANT: Great Lakes Byproduct Management Association ($15,000 FY04) COMPLETED

GLBMA received grant funds to evaluate the issues related to blending byproducts and use on soil in 2 states within Region 5. GLBMA held a meeting with a group of stakeholders in WI to identify the current status of blending and use on soil and to identify outstanding challenges. GLBMA also participated in MI's ongoing regulatory development and provided an overview of that state's efforts. The results were reported at GLBMA's annual meeting in December 2004. Final report available upon request.

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Foundry Sand:

GRANT: Ohio State University ($40,770 FY09) ONGOING

The Ohio State University will be working with a foundry and soil blender in Ohio to evaluate the use of foundry sand as a feedstock for manufactured soil. A case study will be developed. In addition, OSU will evaluate the market potential for foundry sand in soil applications in Ohio.

Implementation of the National Foundry Sand Multi-Stakeholder Action Plan. ONGOING

During 2009, Region 5 helped to develop an action plan for increasing the environmentally safe beneficial use of foundry sand. The action plan was developed with the input of many stakeholders. A list of priority actions was created and an implementation steering committee was formed. Region 5 is chairing the steering committee. New fact sheets and case studies are available on the new website at: http://www.afsinc.org/content/view/791/264/ Exit EPA Disclaimer. Outreach opportunities continue to be identified and prioritized by the steering committee.

National Forum on the Use of Foundry Sand in Soil Applications COMPLETED

On July 23, 2008, EPA co-sponsored a forum on the use of foundry sand in soil applications including manufactured soils and bioretention areas. Results of USDA's risk evaluation were shared. The presentations from this workshop are available at: http://www.foundryrecycling.org/NewsEvents/ConferencesEvents/tabid/309/Default.aspx Exit EPA Disclaimer (a no cost registration is required to access the powerpoints).

National Forum on the Use of Foundry Sand in Infrastructure Applications COMPLETED

On October 31, 2007 EPA co-sponsored, along with the Federal Highway Administration, the Recycled Material Resource Center, and Foundry Industry Recycling Starts Today (FIRST), a forum on the use of foundry sand in a variety of transportation applications including hot mix asphalt; controlled low strength material; unbound pavement and geotechnical uses. Environmental evaluation was also addressed. The presentations from this workshop are available at: http://www.foundryrecycling.org/NewsEvents/ConferencesEvents/tabid/309/Default.aspx Exit EPA Disclaimer(no cost registration required).

GRANT: Foundry Industry Recycling Starts Today, Inc. ($13,500 FY03, $7,000 FY05) COMPLETED

FIRST developed presentation modules that follow the structure and topics of the Federal Highway Administration's Foundry Sand Fact Book for highway Engineers (see below). A demonstration of the modules was provided in October 2005 and presentations are available at: http://www.foundryrecycling.org/NewsEvents/ConferencesEvents/2005/MilwuakeePilotWorkshop/tabid/321/Default.aspx Exit EPA Disclaimer (no cost registration required). FIRST also developed case studies for a variety of applications and an on-site system for gathering additional examples. The case studies are available at: http://www.foundryrecycling.org/TechnicalApplications/CaseStudies/tabid/315/Default.aspx Exit EPA Disclaimer(registration required). FIRST also supported the development of an extensive, online, searchable, technical library of documents and research related to foundry sand reuse (see http://www.foundryrecycling.org/TechnicalLibrary/HowtoUsetheLibrary/tabid/269/Default.aspx Exit EPA Disclaimer (no-cost registration required to view abstracts))

United States Department of Agriculture - Agricultural Research Service (USDA-ARS) Foundry Sand Research Review Meeting ONGOING

USDA-ARS has supported a research effort to evaluate the risks and benefits of using foundry sand in soil applications. Region 5 has helped facilitate state environmental agency input into the research effort. Presentations from two research review meetings (2005 and 2007) and a special soils session after the 2006 Byproduct Summit are available on the FIRST website: http://www.foundryrecycling.org/NewsEvents/ConferencesEvents/tabid/309/Default.aspx Exit EPA Disclaimer (no cost registration required). Results from related research efforts can be found at http://environmentalsoils.cas.psu.edu/ Exit EPA Disclaimer. USDA/ARS is working with US EPA to develop a risk assessment for foundry use in soils based on their research findings. A draft risk evaluation was presented at the 2008 Byproduct Summit in Denver, March 31-April 2 (see http://www.byproductsummit.com/2008/2008presentations.html) Exit EPA Disclaimer. The USDA/EPA risk evaluation was peer reviewed in late 2008. A final report is pending.

Foundry Sand Stakeholder Meeting December 1, 2005 COMPLETED

Region 5 helped plan this national stakeholder meeting to develop a strategy to address obstacles to beneficial use of foundry sand. The agenda and presentations from this meeting in Philadelphia can be viewed at the Foundry Industry Recycling Starts Today (FIRST) website (http://www.foundryrecycling.org/NewsEvents/ConferencesEvents/tabid/309/Default.aspx (no cost registration required)).

GRANT: American Foundry Society, (FY 98, 15,531; FY 00, $38,500) COMPLETED

Two separate grants were issued to AFS. The first grant supported the development of a website to house information related to the recycling and reuse of foundry sands. The web site was established and is now maintained by an independent non profit, the Foundry Industry Recycling Starts Today (FIRST). The web site is available at http://www.foundryrecycling.org Exit EPA Disclaimer. The second grant effort was performed by the newly established FIRST organization. The grant supported the development of a Fact Book for Highway Engineers. The Fact Book was developed under the auspices of the Federal Highway Administration and was modeled after FHWA's fact book on the use of fly ash for highway projects. The Fact Book is available on the FHWA website at http://www.fhwa.dot.gov/Pavement/pub_details.cfm?id=55 Exit EPA Disclaimer.

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Coal Combustion Products:

GRANT: Management Guides for Use of FGD Gypsum in Agriculture ($40,500 FY08) COMPLETED

The Ohio State University Research Foundation produced two field guides for the use of flue gas desulphurization (FGD) gypsum (a synthetic gypsum which is a coal combustion product) in agriculture. Gypsum as an Agricultural Amendment: General Use Guidelines discusses agricultural and land application uses of the material, application rates, economic considerations, and handling, sampling, and storage information; it is intended for use by farmers, university extension agents and agricultural consultants. Environmental and Ecological Guidelines to Gypsum Application for Agriculture discusses FGD gypsum composition, how to calculate nutrient and metals loading rates, and the effects of FGD gypsum land application on soil, water, plants, and soil animals; this additional scientific information may be of use to environmental regulators. The reports are available from Julie Gevrenov (gevrenov.julie@epa.gov).

GRANT: Ohio State University Research Foundation ($13,076 FY03) COMPLETED

The purpose of this demonstration project is to better understand the effects of flue gas desulfurization (FGD) materials on soil properties, crop nutrition, and environmental quality. During the course of this work OSU : 1) characterized representative samples of FGD-gypsum prior to land application; 2) evaluated the impact of FGD-gypsum on no-till crop production (corn/soybeans); 3) created a mechanism to measure future soil carbon sequestration as a result of FGD gypsum application and the adoption of no-tillage practices; and 4) developed an OSU extension program that effectively disseminates information to farmers.  This project was part of a much larger research effort funded by several other stakeholders.  The final report and results are available via Dr. Warren Dick at OSU or via Susan Mooney at U.S. EPA .

GRANT: University of Wisconsin - Milwaukee Exit EPA Disclaimer($10,000 FY04) COMPLETED

A workshop was held in Indianapolis on May 24, 2005 on the utilization of coal combustion products. The target audience for this workshop was engineers, area contractors, ready-mix concrete suppliers, and state government. A total of 42 people registered for the workshop.

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C&D Debris:

GRANT: Youngstown Deconstruction Initiative ($39,000 FY09) ONGOING

The Youngstown Deconstruction Initiative grant proposes to explore and develop the process of deconstruction as a viable alternative to traditional demolition methods. Youngstown will develop policies regarding the management of demolition debris in order to divert building materials from landfill, divert demolition waste from landfills through reuse and recycling, reduce neighborhood blight, and create jobs.

GRANT: ‘Where Shingles Meet the Road' Demonstration Project ($49,900 FY09) COMPLETED

Iowa State University researchers completed a study of a demonstration project that utilized 302 tons of recycled asphalt shingles and 2,676 tons of fractionated recycled asphalt pavement in test sections that the Illinois Tollway paved along I-90 in July of 2009. The researchers evaluated the performance of field samples from several base course, binder course, and wearing surface course mix designs that utilized up to 5% recycled post-consumer asphalt shingles and 50% fractionated recycled asphalt pavement. The researchers found that low-temperature cracking is the most critical issue that may occur with the high recycled-content mixes they tested. The report is available upon request (gevrenov.julie@epa.gov).

GRANT: Building Material Reuse Center Initiative ($39,000 FY08) COMPLETED

As part of an innovative economic development project in Chicago with diverse environmental, community, health and job creation benefits, Delta Redevelopment Institute opened the ReBuilding Exchange in February 2009. The goals of this project included reducing the solid waste stream (823 tons construction materials diverted from landfill in 2009); providing high quality, low cost building materials to consumers; creating a financially viable green business; generating new green collar job opportunities for unemployed and underemployed people (47 FTE and 3 PTE created in 2009); and supporting the development and growth of the deconstruction and material reuse industry in the region (performed a market study, proved a business model, and created a replicable program model for other communities). See http://www.rebuildingexchange.org/ieindex.htm Exit EPA Disclaimer.

ASPHALT SHINGLE RECYCLING FORUMS

U.S. EPA, the Construction Materials Recycling Association, Federal Highways Administration and other stakeholders have hosted several Asphalt Shingle Recycling Forums since 1999. Attendees from across the U.S. and Canada include environmental and DOT officials, recyclers, roofing contractors, and shingle manufacturers. The goals of these Forums are to present results from recent studies in this area, to network, and to engage in in-depth discussions on issues in the areas of policy and education, engineering, the environment and worker safety, and economics and markets. See http://www.shinglerecycling.org Exit EPA Disclaimer for information about past and future Forums.

GRANT: A Green Development & Construction Program in Illinois ($45,861, FY06) COMPLETED

The Illinois Sustainable Technology Center at the University of Illinois created a Green Development and Construction website, which provides information and technical assistance on C&D waste management and recycling to Illinois builders. The grantee hosted three seminars in Illinois on construction recycling, identified recycling markets for C&D materials in Illinois, and performed two demonstration projects in Illinois (40.7 tons of construction and demolition materials were diverted through recycling). See http://www.wmrc.uiuc.edu/main_sections/tech_assist/green_development.cfm Exit EPA Disclaimer.

GRANT: Promoting Recycling in the Construction Industry in Michigan $15,470, FY06) COMPLETED

MDEQ promoted environmental stewardship in the construction industry in Michigan by holding town hall type brainstorming meetings to share existing resources, collect information on local recycling resources, and identify barriers to recycling. The grantee then expanded the DEQ's existing "Green Construction and Deconstruction" website (http://www.michigan.gov/deqconstruction) Exit EPA Disclaimer to include resources on construction waste recycling such as fact sheets, case studies, and Michigan regulatory information;local recycling markets for construction and demolition materials; and a guide for developing waste management plans.

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GRANT: WI DNR C&D and Electronic Tracking ($35,000, FY05) COMPLETED

Working with WasteCap Wisconsin, WI DNR proposed to develop a training class for contractors that generate construction debris; develop an outreach mechanism to promote the toolkit to other contractors in the state; and develop and implement on-line tracking systems for both C&D and electronic recycling. The on-line tracking systems will provide a model for voluntary reporting systems. This approach to data collection could be used throughout the region.

GRANT: Construction Materials Recycling Association Tear-Off Asphalt Shingles Recycling ($74,625 Innovations Workgroup Pilot, FY05) COMPLETED

An estimated 11 million tons of waste shingles are generated every year in the United States. The overwhelming majority of them are post-consumer, mostly from tear-offs generated during re-roof construction projects. This pilot addressed barriers to full-scale implementation of tear-off shingle recycling technology, including environmental, engineering, operations, and economic barriers. The CMRA developed Recycling Tear-Off Shingles: Best Practices Guide,Environmental Issues Associated with Asphalt Shingle Recycling, Exit EPA Disclaimerand updated http://www.shinglerecycling.org, which was created under a previous grant from U.S. EPA.  All of these products were presented at the 3rd Asphalt Shingle Recycling Forum Exit EPA Disclaimer (November 1-2, 2007). 

GRANT: WasteCap Wisconsin, ($10,000 FY 04) COMPLETED

WasteCap Wisconsin Exit EPA Disclaimer received a grant from EPA Region 5 to create a C&D Waste Management toolkit. This kit supports WasteCap Wisconsin's C&D outreach activities across the state. Working with several construction firms they developed a short course that will take site managers through all aspects of effectively recycling C&D waste. Topics include several case studies of successful projects in the state, how to target C&D materials for recycling, creating a waste management plan, how to work with haulers, and how to measure results.

The ABCs of C&D Debris: Tribal Construction and Demolition Debris Management Training COMPLETED

EPA Region 5 and the Tribal Association of Solid Waste and Emergency Response cosponsored a pilot course in C&D debris management-The ABCs of C&D Debris. The course was hosted by the Bois Forte Band of Chippewa in Tower, Minnesota on June 15, 16, and 17, 2004. Participants represented tribal solid waste, construction, housing, planning, and environmental staff. The training provided an overview and hands-on exercises of C&D debris management including planning and funding, C&D debris source reduction, deconstruction and recycling, C&D landfills, waste screening, and safety. The course also provided information on compliance including applicable regulations and best management practices. Tribal specific issues, experiences, and case studies were featured throughout the course. The training also included a site visit to the Bois Forte C&D landfill providing a practical example of how a tribe can plan, site, and fund the operation of a C&D landfill facility on a scale best suited for its reservation. View the training manual at http://www.epa.gov/epaoswer/non-hw/tribal/resource.htm

GRANT: Drywall Recycling Website ($10,000 FY03) COMPLETED

The Construction Materials Recycling Association developed an Internet web page (http://www.drywallrecycling.org) Exit EPA Disclaimer dedicated to gypsum wallboard recycling. The website provides information on the recycling of gypsum wallboard. The CMRA partnered with WasteCap Wisconsin, the University of Florida and U.S.Gypsum.

GRANT: WasteCap Wisconsin, Inc. ($10,000 FY02) COMPLETED

The project tested scrap drywall generated during construction projects as a substitute for agricultural gypsum in partnership with a fertilizer manufacturer. This market has the potential to utilize all of the drywall generated in Dane County and will set a precedent for other recyclers to work with fertilizer manufacturers in other parts of the state and country. Another component of the project involved documenting available research on the land application of crushed drywall board.

GRANT: Reuse Development Organization ($20,000 FY02) COMPLETED

The Reuse Development Organization (ReDo) Exit EPA Disclaimer developed a targeted donations project for hardware and home furnishings. ReDo's national donations program creates an alternative to disposal for manufacturers of obsolete, off-spec or still functional and usable inventory. Such materials are transported to non-profit reuse centers across the country who distribute the materials to needy populations and programs, such as Habitat for Humanity building projects.

GRANT: Construction Materials Recycling Association ($10,000, FYO1) COMPLETED

A website for asphalt shingle recycling (http://www.shinglerecycling.org) Exit EPA Disclaimer was developed. This site provides extensive information on asphalt shingle recycling, including research resul ts, market data, regulatory information, and additional links. A main focus of the site is outstanding environmental health and safety issues such as asbestos content.

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Scrap Tires:

EPA Region 5 Scrap Tire Initiative COMPLETED

Between 2004 to 2006 Region 5 received funding from the Great Lakes National Program Office and the Land Revitalization Program to develop a series of maps illustrating where scrap tire piles were located in eight states, conduct seven Scrap Tire Cleanup Forums in six states, and produce the 'Scrap Tire Cleanup Guidebook, a Resource for Solid Waste Managers Across the United States'. The products from this project will help states to cleanup their remaining scrap tire piles, thus recovering resources, and preventing pollution from tire fires and mosquito-borne diseases.

Rubber Manufacturers Association Exit EPA Disclaimer COMPLETED

Several EPA Regions partnered with the Rubber Manufacturer's Association to hold the Tri-Regional Scrap Tire Conference in Memphis, Tennessee on December 4-6, 2002. The program agenda was developed by a multi-state planning committee, and the program included a regulator-only forum to discuss program, enforcement and consistency issues.

Scrap Tire Conference Scrap Tire Management Council Exit EPA DisclaimerCOMPLETED

The Indiana Department of Environmental Management, Department of Commerce, Scrap Tire Management Council and EPA hosted a regional scrap tire conference in Indianapolis on June 4-6, 2001. A regulators roundtable was held during which discussions took place regarding scrap tire regulations, fire prevention and market development. A full-day training on Civil Engineering applications for scrap tire derived chips was also held for highway engineers. EPA Regions 4, 5 & 6 will co-sponsor a Tri-Regional Scrap Tire Conference on December 5 & 6, 2002.

Industrial Byproducts:

GRANT: National Council for Air and Stream Improvement, Inc Exit EPA Disclaimer ($4,600 FY03) COMPLETED

NCASI developed a compilation of case histories of both industrial and municipal landfill closure using paper industry wastewater treatment plant residuals as the hydraulic barrier layer. The report documents technical information and engineering practices where residuals were used. The technical bulletin (#900)is available to the public on NCASI's website: www.ncasi.org Exit EPA Disclaimer.

GRANT: Department of Agriculture, Trade & Consumer Protection ($25,000 FY02)  COMPLETED

This grant supports development of an organic byproduct GIS database by the University of Wisconsin Exit EPA Disclaimer. The goal was to provide generators and potential users of organic byproducts with information to facilitate the beneficial use. The project involved working with generators to characterize the types of organic waste generated, the amounts, and their current disposition. Organic byproducts generated in the area include biosolids from POTWs, yard debris, cheese manufacturing residuals, cannery wastes, meat processing wastes, wood lumber mill wastes, paper mill residuals, tannery wastes, animal manures.

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